What’s New in Process Technology August 2012

Shouldn’t you know your safety loops from the inside out?

With a smart safety instrumented system you can. DeltaV SIS. Smart.

DeltaV SIS is the only logic solver to digitally diagnose and automatically proof test components of your entire safety loop.

No more second guessing–the health of each element in the safety loop is continuously monitored. This valuable information is easily accessed by operators without data-mapping and multiple databases. DeltaV SIS shuts down your plant when needed for safety, but keeps you running safely when components fail–reducing spurious trips.

DeltaV SIS is the first to use predictive intelligence and device diagnostics to enable safer facilities, improve availability, lower life-cycle costs, and ease regulatory compliance. For more insight, visit: www.DeltaVSIS.com

The Emerson logo is a trademark and a service mark of Emerson Electric Co. ©2010 Emerson Electric Company

0812

ON THE COVER

WHAT'S NEW IN PROCESS TECHNOLOGY AUGUST 2012

The newly expanded programmable

CONTENTS

automation controller (PAC) offering from Rockwell Automation now brings Integrated Architecture to smaller applications.

Right-sizing your architecture with Rockwell Automation achieves significant long-term cost

4

Enabling rapid line changeovers

and time savings as it combines scalability with

Electronic work instructions help improve productivity

optimum performance and system longevity

8

New products

10

Hot products online

20

Accurate process viscosity measurement

simplification tools, including integrated motion

Increasing productivity and profitability in asphalt and lubrication

on EtherNet/IP.

oil refineries

Expanding on the scalability of the Logix family

36

Bridging the intrinsically safe fieldbus disconnect

52

A breath of clean, fresh air for industry

62

As I see it

advantages.

The midrange system includes a new series of CompactLogix controllers, scalable servo drives, I/O devices, visualisation and

Adding devices while limiting energy

Improving manufacturing competitiveness with modern communication technology

of controllers, the new CompactLogix L3ER series of PACs offers a wide variety of options to match your specific application requirements.

With up to 3 MB user memory and supporting up to 16 axes of motion, these controllers are ideal for small, stand-alone equipment to

general-purpose machine control in applications such as indexing tables, process skids, case packers and packaging lines.

The Kinetix 350 is a single-axis EtherNet/IP servo drive designed for coordinated motion applications. When combined with a logic controller, it significantly lowers the cost to deploy integrated motion in a variety of machine applications. This integrated solution allows machine builders to minimise the lengthy control selection processes, better accommodate changing design parameters or expansion of the end-customer’s application needs, and dedicate more engineering resources to drive machine innovation. Whatever your safety, motion and operator interface machine requirements are - the Rockwell Automation midrange system has a solution for you.

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

Rockwell Automation Australia www.apac.rockwellautomation.com/oem/midrange/WNIPTAA

© iStockphoto.com/IP Galanternik D.U.

ENABLING RAPID LINE CHANGEOVERS 4 WHAT'S NEW IN PROCESS TECHNOLOGY - AUGUST 2012

Using electronic work instructions to improve changeover processes paves the way for manufacturers to recover valuable production time, accelerate margin and control product quality.

I

n today’s fiercely competitive economy, manufacturers face intense pressures to boost production efficiency and meet increasing consumer demands. Now more than ever before, consumers expect a constantly changing range of diverse, innovative products, and inventory managers everywhere have had to adapt to smaller, more targeted runs to meet demand and minimise excess inventory.

Many plants are running multiple products per line per day, including varieties of the same products as well as entirely different ones. All these different products being produced on the same line have resulted in many more production line changeovers in the factory compared to even just a few years ago - requiring processes, people and equipment to adapt.

With capitalisation of new equipment out of the question in this current ‘hold your cash’ world, manufacturers need to look at improved changeover procedures.

A critical enabler is speed, because the number of changeovers a plant can perform is limited by the amount of time it spends on each changeover. Most plants today spend a significant amount of time on them between runs - translating into non-production time and higher costs per unit. Key obstacles include manual processes, which are more time-consuming and prone to increased quality risk, and the time required to train operators to constantly perform new changeovers.

Many companies have successfully enabled rapid changeovers through the use of electronic work instructions, also referred to as electronic standard operating procedures (eSOPs), to effectively guide operators through the process. Electronic work instructions help manufacturers gain the agility and speed needed to efficiently produce many different products on the same line without changeover delays - enabling the recovery of valuable manufacturing time, consistent product quality and reduced

excess inventory, all of which are critical to a better bottom line.

Guiding operators through changeover processes It is no secret that line changeovers cost money. In the past, most companies built this into the base cost because it was not performed frequently enough to track during their large production runs. But today, manufacturers find this formerly hidden cost growing exponentially as the number of changeovers increases and production run lengths are cut to reduce inventories.

In a recent survey of food manufacturers, the majority of plants (57%) reported that they run two or three different products per line per day; 30% of respondents reported that line changes involved a change to an entirely different product; and 17% run more than 10 packaging changes per day. Line changeovers equate to non-production time with many labour hours spent cleaning, adjusting and verifying machine set-up. They also introduce greater risks because issues not addressed properly during changeovers can cause longer start-up cycles, more rejected product and increased machine malfunctions. It stands to reason that the more often changeovers occur, the higher the likelihood of negative effects.

Changeover costs are seldom measured, but can total as much as tens of thousands of dollars per hour, according to John Henry, President of Changeover.com. It is estimated that for a one-hour daily changeover on a fairly significant packaging project with the line running 240 days per year, the annual cost is $1.8 million.

For example, one manufacturer adjusted its production run to half the amount of product, allowing it to change flavours and sizes on the line to gain a more flexible production inventory level. But when it changed from a one-line changeover per week to six-line changeovers per week, the plant’s equipment failure rate doubled,

AUGUST 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 5

Line management

Figure 1: Operator with HMI and workflow. which slowed down production, increased product rejects and also resulted in extremely high operator overtime.

The company decided to take a step back and examine what happened. At the top of the list were ineffective changeovers. As it moved from one changeover to six changeovers per week, many new operators were brought into the process, but there was a lack of changeover procedures to guide them. Additionally, the new operators did not have the tribal knowledge or expertise of the original operators, opening the lines to more errors and lost time during line changeovers.

To address this challenge, the manufacturer implemented new electronic work instructions for changeovers to guide each worker through the tasks required to get the line ready for the next product or size change. These workflows captured the tribal knowledge of the company’s most experienced operators to help make every worker ‘the best worker’ and incorporated best practices into the work processes for faster and better production set-up. As a result, the company reduced its line changeover time by 25% and line start issues by 50% for significant time and cost savings.

Speeding up the most costly part of a production line When asked about the time required to change over a production line, many companies will give general answers like, “We do that off shift” or “half a shift” or “a whole shift depending on the type of changeover we are performing”. The unfortunate issue is that they do not understand or know how long changeovers - a costly, nonsalable action - really take, particularly because in the past when changeovers were completed less frequently, the impact was minimal.

In today’s environment where there are constant changeovers, manufacturers that view line changeovers as a production run can leverage the power of information to quicken changeovers, hence driving increased productivity for a better bottom line. The use of eSOPs help systematise best practices and provide valuable information and critical visibility into changeover processes, including how long each actually takes and where and why issues occur - enabling improvements for effective production planning. For example, one food manufacturer imple-

6 WHAT'S NEW IN PROCESS TECHNOLOGY - AUGUST 2012

mented an eSOP solution and turned its process improvement team onto the data.

The team discovered that the same tasks were taking different amounts of time to perform, depending on the operator shift, which pointed to the need for better training. Additionally, it discovered that moving through the production mix worked better in one direction than others; for example, reducing bottle size was faster and easier than increasing bottle size.

Using the information from electronic work instructions to gain better insight about its changeovers, the company incorporated training and also changed its production to go from largest bottle size to smallest bottle size, reducing the overall time of a line changeover by 35%. The significant improvement resulted in less operator overtime, fewer product rejects and reduced equipment failures - driving speed and production efficiency.

Ensuring high product quality with accurate set-up Quality as explained by one manufacturer’s Vice President of Quality is

www.ProcessOnline.com.au

Line management

WITH THE IMPLEMENTATION OF NEW ELECTRONIC WORK INSTRUCTIONS TO EFFECTIVELY GUIDE ITS NEW OPERATORS THROUGH CHANGEOVER PROCESSES WITH INCREASED ACCURACY AND SPEED, A MID-SIZED CONSUMER PRODUCTS MANUFACTURER SAVED 25% OF ITS LINE CHANGEOVER TIME AND CUT ITS LINE START ISSUES BY 50%.

“a game of trust but verify”. Generations of companies have taken on different mantras to ensure quality, including “do it right”, “continuously improve” and “Lean/ Six Sigma”. Furthermore, many of these companies have realised that the operator is the first line of defence and have moved towards having the operator perform many of the quality verification steps.

For instance, one company realised that changeovers were impacting its product quality and implemented eSOPs to ensure that its operators would not miss any changeover steps, which if omitted, resulted in set-up errors and rejected product. The use of electronic operating procedures prevented its operators from inadvertently skipping a step, ensuring production compliance with defined processes and minimising errors that can lead to quality issues.

The workflows also enforced operators to enter critical parameters along the way, which could be verified against quality standards automatically - helping to ensure that the line was set up correctly and ready to run. With valuable information on product quality, operators could quickly respond to issues, allowing them to gain tighter control without additional headcount and reducing the reject rate.

Winning the excess inventory battle Companies with high volumes and low margins know that razor-thin inventories are paramount to their success. Reducing excess inventory can mean millions of dollars added back to the bottom line, which is why companies continue to push their supply chains to be more agile and drive towards a ‘make-to-order’ nirvana.

To achieve this, companies must stop treating their manufacturing sites as black boxes that only report the finished product and instead gain more information about the build process as it is happening. Realtime production information helps companies drive out unpredictability, which

www.ProcessOnline.com.au

can then help them to reduce their safety stock to new lows - freeing up cash that would otherwise be tied up in product.

The advantage of successful line changeovers enabled by electronic work instructions expands beyond product quality and speed to improved predictability.

Reliable changeovers allow companies to gain better insight into real-time production and the impact on inventory to enable proactive scheduling and planning of resources and materials. Therefore, companies do not have to hold unnecessary inventory levels - tying up real money that could be invested for growth or other strategic initiatives.

As a case in point, a warehouse manager for one of the world’s largest CPG companies previously had to rent three separate warehouses to hold excess inventory because the company could not accurately predict expected production.

After implementing eSOPs, his production became much more reliable, whereby safety stock could be better aligned with actual production levels.

As a result, the company was able to reduce its excess inventory across its product lines, eliminating the need to rent three warehouses and saving the company millions of dollars per year in rental space.

Electronic versus paperbased operating procedures The significant advantages of eSOPs include: • Strong adherence to standard operating procedures as eSOPs can be used to ensure that lessons learned actually stick.

• Improved accuracy and repeatability as eSOPs are much less open to interpretation and abuse, either intentional or unintentional.

• A direct link to the plant to ensure that safety interlocks remain uncompromised and changeovers are followed in exact sequence.

• The ability to do what people are

poor at doing: routinely collecting and collating masses of data.

• Powerful reporting tools that transform data into meaningful information, which is consumable by stakeholders across the organisation for better decision-making.

Conclusion With increasing consumer demands for an endless variety of new products, manufacturers have had to keep up with smaller, more targeted runs and multiple products per line per day. In turn, a growing area of concern for manufacturers in today’s fast-paced environment is the increased frequency of line changeovers, which results in significant non-production time, in addition to increased quality issues and costs.

As some leading companies have begun to discover, the key to quickening line changeovers without compromising quality relies on guiding operators through changeover processes with electronic work instructions. The faster operators can set up machines and recipes correctly, the more efficiently manufacturers can produce many different products on the same line without changeover delays and errors - recovering valuable production time and delivering consistent product quality.

Furthermore, rapid and reliable changeovers enabled by electronic work instructions help manufacturers leverage improved predictability to drive proactive planning of resources, including the reduction of excess inventory. The critical insight that manufacturers gain into realtime production helps drive increased agility across the plant - accelerating profit margins for a stronger bottom line.

GE Intelligent Platforms Asia Pacific Pte Ltd Contact info and more items like this at wf.net.au/N670

AUGUST 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 7

NEW PRODUCTS

MULTILOOP PID CONTROLLER Invensys Operations Management has

MOTOR CONTROL DEVELOPMENT TOOLS

introduced EtherNet/IP communications to

MathWorks has announced that Simulink

its Eurotherm Mini8 multiloop PID controller.

code generation targets have been built

The Mini8 controller is a suitable partner

into Freescale’s Motor Control Develop-

to a PLC in multiloop PID applications such

ment Toolbox through Embedded Coder.

as plastics extrusion and multizone furnaces.

The toolbox, consisting of Simulink motor

Leveraging the Mini8 controller’s built-in loop

control blocks and target-ready code

control, the PLC can concentrate on provid-

generation support, lets automotive and

ing faster, more effective logic control without the

industrial controls engineers design

burden of running complex control algorithms.

motor control systems using Freescale

The Mini8 controller supports serial, fieldbus and ethernet protocols, including

microprocessors in IEC 61508 (SIL3) and

EtherNet/IP, making it easy to interface to intelligent masters such as programmable

ISO 26262 (ASIL-D) compliant systems.

logic controllers. A cost-effective alternative to designing and implementing accurate

With the Motor Control Development

control loops in a PLC, the Mini8 controller not only provides better performance and

Toolbox, engineers can design motor

easy configuration, it offers the same deterministic response and auto-tune feature as

algorithms as well as configure and gen-

other Eurotherm panel-mount controllers from Invensys, and it can be easily integrated

erate all software needed to execute the

into the wider plant network, including other third-party systems.

algorithms on any Freescale MPC5643L

Input accuracy is ±0.1% or better, significantly better than analog control in small

or PXS20 hardware platform. The toolbox

or medium PLCs, and the Mini8 is suitable for use in regulated industry applications,

includes a Motor Control Library devel-

including aerospace metal heat treatment.

oped by Freescale’s Motor Control Center

Invensys Process Systems (Australia) Pty Ltd

of Excellence. With this library, engineers

Contact info and more items like this at wf.net.au/Q663

can model their designs using blocks optimised for fast execution on Freescale MCUs and run bit-accurate simulations

ETHERNET/IP ENCODERS

of those designs. The toolbox offers

The AFS60 EtherNet/IP single-turn encoder

optimised code generation and support

and the AFM60 EtherNet/IP multi-turn encoder

for model-in-the-loop (MIL), software-in-

provide comprehensive diagnostic capabilities

the-loop (SIL) and processor-in-the-loop

and the integrated transmission function for

(PIL) testing through Embedded Coder

rotary axes. Their device level ring functionality

from MathWorks.

(DLR) allows active and continuous monitoring of network ring topology and its participants.

The diagnostic functions integrated in the

The Motor Control Development Toolbox supports the MPC564xL, MPC567xK and PXS30 and PXS20 MCU families.

EtherNet/IP encoders include monitoring of

Block libraries in the Motor Control

the temperature within the encoder to warn of

Development Toolbox provide base

potentially critical operating states. In addition,

math functions including trigonometry,

they are equipped with two operating-hour

PI controllers, FIR and IIR filters, and

counters - one starts when power is supplied

motor control operations including Park

while the second counts the time of actual shaft

and Clarke transforms. Peripheral block

rotations. Five dual LEDs on the encoder show

support includes ADC and PWM, as well

the current operating state of the two ports, encoder functions and data transfer.

Programmable position limit values can also be monitored. Finally, the detection of speed protects the encoder from overloading.

as SPI and CAN buses.

The generated C source code can be automatically built with Freescale

The EtherNet/IP DLR functionality sends beacon frames via its dual-port switch at

CodeWarrior IDE, Wind River Diab, Green

brief intervals. In this way, the sensor carries out continuous and active availability

Hills Software Multi, and other compilers.

tests on the network participants as well as on the connections between them. In

For examining software on target hard-

the case of a fault, a change in direction of the beacon frame transmission in less

ware, the toolbox provides FreeMaster,

than 3 ms restores communication between the devices and the controller.

which enables parameter tuning, real-time

The AFM60 EtherNet/IP multi-turn encoder also includes a rotary axis function that

monitoring and data logging.

allows the steps per rotation to be represented as a fraction. This function saves the machine constructor complicated drive calculations and control programming.

Sick Pty Ltd Contact info and more items like this at wf.net.au/Q216

8 WHAT'S NEW IN PROCESS TECHNOLOGY - AUGUST 2012

MathWorks Australia Contact info and more items like this at wf.net.au/N722

www.ProcessOnline.com.au

The impossible made possible Combining advanced functionality with ease-of-use

Beamex MC6 Advanced Field Calibrator and Communicator

The Beamex MC6 is an advanced high-accuracy field calibrator and communicator. It offers calibration capabilities for pressure, temperature and vaious electrical signals. The MC6 also contains a full fieldbus communicator for HART, FOUNDATION Fieldbus and Profibus PA instruments.

HOT PRODUCTS

ON WWW.PROCESSONLINE.COM.AU THIS MONTH INDUSTRIAL TABLET PC This 13.3" touch screen industrial tablet PC is IP65 rated and has watertight USB, audio and RJ45 interfaces.

>

Phoenix Contact Pty Ltd

WF.NET.AU/Q492

>

>

INTRINSICALLY SAFE PRESSURE CALIBRATOR

DATA ANALYSIS SOFTWARE

With an accuracy of 0.025 % of

DIAdem 2012 is the latest version of a software tool

span and various additional func-

specifically designed to help engineers and scientists

tions, this instrument is suited to

interpret and share data.

a wide range of applications in

National Instruments Australia

hazardous areas.

WF.NET.AU/Q335

WIKA Australia

WF.NET.AU/Q669

>

WIRELESSHART ADAPTER

MULTIPARAMETER CONTROLLER

The Bullet can send process sig-

The mxControl 8620 multiparameter

nals from just one or up to eight

controller is designed to automate the

multidropped smart HART trans-

control of process variables within a water

mitters on a WirelessHART link.

treatment system.

Moore Industries Pacific Inc

B端rkert Fluid Control Systems

WF.NET.AU/Q483

WF.NET.AU/N811

>

10 WHAT'S NEW IN PROCESS TECHNOLOGY - AUGUST 2012

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NEW PRODUCTS

NEW White Papers

now available online!

Flammable gas detection technology - selection and application tips Gas detection technology should always be chosen based on the hazard faced. Selecting the right technology and applying it correctly will prevent injuries, save lives and save money in the long term. This white paper provides insightful selection and application tips - download now to ensure you are prepared.

EMBEDDED COMPUTER WITH CARBON FIBRE CHASSIS Crystal Group has released the RE0412, a small form factor rugged embedded computer in a carbon fibre chassis.

The RE0412 is suitable for environments where performance, ruggedness and reliability are imperative. This rugged embedded carbon fibre chassis computer is designed for airborne and ground mobile applications where significant processing power is required in a lightweight and rugged package.

The carbon fibre RE0412 chassis measures 7.95 h x 27.33 w x 20.65 d cm and weighs 1.72 kg fully loaded with up to two 6.35 cm solid state drives, a PCIe x16 expansion slot and up to 16 GB DDR3 RAM. The RE0412 features an Intel mini-ITX

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

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

board, i3 (Desktop) CPU, DC power inputs from 18-36 VDC, a single cooling fan and has conformal coating options for humidity protection. Extensive thermal design enables -40 to +55°C operation with full CPU load, without throttling. MIL-STD-810 vibration and shock performance testing is underway, followed by MIL-STD-461 CE102 and RE102 testing. The full complement of I/O makes the platform suitable for general-purpose processing in the field.

The RE0412 is a product that came out of the UAV and soldier deployed markets. The emphasis on light weight and low power

Eliminate impulse piping, heat trace and purge lines on DP level measurements

has seen a significant amount of interest in the ground vehicle

Measuring level with differential pressure is a well understood and reliable method, although accurately measuring differential pressure on tall towers and tanks has always been challenging.

For information on a possible solution to better enable operators to control tank level and pressure, download this paper.

Metromatics Pty Ltd

market due to the extreme thermal performance and durability.

Contact info and more items like this at wf.net.au/N726

CONTROL MODULES FOR ENGINE PROTOTYPING

Business impact of application performance problems Issues with the performance of business-critical applications can cause deterioration of an organisation’s business performance.

Slow applications that support key business processes can cause revenue loss and a decline in customer satisfaction and employee productivity. To ensure you’re informed, be sure to read this white paper.

National Instruments has released six Drivven C Series engine control modules, which provide engine researchers with rugged, modular engine-specific I/O for interfacing directly with internal combustion engine subsystems and actuators. Using these modules, which are programmed with LabVIEW FPGA, engineers can rapidly prototype engine control algorithms without having to create custom hardware or request lengthy code changes.

C Series modular hardware offers plug-and-play I/O flexibility to change engine interfaces in seconds. The direct injector module for example makes it possible to get the piezoelectric injector working well in a very short time. Combined with LabVIEW system design software, the series gives researchers flexibility with engine parameters

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

such as spark and fuel-injection timing.

National Instruments Australia Contact info and more items like this at wf.net.au/Q334

12 WHAT'S NEW IN PROCESS TECHNOLOGY - AUGUST 2012

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Network security for automated production Virus problems in the office network are merely inconvenient when compared to expensive virus disruptions and unwanted data traffic in a production network. In order to minimise the risk of disturbances and production downtime caused by unauthorised access or malware, one leading manufacturer decided to implement greater security precautions.

ZF Sachs (www.zf.com), with 16,500 employees, has been a renowned partner in the automotive industry for more than 100 years.

Its drive train and chassis components are also used for commercial transportation, rail transportation, construction vehicles, agricultural vehicles and motorsports. The traditional office network solution, using virtual local area network segmentation with VLAN-compatible switches, was rejected by ZF Sachs as being expensive, complex to implement, difficult to control, insufficiently secure and potentially unreliable in the harsh environment of the plant floor.

“We evaluated different firewall security products under two main criteria. Industrial suitability with, for example, an extended temperature range was particularly important to us. We also needed a solution that could be integrated into our automation component environment as flexibly as possible and with a low level of complexity,” said Asmund Hey, head of automation technology for ZF Sachs Technical Services.

Ultimately, they chose to utilise a small, industrial module called FL mGuard, a product of Phoenix Contact, created and developed by Innominate Security Technologies. The hardened product’s Linux-based system incorporates router and firewall capabilities, as well as encrypted VPN (virtual private network) tunnels, filtering of incoming and outgoing traffic, and other functions to provide layers of distributed ‘defence-in-depth’ economically and without disturbing production.

Sealing off the office network from the production network was carried out with individual industrial firewalls behind a production firewall to create a multilayered defence architecture within which critical production lines and individual systems could be doubly safeguarded. Network traffic could be controlled and filtered with a greater degree of flexibility and lower costs using distributed industrial firewalls rather than delicate IT

network equipment. A total of 40 decentralised machine networks were implemented and each of these subnetworks was secured by an mGuard firewall. The automation technology and machine maintenance departments were responsible for the implementation, in coordination with the IT department. Along with the use of virus scanners in the production area, the most important measure became the segmentation of the production network into small and manageable machine networks. The assignment was conducted spatially based on building zones with additional Profinet components for individual installations.

Implementation of the decentralised security architecture was based on a network structure

plan. This describes the individual network segments and contains specifications concerning which device is attached to which port, as well as which IP addresses, MAC addresses, firmware version and product designations are given.

To ensure that the decentralised architecture with 40 individual machine networks did not lead to greater configuration and operative effort, a basic set of common firewall rules for all subnetworks was developed first as an overriding control. This meant that most of the requirements were already covered and only individual rules had to be added for special cases, such as for controller access to office server shares.

A three-month introductory and learning phase followed start-up, allowing any missing accesses or ports to be included. “During this phase, we realised how important a careful network architecture plan is. The more time invested here, the smaller the correction effort will be later. We also discovered the advantages of central device management,” recalled Hey. Various special requirements were desirable and taken into account in setting up

14 WHAT'S NEW IN PROCESS TECHNOLOGY - AUGUST 2012

the decentralised security architecture. The production facility with Profinet components needed to be sealed off from disturbances from the network. For example, a jitter of less than a microsecond was necessary for the response time behaviour of critical components, and these needed to be consistently sealed off from disturbances such as those caused by a typical IT network broadcast. A further requirement was 1:1 NAT (network address translation) for DNC (distributed numerical control) machines. This concerned the software for the distribution of the DNC programs running in the office network.

Since the mGuard components support 1:1 NAT, no adjustments to the internal address space of the machines were necessary for the software.

Setting up port forwarding was a further important requirement, as central databases had to be accessed from the outside in the plant stations. Strict outgoing rules were also necessary. The spatial separation of plants leads to a distribution of the software and process data, which must then be centrally merged again on a server. Access to the central server is enabled through rules in the central firewalls, but any other uncontrolled access is prevented.

The mGuard security solution has been used at ZF Sachs for two years now. The decentralised firewalls in new plants and in plants with Profinet components are now equipped to protect against disturbances.

“The decentralised networks run smoothly.

There is nothing that halts the automation technology and operation continues largely without maintenance. We also successfully protected several older machines without virus protection from disturbances and attacks. Thanks to the segmentation, any virus brought in by a technician has not been able to spread into the network,” said Hey. And he has good evidence, as the virus problems continue to be present in the office area and in old machines without firewall protection. Asmund Hey emphasises that a secure production flow is also guaranteed when other network components fail. If this is the case, the firewall protects the plants from disruptive broadcasts or defective packet transmissions.

Phoenix Contact Pty Ltd Contact info and more items like this at wf.net.au/Q407

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NEW PRODUCTS

REDUNDANT PROFINET CONTROLLER A redundant control system for Profinet can be created with the RFC 460R PN 3TX controller from Phoenix Contact. This makes it possible to reduce system shutdowns and prevent dangerous situations.

Two RFC 460R type Profinet controllers are used to build a fail-safe automation system. One controller controls and manages the process while, in the event of a failure, the second controller is seamlessly activated to perform processes at both the lower and higher levels.

To create redundancy, the user connects both controllers via a fibre-optic synchronisation cable and then programs one of the two controllers. The second PLC is automatically configured for all redundancy functions via AutoSync technology, after which it is automatically started. Both controllers are continuously synchronised.

The redundant controller for Profinet can bridge over distances of up to 80 km between controllers via fibre-optic cables, with an optional pluggable SFP module. A high-resolution display allows for viewing status reports and error message as plain text, and data visualisation is also redundant due to a redundancy-capable OPC server.

Phoenix Contact Pty Ltd Contact info and more items like this at wf.net.au/N920

INDUSTRIAL VGA SPLITTER/EXTENDER The Vopex-M12V-4 industrial VGA video splitter/extender simultaneously broadcasts highresolution video from one computer to up to four remote monitors located up to 200 m away using CAT5/5e/6 cable. M12 connectors are used for all CAT5/5e/6 cable runs. The robust M12 connector system is harsh industrial environments where reliable vibration-resistant connections are required.

The Vopex-M12V-4 splitter/extender system has two components: the Vopex-M12V-4 VGA broadcast unit, which connects to the host computer and also supplies video to a local monitor, and an Xtendex ST-M12V-R-600 remote unit for each remote monitor. The 8-pin M12 connectors are sold separately, allowing end users to field-assemble cables to their required lengths.

Both the local and remote displays can support VGA resolutions up to 1920 x 1440 resolution. The units can also be daisy-chained to increase the number of remote displays.

Interworld Electronics & Computer Industries Contact info and more items like this at wf.net.au/Q219

SPEED-MONITOR RELAY Sick’s MOC3SA speed monitor is part of the company’s sens:Control safe control range, and is designed for the safe monitoring of drive rotational speeds. The monitor meets the safety levels of PLe according to EN ISO 13849, SIL3 in compliance with IEC 61508 and SIL3CL according to EN62061. Typical applications include the speed-dependent release of mechanical door latches during machine operation or the operation of drives with safely reduced and monitored speeds, such as in maintenance or set-up modes.

The speed monitor allows the simple, flexible and economical monitoring of safe stops and safe rotary speeds of drives. The best operating mode for a particular use is automatically suggested by the design aid software tool - useful for project planning. Configuration is then easily undertaken via two rotary switches on the module housing.

The speed monitor also supports a wide range of sensors and signals - including ‘non-safe’ - so that the same motion control module can always be used regardless of the sensor involved.

The device permits the monitoring of mechanical door latches on palletisers, processing machines or transfer stations between handling systems or robots and persons. It is also suitable for the operation of a drive during maintenance, set-up or testing, in order to safely reduce and monitor the drive speed during these operating modes.

Sick Pty Ltd Contact info and more items like this at wf.net.au/Q379

16 WHAT'S NEW IN PROCESS TECHNOLOGY - AUGUST 2012

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NEW PRODUCTS

SUBSTATION-RATED ETHERNET SWITCHES The Indura series of industrial, managed switches from Transition Networks provide fully hardened solutions designed to operate reliably in harsh environments. Indura is designed to meet IEC 61850-3, ATEX Zone 2 and UL Class 1 Div 2, and offers advanced industrial ethernet management, redundancy and security features coupled with rugged

AUSTRALIAN-ASSEMBLED MINING DRIVE

hardware performance for industrial or out-

SEW-Eurodrive is now locally assembling its mining drive at its new 10,000 m2 IG facility

door environment applications requiring high

in Melbourne. The mining drive features bevel-helical technologies and is suitable for motor

reliability and availability. Its four gigabit SFP

powers up to 1500 kW. Assembled with a purpose-designed thermal housing, the mining

ports allow a wide range of fibre supported

drive is designed to make a significant reduction to energy usage in heavy industry through

network architectures.

the lessening of thermal losses. With torque ratings ranging from 58-465 kNm, local assem-

Indura supports IEEE 1588v2 Precision Time

bly of the mining drive includes eight sizes, taking torque range assembled to 175,000 Nm.

Protocol for real-time automation applications

SEW-Eurodrive Pty Ltd

and IEEE 802.3ah/IEEE 802.1ag/ITU-T Y.1731

Contact info and more items like this at wf.net.au/Q275

make Indura a suitable choice for networks that need fault detection and fault isolation.

The passive cooling design maintains

PULL-WIRE ABSOLUTE ENCODER

operating temperature of SFPs, through the

The Elap WDS absolute multiturn pull-wire encoder

extended operating temperature range of

features Profibus, CANopen or SSI outputs. Measure-

-40 to 75째C. Fault recovery time is less than

ment strokes from 3 to 15 m are available as standard,

50 ms, with STP/RSTP/MSTP. System alarms

with resolution ranging from 0.6 to 1.5 mm. Special

are provided via a fault output relay, Syslog

lengths of 30-50 m are available on request.

and SNMP traps (SNMP v3). For security the

The WDS cable mechanism, constructed with an

Indura supports IEEE 802.1x user authentica-

aluminium case with coated polyamide stainless steel pull wire, is built to suit harsh

tion, RADIUS and TACACS+.

environments and temperature range -20 to +80째C. Coupled with the MEM520 multiturn absolute encoder with 29-bit resolution, industry standard fieldbus protocols are now

T Data Pty Ltd

available for long-length measurement applications requiring absolute position feedback.

Contact info and more items like this at wf.net.au/Q475

Motion Technologies Pty Ltd Contact info and more items like this at wf.net.au/Q482

18 WHAT'S NEW IN PROCESS TECHNOLOGY - AUGUST 2012

www.ProcessOnline.com.au

ACCURATE PROCESS VISCOSITY MEASUREMENT Robert Kasameyer, PAC

INCREASING PRODUCTIVITY AND PROFITABILITY IN ASPHALT AND LUBRICATION OIL REFINERIES

There are more than 700 refineries worldwide, operating in virtually every country on earth, with a capacity to produce 82 million barrels of oil per day. Viscosity is one of the most critical measures of product quality for virtually every refinery product.

I

n Australia, seven major refineries currently operate, with a capacity to produce 750,000 barrels of oil per day.1 The demand for energy continues to rise, placing increased pressure on producers to streamline and speed production, increase yield and operate more efficiently.

A barrel of crude oil typically yields 50% gasoline, 15% fuel oil and 12% jet fuel - with the remainder used for diesel, asphalt, lubrication oil and other refined products - but output varies by refinery. Viscosity is one of the most critical measures of product quality for virtually every refinery product. New developments in viscosity measurement are enabling refineries to significantly improve production quality, cost and output. Methods for effectively managing asphalt and lubrication oil viscosity are discussed below.

Asphalt Asphalt is critical for road paving. Roads are subject to radically different environments worldwide and to seasonal changes that

20 WHAT'S NEW IN PROCESS TECHNOLOGY - AUGUST 2012

impact road quality. Asphalt must be suitable for local conditions and asphalt suppliers must meet pavement specifications unique to each customer’s region.

The raw material for making asphalt is basically what remains in the bottom of a barrel of crude oil when all higher value materials have been extracted and refined. This raw material is typically non-homogenous and may vary radically in make-up from barrel to barrel depending on the source of the crude oil. Variations in refinery process conditions can also have an impact.

Customer specifications are based on international standard test methods that utilise standard laboratory test equipment.

These lab tests are done periodically throughout production and the process is adjusted based on the test results. The material is then tested in the storage tank, and re-blended to meet the exact customer specifications. Unfortunately, the asphalt characteristics can vary significantly between lab tests. Therefore, significant post-process blending is typically required to meet customer specifications (see the example in Figure 1).

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Instrumentation

Š iStockphoto.com/Alexander Chernyakov

Lubrication oil

Since lab analysis is run only a few times per day, refineries utilise inline measurements to enhance production consistency.

Three technologies are commonly used for inline viscosity measurements: capillary, vibrational and oscillating piston. All require conditioning of the fluid being tested so that it is as consistent as the lab samples are in terms of temperature, flow and particles.

Capillary systems require high-precision pumps for accuracy, as well as frequent and costly maintenance and recalibration.

Vibrational-based viscometers can cause resonance frequencies in fluids and are subject to process equipment vibrations, which can lead to inaccurate measurements. The oscillating piston technology is preferred for its accuracy, reliability and ease of installation.

In a typical asphalt process, an oscillating piston viscometer is installed in the main asphalt line or in a bypass to the asphalt line (see Figure 2). In this example, the viscometer is located in a 5 cm bypass line of a 30 cm main line and is used to maintain the diluent addition to achieve the ideal customer specification the first time it goes through the process.

www.ProcessOnline.com.au

All lubrication oils are graded and sold based on their viscosity characteristics. Viscosity is the measure of a fluid’s resistance to flow, so the ideal lubricant is frequently one that keeps moving parts separated, at the lowest viscwosity possible. The industry typically uses VI, or the viscosity index, to characterise lubricants.

The VI is a ratio comparing the viscosity of oil at two different temperatures and is a governing specification for any lubricating oil.

Highly precise viscosity measurements are required for lubricant production. Obvious cost advantages exist from producing lubricants with the specified characteristics the first time they are run through the process, rather than trying to blend them in later. Meeting laboratory results inline typically requires process instruments to be installed in a bypass line that is conditioned for constant temperature and flow and with particulate filtering.

Oscillating piston viscometers, such as those of Cambridge Viscosity by PAC, can offer in-process measurement with a high degree of accuracy - and with results that match the lab for most lube oils. Figure 3 demonstrates the high correlation between Cambridge Viscosity viscometers and the results found during lab analysis.

For higher accuracy, some refineries use dual viscometers at slightly different temperatures and average their results as the basis for each measurement. An example of this is shown in Figure 4. Achieving these results requires viscometers that are extremely accurate and reliable in the widely variable environmental conditions refineries are subject to. Oscillating piston technology is the preferred solution for a growing number of refiners over pressure and vibrational measurement approaches. Sensors utilising oscillating piston technology outperform sensors using the other approaches due to their high accuracy and repeatability, robust design, low maintenance and vibration insensitivity - as well as their inherent small size for ease of installation and reduced sample conditioning costs. In addition, oscillating piston sensors typically offer the lowest total cost of ownership.

Figure 1: Asphalt characteristics can vary significantly between lab tests.

AUGUST 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 21

Instrumentation

O S C I L L AT I N G

P I STO N

VISCOMETERS

ARE

FUNDAMENTALLY SIMPLE, RUGGED, ACCURATE AND REPEATABLE DESPITE OPERATING ENVIRONMENTS WITH SIGNIFICANT VIBRATION. A KEY TO THE TECHNOLOGY IS ITS USE OF A SINGLE, NON-CONTACT MOVING PART BOTH TO CLEAN AND MEASURE.

Figure 2: In a typical asphalt process, an oscillating piston viscometer is installed in the main asphalt line or in a bypass to the asphalt line.

Figure 3: Results from oscillating piston viscometers correlate well with lab tests.

Increase productivity and profitability

How oscillating piston viscometers work

The profitability of in-line control for lubricant production is significant. At some refineries, it takes 4-12 hours to realise and correct off-spec production. This can cost a refiner $150,000 per off-spec occurrence for a low-value material, such as asphalt, and up to up to $500,000 for a high-value material like lube oils. Alternatively, installation of an in-line viscometer costs between $25,000 and $50,000 (total installed cost). In addition to this saving, one refinery reports that maintaining tighter control on their lube oil viscosity results in a 0.5% production improvement, or $600,000 in revenue per line, per year.

Oscillating piston viscometers are fundamentally simple, rugged, accurate and repeatable despite operating environments with significant vibration. A key to the technology is its use of a single, non-contact moving part both to clean and measure.

The viscosity measuring technology is based on a simple and reliable electromagnetic concept, as shown in Figure 5. Two coils move a piston back and forth, within a chamber, magnetically at a constant force. The motion of the piston is controlled and the piston’s two-way travel time is measured to determine absolute viscosity. As the viscosity is increased, the travel time is also increased.

The motion of the piston is controlled so that it monitors the fluid viscosity and keeps the sensor’s measurement chamber clean, so that the sensor requires minimum operator attention.

A temperature detector is included in the measurement chamber so that both temperature and viscosity are known for every measurement.

Proprietary circuitry is used to analyse the piston’s travel time to measure absolute viscosity and monitor temperature. With all wetted parts stainless steel, the constant motion of the piston

Combustion products Precise control of the fuel viscosity is important as well. Viscosity controls the droplet size in fuel atomisation, which is essential for efficient combustion. This includes fuels ranging from heavy fuel oil to diesel and gasoline, plus jet fuels. Real-time monitoring enables producers to meet tight regulatory standards and provides audit trail confirmation of the product quality.

22 WHAT'S NEW IN PROCESS TECHNOLOGY - AUGUST 2012

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Instrumentation

Figure 4: Dual viscometers at different temperatures are often used to further improve accuracy.

Figure 5: In an oscillating piston viscometer, the travel time of the piston moved with constant force is used to measure viscosity.

keeps the measurement sample fresh while mechanically scrubbing the measurement chamber. An example of an oscillating piston viscometer is the Cambridge Viscosity VISCOpro 2000 (Figure 6).

This viscometer, combined with a 392 or 301 sensor, is capable of providing viscosity, temperature, temperature-compensated viscosity (TCV) and optional density readings. It is suitable as an in-tank or inline viscometer for any process environment. Thirteen factory-set standard measurements range from 0.2 to 20,000 cPl. Operating characteristics, control set points and alarms are set using a menu-driven interface with RS232 (standard) and RS485 (optional) communications ports. A built-in 1000-point data logger captures key data in real time that can be readily exported to common graphing programs for analysis. The VISCOpro 2000 can be programmed for up to 40 different fluid settings, enabling rapid changeovers in production processes.

Conclusion In refinery applications where producing off-spec material can cost hundreds of thousands of dollars per day, refiners are increasingly relying on real-time, continuous inline measurements to extend traditional offline lab tests to assure product quality.

www.ProcessOnline.com.au

Figure 6: A Cambridge Viscosity VISCOpro 2000 oscillating piston viscometer.

With process results that highly correlate to lab results, refineries: • reduce costs with accurate viscosity measurement • avoid off-spec materials waste • quickly detect viscosity deviations • avoid post-process blending re-work The return on investment for inline viscosity control is seen within days for asphalts and lubrication oils. Oscillating piston technology offers distinct advantages over pressure and vibrational measurement approaches for inline viscosity management due to its inherent accuracy and reliability, robust design and vibration insensitivity. For refinery operations hard pressed to keep up with demand, streamlining production and maximising efficiency ultimately increases profitability.

Resources 1. Australian Government, Department of Resources, Energy and Tourism http://www.ret.gov.au/resources/fuels/petroleum_ refining_and_retail/petroleum_refining_in_australia/Pages/ PetroleumRefininginAustralia.aspx AMS Instrumentation & Calibration Pty Ltd Contact info and more items like this at wf.net.au/Q638

AUGUST 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 23

270x88mm HACH PACIFIC_WWF

9/6/11

9:31 AM

Page 1

INSTRUMENTATION PRODUCTS

INSERTION MAG FLOW METER Bürkert has re-engineered its Type 8045 insertion electromagnetic flow meter.

It now offers a cut-off feature, designed to optimise use in low flow applications.

This function allows the operator to set a lower limit under which the measurement value is set as zero. This parameter feeds

Products. Support. Expertise.

When you buy direct from Hach Pacific you will receive access to the largest offering of the highest quality lab and process water analytics as well as outstanding service and application support. Hach is your trusted partner in water analysis.

through to display, totalisers, outputs and downstream process conditions.

A digital input has also been added to the 8045 electromagnetic flow meter, allowing control system initiated reset of totalising functions, hold mode go-to, zero-point calibration and other functions.

This feature has been added to facilitate remote control capabilities, via site control systems.

An adjustable backlit display has been added for reading and programming in dim conditions. The re-engineered 8045 mag flow meter features integrated diagnostics to support local operation, with a simple and conspicuous green/orange/red LED status indication.

The 8045 electromagnetic flow meter is an all-purpose unit with no moving parts, making it suitable for demanding processes including

Innovative Process Instrumentation

Integrated Lab Solutions and Chemistries

those with particulate contamination. Processes must be conductive, measuring >20 µS, and pipe diameter may be up to 400 mm.

Insertion mag flow meters poke a sensor finger with integrated electronics into the process flow, rather than replacing a portion of the pipework as full bore mag flow meters do. Insertion mag flow meter types have therefore proved advantageous where the extreme accuracy (~0.5%) of a full bore mag flow meter is not required and ~2% accuracy will suffice.

Expert Support

Dependable Service

The Type 8045 mag flow meter is suitable for CIPO systems, the water treatment industry and water applications.

Burkert Fluid Control Systems Contact info and more items like this at wf.net.au/Q555

Contact a Hach Pacific office near you for direct order and sales support: AUS: 1300 887 735 NZ: 0800 50 55 66 www.hachpacific.com

TEMPERATURE AND PRESSURE TRANSMITTER The STS ATM.1ST/T and ATM.1ST/N/T are combined analog pressure and temperature transmitters for highly dynamic measurements. Both the pressure and temperature process functions are contained in one elastomer-free process connection (all connections are welded). This means that the temperature sensor is located in the medium. The pressure-measuring range is 100 mbar to 25 bar, with an accuracy of ≤ ±0.25 at 0.10% FS. The (process) temperature measuring range is -50 to 150°C, with an operating temperature range of -40 to 125°C. The units are made of stainless steel and provide a 4-20 mA analog output.

Automated Control Engineering Contact info and more items like this at wf.net.au/Q642

24 WHAT'S NEW IN PROCESS TECHNOLOGY - AUGUST 2012

www.ProcessOnline.com.au

INSTRUMENTATION PRODUCTS

FLOWMETERS

GASKET-FREE INSTRUMENTS

Originally developed by Moore Products, WIKA has introduced pressure- and

Hawk Measurement’s Model 140MX is

temperature-measuring instruments with

an oscillatory flowmeter which utilises

gasket-free Neumo BioControl CS hous-

a specially designed geometric shape

ings. The 1.4435 stainless steel connection

to produce self-induced oscillations.

combines measuring instruments and

The 140MX has no moving parts or bluff

BioControl CS housings on an all-metal

bodies to wear or jam. This ensures years

basis, and is primarily designed for the

of reliable service and coupled with its abil-

pharmaceutical industry.

ity to handle high-viscosity fluids and low

In comparison with connections using

flow rates, provides performance in tough

elastomer sealings, it is unaffected by

applications. In addition, the lack of piping

temperature influences and aggressive

run requirements simplifies installation and

products and media. The risk of defective O-rings and thus cross contamination is

yields cost savings.

eliminated. These measuring instruments - in combination with diaphragm seals or

Accuracy is typically 1% of flow rate

thermowells - can therefore be used exceptionally safely. The sealing contour is not

and repeatability is 0.25% of flow rate.

affected by repeated resealing.

Flow turndown is 12:1 and it can handle

At the same time, maintenance and replacement tasks, which occur regularly with

viscosities up to 80 centistokes. Pipe

worn plastic sealings, are eliminated. The operator increases safety and minimises

sizes supported are 1.9, 2.5 and 3.8 cm.

costly process downtime.

WIKA Australia Contact info and more items like this at wf.net.au/Q678

www.ProcessOnline.com.au

Hawk Measurement Systems Pty Ltd Contact info and more items like this at wf.net.au/Q420

AUGUST 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 25

INSTRUMENTATION PRODUCTS

TDR LEVEL TRANSMITTER

CORIOLIS MASS FLOWMETERS

The Optiflex 1100C from Krohne is a

The FCB330 and FCB350 are part of the ABB CoriolisMaster

2-wire TDR level transmitter for measur-

family of direct mass flow measurement products and provide

ing distance, level, volume and mass of

accurate measurements of multiple variables with a single, compact device: flow

liquids and solids. It is available with a

(mass and volume, with accuracies to 0.1%), density, concentration, and temperature.

20 m cable or segmented coaxial probe for

The double tube design has no moving parts and requires no up- or downstream

liquids and a 10 m cable probe for solids.

piping, saving more than 40% in length and meter volume. The design also uses

Its simple, compact design allows users to

wider inner tube diameters, producing lower pressure drops and higher capacities.

quickly assemble the probe and attach it

The FCB330 and FCB350 are designed for applications in the oil and gas, chemical,

to a threaded connection. The device has

power, and food and beverage industries. The meter features an optimised sensor

been designed with no brittle parts and is

with high zero point and temperature stability. A sturdy design and advanced DSP

always top-mounted or in a bypass cage.

technology allow detection of low flow signals and minimise the effects of pipeline vibration and interference. The meter is self-draining so no measuring media residues can remain inside. An easy-to-use, three-button menu and text display reduce installation and training time, and the display indicates mass or volume flow rate, percent maximum flow, flow rates in bar graph form, temperature, density and forward or reverse totalisation.

The meters support pipe sizes from DN15 to DN150, and the devices are available as an integral mount design with internal transmitter and as a remote mount design with external transmitter.

Approvals include FDA/3A/EHEDG for hygienic applications. Currently, these devices are available with ATEX or FM hazardous area approvals, with IECEx pending.

ABB Australia Pty Ltd Contact info and more items like this at wf.net.au/Q172

It is suitable for applications that do not require a high level of accuracy and is an alternative to traditional level controls such as RF capacitance, conductive and DP transmitters.

The 1100C is available with an integrated display and keypad in the cover so that it is necessary to open the housing cover for configuration, and a blind version is also available. Multiple blind versions on a site can be configured using a single HMI service tool. Its performance is not influenced by sludge in the bottom of a tank, nor by dust, foam, vapour, agitated

TEMPERATURE TRANSMITTER Acromag’s Model ST133 temperature transmitter is an isolated thermocouple/millivolt signal conditioner. This high-performance version of the economy-level ST132 also converts sensor input signals from eight thermocouple types or a ±100 mV range and outputs a proportional 4-20 mA process control signal, but with the addition of 1500 V isolation between the input and output circuits to shield equipment from high-voltage surges and transient signals. Units support mounting in DIN Form B sensor heads or on a DIN rail.

They are CE compliant with pending UL/cUL Class 1 Div 2 Zone 2 approvals and operate reliably over a -40 to 80°C operating range.

Many applications require high isolation to combat and reject the effects of large common-mode voltages, electrical noise, surges and system ground loops.

The ST133 bridges the gap between economy units and more expensive

or boiling surfaces, changes in pressure and temperature or changes in dielectric constant and density.

The transmitter offers good repeatable signal for storage of general liquids and solids, buffer tanks, sludge and condensate collectors and more simple process applications.

Krohne Australia Contact info and more items like this at wf.net.au/Q491

26 WHAT'S NEW IN PROCESS TECHNOLOGY - AUGUST 2012

high-performance isolated transmitters.

Other features include signal linearisation and cold-junction compensation functions, with response times as low as 30 ms. Windows software helps quickly configure the transmitter using a USB cable connection.

A rugged design helps these transmitters operate reliably in harsh industrial environments. Ambient temperature drift is less than 75 ppm/°C for longterm stability. The ST133 is shock (50g) and vibration (5g) resistant and includes high-level electrical noise immunity (RFI, EMI, ESD, EFT and surge protection).

Metromatics Pty Ltd Contact info and more items like this at wf.net.au/N230

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Six of 500+ panels we built in 2011

Competence, capability, quality This picture shows six of the 500+ panels Bürkert Australia built in 2011.

Our Sydney Systemhaus is ISO 9001 certified for the ‘development, assembly and distribution of customised system solutions,’ making Bürkert the ideal partner for large and small scope projects. In addition to standard panels, we engineer custom panels with pneumatics, I/O, transmitters and programming designed to meet your wider control system needs.

Call on Bürkert to build your 2012 panels.

www.burkert.com.au | 1300 888 868 www.burkert.co.nz | 0800 BURKERT (0800 287 537)

We make ideas flow

NEW PRODUCTS

MULTIPURPOSE FILLER A multipurpose filler introduced by Flexicon, dispenses bulk solid materials into boxes, drums and bulk bags, by weight. The unit features a fill head that seals dust-tight against the inlet spout of bulk bags, or connects to transition adapters that seal against open boxes or drums.

The filler is mounted on load cells tied into a PLC that controls upstream devices to fill containers at high rate, and then at trickle-feed rate to maximise the number of containers filled per hour, while still achieving required accuracies. An automated vibratory system raises and vibrates the container

SAFETY I/O Rockwell Automation have upgraded their allen-Bradley Guard I/O safety I/O range. Guard I/O provides all the advantages of traditional distributed I/O for safety systems. It reduces wiring costs and startup time for machines and cells, as compared to in-chassis I/O. Guard I/O can be used with any safety controller that communicates on DeviceNet or EtherNet/IP networks. Several Guard I/O block variants are available, providing a variety of features for both in-cabinet and on-machine mounting.

deck to deaerate and densify material, stabilising the container. The low-profile configuration of the filler also allows removal of filled containers using a pallet jack, eliminating the need for a fork truck.

Bulk bag filling-related features include manual fill head height adjustment to accommodate all popular bag sizes, pneumatically retractable bag hooks, an inflatable connector to seal the bag inlet spout, and a feed chute outlet port for dust-free

Rockwell Automation Australia

air displacement during filling.

Contact info and more items like this at wf.net.au/N992

A transition hood is connected to the fill head using quick-action clamps, to fill boxes from 915 to 1220 mm on a side and 990 to 1117 mm overall height.

HD37 SERIES PORTABLE LOGGERS FOR °C,Rh, CO, CO2

■ Two versions cover relative humidity, environmental temperature, carbon dioxide & carbon monoxide measurement ■ 20,000 reading memory ■ Sampling interval from 3 secs to 1 min ■ 8 hours continuous operation from internal rechargeable batteries ■ Downloadable via USB port with software provided For filling of drums from 114 to 208 L, a pneumatically actuated, telescoping drum-filling adapter swivels inward for rapid connection to the fill head using quick-action clamps, after which an inlet plate is sealed against the rim of the drum.

Flexicon Corporation (Australia) Pty Limited Contact info and more items like this at wf.net.au/Q408

28 WHAT'S NEW IN PROCESS TECHNOLOGY - AUGUST 2012

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Optimal planning of solar power plants

In the future, large PV plants such as the Siemens solar farm that went into operation in 2011 in Les Mées, France, can be planned quickly and efficiently using the PVplanet software solution. (© Siemens AG) The share of renewable energies in the overall energy mix is rising rapidly worldwide. With three-figure growth rates, photovoltaics (PV) play a major role.

According to market research organisations, the PV market grew by 139% in the year 2010. Germany is among the world‘s leaders in this technology that uses solar cells to convert sunlight straight into electrical energy. Yet the task of planning largescale PV power plants spanning several square kilometres is a complex one. With customer specifications, regulations and government subsidy programs to consider, designers must also account for numerous other factors including weather, climate, topography and location. These factors, in turn, influence the selection and placement of the individual components - which include the PV arrays with their solar modules, inverters and wiring, not to mention access roads.

Until now, engineers have designed solar power plants using CAD programs, with every layout and every variation

painstakingly generated separately. This is a very time-consuming approach. To improve a planned power plant in terms of certain criteria or to compare different concepts with one another, oftentimes the entire planning process has to be repeated.

In the future, this approach will be improved considerably: researchers at the Fraunhofer Institute for Industrial Mathematics ITWM in Kaiserslautern, in collaboration with Siemens Energy Photovoltaics, have developed new planning software that makes it possible to build solar power plants better and more quickly.

“Our algorithms programmed exclusively for the Siemens PVplanet (PV Plant Engineering Toolbox) software provide engineers with several hundred different plant designs in a single operation. It takes less than a minute of computation time,” ITWM researcher Dr Ingmar Schüle points out.

The only user inputs are parameters such as the topography of the construction site and the module and inverter types that will

30 WHAT'S NEW IN PROCESS TECHNOLOGY - AUGUST 2012

be used. The user can also change a number of parameters - such as the orientation, spacing and inclination of the solar arrays - to study the impact on the quality of the planning result.

To evaluate the designed PV power plants, an income calculation is performed that includes a simulation of the weather in the region in question, the course of the sun throughout the year and the physical module performance including shading effects.

With the results of this computation and an estimate of the investment and operating costs, the planning tool can come up with a figure for the LCOE (levelised cost of energy). By comparing the plant with a large number of similar configurations, the planners can investigate the sensitivity of the various parameters to find the right solution from a large array of options.

“The software assists the expert with decision-making and helps with the design of the best possible PV power plant for the site involved. Which one is best depends on a number of aspects - from the customer’s objectives to the site and environmental conditions, but also on the financing concept and the financial incentives for photovoltaics in the target region. All of these criteria are taken into account,” Schüle points out.

Dr Martin Bischoff, Project Manager at Siemens AG, Energy Sector, is also convinced of this approach: “Aside from savings, more than anything else the planning tool provides an overview of the scope for optimisation. This provides the best possible support for planning the most cost-efficient systems. There has been no other planning software with this scope or level of detail until now.”

The software was recently premiered publicly by ITWM and Siemens Energy Photovoltaics at the Intersolar Europe trade fair in Munich in June.

Fraunhofer-Gesellschaft www.fraunhofer.de

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High performance for harsh environments.

The EtherCAT Box in IP 67 protection.

www.beckhoff.com.au/EtherCAT-Box Universal EtherCAT performance into the IP 67 world Extremely compact and robust I/O modules Outstanding performance through EtherCAT EtherCAT communication up to each device, without subsystems Flexible topology, simple conďŹ guration eXtreme Fast Control (XFC) in IP 67 IPC I/O Motion Automation

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NEW PRODUCTS

REDUNDANT I/O PLATFORM Rockwell Automation’s Allen-Bradley 1715 redundant I/O platform requires no user programming code or add-on instructions, special wiring or additional hardware to operate. It supports multiple configurations and applications in standard and harsh environments.

Rockwell claims the 1715 I/O lets users put redundancy where it is needed. It offers simplex (non-redundant) or duplex (redundant) module operations. Modules offer native device intelligence so that they can monitor their own health with internal diagnostics. The modules perform multiple samples of a single signal using different criteria to alert users to issues such as open and short circuits, unexpected rate of change and thresholds.

In addition, the 1715 platform includes redundant ethernet adapters, which may be used to provide greater fault-tolerant capabilities.

Rockwell Automation Australia Contact info and more items like this at wf.net.au/Q193

INTRINSICALLY SAFE FIELD DISPLAY Michell Instruments’ MIC0005-IS intrinsically safe field display provides a cost-effective, easy-to-install solution where a local display is required directly in hazardous areas.

Primarily intended to act as a monitor for a locally-installed intrinsically safe dewpoint transmitter - such as the Easidew TX I.S. or Easidew PRO I.S. - the loop-powered display is certified by ATEX, FM and IECEx for use in hazardous areas and has an IP66 rating. It also complements Michell’s Liquidew I.S. and Promet I.S. process analysers for moisture measurements in process gases and liquids, as it can be installed either as part of the sampling system or in a convenient position nearby.

The monitor may be configured to display measurements in ppmV (for moisture in gases), ppmW (for moisture in liquids), as well as dewpoint in °C or °F. The easy-to-read, 4-digit LCD gives scope for showing wide ranges and high resolutions. A range of optional extras is also available, including a loop-powered backlight to allow easy reading in low light conditions, a keypad for re-ranging and also a tag-plate to aid identification.

AMS Instrumentation & Calibration Pty Ltd Contact info and more items like this at wf.net.au/Q164

34 WHAT'S NEW IN PROCESS TECHNOLOGY - AUGUST 2012

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BRIDGING THE INTRINSICALLY SAFE FIELDBUS DISCONNECT

At first glance, the concept of intrinsically safe (IS) fieldbus is a study in opposing concepts.

After all, fieldbus is about powering multiple devices, while the idea of IS is to limit energy flowing into hazardous areas.

T

he fact that multiple devices can be powered from the same wire pair only adds to the design challenges that engineers face when developing their own systems. Typically, this can lead to complex installation schemes as users mix wiring methods such as Zones 0, 1 and 2 (Division 1 and Division 2) in order to accomplish their task.

The ideal solution allows users to connect multiple devices (for Profibus PA or FOUNDATION fieldbus H1 networks) without compromising area requirements or using expensive installation methods.

Until recently, this was a pipe dream. But recent breakthroughs in design have brought together many of the best features of different IS techniques. Specifically, the use of the ‘High Powered IS Trunk’ concept greatly simplifies the installation and footprint for intrinsically safe segments.

The sections below provide an overview of the existing technologies and methods that fieldbus users have at their disposal when they embark on designing and installing fieldbus in hazardous areas.

These sections assume that there is a general understanding of fieldbus segment topology and design.

36 WHAT'S NEW IN PROCESS TECHNOLOGY - AUGUST 2012

Entity Before discussing the latest wave of intrinsically safe fieldbus methods, it is important to cover the traditional methods of dealing with intrinsically safe wiring for fieldbus. Initial designs for fieldbus used barriers that had been successfully used in the 4-20 mA world. These barriers use an infallible resistor (wirewound), Zener diodes and a fuse, and require a good intrinsically safe ground. While this barrier limited energy sufficient for Zone 0/1 all Gas Groups (Class I Div 1 all Gas Groups), it only provided 80 mA for the fieldbus segment (see Figure 1).

This optimistically could only power four fieldbus devices which typically take 15-26 mA each. The Entity barrier concept is safe, but its low power limitations and engineering requirements effectively eliminate many of the benefits of using bus technology.

FISCO In response to the lack of bus power, several alternative designs were developed to simplify the process and allow more use of the fieldbus technology. One of the most popular is the Fieldbus Intrin-

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Fieldbus

(and allow more devices per segment) than the Entity barrier solution.Up to 110 mA can be generated for Zone 1 Group IIC (Class I, Div 1, Group A and B) applications and up to 250 mA generated for Zone 1 Group IIB and IIA (Class I, Div 1, Group C and D) applications.

However, FISCO power supplies also have their limitations. Not using infallible components and the use of multiple current limiting designs restricts the power conditioner to Zone 1. Furthermore, the complexity of FISCO designs typically means a decrease in mean time between failures (MTBF) versus traditional fieldbus power conditioners.

While it does provide more power than the Entity barrier approach, a 110 mA Zone 0/1, Group IIC (Class I, Div 1 Group A and B) system can only support four to five devices per segment using the FOUNDATION fieldbus method for segment load current (ie, Segment Load Current = sum of device loads + device coupler + short circuit for one device + one handheld tester). This is still well short of the eight to 12 devices per segment typically required by most users. It can also be a very expensive system to implement when using repeaters and additional field-based barriers for Zone 0 devices and non-FISCO (Entity) devices.

High Power Trunk using field barriers

sically Safe Concept (FISCO), which was first developed by PTB (Physikalisch-Technische Bundesanstalt, the national metrological institute of Germany) as a method to provide higher power to a fieldbus segment in hazardous settings.

A more recent enhancement for intrinsically safe applications is the High Power Trunk (HPT) with field-based field barriers (FBs), which limits power at the spur rather than the trunk (see Figure 3).

Since the trunk is not IS, it and the field barriers must be installed in Zone 1 or Class I, Div 2 (Ex e wiring). Spurs can be intrinsically safe and can be connected to a combination of Entity or FISCO devices located in either Zone 0/1 or 2 (Division 1 or 2) areas.

This method significantly changes the equation for end users of fieldbus in hazardous settings. It increases the amount of available power and therefore the number of connected devices on a segment. It also lets end users maximise the length of their trunk cables without the restrictions of FISCO. While the HPT model does provide some significant improvements, it is not without its downsides. The field barrier is in essence a

The FISCO concept considers the entire circuit of the fieldbus segment. This solution requires that each part of the system, including devices, cables and power conditioners, is FISCO certified and that FISCO design and installation rules are strictly followed (IEC60079-27).

For instance, the maximum total cable length in a FISCO system is 1 km in Gas Groups A and B (IIC) and 1.9 km in Gas Groups C and D (IIA and IIB), while the maximum allowed spur length is 60 metres for Gas Groups A through D (IIC, IIB and IIA). Additional constraints are also placed on the power conditioners. For example, load-sharing redundant power conditioners are not allowed in a FISCO power supply. Certifying devices to a standard before implementation allows them to be integrated into systems without the engineering requirements necessitated by the Entity approach.

This then allows FISCO power supplies to generate more power

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Figure 1: The Entity barrier is a safe but low-power concept that eliminates many of the advantages inherent in fieldbus technology.

AUGUST 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 37

Fieldbus

Figure 2: FISCO provides more power than Entity barriers, but still lacks the ability to support eight to 12 devices per segment in Gas Groups AB and IIC.

Figure 3: Utilising a High Power Trunk with field barriers increases the amount of power and number of connected devices available for fieldbus applications in intrinsically safe settings.

SAFE

HAZARDOUS Zones 0, 1 & 2 IIB, Groups C & D

Control System I.S. Isolator

350 mA

Ex ia

1900m

Trunk

Device Coupler

Ex ia I.S.

Spur

I.S.

Zones 0, 1, 2 IIC, Groups A, B, C & D

field-based isolated power conditioner. So even though the segment can be powered by load-sharing redundant power conditioners at the host, the practical MTBF is still that of a single power conditioner, since most field barriers are not redundant. Also, the field barrier must have at least 16 V to operate, so the minimum or threshold voltage is no longer 9 V at the device, but 16 V minimum at the field barrier. Furthermore, the field barrier itself is complex since the conversion from non-IS to IS must take place in the field barrier, which is in the field enclosure. Since the enclosure uses both intrinsically safe and non-intrinsically safe wiring methods, it can confuse field technicians and unfamiliar contractors.

High Power Intrinsically Safe Trunk The HPT concept solves some problems associated with Entity and FISCO solutions, but it is far from perfect. There is one additional option in the evolution of hazardous area fieldbus installations that involves something tried and true and something new. The High Power IS Trunk (HPIST) technique provides an enhanced level of safety and simplicity in installation, along with the ability to use it for all devices (FISCO and Entity) and hazardous Zones and Divisions.

An example of this is the Route-Master Fieldbus System from MooreHawke, which delivers 350 mA of IS power to segments located in hazardous areas.

The first question many ask is: how do you get 350 mA into a hazardous area? The Route-Master does this by utilising a splitarchitecture design that puts part of the barrier in an isolator card located in the safe area (power supply rack), with the other part in each of the spurs of field-mounted device couplers (see Figure 4). The barrier in the isolator allows 350 mA to be run into IIB, Groups C and D. The additional barrier in each spur is sufficient for IIC Groups A, B, C and D. Since infallible resistors are used, devices from Zone 0/1 or 2 can be direct connected. Having 350 mA now allows end users to power up to 16 fieldbus devices (20 mA each) at 500 m while retaining intrinsic safety for hydrogenrich areas at the individual spur connections.

38 WHAT'S NEW IN PROCESS TECHNOLOGY - AUGUST 2012

Figure 4: The High Power Intrinsically Safe Trunk concept delivers 350 mA of IS power into hazardous areas for use with FISCO and Entity devices.

This is a major improvement over the number of devices that can be connected via Entity barrier and FISCO systems, while allowing connections for all devices (FISCO and Entity) in all hazardous area Zones and Gas Groups. Since the field enclosure now contains only a relatively simple IS 12-way device coupler, the size and complexity of the field enclosure is greatly reduced.

The HPIST does use an Entity-based power supply, so Entity calculations are required to confirm the design does not exceed area Entity requirements. However, because of the split architecture design (part of the safety barrier in the isolator card and part in the spur of the field mounted device coupler), these calculations only need to be done once for the longest trunk and spur (if not FISCO), and will cover the entire plant installation.

Conclusion The increasing implementation of fieldbus shows that end users are realising its value beyond the cost savings associated with having reduced and simplified wiring. Now they are using it in intrinsically safe areas where fieldbus applications were once considered to be impractical. It is apparent that the High Power Intrinsically Safe Trunk concept allows plenty of power for fieldbus installations and still retains all of the intended live working and safety features of intrinsic safety, generally regarded as the safest of all Ex protection techniques.

Moore Industries Pacific Inc Contact info and more items like this at wf.net.au/N901

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NEW PRODUCTS

CHILLED MIRROR HYGROMETER The Michell S8000 RS chilled mirror hygrometer has been designed to provide fundamental, depend-

REDUNDANT NETWORK ACCESS POINT Siemens has expanded its range of industrial network products with a fault-tolerant system solution for smooth and delay-free redundancy in industrial ethernet networks.

able measurements in a range of industrial applications where highest precision of dry gas measurement is critical and the ease of use is essential. It is capable of measuring dry dewpoints precisely to -90°C (0.1 ppmv) at 0.1°C accuracy with no need for additional, external cooling equipment.

Chilled mirror hygrometers have accuracy and repeatability because they base their measurements on the formation of condensed water or frost on a mirror surface. This is a primary characteristic of moisture so will not drift over time, as can occur with calculated or inferred variables.

The S8000 RS has an optical system that detects very small changes in moisture condensed on the mirror surface and is available with UKAS and NIST accreditation.

With a high-contrast LCD touch screen, the S8000 RS is easy to operate and interrogate. USB or ethernet connections are supplied as standard to enable remote operation and data logging via a PC or network.

The robust overall design and practical features such as alarms make the S8000 RS reference hygrometer a multipurpose tool for a wide range of applications in an industrial environment as well as for calibration facilities.

AMS Instrumentation & Calibration Pty Ltd Contact info and more items like this at wf.net.au/Q163

The Scalance X-200RNA (Redundant Network Access) network access points have been designed for all applications and sectors in

DIGITAL CALIBRATION PRESSURE GAUGE

which a network connection with particularly

The Series DCGII digital calibration pressure gauge offers a

high fault tolerance is required. In addition to

precise 0.05% full-scale accuracy and large 5-digit display

the Scalance hardware, Siemens also offers the

resolution, and can be used in critical industrial applica-

Softnet-IE RNA software package with which

tions where precision is most important. It requires one

PCs can be connected to parallel networks.

9 V battery or power adapter and can operate up

Typical areas of application for fault-tolerant

to 5000 working hours.

redundant connections can be found in the

The Series DCGII can display percent of

energy sector as well as in process automa-

range, pressure swings or alarm set points.

tion; for example, in the pharmaceutical or

The gauge comes with 11 selectable pressure

chemical industries.

units, backlight and zeroing capability.

Siemens offers the access points as Sca-

It also features a temperature indication

lance X204RNA in a plastic enclosure with

and a stainless steel ½″ male NPT connection.

four RJ45 ports as well as Scalance X204RNA

Applications include field gauge calibration,

EEC (Enhanced Environmental Conditions)

permanent installation, burst disc testing, torque

in a metal enclosure with two ports and

data logging, pressure regulator testing and hydro-

two electric/optical combined ports for SFP (small form-factor pluggable) transceivers and wide-range power supplies. Various types of management and diagnostic information is

static leak testing.

Dwyer Instruments (Aust) Pty Ltd Contact info and more items like this at wf.net.au/Q160

available via SNMP. Siemens Ltd Contact info and more items like this at wf.net.au/Q187

40 WHAT'S NEW IN PROCESS TECHNOLOGY - AUGUST 2012

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NEW PRODUCTS

LASER SENSORS The Telemecanique OsiSense XUE laser sensors are designed for applications that require long-range detection. The sensors also offer enhanced accuracy over distance and long-distance background suppression. This includes measuring position in automation applications such as precise robot control, coil diameter monitoring, error proofing, overhead cranes and anticollision systems.

The OsiSense XUE laser

LOW-TEMPERATURE DRY BLOCK CALIBRATOR

sensors include flexible opti-

The Isotech Isis dry block cali-

cal systems including diffuse

brator from Zedflo offers operation to

and reflex measurement for

temperatures as low as -100째C. It is now possible to calibrate temperature

enhanced accuracy, repeat-

sensors such as RTDs, thermocouples and thermistors at ultra-low tem-

ability and long detection

peratures without the need for a liquid bath.

range. Diffuse measurement

Unlike liquid baths, the Isis requires no costly or hazardous fluids and

of over 6 m on white objects

offers much greater portability and flexibility. This will be of particular value

with background suppres-

to calibration engineers working on site with low-temperature freezers,

sion are possible, and up to

as encountered in pharmaceutical, aeronautical and food environments.

30 m with a reflector for the

The minimum operating temperature is lower than stirred liquid calibration baths and users in laboratories can also benefit by avoiding the ongoing

reflex model.

Multiple programmable outputs provide extended flexibility through two configurable discrete NO or NC outputs (PNP)

need (and costs) for expensive fluids.

The maximum operating temperature is 40째C, a little higher than the minimum operating temperature of Isotech hot blocks. This permits covering

and a 4-20 mA analog output.

OsiSense XUE sesnors use visible red Class 2 lasers, which

temperature ranges from -100 to 650째C or higher with two Isotech blocks.

allow for a more rapid alignment between the sensor and object

The Isis has a large insert, at 35 mm diameter by 160 mm deep, allow-

being detected. In normal operating mode, the sensor switches

ing for calibration of multiple sensors. For thermal validation applications,

to the low-risk Class 1 mode for maximum operator safety.

there is also an insert with pockets for a reference probe (6.5 mm) and

Schneider Electric (Australia) Pty Ltd

20 3.5 mm pockets for thermocouples. This allows a single calibration cycle to validate up to 20 probes at a time.

Contact info and more items like this at wf.net.au/N909

Zedflo Australia Contact info and more items like this at wf.net.au/Q659

Is your

Emission Monitoring System saving you money and fully compliant with EPA requirements?

Leading technology for emission monitoring and process control Tel: 07 3255 5158

Fax: 07 3255 5159

info@groupinstrumentation.com.au

42 WHAT'S NEW IN PROCESS TECHNOLOGY - AUGUST 2012

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NEW PRODUCTS

SMALL INDUSTRIAL ROBOT The IRB120T is a variant of the IRB120 robot. While keeping its compact, agile and lightweight features, the 6-axis variant delivers a substantial increase in

HIGH-VOLUME TANK CELL Outotec has launched TankCell e500, with a 500 m3 float capacity. Larger float cells mean lower greater efficiency - on an average rougher/scavenger duty, for example, all things being equal, six 500 m3 cells would need only 75-80% of the installed power

the maximum speeds of axis 4, 5 and 6, resulting in cycle time improvements of up to 25%.

This agile and fast robot also offers a repeatability of 0.01 mm. It can also be mounted

of ten 300 m3 cells or little more than half the installed power of thirty 100 m 3 units.

at any angle, either in a cell, on

Advances in flotation technology have

top of a machine or close to

contributed to developments in the large

other robots on the manu-

float cell category, with the TankCell e500

facturing line. Its faster

incorporating features such as forced-air

speed improves its suit-

technology. This feature offers the flex-

ability for pick-and-place

ibility to decouple air addition and mix-

applications, particularly in

ing to avoid sanding, provides separate

the food and beverage and

areas within the FloatForce mechanism for pumping and air dispersion, and delivers more efficient pumping even at highest air-feed rate, delivering maximum performance with low power draw.

The TankCell e500 also has a direct gearbox drive, so there is no belt/pulley arrangement or external motor cooling system, and mixing is driven by a standard 4-pole motor. This results in a smaller drive footprint, simplified maintenance, and greater reliability with a purpose-designed gearbox.

packaging industries. There are also benefits for assembly applications for electrical and electronics and automotive parts manufacturers.

The robot comes with the ABB IRC5 compact control, including superior path motion, user-friendly FlexPendant programming, RobotStudio offline programming, flexible RAPID language and powerful communication capabilities.

ABB Australia Pty Ltd

Outotec Pty Ltd

Contact info and more items like this at wf.net.au/Q403

Contact info and more items like this at wf.net.au/Q658

Global Support. Local Address.

Peace of Mind. And We Mean it.

By leveraging our global infrastructure of support centres and subject matter experts, we’re here to help you protect your automation investment.

Beyond providing you peace of mind, as we help you keep your plant running, we’ll assess your entire operation and recommend the right mix of services to help maximise productivity, optimise plant assets and improve your overall financial performance.

Visit: www.RockwellAutomation.com.au

ServSupport_WNIPT-Half-Page_August-2012.indd 1

44 WHAT'S NEW IN PROCESS TECHNOLOGY - AUGUST 2012

10-Jul-12 10:28:51 AM

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NEW PRODUCTS

SUBSTATION ETHERNET SWITCH The Moxa PowerTrans PT-7528 is a 28-port rackmount switch with 24 fixed 10/100BaseTx RJ45 copper ports. With IEC 61850-3 and IEEE 1613 certifications, modular design and high copper port density, the switch is suitable for station-level deployments in power substations.

To offer higher deployment flexibility, the PT-7528 works with PM-7500 series modules, which allow users to add up to four fibre ports that are dedicated to upstream or backbone connectivity, and are popular for bay-level communication. In addition, IEC 61850-3 and IEEE 1613 standards’ compliance combines with Layer 3 management, giving the PT-7528 the environmental endurance and network capabilities needed for power substation applications.

The PT-7528 features Moxa’s Turbo Ring and Turbo Chain (recovery time < 20 ms @ 250 switches), RSTP/STP and MSTP for network redundancy. It also supports priority-tagged frames to be received by specific IEDs. Isolated redundant power inputs are provided, with a universal 24/48 VDC or 110/220 VDC/VAC power supply range. The operating temperature range of the PT-7528 is -40 to 85°C. Madison Technologies Contact info and more items like this at wf.net.au/Q500

PORTABLE LOOP CALIBRATOR WITH HART The LC-110H from Martel Electronics is a loop calibrator that includes true HART communications technology.

It supports Universal and Common Practice commands that let the user read, display and store the full configuration data of any HART device, adjust the upper range and lower range values of any HART device, and perform full analog output trim and instrument zero.

By using the optional BetaLOG HART software, the previously stored HART configuration data can be uploaded as well as up to 9800 data points from any HART device including the 4 PV values and the analog output.

The LC-110H offers enough power for everyday HART loop calibration in a portable tool without the complexities of a more expensive and less portable HART communicator or calibrator.

Zedflo Australia Contact info and more items like this at wf.net.au/Q405

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AUGUST 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 45

Dematic’s smart robot wins SCLAA awards for Nestlé

Selecting a Dematic robotic layer picking system proved to be a wise choice for Nestlé Australia.

It received three logistics awards for its Arndell Park national distribution centre (DC), which uses a Dematic system. Another Dematic user, The Just Group, was presented with the SCLAA’s Information Management Award for implementing Dematic’s RapidStocktake stocktaking solution.

The 2011 Australian Supply Chain and Logistics Awards were presented by the Supply Chain and Logistics Association of Australia (SCLAA) in Perth. Nestlé picked up three awards: the Supply Chain Management Award, the Australian Storage and Handling of Materials Award and the Australian Manufacturing Logistics Award.

Nestlé’s DC is used to store and distribute several

hundred Nestlé products, with about 80% of the orders distributed as full pallets. The remaining 20% of orders are distributed in pallet layer and full-case quantities, which had previously required manual handling of around five million cases each year. Installing the Dematic system has improved this OHS challenge, handling four million of these cases.

The Dematic four-axis robotic layer picker has a dual bellows and vacuum-gripping head that is capable of handling almost 80% of the Nestlé product range, from cartons to bags to bottled beverages.

Orders from Nestlé’s SAP warehouse management system are downloaded into Dematic’s PickDirector warehouse control system. Interfacing with Dematic’s FreePick

46 WHAT'S NEW IN PROCESS TECHNOLOGY - AUGUST 2012

Maximiser software, PickDirector orders the stock required for layer picking in the sequence required to fulfil the next wave of orders.

When new pallets of stock enter the system, the layer picker selects the required layers and transfers the stock to one of four pallets for customer orders. The system’s software allocates remaining stock to other orders or to storage bays to be combined with later orders.

Orders are check weighed, stretch wrapped and labelled as they are conveyed through the system. Any orders that need individual case picks are completed using the DC’s voice picking system.

Dematic’s FreePick Maximiser software enables the system to achieve high throughput rates. The software enables 20-50% of goods to be distributed without needing to be physically picked by crossmatching orders and pairing them with compatible order profiles.

Dematic’s products have also helped award winner The Just Group make its twice-yearly stocktake more efficient. The RapidStocktake solution is a Bluetooth-enabled system that has meant considerable time and cost savings for the retail group, which previously had to close its stores for a full day of trade when stocktaking.

The group includes outlets such as Just Jeans, Portmans, Peter Alexander and Jay Jays.

Other high-profile awards included the Australian Training, Education and Development Award, won by the University of Wollongong’s Sydney Business School, and the Environmental Excellence Award, presented to the Waste Contractors and Recyclers Association of Queensland (WCRAQ). Rick Ralph received the Australian Industry Excellence Award and Amy Vassallo took home the 2011 Australian Future Leaders Award.

Dematic Pty Ltd Contact info and more items like this at wf.net.au/Q655

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NEW PRODUCTS

CUSTOMISED HIGH-TORQUE COUPLINGS AUTOMATED PRESSURE CALIBRATOR

Customised high torque CD couplings up to 50 cm in diameter handling 78,000 Nm peak torque are now available from Zero-Max. Available to system designers seeking the

The ConST 811 auto-

most robust coupling for extremely large and challenging

mated pressure cali-

applications, these ‘super-sized’ couplings combine highest

brator, from Zedflo,

torsional stiffness and high load capacity.

is a compact, light-

With torsional stiffness of 419,000 Nm/deg and continuous

weight pressure calibrator that

torque of 39,000 Nm, these CD couplings have angular

can generate from 90% vacuum to +25 bar (375 psi)

misalignment capacity of 1.5° with axial misalignment of 6.5 mm and parallel misalignment of 0.24 mm.

Designed around a composite centre disk, super-sized CD couplings perform at these peak torques in the most hostile operating environments - from extreme cold to hot

using its integral high-performance pump.

The easy-to-use calibrator can automatically provide the required pressure with a control stability of 0.005% FS and accuracy of 0.02% FS. The unit has a large easy-to-read display with 7″ colour screen and an icondriven menu structure for device-under-test and task selection.

weather conditions (-57 to +121°C). Applications include

Hart communications is supported and 24 VDC loop power is provided, as

drive trains, gear boxes and generators providing trouble-free

well as reading the current or voltage of the pressure transmitter or transducer

operation in seawater and abrasive desert sand conditions.

under test. With optional external pressure sensors, the calibrator can measure

The hub material is 1045 HR steel with fasteners made

pressures up to 700 bar (10,000 psi), with 0.025% accuracy.

of titanium 6AL4V grade 5 materials. All components

The ConST 811 has a rechargeable battery that supports eight hours of op-

are tested with finite element analysis (FEA) software for

eration between charges, an internal memory that can store up to 120 tasks,

predictable characteristics.

and full documenting facilities.

Naismith Engineering & Manufacturing Co Pty Ltd

Zedflo Australia

Contact info and more items like this at wf.net.au/Q630

Contact info and more items like this at wf.net.au/Q661

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AUGUST 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 47

NEW PRODUCTS

REMOTE RELAY CONTROL SWITCH The CCM-1422 Remote Relay Controller from Western Telematic is designed to provide secure reliable control of remote relays on high-current devices. The controller can open, close, reboot or default relays on high-current devices, on demand, in response to alarm conditions or according to a user-defined schedule. CCM-1422 units feature four switched relays, plus a switched IEC C13 AC outlet which also includes current-metering capabilities.

ANDROID MOBILE FIELD ASSISTANT

authentication features plus HTTPS communication and

IEI Technology’s Icecare Mobile Field

SSHv2 encryption to protect relay-switching commands

Assistant 7″ tablet PC comes with a

and configuration functions from unauthorised access.

TI Sitara ARM Cortex processor and

Supported authentication protocols include LDAP, Kerberos,

The controller supports a broad array of security and

Android 2.3.4 OS. The tablet PC is

TACACS+ and RADIUS. The CCM-1422 also features an IP

integrated with a selection of wireless communication technologies such as

address feature to block access by unfamiliar IPs, plus a

WCDMA/HSDPA, Wi-Fi 802.11b/g/n and Bluetooth 2.1 to keep mobile workers

unique callback security feature for dial-up communication.

connected with the back office. In addition, the built-in GPS antenna provides

In addition to providing on-demand switching control

access to location-based services, tracking and navigation applications.

for dry contact relays, the device can also automatically

The tablet PC comes with front and rear-facing CMOS cameras, a 13.56

open, close, default or reboot relays in response to user-

MHz RFID reader and a 1D laser/2D imager scan engine, which provides dif-

configurable temperature alarms, ping response monitors,

ferent data-collection methods that help to eliminate risks of human error. To

invalid access alarms and power-supply instability alarms.

better fulfil the needs of extensive operation time, the device is designed to manage power efficiently with two hot-swappable battery packs that provide 11.1V 1880 mAh capacity.

In order to meet the demands of tough outdoor environments, the tablet PC has been approved for its semi ruggedness. It is dust tight and protected against water splashed against the component from any direction, with an IP rating of 64. The device can be operated under temperature -10 - 40°C, can be stored under temperature -10 - 60°C and has passed the 1.2 m drop test on all sides 26 times.

The switched AC outlet can measure current and

The tablet PC allows field workers to capture and record, track and locate,

power consumption using true RMS current metering,

access and update information in real time, which can increase field service

and can also be used to reboot or switch an additional

productivity and efficiency.

AC powered device.

ICP Electronics Australia Pty Ltd

Interworld Electronics & Computer Industries

Contact info and more items like this at wf.net.au/Q632

Contact info and more items like this at wf.net.au/Q640

48 WHAT'S NEW IN PROCESS TECHNOLOGY - AUGUST 2012

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NEW PRODUCTS

GIGABIT POE SWITCH The Moxa EDS-G205A-4PoE switches are 5-port, unmanaged full-gigabit ethernet switches supporting Power-over-Ethernet on ports 2 to 5.

The switches are classified as power source equipment (PSE) and, when used in this way, the switches enable centralisation of the power supply, providing up to 30 W of power per port and reducing the effort needed for installing power. The switches can be used to power IEEE 802.3af/at standard devices (PD), eliminating the need for additional wiring, and they support IEEE 802.3/802.3u/802.3x with 10/100/1000M, full/half-duplex, MDI/MDI-X auto-sensing to provide an economical high-

STAINLESS STEEL FIELDBUS JUNCTION BOX

bandwidth solution for industrial ethernet networks.

Madison Technologies Contact info and more items like this at wf.net.au/Q382

Turck has introduced a stainless steel version of the company’s junction boxes, featuring FM approval for Class 1, Division 2, Groups A, B, C and D hazardous locations and rated IP67.

The junction box features a cast 316 stainless steel housing to resist corrosion in salt-spray environments, including chloride corrosion, to ensure continuous connectivity operation. Designed for use on offshore drilling platforms and other ocean-bound equipment, the company’s stainless steel junction boxes can be mounted directly on the machine in hazardous environments, with no enclosure required. Further, to ensure the device meets industry specifications, the junction box receptacles are also stainless steel and rated IP67 as long as the ports are covered or connected.

The stainless steel junction boxes are available in six and eight port models, and can be utilised with M12 and 7/8″ connector sizes.

They can also be used with the company’s minifast connectors.

Stainless steel junction boxes are designed to house existing circuit boards and receptacle housings.

These junction boxes simplify the connection of multiple field devices for Profibus-PA and Foundation fieldbus networks.

Turck Australia Pty Ltd Contact info and more items like this at wf.net.au/Q109

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AUGUST 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 49

NEW PRODUCTS

OIL-IN-WATER MONITOR

SAFETY GATE SWITCH INTERLOCKS Fortress Interlocks amGard is

The Sigrist OilGuard provides online

a range of modular safety gate

continuous monitoring of water for

switch interlocks for heavy-duty

traces of mineral oils, using the

applications. A modular con-

fluorescence principle. It can be

struction allows easy configura-

used to monitor any water type,

tion for safeguarding applications

including process, waste, raw and

up to SIL3 (EN/IEC 62061) Cat-

potable water. Oil in water detection

egory 4 and PLe (13849-1). Now

is often essential to meet licence

Fortress Interlocks has further

conditions and to protect equipment.

developed its amGard range of

The product offers virtually main-

heavy-duty safety gate switch

tenance-free operation by using a

interlocks to create amGard Pro.

non-contact flow cell and a dual UV

amGard Pro builds on the

beam. These features eliminate sig-

modularity and robust design of the existing amGard range. Added fea-

nal drift, as commonly experienced

tures include forward and backward compatibility, stainless steel heads,

with other types of monitors, and

emergency release options, antivibration parts and non-contact technology.

compensate for any UV light intensity

The Pro range integrates modern technology to deliver updated control

degradation. The non-contact flow

functionality but still offers the option for traditional lockout retrofitting,

cell means no regular cleaning is required and ensures long-

creating a variety of new configurations. amGard Pro has been tested

term stable operation. The product is also available in an IECEX

to withstand up to 10 kN retention force.

certified hazardous area version.

B-R Controls Pty Ltd

Fortress Systems Pty Ltd Contact info and more items like this at wf.net.au/Q476

Contact info and more items like this at wf.net.au/Q712

50 WHAT'S NEW IN PROCESS TECHNOLOGY - AUGUST 2012

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NEW PRODUCTS

MECHANICAL DESIGN SOFTWARE MathWorks has announced an updated version of SimMechanics that enables users to create realistic parts and geometry by leveraging MATLAB. SimMechanics automatically creates a 3D animation during simulation that can be replayed without re-running the simulation.

Engineers can re-use their custom parts and mechanisms in new designs, thus shortening the modelling process.

With SimMechanics, engineers in industries such as aerospace and defence, automotive, and industrial automation and machinery can model 3D mechanical systems in a Simulink block diagram using bodies, joints, constraints and force elements. SimMechanics models can connect to Simscape and other Simulink products for physical modelling, such as SimElectronics and SimHydraulics.

This helps engineers to detect integration issues between electrical, mechanical and control systems early in the development process before any physical hardware is built.

Additional key features include: rigid body definition using standard geometry and custom extrusions defined in MATLAB for quickly prototyping mechanical parts; automatic calculation of mass and inertia tensors for ensuring accurate models; visualisation and animation of multibody system dynamics with 3D geometry for rapid analysis of simulation results; the ability to enter exact and approximate state targets for simplifying the specification of the initial state; block diagram representation for clearly documenting connections to other parts; and Simulink libraries for sharing and re-use of parts and mechanisms.

MathWorks Australia Contact info and more items like this at wf.net.au/Q384

CONNECTOR RANGE Turck’s powerfast connectivity products are designed to replace expensive, time-consuming hardwiring methods, and to provide a robust and reliable modular wiring solution. A full line of cordsets, receptacles, reducers, reducer tees, field wireables, rotary disconnect switches and powerlock devices provides users with the ability to configure a custom power-distribution system. powerfast connectivity components are UL approved and available in A-Size (7/8″), D-Size (1-3/8″), M16, M23 and M40 and are rated for up to 40 A for a wide range of operation. Offering easy installation and customisation, the powerfast system delivers flexible design capabilities, quick modifications and expandability options.

The products can be used in multiple devices, including motors, lights, heaters and other electrical devices, and are suitable for applications such as conveying, machine building, food and beverage processing, sorting machines, and packaging and palletising.

Turck Australia Pty Ltd Contact info and more items like this at wf.net.au/Q383

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AUGUST 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 51

© iStockphoto.com/Trout55

A BREATH OF CLEAN, FRESH AIR FOR INDUSTRY

Compressed air

The cleanliness and quality of compressed air used in many industrial processes is vital to prevent contamination of the end product in food and pharmaceutical manufacturing, and to provide safe operation of specialised equipment in hazardous environments.

C

ompressed air is an important and major part of most manufacturing and industrial processes. Knowing the proper air-quality level required for effective and efficient operation of equipment or a manufacturing process is an important factor in containing compressed-air energy and other operating costs. Higher-quality air is more expensive to produce and requires additional air treatment equipment, which increases capital costs as well as energy consumption and maintenance needs.

The degree of dryness and filtration of compressed air required for a process and the minimum acceptable contaminant level of any finished product should determine the quality of air required.

One of the main factors in determining air quality is whether oil-free air is required. If only a single process requires this type of air, it may be supplied by a dedicated oil-free compressor or by the necessary filtration equipment at the point of use. If the end uses in a plant require different levels of air quality, it may be advisable to divide the plant into different sections so that airtreatment equipment that produces higher-quality air is dedicated to the end uses that require the higher level of compressed-air purification.

In order to prevent contamination of the end product and possible harm to patients, the cleanliness and quality of the compressed-air supply is vital to eliminating the risk of rejections and/or health risks associated with oil contamination.

Using clean and pure compressed air

Sources of contamination

For the taste of it Food and beverage manufacturers use compressed air to push food stuffs, such as powders and cereals, through pipes and it often has direct contact with the product during processing. It may also be used to cool down baked goods, clean bottles or spray produce. In some applications, compressed air supplies oxygen to bacteria for fermentation or is pumped into liquids to raise dissolved oxygen levels. The cleanliness and quality of compressed air used in food and beverage processing is therefore vital to prevent contamination of the end product and potential harm to the health of consumers.

Food product recalls and food safety concerns are increasingly influencing consumer shopping behaviour. A recent study found that such concerns prompted 38% of consumers surveyed to stop purchasing certain foods. Compressed air is often identified as a potential source of contamination. While the majority of consumers acknowledge that they have some level of responsibility for ensuring the products they consume are safe, a growing number of consumers ultimately hold the manufacturers accountable.

Improved product purity Compressed air is used in a variety of manufacturing processes in the pharmaceutical industry. It is frequently used to de-dust tablets or spray on pill coatings. Compressed air is used to maintain overpressurisation in mixing and holding tanks to ensure product integrity. It may also have direct contact with the product or packaging during dosing and filling, or when the application demands aseptic air. Pharmaceutical industry regulations state that "each manufacturer shall establish and maintain procedures to prevent contamination of equipment or product by substances that could reasonably be expected to have an adverse effect on product quality".

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Safe operation in hazardous areas Oil and gas production and handling can be dangerous processes in which health and safety are paramount. Compressed air is nonflammable so it can be used in hazardous environments and be used in a multitude of applications in these industries. Whether used for breathing air or operating manufacturing equipment used in many processes, compressed air is the first choice for safety.

Compressed air is used in a vortex tube for cooling processes and to drive air-operated pumps as an alternative to electrically driven pumps which could spark and cause an explosion.

Compressed air is also used in a variety of cleaning processes such as reverse air jet purging of filters or as the propellant for the cleaning 'pig' when clearing the inside of pipelines. Portable compressed-air systems can be used for the internal de-scaling of mobile oil and gas tanks or as a stand-by backup for a site's stationary compressors.

The three primary contaminants of a compressed-air system are airborne particulates, water and oil. It is possible for a single drop of unwanted oil to cause an entire automated process to malfunction by causing seals to swell which may result in complete seizure of moving parts. Other contaminants that may impact production processes include solid particles such as dust and rust; condensed water droplets from ambient humidity, and liquid oil and oil vapours.

Solid contaminants can wear out compressor machinery, cause motors to jam and block valves and vent orifices. Airborne particulates will cause pneumatic equipment to malfunction, failure of instruments and control systems, and contamination of end products.

These events increase the cost of running the compressors by increasing the maintenance required to clean and repair components.

Water, both liquid and vapour, will oxidise pipework and pneumatic equipment, ruin paint finishes and can potentially make the products being manufactured unable to be sold. Oil-based vapour and liquid can have similar effects on machinery and end products.

In addition to the cost of increased maintenance and loss of manufactured product, sudden equipment stoppages are expensive in terms of loss of product and time to repair and restart a production line.

Setting the standard The International Organization for Standardization (ISO) developed the compressed-air quality standard - ISO 8573 - in 1992. The standard was designed to provide plant engineers and equipment suppliers with an internationally known and accepted unit of measure. The standard defines a series of 'quality classes' relating to the concentration of solid particulates, water vapour and oil in output of an air compressor.

AUGUST 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 53

Compressed air

THE THREE PRIMARY CONTAMINANTS OF A COMPRESSEDAIR SYSTEM ARE AIRBORNE PARTICULATES, WATER AND OIL. IT IS POSSIBLE FOR A SINGLE DROP OF UNWANTED OIL TO CAUSE AN ENTIRE AUTOMATED PROCESS TO MALFUNCTION BY CAUSING SEALS TO SWELL WHICH MAY RESULT IN COMPLETE SEIZURE OF MOVING PARTS.

For example, ISO 8573-1:2010 Class 1.2.1 specifies a particular air quality. The last three digits in the designation - in this case 1.2.1 - relate to the purity classifications selected for solid particulates (1), water (2) and total oil contamination (1). The designation begins with the name of the standard document and its revision number.

Class 1 for solids means that in each cubic metre of compressed air, not more than 20,000 particles in the 0.1 - 0.5 micron size range, 400 particles in the 0.5 - 1 micron size range and 10 particles in the 1 - 5 micron size range are permitted. The 2 classification for water indicates that there must be a pressure dewpoint (PDP) of -40째C or better and that no liquid water is allowed in the output air. The third digit, 1 in the example, indicates that the total level for liquid oil, oil aerosol and oil vapour must not exceed more than 0.01 mg of oil in each cubic metre of compressed air.

Class 0 is the most stringent air-quality classification, strictly limiting oil contamination in liquid, aerosol and vapour forms. This classification requires agreed and measurable contamination levels that are included as part of a written specification for a compressor. Air for critical applications such as breathing or medical and food production may still require additional purification equipment in both the compressor room and at the point of use depending on the nature of the air being drawn into the compressor.

Oil-free compression Rotary-screw compressors use two meshed rotating helical screws to force the gas into a smaller volume and are usually used for continuous operation in commercial and industrial applications.

This type of compressor can have engine sizes from 2.2 kW to more than 890 kW and from low pressure to moderately high pressure more than 8.3 MPa. The gas compression process of a rotary screw is a continuous sweeping motion, which minimises pulsation or surging of the discharge flow.

In an oil-free version, the air is compressed entirely through the action of the rotary screws, without the assistance of an oil seal.

These units often have lower maximum discharge pressure, but multistage oil-free compressors - where the air is compressed by several sets of screws - can achieve greater pressures and output volumes of more than 50 cubic metres per minute.

Oil-free compressors are used in applications where oil contamination is not acceptable, such as medical research and semiconductor manufacturing. Some form of additional filtration is often required as contaminants can be drawn in from the ambient air

54 WHAT'S NEW IN PROCESS TECHNOLOGY - AUGUST 2012

and must be removed prior to where the compressed air is used.

Oil-free rotary-screw and reciprocating compressors usually have higher initial costs, lower efficiency and higher maintenance costs than their lubricated counterparts. However, the additional separation, filtration and drying equipment required by oil-injected compressors will generally cause some reduction in system efficiency, particularly if the system is not properly maintained.

By providing pure air, free from additional contaminants, these compressors minimise downtime associated with cleaning filters and other air system components. Oil-free technology increases productivity and ensures higher overall product quality.

Summary Class 0 compressed air ensures higher product purity and process integrity, minimising the risk of oil contamination being transferred directly to a product being manufactured or interfering with the operation of equipment.

By selecting certified oil-free compressors, food and beverage manufacturers, pharmaceutical companies and process operators can enjoy the peace of mind that comes with knowing their critical air supply is completely free of compressor-created contaminants.

CAPS Australia Pty Ltd Contact info and more items like this at wf.net.au/L839

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NEW PRODUCTS

MOBILE BULK BAG DISCHARGER Flexiconâ&#x20AC;&#x2122;s latest mobile half-frame bulk bag unloader with multipurpose hopper allows material to be discharged from bulk bags, manually tipped from sacks, and conveyed to downstream processes and storage vessels dust free. For in-plant mobility, the system minimises weight and achieves a low centre of gravity by eliminating upper frame components, relying instead on the userâ&#x20AC;&#x2122;s forklift or plant hoist to suspend the bag above the unit during operation.

The bulk-bag-to-hopper interface consists of a Spout-Lock clamp ring positioned atop a Tele-Tube telescoping tube, allowing dust-tight connections and unrestricted flow between the bag spout and hopper, as well as automatic tensioning of the bag as it empties to promote flow and evacuation. The telescoping tube raises the clamp ring assembly that seals the clean side of the bag spout to the clean side of the telescoping tube and then lowers until the bag spout is pulled taut. Once the spout is untied, the telescoping assembly exerts continual downward tension on the spout, elongating the bag as it empties.

An integral Bag-Vac dust collector creates negative pressure within the dust-tight system to collapse empty bags prior to retying and disconnection, eliminating dust emitted during manual flattening of empty bags. Flow-Flexer bag activators raise and lower opposite bottom edges of the bag at timed intervals, loosening compacted materials and promoting material flow into the bag discharge spout.

For manual tipping the operator raises a hinged bag-dump support shelf and a hinged hopper door, and pours material through a coarse screen into the hopper.

Flexicon Corporation (Australia) Pty Limited Contact info and more items like this at wf.net.au/N896

EtherNet/IP ENABLING BOTH AUTOMATION AND SAFETY CONTROL ON STANDARD, UNMODIFIED ETHERNET. Integrate the safety in your plant using the same unmodified Ethernet network you use for information sharing and automation control. By integrating automation and safety control on the same network, you could lower life-cycle costs, streamline work processes and protect equipment and employees. Rockwell Automation and its partner, Cisco, have been driving these developments so that you can take standard, unmodified Ethernet and do extraordinary things.

See something extraordinary at: www.apac.rockwellautomation.com/ethernetip/WNIPTAUS

EIP_wnipt_half-pg_aug12.indd 1

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02-Jul-12 2:20:57 PM

AUGUST 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 55

NEW PRODUCTS

PANEL PC The Avalue LPC-1203 touch panel PC is powered by an Intel Atom N270 processor, which reduces the power usage and saves operation costs. The decrease of thermal energy makes the computer a high safety and green product under a fanless condition. The LPC-1203 comes with a 12â&#x20AC;ł touch-panel LED backlight screen that supports resolution up to 1024 x 768.

Using the modular system-on-module design concept, the LPC-1203 supports diversified performance levels such as COMe/ETX CPU modules and lower scalable baseboard. It also allows the user to group the boards according to individual needs. Its modular design makes this computer price-competitive for users to choose system requirements freely and upgrade it anytime, extending the product life.

Featuring an IP65 rating, the entire LPC-1203 is waterproof, including front panel, rear data transmission connectors and power sources. The setting of the front side power button is covered by a waterproof membrane for easy use. Furthermore, the computer combines a rear side heat-dissipation aluminium case and unique I/O connectors to reach a higher level of dust/waterproofing than other panel PCs, and enhances the convenience and safety for extreme environment applications.

Backplane Systems Technology Pty Ltd Contact info and more items like this at wf.net.au/N718

REMOTE ACCESS FOR MOBILE DEVICES Secomea has announced a new mobile software application for allowing secure and remote access to industrial equipment. The solution consists of a control unit at the factory (SiteManager) and a web- or Windows-based client (LinkManager) for an end user. These two components are tied together via an M2M communication server (GateManager) that is available as both a cloud-based service and a stand-alone server.

Where the original LinkManager is intended for remote programming from a Windows PC, the LinkManager Mobile is designed for accessing web-enabled applications such as a custom web GUI of a PLC, an HMI or a webcam. Further, LinkManager Mobile can establish connection to the desktop of equipment running Linux or Windows. Using VNC or an MS Remote Desktop client allows secure remote control of the unit.

LinkManager Mobile can run on an iPhone, iPad or Android smartphones and tablets.

The system is suitable for end users that need to remotely access equipment for monitoring status or perform typical operator tasks. LinkManager Mobile supports two-factor authentication login and encrypts all connections, thus ensuring high security.

Daanet Pty Ltd Contact info and more items like this at wf.net.au/Q628

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NEW PRODUCTS

I/O SERVER The Acromag IOS-7400 industrial I/O server has built-in carrier cards which interface up to four plug-in I/O modules to the CPU. The embedded computer supports video, audio, ethernet, serial and USB devices.

CABLE AND HOSE CARRIER

A wide variety of I/O modules provide mix-and-match flexibility, high channel density and a clean cable interface.

The I/O Server's fanless design employs advanced thermal technol-

The TKA55 cable and hose carrier

ogy and high-performance components to accommodate a wide operating

from Tsubaki Kabelschlepp was

temperature range of -30 to 75째C. Conduction cooling plates and thermal pads

developed specifically for use in

wick internal heat away to the aluminium enclosure where external cooling fins

environments with heavy contami-

dissipate the heat. The IOS-7400 PC has an Intel Atom N270 1.6 GHz CPU processor. PC Interfaces include

nation from chips and dirt. The all-

VGA, for up to 2048 x 1536 display, speaker out and microphone in. DRAM is 1 GB DDR533, with a 2.5"

round closed structure effectively

16 GB solid-state drive (SSD) option. There is also a Compact Flash card slot, two serial ports (1 x RS232

prevents the intrusion of foreign

and 1 x RS232/422/485), two 10/100Base-T ethernet ports (switched) and four USB ports 2.0 ports. More than

bodies into the cable space, and

20 I/O modules are available for a wide variety of analog, digital and serial I/O functions and the unit has UL/

allows for reliable protection right

cUL Class 1, Division 2, Groups A,B,C,D or non-hazardous location only approvals.

up to the connection area.

An optimised sideband and a cover contour with minimised gap

Metromatics Pty Ltd Contact info and more items like this at wf.net.au/N991

dimensions effectively prevents functional faults caused by chips and dirt entering into or sticking to the cable carrier. The compact cover design fits seamlessly into one another and reaches over the sidebands to form a compact, closed unit. They offer secure hold, even under severe mechanical stresses such as when used with hydraulic lines. The smooth, dirtrepellent contour of the sidebands with their encapsulated stroke system prevents the intrusion of any foreign bodies. The covers can be opened and removed easily on the inside or outside to load the cable carriers. The interior of the TKA55

SOLUTION BASED...

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can be modularly partitioned with various divider solutions for even cable distribution.

The optimised geometry of the chain links and a triple encapsulated stroke system allows the TKA55 to span extensive unsupported sections. The integrated gliding surfaces make the cable carrier a suitable solution for long travel lengths. Integrated noise damping ensures that the cable carrier runs silently and with low vibration at all times. The TKA55

555

93 7

closed cable carrier is available

95 T 03

in six interior widths between 50 and 175 mm.

Tsubaki Australia Pty Ltd Contact info and more items like this at wf.net.au/Q276

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CALL US!

OR VISIT OUR WEBSITE!

www.ieci.com.au

AUGUST 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 57

NEW PRODUCTS

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

RING LUG SCREW TERMINAL BLOCKS The RSC Series ring lug

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screw terminal blocks

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with a screw connection from

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Phoenix Contact include terminal blocks with

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with a rated current of 57 A, as well as 35 mm2 with a rated current

rated cross-sections of 4 mm2 with a rated current of 32 A, 10 mm2 of 125 A. Blocks are easy to form in direct mounting using engagement pins. The threaded nuts and current bars are also locked in the insulation housing. The rated voltage of 800 V according to IEC and 600 V according to UL make the terminal blocks safe solutions for applications worldwide.

The measuring transducer disconnect terminal blocks in the RSC 5 series are designed for a rated cross-section of 10 mm2 with a maximum current of 50 A. They are permissible for a rated voltage of

A^c`BVcV\Zg

800 V according to IEC and 600 V according to UL. The separating plate can be moved via a screw in order to prevent unintentional switching. All models have a central screw bridging channel for distributing potential. There is a comprehensive range of acces-

<ViZBVcV\Zg

sories available for the RSC terminal block range. Fixed bridges are mounted in the bridging channel to distribute potential. Isolator bridge and switch bars for switchable cross connections between the individual terminal blocks are available, as are separating plates for separating neighbouring bridges. Separating plates can be inserted to avoid division losses, which is particularly important in tight spaces.

Phoenix Contact Pty Ltd

H^iZBVcV\Zg

Contact info and more items like this at wf.net.au/N815

ENERGY AND POWER METERS Schneider Electric has released the iEM3000, EM3500 and PM3200 series, three-phase, DIN rail-mounted energy and power meters designed for energy re-

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

porting, bill validation and cost allocation applications. Designed to be simple, reliable and efficient to use, the iEM3000, EM3500, PM3200 series makes energy efficiency more accessible for tertiary and industrial buildings.

The iEM3000 offers both direct connect and CT-connected meters, basic meters for manual reading, pulse outputs for water, air, gas, electricity, steam (WAGES) applications, and multitariff meters with digital inputs, digital outputs and communications, so users can divide consumption over four periods to help discriminate peak and off-peak consumptions, workdays and weekends, or different

,i«ÀiÃi Ìi`Ê >Ì > Þ]ÊV> Ê £ÎääÊ /Ê­£ÎääÊÎÓÓÊÈÎn®Êv ÀÊÞ ÕÀÊ V> Ê-iV i>Ê` ÃÌÀ LÕÌ À° `>> iÌ°V °>ÕÉÃiV i>

energy sources (such as utility versus generator).

The iEM3000, EM3500 and PM3200 series meters share numerous design features that help save time, cost and space for panel builders.

Schneider Electric Australia Pty Limited Contact info and more items like this at wf.net.au/Q643

58 WHAT'S NEW IN PROCESS TECHNOLOGY - AUGUST 2012

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NEW PRODUCTS

IS DIGITAL MULTIMETER The Fluke 28 II Ex DMM is a rugged, intrinsically safe, digital multimeter.

The 28 II Ex meets intrinsic safety (IS) standards worldwide, including ATEX, IEC Ex, ETL and GOST for safe use inside potentially explosive environments, making it suitable for use in petroleum, chemical and pharmaceutical facilities.

It is drop-proof up to 3 m with a totally sealed, IP67-rated case for complete protection against dust and water, and can withstand hazardous 8 kV spikes caused by load switching and faults on industrial circuits.

The 28 II Ex features a high-resolution 20,000 count display and true

ANALOG SERVO DRIVES

RMS AC voltage and current measurement. It measures up to 1000 V

Elmo’s analog servo drives, the Dragonfly, Butterfly, Robin, Condor,

and 10 A AC and DC, and its low pass filter ensures accurate voltage

Canary and Raven, use a low-voltage DC input and are built to military

and frequency measurements on variable speed motor drives. The built-in

standards for extreme environmental conditions including, but not

thermometer function measures temperature from -200 to 1090°C, reducing

limited to, vibration, temperature and altitude.

the number of tools that need to be carried.

They are current mode pulse width modulated servo amplifiers

Backlit keypad buttons, large display digits and a two-level bright white

for brush and brushless motors. The ExtrIQ analog amplifiers are

background for visibility make it easy to use even when wearing full per-

highly durable and capable of operating under extreme environmental

sonal protective equipment. The battery lasts up to 800 h and the separate

conditions.

battery compartment makes it easy to change batteries or fuses on the

Each amplifier series is claimed to exhibit high servo performance,

job without jeopardising the meter’s IS or IP ratings or sending the unit

efficiency, high quality and reliability. Elmo’s proprietary switching and

for servicing. The 28 II Ex comes complete with TL175 test leads, AC72

control methods are enabled by fully customised dedicated ICs and

alligator clips, red holster, 9 V battery (installed) and manuals. An optional

advanced heat transfer and dissipation. Elmo also has a range of

magnetic hanger is available for easy, hands-free set-up and viewing.

digital servo drives for the same extreme environments.

Fluke Australia Pty Ltd

Motion Technologies Pty Ltd

Contact info and more items like this at wf.net.au/Q095

Contact info and more items like this at wf.net.au/Q185

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AUGUST 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 59

PROCESS CONTROL | AUTOMATION | INSTRUMENTATION | SAFETY

Process Technology Regional Roadshow

2012 8

NOW IN ITS TH

YEAR

vend NEW or sess training ions

Western Australia

Coming soon ... to a city near you!

If you work in mining, minerals, metals processing, utilities, food and chemical manufacturing and processing then the Regional Roadshows are designed for you.

Don’t miss out ...

NEW TRAINING SESSIONS FOR 2012 • Tune a PID flow loop • Troubleshoot a simple TCP/IP industrial ethernet network using four simple utilities • Write, install and test a motor control PLC ladder logic program • Basics of Modbus data communications protocol installation and troubleshooting • Arc flash protection and protective safety equipment • Variable speed drives— testing and troubleshooting

Perth • 10 Sept Bunbury • 11 Sept Rockingham • 12 Sept Karratha • 14 Sept

Supported by:

Training by:

Exhibiting companies include:

Includes FREE: • Access to exhibition • Training sessions - NEW • Lunch and networking drinks • Product demonstrations • Prize draws

To register or for more info visit: www.regionalroadshows.com.au

NEW PRODUCTS

EXPANDED AC DRIVE RANGE Rockwell Automation has extended the power range of its Allen-Bradley PowerFlex 755 AC drives to 900 kW and added 600/690 V ratings. The new drives, designed for use in heavy industrial processes, provide users with increased flexibility, advanced diagnostics and a common DC bus option.

The PowerFlex 755 is designed for applications ranging from simple variable speed and variable torque control to demanding systems requiring constant torque control. Applications include fans, pumps, mixers, compressors, conveyors and extruders. Like other PowerFlex 755 drives, this latest frame size includes an embedded ethernet port and five option slots so that users can tailor it to their requirements. Optional modules include I/O feedback, safety, additional communications and an auxiliary power supply.

A rollout design allows easy access to the drive for fast installation and maintenance. The driveâ&#x20AC;&#x2122;s converter and control pod can remain in the unit while the inverter is rolled out, ensuring that control wiring remains connected.

In addition to the extended power range, a firmware upgrade for PowerFlex 755 drives will contain Interior Magnet Motor Control, which delivers increased application flexibility and high-energy efficiency. Also, a stop dwell feature helps prevent a motor from coasting to a stop; it allows users to preconfigure the motor to perform a controlled stop to help protect valuable motor investments.

Rockwell Automation Australia Contact info and more items like this at wf.net.au/Q092

ANALOG STEPPER DRIVES The ADW series stepper drives from RTA have an analog speed control input instead of traditional step and direction signals. They are designed for variable speed applications rather than position control and are suitable for small conveyors and feed-rate control in machines.

In small machines, stepper motors are claimed to have several advantages over variable-speed AC or DC motors and drives. Their size is smaller for the same torque and, in some cases, gearboxes can be eliminated. The speed is constant and does not fluctuate with applied mechanical load or supply voltage. Speed can be controlled down to very low speeds, approaching zero revolutions per second. Synchronising of multiple motors is possible and stepper motors will automatically act as a brake at zero speed.

Motor speed can be controlled by an external potentiometer, external variable analog voltage or internal adjustment on the drive.

Ramping of motor speed can be adjusted on the drive.

The ADW drives can run in four operation modes. In the Run mode, the motor start and stop are controlled by a single enable input. In the CW/CCW mode, the motor runs clockwise when one input is enabled and counterclockwise when another input is enabled. In the Start/Stop mode, the motor starts on the Start input signal and stops on the Stop signal input. In the Limit Switch mode, the motor will swing back and forward continuously, stopping and reversing when Fwd and Rev limit switches are hit.

Automated Motion Systems Pty Ltd Contact info and more items like this at wf.net.au/Q381

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AUGUST 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 61

AS I SEE IT IMPROVING MANUFACTURING COMPETITIVENESS WITH MODERN COMMUNICATION TECHNOLOGY

I

t often seems that the cards are stacked against Australian manufacturers and the industry in general. If we’re not facing a global financial crisis (followed by GFC 2.0), it’s a high Aussie dollar attacking export opportunities and expected increases in energy prices.

Although manufacturing in this country is doing it tough, we believe Australia can and should be one of the world’s industrial powerhouses. For instance, in Germany where the euro is high and labour rates are similar to those here, manufacturing remains very strong. The right mix of innovation, technology and collaboration has ensured the country’s global competitiveness.

We know that, in order to remain competitive from our corner of the world, Australian companies need to adopt these principles to increase their productivity. In other words, we all need to produce more for less, and reduce waste.

At Siemens, we see technology as playing a major part in helping businesses achieve their increased productivity goals.

We’ve witnessed companies implementing technologies to better manage their energy and water usage. Yet we still encounter manufacturers who have identified where savings can be made but haven’t set up any monitoring methods to ensure they are adhering to their strategies or getting the most out of their initiatives. Sometimes they tell us that the communications platform they have in their plant doesn’t allow them to easily add measurement or monitoring equipment, or that the infrastructure they have is proprietary and their supplier doesn’t have the equipment they need (or can provide it at a competitive price).

We feel that a lot of money (and angst) could be saved by using a common protocol - just the one bus cable to run an operation, such as either Profibus or Profinet.

The advantage we see with using an open ethernet standard like Profinet are the savings that companies can achieve by hanging all their instrumentation off the one cable - Profinet can support IT, SCADA, PLC

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level, distributed I/O, field instruments and even real-time motion control.

Profinet is independent of manufacturers so that means no lock-in contracts with suppliers and their proprietary systems that can add thousands of dollars, if not more, to the cost of equipment, upgrades and servicing.

To m e i t m a ke s s e n s e t o re d u c e infrastructure costs in the short term with a one-cable system. However, greater savings can be made in the longer term through access to a wider range of technologies that allow owners/operators to add, upgrade or replace devices that can outperform proprietary products and systems. It’s just good business sense.

Having a choice of an ever-increasing number of suppliers supporting Profinet will only sharpen competition and help keep prices in check - exactly what Australian companies need. Another advantage of communication systems like Profibus/ Profinet is that they have their own local support in Australia. Training is run by Profibus International throughout Australia, so practically any company can access it.

And with an updated standard (v2.3 Profinet for process automation) recently released, now is a good time to jump on board if you haven’t already done so.

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

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March 2012 total CAB audited circulation (Aust + NZ) 7,282 readers (89% personally requested)

Fa l k H o h m a n n i s Pr o d u c t Ma n a g e r, PLC and Networks for Siemens Australia, and has worked in the automation sector for over 17 years.

In that time he has been actively involved in the development of industrial communication standards, and has worked on several automation projects in Germany, USA, Malaysia and the Philippines for companies such as VW, Mercedes, BMW and Audi.

62 WHAT'S NEW IN PROCESS TECHNOLOGY - AUGUST 2012

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