What’s New in Process Technology May 2014 by Westwick-Farrow Media

May 2014 vol.27 no.11 PP100007403

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0514

ON THE COVER

WHAT'S NEW IN PROCESS TECHNOLOGY MAY 2014

CONTENTS

If a flowmeter’s electronics are functioning correctly within specific, traceable and tightly defined tolerances, then it follows that it will be functioning with high accuracy and maximum reliability - which is essential for

Monitoring cement kilns

measuring points relevant to quality. So how

Thermal imaging gives early warning of lining failure

do you verify that this is the case?

New Products

Hot Products online

Endress+Hauser’s Proline devices that, in

Self-verifying flowmeters

enables continuous diagnostics as well as

Modern technology improves instrument management

comprehensive meter performance verification

As I see it

The revolution is coming

Heartbeat Technology is a new function integrated into the latest generation of addition to their stable long-term measurement,

at the push of a button. This makes it possible to fulfil traceability requirements in the context of ISO 9001 without problems - where and when requested, without prolonged interruption to the measurement. In fact, verification takes on average a matter of minutes, if not seconds. There is no need to dismantle the device, and compliance testing is based on traceable references, while the transfer of inspection reports can be performed via a web server or asset management system. Endress+Hauser’s Heartbeat Technology allows for complete documentation of a measuring device’s performance, and provides evidence and clarity regarding the condition of safety-critical measuring points. Verification report results are automatically saved directly in the device memory. Heartbeat Verification allows users the freedom to perform meter verifications triggered either on-site or remotely, according

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to either regulatory or specified industry time frames - or at any interval of choice. www.au.endress.com

MONITORING CEMENT KILNS

THERMAL IMAGING GIVES EARLY WARNING OF LINING FAILURE

4 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2014

www.ProcessOnline.com.au

In cement production, the furnaces or kilns that are used for blending the raw materials are a critical asset, which are often at risk of overheating, which can cause serious damage to the kiln shell. It is therefore important to have an effective way of monitoring the heating process to prevent damage to these critical assets.

ement production is a complex process in which one of the steps consists of blending limestone - cement’s main ingredient - with other components in large rotary furnaces. These furnaces or kilns are a critical asset of a cement production plant, heating their contents to temperatures up to 1500°C. There is, however, a risk of overheating, which can cause serious damage to the kiln shell.

How cement is made To understand the importance of the rotary kiln in the cement production process and the use of thermal cameras for this process, let’s first take a look at the cement production process. Cement plants are usually located closely either to hot spots in their downstream market or to areas with sufficient quantities of raw materials. Basic constituents for cement (limestone and clay) are taken from quarries in these areas. The production of cement requires two main steps: first, clinker is produced from raw materials, and then cement is produced from cement clinker. The raw materials are delivered in bulk, crushed and homogenised into a mixture which is fed into a rotary kiln. This is an enormous rotating pipe 60 to 90 m long and up to 5 m in diameter. This huge kiln is heated by a flame inside the structure to a temperature of 1500°C. The kiln is slightly inclined to allow for the materials to slowly reach the other end, where it is quickly cooled to 100-200°C. Four basic oxides in the correct proportions make cement clinker: calcium oxide

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(65%), silicon oxide (20%), alumina oxide (10%) and iron oxide (5%). These elements mixed homogeneously when heated to over 1450°C will combine to form the product of this phase, called ‘clinker’. The resulting solid grains are then stored in silos. The second phase is handled in a cement grinding mill, which may be located in a different place to the clinker plant. Gypsum (calcium sulphates) and possibly additional cementitious or inert materials (limestone) are added to the clinker. All constituents are ground, leading to the fine and homogenous powder that we know of as cement.

The rotary kiln Inside the rotary kiln, there is a refractory lining which insulates the steel shell from the high temperatures inside the kiln and protects it from the corrosive properties of the process material. This lining consists of refractory bricks or cast refractory concrete and needs to be replaced on a regular basis whenever the lining gets worn. The lifetime of the refractory lining can be prolonged by maintaining a coating of the processed cement material on the refractory surface. The thickness of the lining is generally in the range 80 to 300 mm. A typical refractory layer will be capable of maintaining a temperature drop of 1000°C or more between its hot and cold faces. The shell temperature needs to be maintained below around 350°C in order to protect the outer steel from damage. This is where thermal imaging comes in. Using thermal imaging cameras, the kiln shell can be continuously monitored and when needed, early warnings of

MAY 2014 - WHAT'S NEW IN PROCESS TECHNOLOGY 5

Asset Management

Figure 1: A typical cement kiln.

‘hotspots’ indicative of refractory failure can be given.

Thermal imaging Thermal imaging is the use of cameras constructed with specialty sensors that ‘see’ thermal energy emitted from an object. Thermal, or infrared energy, is light that is not visible to the human eye because its wavelength is too long to be detected. It’s the part of the electromagnetic spectrum that we perceive as heat. Infrared allows us to see what our eyes cannot. Thermal imaging cameras produce images of invisible infrared or heat radiation. Based on temperature differences between objects, thermal imaging produces a clear image. It is an excellent tool for predictive maintenance, building inspections, research and development, and automation applications. It can see in total darkness, in the darkest of nights, through fog, in the far distance and through smoke.

Figure 2: Schematic representation of a rotary kiln.

easily leads to problems with the refractory material and can cause refractory bricks to fall off. As the protecting layer is then damaged and its thickness reduced, hot spots are formed inside the shell, which results in loss of energy and disturbed kiln operation. To protect the steel shell from damage, its temperature should remain below 350°C. This can, of course, easily be monitored with thermal imaging cameras.

A kiln monitoring system

The shell is critical for the operational performance of the kiln. Thermal imaging cameras can at least detect two different problems regarding this shell. Firstly, during operation, a ring of cement coating is piling up inside the shell on the refractory brick surface. On the one hand, this is beneficial, because it lowers the shell temperature, reducing heat losses and protecting the refractory material. On the other hand, furnace operators need to be aware that this coating doesn’t get too thick, because this will reduce the internal diameter and, as a result, reduce the furnace’s production performance. By detecting low temperatures on the kiln shell, thermal imaging cameras can make operators aware of this problem.

Two companies recently teamed up to develop the IRT KilnMonitor, a computer system that allows cement production operators to monitor, process and trace data from several kilns at once. The first company, INPROTEC IRT, is an official FLIR Systems distributor for Italy. Based in Milan (Italy), INPROTEC IRT has a wide expertise in high-tech equipment for industrial safety applications. The second company, Grayess (USA), specialises in the design, manufacture and marketing of special customised infrared thermal imaging solutions and software for a wide variety of applications. The IRT KilnMonitor system includes FLIR A-Series cameras, which monitor the kiln temperature in real time. In addition, it includes a kiln visualisation module (2D and 3D) and a thermographic analysis module. The system makes use of three A315 cameras each scanning one third of the 60 m long rotary kiln. These thermal video streams are distributed to a visualisation system inside the central control room and provide operators with a 24/7, real-time view of the kiln operation and performance. The kiln has a rotation time of around 30 seconds and the IRT KilnMonitor is synchronised to the rotation time to build up a thermal image.

Secondly, unstable cement coating or sudden detachment of coating material

Whenever the kiln shell reaches an undesired temperature, operators receive

Protecting the kiln shell

6 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2014

dedicated software alerts which allow them to take the appropriate remedial actions. For example, hot spots in the thermal image of the furnace can indicate that refractory bricks got detached from the refractory lining and that the protective kiln layer is getting less thick. This may require the furnace operators to reduce the temperature of the burner or even shut the system down in order to prevent severe damage and avoid excessive costs.

Accurate thermal views To give control room operators the best possible view of the situation, the IRT KilnMonitor generates several different viewing modes based on the information received from the thermal imaging cameras: • A three-dimensional view of the whole kiln, rotating in real time, and showing the temperature distribution along the kiln. • A three-dimensional view of the kiln interior at a cross-sectional ‘slice’, showing the refractory bricks and coating. • A kiln end view in section.

Thermal imaging cameras versus scanners Previous solutions for kiln monitoring have used thermal imaging scanners, rather than cameras. When scanners are used, then theoretically one scanner unit can suffice to monitor an entire 60 m rotary kiln. However, when using a scanner, the unit needs to be placed at a certain distance so ‘see’ the whole kiln, and the view of the kiln should not be obscured. In practice, this is not always possible. Thermal scanners can be quite bulky and are not very flexible in terms of installation. In many cases, a rotary kiln is installed inside a dedicated production hall, so taking into account that a thermal imaging scanner

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Asset Management

Figure 3: This view presents the kiln ‘pipe’ temperature on the surface as a thermal image. The kiln is rotating in real speed. has a maximum viewing angle of 120°, it is very often impossible to install a thermal scanner at sufficient distance from the rotary kiln and avoid obstacles that are blocking the view. For example, with many rotary kiln installations, there is a secondary air tube which directs hot air out of the rotary kiln to be used as an energy source. This secondary tube will often be an obstacle. In contrast, although multiple thermal imaging cameras will be needed to replace a single thermal scanner, they are much smaller, much lighter and much more flexible in terms of placement and installation. They are therefore the preferred solution for installations where space is limited. In the KilnMonitor system design, a FLIR A315 camera with a 90° lens is

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Figure 4: This viewing mode virtually cuts the kiln at some position and shows the kiln interior (bricks and coating).

used. In this case, three thermal imaging cameras cover the total pipe length of 60 metres, which is still lower in cost than one thermal imaging scanner. In addition, when comparing thermal cameras with thermal imaging scanners, the thermal imaging cameras offer the end customer a less expensive solution.

High resolution The FLIR A315 and A615 are compact and affordable thermal imaging cameras, fully controlled by a PC. With a thermal sensitivity of <50 mK, they can capture fine image details and temperature difference information. “We definitely need the high resolution,” said INPROTEC’s Roberto Ricca. “For an ideal installation, we often opt for

a 90° lens, because then you only need to use two or three cameras to cover the entire kiln length. For a German customer, we integrated the FLIR A315 with 90° lens and it delivered on the promise: very high image quality and very accurate detail.” Using the higher resolution of the FLIR A615 for future installations of the IRT Kilnmonitor system will provide even higher resolution. The FLIR A615 has a resolution of 640 x 480 pixels that allows more accuracy and shows more detail at a greater distance. Taking into account a rotary kiln of 60 metres length, it would provide an image where each pixel represents 10 cm of the pipe. FLIR Systems Australia Pty Ltd www.flir.com.au

MAY 2014 - WHAT'S NEW IN PROCESS TECHNOLOGY 7

NEW PRODUCTS

ULTRASONIC FLOWMETER FOR OIL AND GAS The USM GT400 ultrasonic flowmeter is designed to help reduce the amount of effort needed to maintain pipeline metering. It can be used to measure the volume of natural gas at every stage of its movement, storage and utilisation. Compliant with CEESmaRT technology - a secure, cloud-based solution for condition-based monitoring - the USM GT400 provides stability during flow perturbations due to its direct-path technology with six measuring paths on three levels. The paths are

PHOTOELECTRIC SENSOR

arrayed in an ‘X’ pattern in horizontal planes. This orientation enables measurement of swirl, crossflow

The DeltaPac photoelectric sensor from Sick enables objects to be reliably

and asymmetry, as well as transparent path velocity

detected in a gapless product flow.

weighting per the Gauss-Chebyshev profile model for

The system uses the company’s Delta-S Technology: two energy scales

compressible fluids.

each with two receivers and four PinPoint2.0 LEDs combined with Sick’s specific ASIC technology SIRIC and integrated distance measurement. DeltaPac’s principle of operation makes use of edge contours of objects. The edges cause the reflective behaviour of the packaging surface to change in the gapless transition from one object to another. This changed direction of reflectivity is used for the output of switching signals. According to the company, object contours with radii between 1 and 20 mm are reliably identified by the system, and its high-precision evaluation characteristic ensures that small changes in angles are reliably detected. The company claims it is possible to reliably identify up to 20,000 pieces/h with conveyor speeds of up to 3 m/s. The system is able to detect objects aligned in a push-push configuration. Machine elements for packaging buffering and separation mechanisms are no longer required when using the DeltaPac, which can improve space utilisation. Product flow is stabilised because collisions due to falling packaging are

The USM’s electronics are used to handle path-

reduced. Machine downtime, incorrect loading when grouping items and

specific measurements while optimising internal

loss of quality due to crashes can be avoided by using the system, the

diagnostics. It includes speed of sound (SoS) and

company claims.

flow velocity calculations, signal processing and

The system is easy to operate. A sensor version with IO-Link is available,

data storage capabilities, and can interface to flow

allowing configuration of the sensor according to application conditions.

computers, gas chromatographs and SCADA systems.

Sick Pty Ltd

The meter’s transducer - which operates at standard

www.sick.com.au

frequencies of 120 or 200 kHz, and alternative frequencies are available for noisy environments - consists of piezoelectric crystals fully encapsulated in titanium housing for resistance to dirt. This configuration is field-replaceable under pressure. Regulator noise has marginal impact on the flowmeter’s measurements, due to Honeywell’s proprietary, MID-approved detection algorithm, coupled with the unique transducer design. This combination extends signal amplitude for a high signal-to-noise ratio (SNR) versus traditional intrinsically safe transducers. Additionally, Honeywell’s Precision Adjustment maintains the measurement accuracy of the meter at all times. Honeywell Limited www.honeywell.com

8 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2014

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NEW PRODUCTS

THERMAL IMAGING CAMERA The lightweight Flir T390, with a range of -20 to 1200°C, is suitable for almost any thermal imaging application. The Flir T390’s high-temperature infrared camera can be used for electrical surveys, building diagnostics and mechanical inspections. It is available to rent. With an improved refresh rate (50 Hz PAL) and laser locator, the Flir T390 is suitable for inspecting moving targets. A 3.5″ colour touch screen, auto and manual focus, target illuminator and voice/text annotation all make for a user-friendly IR camera. The T390 is also equipped with a 3.1 MP visual light camera to complement the 320 x 240 thermal images. It also features

3G SECURITY ROUTERS

picture-in-picture overlay, panoramic image stitching,

Industrial telecommunication products

automated periodic frame capture options with intervals

are key components within remote

from 10 s to 24 h and a USB connection allowing for

control and maintenance solutions.

16-bit radiometric infrared image streaming to a PC.

Internet and VPN based solutions

TechRentals

therefore replace modem dial-up

www.techrentals.com.au

connections and pose new challenges for products: the transmission of large amounts of data, high transmission speeds and protection against unauthorised access must

LOADING CONTROLLER

also be guaranteed.

Honeywell Enraf has released the Fusion4 MSC-L, a multistream controller for

The mGuard security routers from

loading products from refineries and chemical plants into transports such as

Phoenix Contact with integrated mo-

railcars, tankers and barges.

bile phone network interface make

Claimed to be highly accurate, scalable and

industrial communication over mobile

versatile, Fusion4 MSC-L offers a an intuitive

phone networks more secure, through

device interface to enable every installation,

integrated security technologies such

operation and maintenance function to be

as VPN and a built-in firewall. Ameri-

controlled in the field using a large display

can CDMA mobile phone networks

and integrated keyboard that works as

are also now supported in addition

a complete hazardous area operating

to UMTS/HASPA.

station. The controller can operate up to

The products have a robust metal

six loading arms simultaneously, providing

housing, two SIM card slots and a

safe, reliable control for road loading, as

GPS receiver, and support 2 or 10

well as tank farm transfers and marine and

VPN tunnels, depending on the model.

rail-terminal operations.

In addition, the new devices offer

Based on mobile phone and tablet computing

an integrated 4-port switch - either

‘apps’, on-screen icons make it more intuitive to use,

managed or unmanaged, depend-

cutting training times and reducing the risk of human error. Combined

ing on model. SD memory cards

with the installed keyboard, it offers simple, secure and fully functional control

are supported and can function as

of the loading system from the unit itself.

a replaceable configuration memory

The hazardous area, explosion-proof design of the MSC-L allows live data

for fast start-up and easy device

transfer in hazardous areas, with safe, secure two-way data communication,

replacement.

using the handheld Fusion4 LAD (local access device) for rapid transfer of

Phoenix Contact Pty Ltd

transaction data, configuration files and calibration records. It also offers user

www.phoenixcontact.com.au

configurable and expandable I/Os, and has a start-up time of under one minute, with calibration wizards and zero downtime upgrades. Honeywell Limited www.honeywell.com

10 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2014

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No order is too small and we offer industry-standard packaging ready for production.

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*See website for Terms & Conditions.

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HOT PRODUCTS

ON WWW.PROCESSONLINE.COM.AU THIS MONTH ULTRASONIC LEVEL TRANSMITTER

The non-contact Hawk MiniWave is a cost-effective, loop-powered

PRESSURE TRANSMITTER

ultrasonic level transmitter designed for reliable, continuous measurement of liquids up to 8 m.

The WIKA UPT-20 is a

Hawk Measurement Systems Pty Ltd http://bit.ly/1sqlFzt

HART pressure transmitter featuring HART 7 firmware and a large LCD 4Â˝-digit WIKA Australia http://bit.ly/1mTyMbl

14 mm display.

DUAL SENSOR MAGMETER

The FPI-X Dual Sensor electromagnetic flow meter is designed to deliver accurate and repeatable measurement under extreme flow conditions, said to be unachievable with other technologies. AMS Instrumentation & Calibration Pty Ltd http://bit.ly/1oFtj9X

VOLUME FLOW SENSOR The Bulkscan LMS511 uses time-of-flight technology for non-contact measurement of volume flow on conveyor belts.

Sick Pty Ltd http://bit.ly/1e3UYwr

VISUALISATION APP

The Visu+ mobile visualisation app brings system visualisation to smartphones or tablets. Phoenix Contact Pty Ltd http://bit.ly/1kPtvgN

12 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2014

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CASE STUDY

Harnessing the power of a tornado in a tank

It does not always follow that the more complicated the technology and the more advanced the system, the better the outcome. A smart mixing technology called swirl flow, developed by CSIRO and Queensland Alumina, greatly simplifies the mixing of solids in suspension in mineral processing. It works by creating a novel fluid flow pattern within large-scale tanks that mimics a tornado. Suspension mixing is usually achieved using massive impellers attached to long shafts, at times 20 metres or more in length, resulting in the mixing equipment being heavy, unwieldy and costly. The mixing is not entirely efficient using this approach and the equipment can be costly to maintain. Dr John Farrow, CSIRO’s commercial manager of swirl flow, says its unique mixing offers many advantages over traditional mixing systems. “Swirl flow uses a radial agitator located just below the liquid’s surface to create a tornado-like flow pattern. The tornado effect extends all the way from the bottom of the tank, sometimes 30 metres or more, to lift any settling solids to the top of the tank. The fluid and solids then swirl downwards and repeat the process,” says Dr Farrow. “The capital cost of swirl flow is around 50% less than traditional technologies, and likewise the maintenance costs are also much lower, in part due to the lower wear rates than the impellers used in traditional systems. “Maintenance can also be done without entering the tank, creating a significant health and safety advantage.” Swirl flow has been successfully used for more than 15 years by Queensland Alumina at its Gladstone refinery. Currently, 21 large tanks are operating with the technology, and the company has plans to convert more tanks to swirl flow. Conversion to swirl flow is not only a major capital cost saving, but also provides

14 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2014

long-term operating advantages such as a significant reduction in the tank scaling rate. This allows the tank to stay in operation for much longer periods, increasing production and reducing the costs. “A particularly important feature of swirl flow is the ease at which remixing of the suspension can commence after a power failure, since the agitator is close to the liquid’s surface and away from the settled solids, unlike traditional systems in which the settled solids may cause the impeller to get stuck,” Dr Farrow explains. Swirl flow can be applied throughout the minerals industry for a wide variety of mixing. “We’re doing work for both the gold and zinc industries,” Dr Farrow says. “Gold production also has a crystallisation issue, and like the aluminium mixing, the process needs the best form of agitation to make sure particles are kept in suspension with no scale. “For all applications the prime need is to ensure no solids settle to the bottom of the tank, but swirl flow can also address the need to avoid particle attrition (for example, when resins are used to absorb valuable metals), to provide effective oxygen transfer or to minimise scale formation.” The Minerals Down Under Flagship of Australia’s national science agency, CSIRO, is one of the largest minerals research groups in the world and has a proven track record of working with industry to deliver innovative solutions. Through targeted research CSIRO addresses the industry’s challenges, driving sustainability, productivity and innovation for its collaborative partners and clients. This story first appeared in resourceful: www.csiro.au/ resourceful. CSIRO - Manufacturing, Materials and Minerals www.csiro.au

www.ProcessOnline.com.au

Eclipse ®

Model R95

Model R82

Model TD2

Aurora

Thermatel® – Thermal Dispersion Flow Switches & Transmitters Eclipse® – Guided Wave Radar Level Transmitters Echotel® – Ultrasonic Level Switches & Transmitters Pulsar® – Pulse Burst Radar Level Transmitters Atlas, Aurora, Gemini – Magnetic Level Gauges & Jupiter Magnetostrictive Level Transmitters

Magnetrol International, an innovator and leader in Process Control Level and Flow Instrumentation, has a strong on-going commitment to advance the state-of-the art in level and flow technologies. The Eclispe 706 GWR offers best-in-class signal strength and signal-to-noise ratio (SNR) resulting in enhanced capacitity in difficult low dielectric applications. Multi-technologies of level/flow are available in the product range, specialising in high pressure/temperature, cryogenic applications up to ANSI 2500# and -195°C. IEC EX approved and SIL rated Magnetrol fuse market-tested design principles with advanced level sensing technologies. Aurora and Gemini MLI’s combine dependable visual indication with innovative Model 706 Eclipse Guide Wave Radar for the leading edge in redundancy.

SALES AND SERVICE IN THE PACIFIC REGION BY POWERFLO SOLUTIONS Tel: 1300 658 701 | Email: sales@powerflo.com.au | www.powerflo.com.au

NEW PRODUCTS

ROTARY ENCODER The housing, flange and shaft of the DFS60I incremental rotary positioning encoder are made of inox steel. The seal ring is made of ethylene propylene diene monomer rubber (EPDM), which offers good resistance to water and water-based systems such as acids and brines. The surfaces and seal ring meet requirements relating to corrosion resistance and chemical resistance during exposure to humidity and aggressive media. The device is therefore suitable for applications in food processing, beverage filling and the pharmaceutical and packaging industries. The encoder has a resolution of 16 bits, (pulses from 1 to 65,536) and the user can set the zero pulse position and zero pulse width, as well as the voltage level of the output-side TTL or HTL interfaces as is necessary for the application. An external power source is not required for the programming. The encoder is connected via the output cable to the PGT-08-S programming tool, which first reads the current DFS60I settings of the electronic-type label and saves the new settings in the encoder. The device has a solid shaft (10 mm in diameter), which provides for a variety of mechanical and electrical adjustments for easy mounting. The compact housing with a diameter of 60 mm facilitates the space-saving installation of the encoder, as does the M12 connector with a radial cable outlet. The encoder includes a 24 V open collector interface, two 6-channel TTL/RS422 interfaces with different signal levels, one 6-channel HTL/push-pull interface, and programmable TTL/HTL interfaces. Sick Pty Ltd www.sick.com.au

FIELD DEVICE MANAGEMENT SOFTWARE Emerson Process Management’s AMS Suite: Intelligent Device Manager is now capable of commissioning Foundation fieldbus devices faster with the updated version 12.5 software. The company says users can bring devices online with the features, options, and alerts they select - in a fraction of the time it would normally take. With the software’s new func-

CONNECTORS WITH EMC PROTECTION

tionality, Emerson anticipates reduced com-

ifm efector’s ecolink EVC series connectors provide

80% compared to existing work practices.

permanent high EMC protection.

In addition to faster start-up, users can

The asymmetrically acting saw-tooth contoured vibration protection holds the coupling nut tight in

missioning time on smart devices by almost

now make online changes to many devices simultaneously.

position. In addition to screening, this ensures a

The User Configurations tool enables us-

low contact resistance between the nut of the con-

ers to standardise asset configuration and

nector and the housing of the connected device.

eliminate configuration errors. Users have

This ensures a permanent high protection against

the option to apply configuration templates

interfering fields.

to device placeholders or live devices. The

Connectors are often exposed to harsh environ-

devices can be commissioned one by one

mental conditions. The ecolink connectors’ integrated

as field engineers are wiring the segments

mechanical end stop made from FKM protects

or automatically in groups. Built-in reporting

against destruction from overtightening of the nut.

allows users to quickly validate that parameters

A torque wrench is not necessary.

have been applied correctly.

ifm efector pty ltd

Emerson Process Management

www.ifmefector.com

www.ap.emersonprocess.com

16 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2014

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NEW PRODUCTS

SERVO AND STEPPER ACTUATOR CONTROL The ACS actuator control solution from Tolomatic is an easy-to-use, low-cost servo or stepper drive and controller developed specifically for use with electric actuators, providing infinite positioning, precise control and longer life. Originally offered as a stepper system, the newly released ACS with servo drive and control provides over 10 times the power of a stepper system, with the same easy-to-use operating modes. The ACS servo and stepper drives are intended to be controlled from a PLC or master

GWR INTEGRITY TESTING

controller via 24 VDC digital I/O, 0-10 VDC or 4-20 mA analog I/O, Ethernet or Modbus RTU over RS485 (EtherNet/IP or Modbus TCP protocols).

The Verification Reflector function, now avail-

Additional modes include Pneumatic mode, which allows the system to replace pneu-

able with the Rosemount 5300 Series GWR

matic logic without reprogramming the PLC by simply configuring position and velocity

transmitters, is designed for applications

for two or three positions; Index Move mode to allow the user to configure 16 moves

requiring periodic transmitter integrity tests

as absolute, incremental, jog, force or home moves; and Analog Position mode, con-

to ensure that the level measurement device

trolled by a 0-10 VDC or 4-20 mA analog input, with an option to mirror the position via

functions correctly and overfilling will not occur.

0-10 VDC or 4-20 mA analog output.

In the past, most guided wave radar trans-

The ACS servo drive/controller operates on a 10-60 VDC bus and is offered with a wide

mitters have required the fluid level in the

variety of NEMA 23 or 34 frame servo motors. The ACS stepper drive/controller operates on

vessel to be raised to the alarm point. The

24 VDC and is offered with a wide variety of NEMA 11, 17 and 23 frame stepper motors.

Verification Reflector function eliminates the

The digital I/O is configurable in either 24 VDC opto-isolated, NPN or PNP.

need for this procedure by using an adjustable

Pneumatic Products

reference reflector fitted to the probe of the

www.pneumatics.com.au

guided wave radar. During commissioning, the location and amplitude characteristics of the reflector are stored in the transmitter. When the test procedure is later initiated, the stored reflector data is compared to the current measurement to verify the integrity of the measurement electronics and upper part of the probe. Compared with traditional diagnostics that

POINT LEVEL SENSORS

only monitor the transmitter electronics, the

The LMT point level sensors from ifm

verification reflector can also be used to

efector are now available with ex-

diagnose any problems with the upper parts

tended probe lengths.These devices

of the probe inside the tank. These include

monitor the level of virtually any liquid

product build-up, corrosion monitoring and

and viscous media or bulk material in

other process related conditions.

storage tanks. The sensors are resistant

Easy to fit and adjust, the Verification Re-

to build-up due to the utilisation of 200 MHz

flector is suitable for Rosemount 5300 Series

capacitive field technology that accurately detects

guided wave radars with single flexible stain-

the correct level, even with mass build-up on the probe.

less steel probes (4 mm) and firmware 2.H0

The distinction of two media is possible due to the two switching outputs

or higher, with the software option enabled.

which can be set independently. The parameters can be set via IO-Link

Emerson Process Management

and a USB interface.

www.ap.emersonprocess.com

The robust LMT is housed in high-grade stainless steel with protection rating IP68/IP69K and meets all the requirements necessary for hygienic areas. ifm efector pty ltd www.ifmefector.com

18 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2014

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NEW PRODUCTS

HYGIENIC CENTRIFUGAL PUMPS Evoguard pumps from Krones are single-stage, normal-priming, hygienic centrifugal pumps. The quality assurance system applied to the Evoguard series of pumps corresponds to Krones’ quality control concept, with batch tracking provided for each component. The pumps are suitable for delivery flows of up to 100 m3/h, delivery

STAINLESS STEEL SWITCHGEAR ENCLOSURES

heights of up to 80 m and operating pressures of up to PN 16. According to the company, accurately designed flow paths, with all dead spaces eliminated, mean that the centrifugal pumps provide uniform and gentle delivery of the product.

Kraus & Naimer has added

Krones says the pumps’ service routines have been minimised

a 1.6 mm stainless steel enclosure

in order to reduce both the time and manpower required for their cleaning and maintenance, minimising production interruptions. The company developed a new interface with the motor, plus a seal concept that reportedly maximises dependability even when exposed to tough process conditions.

to its 6S Series. The enclosures provide rigorous protection for vital switchgear but have the same footprint as plastic versions. Suitable for use in the dairy, beverage and food industries, the 6S series can withstand aggressive environments. The

The pumps have been designed in compliance with the EU Ma-

enclosures are also used in the marine and mining industries and in

chinery Directive 2006/42/EC. The TÜV SÜD technical inspectorate

sewage treatment plants, material handling and conveyor systems.

conducted the requisite design examination, including pressure

The enclosures are constructed from 316 stainless steel and are

tests, safety tests, checking the pumps’ mechanical strength, etc.

rated to IP66. They are available with bottom-threaded entries and

Seal replacement in the product compartment can be carried out without the need for special tools. Setting of the gap dimensions

four screw cover fixings with or without external mounting feet. With standard sizes of stainless steel, mild steel and plastic

is easy and likewise requires no special parts.

enclosures, custom designs are also available.

JL Lennard Pty Ltd

Kraus & Naimer Pty Ltd

www.jllennard.com.au

www.krausnaimer.com

www.ProcessOnline.com.au

MAY 2014 - WHAT'S NEW IN PROCESS TECHNOLOGY 19

CASE STUDY

SCADA upgrade benefits Yarra Valley Water Yarra Valley Water (YVW) is the largest of Melbourne’s three water corporations providing water supply and sewerage services to over 1.7 million people and over 50,000 businesses in the northern and eastern suburbs of Melbourne. Its substantial water network spreads over 4000 square km, including over 9000 km of water and 18,000 km of sewer mains. Development in Melbourne’s growth corridor to the north is increasing the pressure on Yarra Valley Water to deliver sustainable water solutions. YVW’s 30,000-point SCADA system monitors approximately 550 sites including 11 treatment plants, 67 water pump stations, over 100 sewer relief facilities, over 96 sewer pump stations and 102 sewer flow control facilities. YVW was looking to upgrade its legacy system, which was commissioned in 2001. The system had received minimal updates in functionality since that time. It had no graphical interface for mimics and relied on text and tabular displays to show alarms and current status, with basic graphical trending capability for historical analysis. The system was used largely as an alarm system, from which the control room generated work requests for the field crews. Having no graphical context made finding the information needed timeconsuming, and was not very user friendly. Yarra Valley Water identified the need to develop a more open and maintainable system with wide industry acceptance for increased futureproofing and to remove the dependence on a single vendor for support. Bringing the support in-house was a key objective. The new system also had to provide a high level of security, with a secure architecture and current generation security concepts. The telemetry communications system was also no longer meeting YVW’s needs. The system was a mix of analog radio network, NextG, PSTN and GSM dial-up/dial-in modems, spread across its many sites. Separate to the SCADA host upgrade works, a parallel project was needed to upgrade the radio network. Schneider Electric replaced Yarra Valley’s legacy SCADA system with StruxureWare SCADA Expert ClearSCADA, which is Schneider Electric’s telemetry SCADA system for the water industry. Schneider Electric’s solution included over 800 detailed schematics for zones and all of Yarra Valley Water sites. The GUI is a critical aspect of any SCADA system and the ‘look and feel’ of the GUI was co-developed by Yarra Valley Water and Schneider Electric’s Telemetry Competency Centre to incorporate end-user needs and industry best practices. To ensure reliable delivery of alarms to operators using smartphones or tablets, the ClearSCADA Mobile system is used. Data from anywhere in the system can be browsed so that other

20 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2014

statuses can be easily checked by the operator if needed. They can decide how they want to respond to the alarm without having to spend time powering up a laptop and connecting into the system. By using the extensive template feature set of ClearSCADA, Schneider Electric was able to deliver a system that any of YVW’s approved systems integrators can work on without fear of compromising the integrity of the main SCADA system. YVW is now also using the SCADAPack E Series RTUs, where the configuration of the RTU is included in the ClearSCADA objects and can be downloaded to the RTU remotely. “The powerful templating functions in ClearSCADA make it very easy for us to now manage nearly all changes in-house. This has allowed us to add functionality such as communications diagnostics to large numbers of items (over 220 radios and more than 400 NextG modems) easily and with consistency, as the individual items are largely managed from the source templates,” said Yarra Valley Water SCADA & Control Systems Manager Roger Brown. YWV also upgraded its communications systems with over 200 Schneider Electric Trio digital radios and six new radio base stations. This included fully redundant base stations and the capacity to later add diagnostics across the whole network. An interface with the customer’s existing asset management database was also developed to allow for automated work order generation from ClearSCADA alarms, streamlining the process of dispatching work crews and increasing efficiency. Yarra Valley Water staff now have a modern SCADA system that allows them to monitor the distributed assets and perform predictive and reactive maintenance, and be better able to respond to incidents, such as environmental spills, in a timely manner. Reported faults have been reduced by 66% and there has been an 80% reduction in external support costs. The user interface and open database tools allow real-time and historical information to be made available to operations and strategic planning staff for informed decision-making. “Prior to the cutover we were averaging 150 SCADA incidents per month. Within four months of cutover this had reduced to less than 50 per month, and two years later we are at 30 per month and still improving. Much of the credit for these improvements is due to better reliability and functionality in Schneider Electric’s telemetry system, and the ease with which we can add tools to help improvement such as the Alarm Analyst and system diagnostics,” said Brown. A longer and more detailed version of this article can be read online at http://www.processonline.com.au/case_studies/66872SCADA-upgrade-benefits-Yarra-Valley-Water Schneider Electric Industry Business www.schneider-electric.com

www.ProcessOnline.com.au

NEW PRODUCTS

LINEAR INDUCTIVE SENSORS The Turck Q25 high-speed inductive linear sensor has a user-selectable internal measuring frequency up to 5 kHz, resulting in accurate measuring speeds of up to 5 m/s. They do not require a magnetic position device and are unaffected by metal debris commonly found in many industrial applications. The sensors provide high resolution and can be used to accurately measure lengths up to 1 m. Turck’s linear inductive sensor operation is based on the RLC resistance inductance capacitance principle in which the sensors incorporate precisely manufactured printed

DATA LOGGING TEMPERATURE METER

emitter and receiver coil systems. The emitter

The Fluke 54-2B 2Ch data log-

coils are activated with a high-frequency AC field

ging temperature meter with

and produce an inductive RLC circuit with the posi-

FlukeView takes most thermo-

tioning element. The element is inductively coupled with the receiver

couple inputs with the supplied

coils, which are arranged so different voltages are induced in the

K-type thermocouples measuring

coils, depending on the position of the actuator. The voltages serve

a temperature range of -200 to 1372°C. Users can take 500

as a measure for the sensor signal. Q-track sensors deliver maximum

point loggings with adjustable recording intervals that are

measuring spans, with minimal blind zone and high resistance to EMI/

date and time stamped, and includes recordings of minimum,

RFI noise interference.

maximum or average. The device is available to rent.

The high-speed integrated processor converts the signals into a

Logged data can be reviewed on the meter or downloaded

25-bit Gray code SSI signal which can be connected by an 8-pin M12

to PC using the FlukeView software included. The recall func-

connection. Turck offers the Q25 in 10 standard measuring lengths

tion allows users to easily review logged data on the large

starting at 100 mm with 100 mm increments up to 1 m. The Q25 has

backlit dual display.

short blind zones of only 29 mm on each side, is IP67 rated and has

The compact and lightweight unit runs on AA batteries that

a wide operating temperature range of -25 to 70°C.

provide around 1000 hours of typical use. Temperature can

Turck Australia Pty Ltd

be measured in °C, °F or K with an accuracy of ±0.05% of

www.turck.com.au

reading or +0.3°C. TechRentals www.techrentals.com.au

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PR3441

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Measure your tank level

A stable, accurate transducer

• Stainless 316L submersible • Up to 500mWG range • 4-20mA output

• 4-20mA and digital models • -1 to 3000 Bar range • 0.25% accuracy

Display right where it’s needed • 4 digit plug in display • Span and zero adjustable • Set point/alarm option

SEE THE FULL RANGE AT WWW.ADMTECH.COM.AU

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MAY 2014 - WHAT'S NEW IN PROCESS TECHNOLOGY 21

NEW PRODUCTS

ULTRASONIC FLOW METER

IN-LINE DENSITY MONITOR

The Model UFM compact ultrasonic flow meter is a

The Rhotec in-line den-

low-cost, clamp-on, ultrasonic flow meter that uses the

sity monitor continuously

transit-time difference method to measure flow rates in

measures the density of

pipes non-invasively. It has a compact and lightweight

liquids. Centec, a German-

design, featuring an easily installed, all-in-one, clamp-on

based company, designed the

unit. This unit can measure velocity and flow in pipes with

Rhotec for maximum sensitivity and

outside diameters ranging from 24.89 to 117.35 mm. The

high accuracy.

screen offers easy-to-read text with a convenient backlight

The Rhotec can be used in the food industry, breweries, beverage plants

for visual comfort. This model comes with a volume pulse

and pharmaceutical plants to determine the concentration of alcohol, sugar

and 4-20 mA flow rate output.

contents, acids, caustics and other solutions. For density measurement, the

Two sensors located in the guiderail are placed on

liquid flows through an oscillating U-shaped tube; any change in the fluid

the exterior of the pipe, and each transmits an ultrasonic

density causes a change in the oscillating frequency and is used to determine

pulse through the pipe and fluid to the other. The velocity

the density. As a specific property of each liquid, the correlation between

of the liquid flowing through the pipes causes the pulse

concentration and density can be described by a mathematical polynomial.

to accelerate or decelerate. The difference in the transit

With decades of experience and its own laboratory facilities, Centec has

times of the two pulses is used to calculate the flow

the polynomials for a large number of liquids. Temperature changes of the

rate, and the use of transit time allows the flow meter

measured liquid are automatically compensated for by an internal Pt1000

to be unaffected by pressure or temperature changes.

sensor. The Rhotec displays various units, e.g. vol.%, mass %, 째Brix and

Applications include heat metering; chilled water

째Plato. The Rhotec has a SS316 housing and is available with a range of

metering and monitoring; as well as potable water and

wetted part materials to suit most liquids. A range of communication op-

process water metering and monitoring.

tions exist to interface with PLCs and DCS systems.

Dwyer Instruments (Aust) Pty Ltd

B-R Controls Pty Ltd

www.dwyer-inst.com.au

www.brcontrols.com.au

22 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2014

www.ProcessOnline.com.au

NEW PRODUCTS

SCADA SOFTWARE Schneider Electric has announced an updated release of StruxureWare SCADA Expert ClearSCADA, its open software platform for management and optimisation of remote assets in critical infrastructures. The user interface has been updated to make the user experience more seamless and intuitive, and new functionality has been added, including a tabbed document interface, recent documents list, asynchronous server communications and enhanced multimonitor capabilities. These functionalities are embedded in a new ribbon-style framework that is the current standard for other Windows applications, while still providing the familiar core SCADA Expert ClearSCADA functionality. Users will also notice improved security and protection of system information, with restricted access to sensitive IP Address and Node Name information (including servers, clients and other IP-connected devices) and unsuccessful user logons. Operational intelligence has been enhanced, due to an advanced OPC driver, 3D trending and integration with Aquis (Schneider Electricâ&#x20AC;&#x2122;s software for water network modelling). Set-up time has also been reduced, with simplified calculations for internal points and the Bulk Edit tool. SCADA Expert ClearSCADA is suitable for demanding telemetry applications in the oil and gas industry as well as water and wastewater as it eliminates the need for additional software to collect data from remote devices. Schneider Electric Industry Business www.schneider-electric.com

DATA LOGGER The Matrikon Industrial Data Logger is an intelligent automation data gateway that provides third-party connectivity, onboard data collection and intelligent data forwarding in a single box. Suitable for capturing data at remote locations and forwarding it, the logger connects securely to a centralised historian and transfers data to it, even in low bandwidth or unreliable network conditions. The logger combines reliable data delivery, connectivity and secure access control in an easy-to-use, low-maintenance device. It is designed to simplify an inherently complex store-and-forward problem by providing an all-in-one solution in a single appliance. Designed for remote applications, the Matrikon Data Logger is claimed to be easy to deploy, use and maintain. Key benefits include: selective, event-based data collection due to flexible onboard data capture functionality; low bandwidth requirements due to data compression; data integrity and confidentiality enforced via data encryption; and reliable data delivery based on intelligent, loss-free historical data transfer functionality. MatrikonOPC www.matrikonopc.com

www.ProcessOnline.com.au

MAY 2014 - WHAT'S NEW IN PROCESS TECHNOLOGY 23

NEW PRODUCTS

MULTIFUNCTIONAL SAFETY RELAYS PSR-MXF multifunctional safety relays monitor up to three safety functions in one module and are therefore particularly suited to smaller

TEMPERATURE MONITORING RELAY

machine applications. They

Relpol has released the MR-

related control circuits with up

ET1P temperature monitoring

to PLe or SIL CL 3.

can be used to create safety-

relay to the Australian market.

The range comprises four

Sometimes known as a PTC or

different special function mod-

thermistor relay, these devices

ules, with three terminal block

monitor the temperature of a

versions each. Different protection

motor winding by use of up to

areas can be monitored in one machine,

six PTC thermistors. If an over-

due to two local sensor circuits, allowing safety implementations

heat condition is detected, the

to be simplified.

single-pole, changeover contacts

The relays also have a higher-level sensor circuit, which can be

operate and the motor control can

used for emergency stop signals, for example. All relevant sensors

be shut down in time to save the motor from costly damage.

can be monitored, such as mechanical emergency stop signals

Other features of this relay include DIN rail mounting, monitoring

or safety door locking, light grids, and magnetic switches. The

for a short circuit or wire break condition in the thermistor line,

device does not need to be configured and, for this reason, is

the option of an external reset input and a built-in test function

particularly easy to maintain. The push-in fast connection technology

with integrated test/reset key on the front panel.

enables tool-free installation which in turn reduces start-up times.

Control Logic Pty Ltd

Phoenix Contact Pty Ltd

www.control-logic.com.au

www.phoenixcontact.com.au

24 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2014

www.ProcessOnline.com.au

NEW PRODUCTS

PANEL PCS Advantech’s Industrial Automation Group has upgraded its two panel PCs. The 15″ PPC-6150 and the 17″ PPC-6170 models now come with faster processors, RAID control and multiple expansion slots for increased functionality. The entry-level PPC-6170 (17″) and the PPC-6150 (15″) colour TFT LCD displays now come with the Intel Celeron M 1020E processor which offers an increased performance of 20% over the previous Intel Core 2 Duo processor and doesn’t increase the price. For high-end performance, Advantech offers the Intel i5 processor with an increased performance of 260% over the previous Intel Core 2 Duo processor. Both processors support 3D visual computing to improve the capabilities of the panel computer for software operation and multitasking. To further improve the user functionality and performance of the PPC6150, Advantech has also included an optional touch-screen solution with projected-capacitive touch sensors that support multitouch twofinger usage. This enables users to control the user interface with even greater accuracy and speed. With the addition of an additional hard drive, both models now support RAID 0 and 1 providing realtime backup of critical data. In the event of voltage spikes between the PPC and industrial devices, the RS232, 422 and 485 ports are isolated against such energy surges. With a variable configuration of PCI and PCIe slots, the PPCs allow the installation of add-on cards for specific functions such as frame grab, fieldbus communication and digital I/O. The models also include expansion for optical drives or Wi-Fi modules for additional flexibility. Advantech Australia Pty Ltd www.advantech.net.au

DIGITAL I/O MODULE The Unitronics EXF-RC15 digital, high-speed I/O module adds an elevated level of flexibility to the Unitronics Vision series PLC + HMI product line and can be easily configured via software to fit a variety of motion control-related applications where a mixture of high-speed and general-purpose inputs and outputs is required. Compatible with the Unitronics Vision products via CANbus, this I/O module features nine digital inputs and six digital outputs comprising four transistor outputs with high-speed capability, and two relay outputs. The EXF-RC15 supports up to three high-speed counter (HSC) or shaft encoder input channels, at up to 200 kHz. Additionally, it supports up to four pulse width modulator (PWM) outputs or up to three pulse train outputs (PTO), at up to 200 kHz, that can be used for accurate stepper motor control. This enhanced combination of features is designed to enable engineers and systems integrators to benefit from a powerful, upgraded I/O module within a minimum of budget, cabinet space and wiring. Micromax Pty Ltd www.micromaxsa.com.au

www.ProcessOnline.com.au

MAY 2014 - WHAT'S NEW IN PROCESS TECHNOLOGY 25

SELF-VERIFYING FLOWMETERS MODERN TECHNOLOGY IMPROVES INSTRUMENT MANAGEMENT Gernot Engstler, Endress+Hauser Product Management

The process industry is undertaking great efforts to ensure high levels of process reliability, consistent product quality and accurately priced billing of goods. There is also an increasing need to prove that operation is sustainable by meeting environmental regulations.

tate-of-the-art process measuring technology is the key to ensuring reliability, quality and sustainability goals, by ensuring highly stable measurement results over a long period of time. Despite this, it is common practice to inspect quality or safety-related measuring points at regular intervals. Modern flow sensors donâ&#x20AC;&#x2122;t have moving parts that are subject to wear and feature measuring electronics with self-diagnosis. These two aspects make it possible to significantly reduce effort in the management of these devices by preventing unnecessary maintenance work or calibration cycles, while at the same time supporting quick troubleshooting. Verification reports can also be created based on internal device tests which allow the device to document its own health condition. Presently, individual device manufacturers have integrated diagnostics, monitoring and verification functions in the flowmeter so that they can be used in a uniform manner for the entire installed base. Consistent handling and uniform functionality allow end users to simplify their operational workflows by standardising operating procedures. Users only need to learn how to work with a method once, resulting in cost savings through increased efficiency. A device with high long-term stability, which is tested using highly stable, internal references with a redundant design, is a basic requirement for reliable device-internal diagnostic and

26 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2014

verification methods. For devices with internal verification, the traditional method of verification with traceable, external measuring instruments is no longer necessary. Often the intervals between labour-intensive recalibrations can be extended. The advantages of this process include the ease of use and the option for integrating into a higher-level control system or asset management system. All of this saves time and costs, while virtually eliminating the possibility of interference due to incorrect handling.

Industry requirements Individual manufacturers of process measuring technology recognised the trend to reducing costs through simplified management of assets and reduced specialisation years ago, and today offer comprehensive solutions for reducing complexity. The objective here is simplicity obtained by consistent and uniform solutions and by omitting specialised expertise. Standardisation is based both on uniformity (doing the same thing the same way) and consistency (offering one solution for all instruments). Presenting functionality for all instruments and devices in a uniform manner makes handling safer and simplifies the learning curve while streamlining operational workflows and ensuring the sustainability of established processes and acquired knowledge.

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Asset Management

The addition of an integrated self-monitoring system allows safety- or quality-related conditions to be identified in a timely manner if these measurement technologies are used in applications where the process conditions influence measuring performance or harm the integrity of the device. That is to say, measurement technologies can provide other secondary measured variables in addition to the primary measured variable (flow), which are useful for monitoring and documenting the measuring point.

Comprehensive diagnostics Diagnostics are primarily based on constantly monitoring the function of the device’s internal components during ongoing operation, allowing for a rapid response in a timely manner. These messages are typically interpreted in accordance with NAMUR recommendation NE 107 and are displayed by the device as a diagnostic event. This also includes direct instructions on what to do next - ensuring that the process can be up and running again quickly in the case of a shutdown, while preventing unnecessary maintenance measures.

Condition monitoring

The aim of seamless integration is to improve the flow of information between the device and its environment by perfect interaction between device and host. Diagnostics integrated in the device constantly deliver information about the device status or provide notification of events, such as if the current process conditions are interfering with measuring performance. Rapid and specifically targeted troubleshooting is possible since each diagnostic event on the system displays an additional corrective action. Once the device itself generates and stores the information necessary for documenting the device inspection, it is automatically available to all operating and integration interfaces. In addition, integration increases the safety of personnel since, under certain conditions, the operator or technician can call up information in the field without access to the measuring point.

Measurement with consistent quality Measuring with consistent quality requires long-term stability, diagnostics, condition monitoring and verification.

Long-term stability Modern flowmeters, which operate based on a Coriolis, electromagnetic, ultrasonic, vortex or thermal measuring principle, are well known for highly stable measurement results over a long period of time.

www.ProcessOnline.com.au

Diagnostics enable quick and targeted responses to interruptions during operation in case of an error or a device failure. This is enough to guarantee safe, reliable operation for most applications. Faults during operation that go undetected, or are not detected in a timely manner, can result in an unexpected plant shutdown, product loss or a reduction in product quality. This specifically applies to applications where process-related faults during operation are to be expected due to the demanding operating conditions (formation of build-up, multiphase media) or where the device is subject to programmed wear (corrosion, abrasion). Condition monitoring is recommended for these types of applications, since it recognises if the process conditions, the measuring performance or the integrity of the device are impaired.

Verification Verification can be used to take and store a snapshot of the device status. Verification is used to demonstrate that the flowmeter meets specific technical requirements defined by the manufacturer or end user (ie, the process application). During verification, the current conditions of the secondary parameters are compared with their reference values, thereby determining the device status, resulting in a ‘pass’ or ‘fail’ result. A traceable and redundant reference, contained in the verification system of the device, is used to ensure the reliability of the results. In the case of a Coriolis flowmeter, this is an oscillator, which provides a second, independent reference frequency. A verification report can be generated by means of a web server or asset management software. It can be implemented either as quality documentation (for compliance with ISO 9001) or, in safety-related applications, as documentation of the proof test (for functional safety - SIL).

MAY 2014 - WHAT'S NEW IN PROCESS TECHNOLOGY 27

Asset Management

ONCE THE DEVICE ITSELF GENERATES AND STORES THE INFORMATION NECESSARY FOR DOCUMENTING THE DEVICE INSPECTION, IT IS AUTOMATICALLY AVAILABLE TO ALL OPERATING AND INTEGRATION INTERFACES.

Figure 1: Specific categories according to NE 107.

Reliability A flowmeter is expected to demonstrate constant and therefore unchanged measuring performance throughout its entire lifespan. This is necessary to: • guarantee safe plant operation • ensure high product quality • increase system availability and productivity A number of requirements must be met to enhance operational reliability. These requirements are met best by comprehensive diagnostics of the measuring point in running operation and methods for condition-based maintenance. As we have seen, condition monitoring and verification provide efficient methods for measuring point maintenance during the system’s life cycle.

Traceability and long-term stability To ‘measure’ means to compare an actual value to a reference value. In a self-verifying flowmeter, the actual value reported from the sensor is compared to a reference value in the transmitter electronics. In order to produce accurate measuring results, the reference value needs to be reliable. For this purpose, integrated self-monitoring of the reference value is applied. To be effective, such integrated self-monitoring must be based on a traceable reference system with proven long-term stability. This allows a high level of stability - even without verification by external measuring instruments.

Verification of flowmeters To ensure the conformity (quality) of the product, the ISO 9001 requires that: In order to ensure valid results, the measuring equipment shall be calibrated and/or verified at specified intervals or prior to use, against measurement standards traceable to international or national measurement standards. Records must be kept on the results of the calibration or verification.1 ISO 9001 requirements also provide the impetus for today’s common practice of requiring an independent reference system for

28 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2014

device inspection through verification. However, this does not verify the primary measured variable (flow), but rather the device function. In practice, reliable verification of flowmeters can be fulfilled in two ways: either via an external verifier whose references can be traced along the life cycle by recalibrating the verifier at periodical intervals or by an internal verification which is based on factorytraceable references that are stable in the long term. In the past, a method to assure the long-term stability of an internal verification system has not been available. Now, with the latest generation of flowmeters, a reliable internal verification technique has become available for the very first time.

Evolution to internal verification External verification is a very complex procedure that requires access to the measuring point in the field. During verification, the transmitter is opened to input external signals using a special testing adapter. Verification is carried out by a skilled technician and requires approximately 30 minutes. The process requires specific knowledge and relies on the assembly and maintenance of infrastructure. This is why external verification is usually always implemented in the form of a service, eg, as part of a service contract. Internal verification is based on the ability of the device to verify itself based on integrated testing, which is carried out on demand. This is why the most common question is: How can internal verification system achieve the same reliability and test coverage as an external verifier specifically created to do so? Integrated self-monitoring replaces the need for external test equipment only if it is based on factory traceable and redundant references. The reliability and independence of the testing method is ensured by traceable calibration or verification of the references at the factory and the constant monitoring of their long-term stability during the life cycle of the product. By eliminating additional components for inspection and preventing errors during handling, internal device inspection proves

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Asset Management

Figure 2: A number of requirements must be met to enhance operational reliability.

Figure 3: Self-monitoring functionality from all available interfaces.

to be more reliable than external inspection when the inspection process is viewed as a whole.

documentation and makes it possible to create verification reports offline for quality documentation. Furthermore, by comparing the data of multiple consecutive verifications, trends can be detected and systematically tracked during the life cycle of the measuring point.

Advantages of integrated verification The results of internal verification are the same as with external verification: verification status (pass/fail) and the recorded raw data. However, since verification is now a part of the device technology, data acquisition and interpretation are also done in the device. This has the advantage of making the functionality available for all operating interfaces and system integration interfaces. The verification procedure depends on the measuring principle and can last anywhere from a few seconds up to approximately 10 minutes. The true time saving, however, comes from the ease of use, since no complex interaction with the device is necessary to carry out the verification.

Safety and quality Verifying the measuring point is done on demand and via all operating interfaces (local display/HMI or web server) as well as the system integration interfaces, such as the fieldbus. The verification process can also be started via a higher-level system (asset management software or PLC) and reliably reports the device status. Therefore, access in the field is unnecessary, which minimises the risks for personnel. The quality of the verification results will also improve, as there will be less chance for human error. Verification can be carried out much more often - including daily or before starting a production batch - since the function is so easily accessible and the entire process lasts only a few minutes without interrupting operation.

Higher plant availability Devices with internal verification should be capable of storing multiple verification results in the transmitter. This is the case not only for the verification status (pass/fail), but also for the measured data. This has the advantage of making the data available for later

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Summary Flowmeters that include self-monitoring offer the highest reliability. This benefits the customers in three ways: • Continuous self-monitoring is used for diagnostics, in order to react quickly to a device defect or an application problem. Since the diagnostics delivers specific messages and corrective actions to the device and its functions, quick troubleshooting is possible. • If the information identified as part of self-monitoring is exported from the device, it can be used for condition monitoring. This continuous observation of the device and process status also allows proactive measures through early identification of trends, thereby preventing unplanned maintenance or plant shutdown. • Reliable methods of self-monitoring are based on factory-traceable references and have high long-term stability. Only methods fulfilling these criteria are suitable for internal verification of flowmeters and can be used to create proven documentation in the areas of quality (ISO 9001) and safety, and to verify metrological requirements. In order to fulfil the prerequisites of the most widely varying applications and requirements in the life cycle of a measuring point, all three features are needed. 1. Source: EN ISO 9001: 2008; 7.6 ‘Control and Monitoring of Measurement Equipment’. Endress+Hauser Australia Pty Ltd www.au.endress.com

This article is based on the Endress+Hauser white paper ‘Modern flow measuring technology with integrated self-monitoring and verification’. To download the full white paper go to: http://www.processonline.com.au/white_papers/67026

MAY 2014 - WHAT'S NEW IN PROCESS TECHNOLOGY 29

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18 – 19 June 2014

Australian Technology Park What’s On?

Keynotes — Industry leaders will share their expertise and experiences with you. Workshops — Always popular, and included in your general conference registration, the workshops will give you a more in-depth look at selected topics including: • Advanced radio over IP • Mobile broadband and LTE for critical communications • Implementing a digital radio solution — change management Industry stream — Case studies and papers focusing on key sectors and users of radio and converged communications: • Public safety and emergency management • Mining and the wider resources sector • Utilities • Transportation • Government and enterprise Technology @ work stream — A broad selection of papers on technologies used in the field, often using case study examples, will deliver critical technical content to you and your colleagues. Exhibition – and don’t forget, an exhibition with dozens of local and international manufacturers and distributors will have their experts on hand to help you find the solutions you’re looking for. In conjunction with the NSW ARCIA networking dinner, 18 June @ Dockside, Cockle Bay Wharf In association with:

Magazine partner:

Organised by:

Interested in exhibiting or sponsoring?

CALL PAUL OR NARELLE ON

+61 2 9487 2700

www.comms-connect.com.au

NEW PRODUCTS

PALLET LABELLER Domino has expanded its M-Series range of print and apply labellers with the M220 off-shelf pallet labeller. The labeller is designed to meet the tertiary labelling

MES FOR PHARMACEUTICALS

requirements of a range of packaging lines.

Life sciences companies have the dual task of maintaining flexible production lines to respond to changing market demands and cost-effectively managing compliance requirements. The Rockwell Software PharmaSuite v5.2 system (MES) is designed to help manufacturers respond to these challenges and execute electronic batch records in new and more efficient ways. Recipe elements can be executed in parallel by multiple shop-floor operators. On the production line, recipe tasks can be freely moved between electronic batch recording stations or can be fixed to a specific station by recipe design. This allows operators to define and control the level of execution freedom on the shop floor and increases the efficiency of electronic batch recording. In addition, the PharmaSuite v5.2 system supports dynamic registration of

The M220 has a tamp head that allows 180Â° movement,

devices like industrial laptops or tablets to a production line station to enable

allowing labels to be applied on up to two adjacent

worker mobility and collaboration in a more flexible, but still secure manner.

sides of the pallet as dictated by the customer require-

The newest version of the PharmaSuite system also includes native integra-

ment and production line layout. This gives the user

tion with FactoryTalk Historian software and the OSIsoft PI System to increase

a degree of adaptability and can reduce lead times.

insight into production by gathering and archiving actionable information

The labeller is available in either aluminium or stain-

into one deliverable. Historian integration automates the process of collect-

less steel; both versions have optional label check

ing historical data, developing trend charts and attaching this information

scanners and a climate control unit. The stainless

to the batch record. This reduces human error so operators can focus on

steel model is suitable for harsh environments such

production rather than reporting.

as those in the beverage sector as it is more durable

The PharmaSuite v5.2 system also has the ability to export production orders and electronic batch records for long-term archival using PDF and B2MML standards. With this, regulatory requirements for batch record reten-

and can be easily cleaned and sterilised in order to ensure a clean production environment. The system is designed to fit on a single euro pal-

tion can be efficiently supported.

let, minimising shipment space and reducing shipping

Rockwell Automation Australia

costs. It can also reduce the productâ&#x20AC;&#x2122;s carbon footprint.

www.rockwellautomation.com.au

Domino (Australia) Pty Ltd www.domino-printing.com

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

www.ProcessOnline.com.au

info@groupinstrumentation.com.au

www.groupinstrumentation.com.au

MAY 2014 - WHAT'S NEW IN PROCESS TECHNOLOGY 31

NEW PRODUCTS

DIN RAIL UPS 19″ WALL-MOUNTED CABINETS

The PULS UB20.241 DIN rail UPS

The CamRack QX series of 19″ wall-mounted cabinets from

has been designed to be con-

CamdenBoss are designed to house rackmount equipment for

nected on the output side of a

cabling, telecommunications, IT and industrial installations. They

24 VDC power supply and back

are supplied flat-packed, which eases access to the installation

up critical 24 VDC loads such as

site while reducing logistics costs and providing greater protec-

PLCs, RTUs and HMIs in the event of a

tion during transit. Fast and efficient ¼-turn lock fixings allow

power failure.

users to assemble the cabinets without the aid of tools in 3 min.

The UB20.241 individually manages

CamRack QX cabinets are available in five models, each

and monitors two 12 V batteries that are

offering a selection of five standard corner colours (red,

connected in series. When power is present

blue, orange, white and black). A further five colours - yellow,

the UPS charges and monitors the batteries as well as

green, purple, lilac and grey - are available on request. The

isolating the 24 VDC load connected to its output from the input

five models are 6U, 9U, 12U, 15U and 18U, all in a standard

supply. When it detects that power has been lost it provides output

19″ width (580 mm).

power from the batteries while continuing to monitor each battery.

For fast, easy access to the equipment, the cabinets feature a quick-release door with tempered, smoked safety glass and

The UB20.241 can be used with batteries that range from 3.9 to 130 Ah and is compact, measuring 46 mm in width.

removable side panels with two ¼-turn locks. Easily drilled

Other features include adjustable output voltage in buffer mode

plastic blanking covers for cable entry ensure that all cables

and negligible voltage dips or overshoots when transitioning from

are stored neatly and securely. CamRack QX cabinets feature a

normal to buffer mode. The unit also has extensive diagnostic and

maximum recommended load capacity of 45 kg and are epoxy

monitoring functions.

paint finished in RAL 7016 grey.

Control Logic Pty Ltd

RS Components Pty Ltd

www.control-logic.com.au

www.rsaustralia.com

Need to simplify traceability and allocation control? OsiSense™ XG RFID 13.56MHz is a fully open RFID system, which performs object traceability, tracking and access control functions with ease and simplicity, while providing freedom of choice: • 100% compatibility • 30% savings on install and set-up time • 100% RoHS and UL, CE, FCC certification. It also allows automatic integration with your system architecture, as well as adaptation to network protocols such as: • Modbus® TCP/IP • Modbus® RTU • Uni-Telway™ • PROFIBUS-DP • Ethernet I/P.

32 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2014

www.ProcessOnline.com.au

CASE STUDY

Air compressor decision driven by energy savings Started in 1986, Aquaknect Flexible is Australia’s oldest manufacturer of flexible connectors and is now the only manufacturer of flexible connectors in Australia, with around 35 employees. “While we do have a joint venture operation in China, the other companies have shifted all their manufacturing operations offshore, particularly to China and India,” explained Tom Davies, general manager. “By having our manufacturing operation in Meadowbrook, Queensland, this allows us to tailor-make hoses for our customers’ specific requirements with very short turnaround times.” Davies explained that the company uses the compressed air to drive its crimping and cutting machines as well as vital testing equipment and recently needed to upgrade its three ageing Hydrovane compressors. “It’s critical we have a reliable supply of clean air to operate our machines, without them we have no hoses. Reduction of running costs, reliability and cleaner air delivery were the key features why we chose the Atlas Copco GA VSD+ air compressor for our Queensland manufacturing facility,” Davies said. Like most manufacturers in Australia, the ever-increasing cost of electricity was a huge factor when deciding on a new compressor for the manufacturing plant. “We looked at a number of other air compressor manufacturers four other companies with similar styles of machinery in fact. All the companies came out and looked at our requirements and how we operated, but Atlas Copco was the only company that took the time to project savings and recommend things we could do to improve our compressed air supply,” he said. “Now we just have the one latest-generation Atlas Copco compressor, instead of three,” he added. Duncan Vaughan, sales engineer with Atlas Copco’s Queensland Industrial Air Division, said that while Aquaknect Flexible was the first company to invest in the GA VSD+ air compressor in Australia, he is expecting many more manufacturers to follow their lead as word spreads about these ultra-efficient compressors. “These are brilliant machines. The power savings alone are significant enough to justify investing in a new machine. Plus the new compressor delivers far more air, better air quality and far more efficiently than what the company had in the past.” Vaughan explained that the radical new GA VSD+ was officially launched in Australia in October 2013, but he was able to install this compressor a couple of weeks prior to the launch. “It has only been installed for a couple months now, but it is clear the compressor will deliver the savings predicted.

www.ProcessOnline.com.au

Early figures show considerable energy savings already,” he said.Vaughan said the GA VSD+ compressor offers a major leap forward in FAD (free air delivery) with improvements of up to 12% and a breakthrough in energy efficiency requiring on average 50% less energy than a comparable idling compressor. “Plus it’s much quieter than the old Hydrovanes, and other air compressors on the market; down to an unbelievable 62 db(A). In fact it is so quiet that when the compressor was first installed, the workers at the plant often forgot to turn the compressor off at the end of their shift, even though the compressor is in the work area, up on a mezzanine level. To overcome the problem, we simply programmed the machine to turn itself off at the end of every day,” said Vaughan. Being very quiet when running is a great feature of the GA VSD+ compressor; it means the machine can be placed on the workshop floor, with no need for a separate room. It can also be placed against a wall or in a corner due to its vertical design with the ducting on top. “Suitable for a wide range of industries, this rotary screw compressor is driven by a high efficiency interior permanent magnet motor, which exceeds IE 3 rating at 94.5%; corresponding to IE 4 (Super Premium Efficiency motor class),” said Vaughan. The compact motor, which was designed by Atlas Copco, features optimal oil cooling and an oillubricated motor bearing all in a sealed unit, meaning no greasing of bearings or airflow required for cooling of the motor. And unlike traditional compressors, the motor and drive train share one drive shaft and are vertically aligned to allow a smaller footprint of 55% compared to the previous range. There are also no gears, belts or shaft seal to maintain. The whole drive train is completely closed, offering IP66 protection, with one oil-circuit that cools the motor and lubricates the element and bearings. Other energy-efficient components of the GA VSD+ compressor include a more efficient fan, robust air intake system and an innovative air inlet valve, which is maintenancefree. The mechanical polymer inlet valve uses air to open and close (no spring) and with no ‘blow-off’ in operation, resulting in no unloaded power consumption. “With the cost of electricity continuing to rise, I expect more and more customers to take advantage of this new technology we are now offering rather than the old fixed speed technology. Our old machines offered an average of 35% power savings, but these machines offer a massive 50% in power savings,” he said.

Atlas Copco Compressors Australia www.atlascopco.com.au

MAY 2014 - WHAT'S NEW IN PROCESS TECHNOLOGY 33

FLUID POWER PRODUCTS

REFRIGERATION DRYERS The Kryosec series compressed air dryers from Kaeser are claimed

COMPRESSOR

to provide dependable drying with minimal pressure differential even under the toughest of operating conditions, in ambient temperatures up to 50°C, and for compressed air flow rates from 0.35 to 2.2 m3/min. Their performance is made possible through a generously dimensioned heat exchanger and refrigerant liquefaction surfaces, and also by dedicated cooling air flow. All models meet applicable machinery safety requirements (EN 60204-1), including a lockable on/off switch and an integrated power-supply isolating device. Their high-quality construction and compact design make them suitable for localised installation on production and processing machines requiring treated compressed air, and they can be wall mounted. Kaeser Compressors Australia www.kaeser.com

The Centac C800 compressor is built on Ingersoll Rand’s latest generation technology: an integrated and simplified centrifugal compressor platform. The model is an extension of the Centac C1000 product line. Providing 100% clean, oil-free air, the C800 has been certified as ISO 8573-1 Class 0 and is designed to minimise downtime and lower the total cost of ownership. The Centac C800 reduces energy use by up to 6% at full load, significantly reducing overall ownership costs, while the unit’s backward-leaning impellers were designed using computational fluid dynamics to maximise peak efficiency and provide greater turndown. In addition, inlet guide vanes (IGVs) are standard on the C800, delivering up to 10% additional energy savings at partial load. Preventive service and maintenance tasks have become easier with the C800 air compressor, with a one-piece removable inducer, in-place roddable coolers, bull gear inspection ports and an open cooler casing which offer increased access to critical components. The fully configured C800 compressor package also provides for efficient installation, with no special foundation or grouting required. The single inlet and outlet connections for cooling water also reduce installation time and cost. The web-enabled Xe-Series controller enhances productivity and enables plant and operations managers to remotely access and adjust the system. It presents real-time monitoring and trending of critical components, making it easy to predict maintenance needs and correct operating parameters from smartphones, tablets and personal computers. CAPS Australia Pty Ltd www.capsaust.com.au

34 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2014

www.ProcessOnline.com.au

FLUID POWER PRODUCTS

PNEUMATIC VALVE CONTROL UNIT Designed as a more compact version of the type 8690, Burkertâ&#x20AC;&#x2122;s 8697 pneumatic control unit with position feedback and LED status indication is available as a pneumatic unit or feedback for Element valves with 50 mm actuators - as well as a pneumatic control unit for Classic valves with actuator sizes 40, 50 and 63 mm. The head can also be used as a feedback for Classic actuators of all sizes, from 40 to 225 mm. The type 8697 replaces the type 1062, which previously offered position feedback (but no pilot) for Classic valves. It also offers original advancements such as an integrated pilot valve with manual actuation and LEDs for indicating device status. Integrating this head offers a simplified way to create a decentralised automation device, improving overall process speed and allowing independence and therefore creativity in process design, leading to optimised systems. Using the type 8697 as a pneumatic control unit eliminates the need for a control cabinet with hoses leading to the respective valve. This simplifies system design and minimises the control air consumption for drive switching. Combining the type 8697 with a process valve from the Element series results in an efficient process with an EHEDG-compliant valve system - with high-level IP protection, as well as an integrated control air supply with additional spring chamber ventilation. The 8697 is aimed at the hygienic and water segments, however its dynamic design allows it to be used in the general process industry. Burkert Fluid Control Systems www.burkert.com.au

www.ProcessOnline.com.au

MAY 2014 - WHAT'S NEW IN PROCESS TECHNOLOGY 35

FLUID POWER

Ari vAlves… protect you, your plAnt And our plAnet.

PRODUCTS

DEW POINT INSTRUMENT The DryCheck from Michell is an accurate and stable dew point instrument, which includes a built-in simple sampling system. Its compact size

ARI ‘FABA’ Bellow Sealed Globe Valves for Oil & Gas and Industrial applications. Double wall bellow sealed stem ensures ZERO leakage. Ideal for steam, hot water, chemicals, air, gases and thermal oil. Available as dual function check & stop valve. In cast iron, SG iron & cast, forged or stainless steel.

allows the instrument to be easily installed in a number of dew point measurement applications, such as compressed air dryers, ozone generators, plastic moulding machines and industrial gas manufacture. Designed for quick and easy maintenance, the DryCheck is a good choice where ease of use and simple installation are important. All components are housed in a rugged IP65rated polycarbonate case. This can be wall mounted at a convenient point close to the gas sample. A clear cover protects the display and the sample flow meter. Gas connection (gas in and gas out) is provided using ‘quickconnect’ push fittings, suitable for use with 6 mm OD Teflon tubing. Mains power input, and connection to the 4-20 mA analog output, and the two user-programmable, voltage-free relay contacts are all easily accessible behind the lower panel. The device uses the Michell Instruments Easidew On-Line to measure dew point in the range -100 to + 20°C dew point, or moisture content in the range 0-3000 ppm. The sampling system includes a 0.3 micron particulate filter element, a monolithic sampling block to house the Easidew transmitter, as well as a valve and flow meter for setting the sample flow. The device features a clear 20 mm red LED display, which can be programmed to display dew point, in C or F or moisture content in ppm V. AMS Instrumentation & Calibration Pty Ltd www.ams-ic.com.au

COMPRESSOR ARI fABA Bellow seAl gloBe vAlves DIN and ANSI dimensions. Straight, Y Form, Right Angle. Flanged and Butt Weld ends.

Kaeser Compressors is releasing a new generation of its ASK rotary screw compressors, offering further-refined Sigma Profile airends, an innovative cooling concept and high-efficiency IE3 motors. They are claimed to perform up to 20% better than many comparable compressors. ASK models are available for free air deliveries from 0.84 to

Large range of safety and process vaLves in stock for immediate deLivery.

4.65 m3/min, at pressures of 5.5 to 15 bar, and

austraLian agent & stockist

IE3 motors and radial fan (with its own dedicated

feature optional frequency control and an optional integrated dryer. The integrated Sigma Control 2 controller provides efficient and intuitive control, while the energy-saving motor) keep costs for energy use to a minimum. ASK models also offer a logical, user-friendly design, which allows all maintenance parts to be conveniently accessed from one side for easy servicing. Moreover, when closed, the enclosure with its sound-dampening insulation ensures quiet and unobtrusive operation.

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

Kaeser Compressors Australia www.kaeser.com

9193p&ss-Wnipt2

36 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2014

www.ProcessOnline.com.au

FLUID POWER PRODUCTS

AIR-OPERATED DOUBLE DIAPHRAGM PUMP The SP100 Series air-operated double diaphragm pump, by Tuthill Corporation under the brand name Sotera Systems, incorporates several key features unique to this pumping principle. The first is the QuikSeal threaded ring construction. The threaded ring is designed for quickturn access to clear ball checks and replace diaphragms. This design eliminates the need for multiple fasteners (bolts) on the manifolds and fluid caps reducing parts and complexity. It has the added benefit of reducing maintenance time by up to 50%. This design also reduces ‘pinch points’ on the diaphragm resulting in longer diaphragm life. The second is the patented, QuickFlow air valve design. This non-centring ceramic air valve features a fast tripover, resulting in a 67% reduction in pulsation, as well as a high and smooth flow - up to 17.5 gpm for the ½″ model; 57 gpm for the 1″ model. In many applications pulse dampeners can be eliminated, making the pumping system less complex and saving money. The third benefit is a claimed 20% improvement in air efficiency compared to competitive pumps. Less air consumption saves money over the long run. SP100 can be configured in materials compatible with a wide range of chemicals. Hurll Nu-Way Pty Ltd www.hnw.com.au

Projekt9 15.04.14 12:28 Seite 1

www.ProcessOnline.com.au

MAY 2014 - WHAT'S NEW IN PROCESS TECHNOLOGY 37

NEW PRODUCTS

EMBEDDED COMPUTER The Neousys Technology POC-200 is a fanless PC controller with ultra-compact dimensions (146 x 102 x 58 mm), similar in size to a 3.5″ hard disk drive. Powered by the Intel Bay Trail Quad Core CPU, 1.91 GHz E3845, the device is capable of supporting a maximum of 8 GB memory to meet the demands of high-performance applications. Intel’s Bay Trail processor offers enhanced graphics performance that delivers faster high-definition graphics and supports other media conversions. The design of the 22 nm CPU is said to have created a more energy-efficient processor that draws less than 10 W of power. The device offers many I/O interfaces, including four COM ports, four USB ports (including three USB 3.0), four isolated digital I/Os and two PoE Gigabit ethernet ports. The device also provides one Mini-PCIe slot with one USIM socket for wireless requirements. The device’s PoE function is compliant to 802.3at (25.5 W), with a total power budget for two PoE GigE ports of up to 50 W. The POC-200, integrated with the PoE solution, allows users to easily add on different devices such as IP cameras for surveillance usage, VOIP terminals, and to support other wireless applications. The device’s performance-enhancing mechanical and thermal design improves the heat dissipation more efficiently by using an aluminium alloy chassis. With industrial SSD storage, the POC-200 meets an extended operating temperature range of -20 to +70°C suitable for harsh Australian environments. Backplane Systems Technology Pty Ltd www.backplane.com.au

NEW ProBus RS 485 Modbus I/O Modules • Ideal for data acquisition and remote I/O. • Manufactured in Australia • Multi-channel analog and digital I/O modules. • Modbus RTU communications. • Ethernet Modbus TCP and Profibus gateways. • Compact DIN-Rail packaging with integrated Bus connector.

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

www.proconel.com 38 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2014

www.ProcessOnline.com.au

CASE STUDY

Pack integrity vital when transporting food, drink for retail outlets The days of careless wrapping of packaged food and drink bound for retail are all but over as the large supermarket and grocery chains force ever greater liabilities on suppliers who take short cuts. With packaging integrity such a key factor for product placed on shelves, the tiniest blemish or dent during transit renders an item ‘unsellable’, and the burden is instantly shifted back by powerful retailers to the supplier. There are so many examples, but bottled water and other drinks is an excellent case in point, according to packaging specialist Nelson Joyce & Co. Managing director Nelson Joyce says the likes of Coles, Woolworths and other powerful retail giants have very strict rejection criteria to protect their own quality standards and aesthetics, so suppliers need to be wary of the situation. “ T h e re i s s u c h s t ro n g competition to be on the shelf space of the retail giants, so the retailers themselves have to protect their own visual standards and bottled drinks are a very good case scenario where rejection often happens,” said Joyce. “As a packaging specialist, we are regularly consulted by suppliers whose palletised goods have suffered some sort of change before or during shipment and thus paid the price. “For instance, if a mineral water supplier’s pallet moved under its shrink wrap during transport and bottles were bumped so that, say, the tops and necks were bent inwards, the retailer will not place them on the shelves, but will reject the pallet - plus it is highly likely to charge for the space on the shelves reserved for it. “It may sound like rough justice, but the retailers run operations based on margins and quantity sales and will not have time to replace that product with anything else, so the supplier suffers the penalty - which is likely to be written into the agreement. “This is even more prominent in the regional areas to where freighting takes even longer and a Plan B is almost always out of the question. “It is like a demurrage cost in the transport game where the stock movement failures by one party will not be suffered as incurred charges by another.” Various emerging packaging technologies can protect against such incidents; cheap stretch wrap should be

www.ProcessOnline.com.au

avoided, versatile and cost-identifiable machines can replace slow, wasteful and substandard manual wrapping. Even an entire evaluation of a packaging line - which is an inexpensive exercise - can identify so many shortfalls and provide answers as to how a supplier can professionalise, increase quality and speed up its own packaging and delivery systems. Retail-ready packaging often is ignored for the multifaceted approach it needs; for instance, fill form and seal/rewind films and machines, barrier products, carton liners, separation sheets, crate liners, carcass covers and all other manner of products are affordable and can make the ultimate difference in maintaining a profitable supply line free of mishaps, says Joyce. “The bottled water sector is such a good case study on this issue,” he said. “A plant that packs bottled water needs to ensure its product is presented to customers in a uniform way. “The moment a single item moves out of alignment during transit, it can pop out and cause damage to more of the shipment - and bear in mind this type of item can be moved five or six times depending on its final destination. “ F ro m w a re h o u s e t o secondary handlers and finally to retailers, restaurants and cafes, it is multihandled and suppliers need to protect the integrity and clarity of each pack, making sure no deformation takes place. “Once plastic bottle necks are turned inwards, they are harder to stock properly. “Even to take a basic re-evaluation of their heat-induced wrapping systems can make an enormous difference. “In some cases, we have found that reducing heat from 200 to 175°C and increasing the rate of pack movements through blow formers and fillers etc will optimise your bundle shrink systems and positively affect overall productivity and transport quality. “We have seen in so many food and beverage handling plants that making such straightforward analysis of the entire supply procedure can increase the speed and efficiency by 30%, plus protect the packaging integrity.” Nelson Joyce & Co Pty Ltd www.nelsonjoyce.com.au

MAY 2014 - WHAT'S NEW IN PROCESS TECHNOLOGY 39

NEW PRODUCTS

UPS FOR AC LOADS

availability for loads with 120 or 230 VAC and 500 VA

TEMPERATURE SWITCH FOR HYDRAULIC SYSTEMS

power. The output voltage exhibits a pure sine curve,

The ETS 320 is a compact, electronic

so that even sensitive loads can be operated without

temperature switch with 3-character

interference on networks from 80 to 264 VAC.

digital display and integrated tem-

The Quint AC UPS uninterruptible power supply with IQ technology is designed to achieve high system

The offline UPS is combined with power storage

perature sensor. The up to 600 bar

in VRLA technology with 3.4 to 38 Ah capacity. For

pressure-resistant version with an

a longer service life and buffer times of up to 45 min

integrated 18 mm temperature sensor

at 15 W power, additional power storage with lithium-ion technology is available.

can be mounted directly in the pipeline or on the

The UPS-CAP power storage devices with maintenance-free, dual-layer capacitors

hydraulic block and offers a measurement range

achieve a maximum service life of over 20 years at ambient temperatures of -40

from -25 to +100°C.

to +60°C. With VRLA-WTR batteries, buffer times of 2 h at 400 W power or 40 h

Various output variants with one or two switching outputs, optionally with an additional 4-20 mA

at 15 W power can be achieved. The IQ technology communicates with the power storage and determines all

analog output, provide wider application oppor-

relevant states such as voltage or temperature. Intelligent battery management

tunities. The switching points and the associated

detects the current charging state of the connected power storage device and uses

hysteresis can be set up quickly and easily. For

this to calculate the remaining run time. The remaining life expectancy of the battery

adjustment to the respective application, the device

is also known. The information provided by the UPS can be forwarded to higher-

offers many additional setting parameters, such as

level controllers via ethernet or can be implemented directly in control solutions.

switching delay times, open/close functions, etc.

Phoenix Contact Pty Ltd

HYDAC International

www.phoenixcontact.com.au

www.hydac.com.au

Sensor Monitoring Services

CURRENT-TO-PRESSURE TRANSMITTER

Industrial Control ZigSense cloud controller is an

Energy Metering

Moore Industries has released a new version of its IPH2/IPX2 current-

Refrigeration

Tank & Silo Level

to-pressure (I/P) transmitter. Along with updated certifications, the

Gas Monitoring

IPH2/IPX2 features 22 direct and reverse output ranges, with switch-

HVAC Cold Storage Building Automation Water Metering

out-of -the-box solution ready to operate independently or as an interface station between remote ZigSense wireless sensors and ZigCloud online monitoring services sites. Users gain access to live or historic data generated by the monitored process. ZigCloud enables the user to define online: Alarms, Reports, Graphs and Charts. Users receive alert messages and reports via email, SMS or voice. Interface to other devices is Modbus ready.

Pollution Horticulture Aquaculture

selectable reverse output standard on the IPX2. The IPX2 now has a removable electronics module. In certain abnormal conditions, a liquid ‘slug’ can enter the air or gas supply of the IPX2. The removable electronics module speeds the recovery process by allowing the liquid to drain more efficiently. When the removable electronics module is combined with the clog-resistant filtered nozzle and orifice that protects against clogging caused by internal debris, the result is a product that is easier to maintain and less prone to malfunctions caused by unwanted material entering the system. The two-wire (loop-powered) IPH2 and IPX2 accept a current signal from a DCS, PLC or other control system and convert it into a pneumatic signal to provide precise, proportional control of valves, actuators and other pneumatically controlled devices. Both products meet NEMA Type 4X requirements, and the IPX2 can be installed in explosion-proof environments, making it suitable for oil and

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

40 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2014

gas applications in hazardous settings. Moore Industries Pacific Inc www.miinet.com

www.ProcessOnline.com.au

NEW PRODUCTS

HAZARDOUS AREA GEAR UNITS AND MOTORS SEW-Eurodriveâ&#x20AC;&#x2122;s hazardous area motors and gearmotors are now available in the Australian market. They are offered compliant with IECEx according to equipment protection levels (EPL) Gb and Gc (gas protection) and Db and Dc (dust protection). The combined gas/dust approvals for SEW gearmotors simplify the selection process for the relevant drive components, reduce the number of variants and allow the gearmotors to be used in combined gas/dust zones. The 4-pole motors of categories 2 and 3 (or EPL .b and .c) are suitable for operation on a frequency inverter and in field weakening operation. SEW motors and inverters are available as electrical equipment in protection types e (increased safety), nA (non-sparking) and tb and tc (dust explosion protection). The gear units as non-electrical equipment are certified in protection types c (design safety) and k (liquid immersion). The hazardous area gear units and motors are produced with special components and particular attention is paid to quality assurance. These include IP54 (or higher, as an option) for motors in a gas environment and IP5x/IP6x for motors in a dust environment. The gear unit lubricants can withstand high temperatures, and high-quality oil seals are used. Terminal boxes are made from aluminium or grey cast iron, with seals that can withstand high temperatures, and an external protective conductor connection. Improved grounding (EMC) is provided with an additional connection (HF equipotential bonding), and all screws are secured against unwanted loosening. SEW-Eurodrive Pty Ltd www.sew-eurodrive.com.au

www.ProcessOnline.com.au

MAY 2014 - WHAT'S NEW IN PROCESS TECHNOLOGY 41

AS I SEE IT A.B.N. 22 152 305 336 Head Office Cnr. Fox Valley Road & Kiogle Street, (Locked Bag 1289)

THE REVOLUTION IS COMING: Time to get on the journey to industry 4.0

Wahroonga NSW 2076 AUSTRALIA ph: +61 2 9487 2700 fx: +61 2 9489 1265 www.westwick-farrow.com.au Editor Glenn Johnson wnipt@westwick-farrow.com.au Chief Editor

anufacturing has a long history in Australia and is a vital part of our economy. However, we have seen a downturn in the manufacturing sector over recent years and we need to address this urgently. But why do we care and what can be done about it? Industry gross domestic product (GDP) represents a significant portion of Australia’s GDP with mining being around 13.5%, construction around 9.5% and manufacturing around 11%. More importantly, industries such as manufacturing are really like the growth engine of the economy. And it’s important for Australia and Australian companies to realise that competition is global, not local. In the US for instance, they see that for every dollar in manufacturing it adds US$1.48 to the economy, whereas retail adds only a little over US$0.50. President Obama last year announced a proposal to create a National Network for Manufacturing Innovation, with 15 research institutions located all over the country that will encourage industry innovation. In the UK, in February this year, industrial output increased 0.9% from January, the highest increase in eight months. There were upward contributions from three of the main sectors, with manufacturing being the largest contributor increasing by 1.0%. In India, the government has now understood that the service sector alone cannot help the country make broad economic progress so they developed the National Manufacturing Policy (NMP), a plan for industrial growth. The goal is for automation to increase productivity and improve quality, in small and medium-sized companies as well as large enterprises. This policy is projected to increase manufacturing’s share of GDP from its current level of 16% to 25% by 2025. Germany, a country renowned for being a powerhouse in manufacturing, actually faces many similar challenges to Australia in that they have a high standard of living and highly valued currency in the Euro. However, their success is no accident and

Janette Woodhouse

they are constantly looking to the future. A national working group - Industrie 4.0 was set up to look at the future of advanced manufacturing and Siemens is a key member of this working group. The focus of Industry 4.0 is the development of cyberphysical systems, which are aimed at further optimising production. Products, transport options and tools will communicate with each other and will be organised with the goal of improving the overall production even over the boundaries of individual companies. In this production environment, the product itself is an active part of the production process. We’re at an exciting point in time. With the digitisation of the product development process, we are seeing design, production planning, engineering, manufacturing and services merging into one unit, instead of being sequential. Production operations will be more efficient and flexible with rapid innovation cycles. Despite some current setbacks in manufacturing in Australia, we can and should have a successful and robust manufacturing sector. But we need to embrace Industry 4.0 and get on the journey as quickly as possible, find our place in the global supply chain and have the right mechanisms, policies and levers to help Australian companies and industries compete globally. We also need to encourage investment into advanced technologies which are available today, because we are at a critical fork in the road right now and we must make the right choices to become competitive. Jeff Connolly is CEO and Chairman of Siemens Ltd and head of the Industrial sector. Jeff has extensive experience across Asia, Europe and Australia, including his position on the AiGroup Advanced Manufacturing Council, and is in a unique position to provide valuable insights into the future of manufacturing.

42 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2014

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Printed and bound by Webstar +61 2 9748 0020 Print Post Approved PP100007403 ISSN No. 0819-5447 All material published in this magazine is published in good faith and every care is taken to accurately relay information provided to us. Readers are advised by the publishers to ensure that all necessary safety devices and precautions are installed and safe working procedures adopted before the use of any equipment found or purchased through the information we provide. Further, all performance criteria was provided by the representative company concerned and any dispute should be referred to them. Information indicating that products are made in Australia or New Zealand is supplied by the source company. Westwick Farrow P/L does not quantify the amount of local content or the accuracy of the statement made by the source.

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