0914
ON THE COVER
WHAT'S NEW IN PROCESS TECHNOLOGY SEPTEMBER 2014
CONTENTS
OMRON Electronics’ SYSMAC Automation Platform ties together your complete machine solution into one integrated system. Here’s why. The NJ series of controllers simplify programming
4
Flowmeter calibration management
8
New products
10
Hot products online
languages comply with the relevant programming
18
Efficient multitaskers
NJ controllers utilise Atom processors for both
34
As I see it
databases and interface to Matlab.
The sky’s the limit for cloud engineering
Connectivity to third-party devices and the internet
by integrating traditional PLC ladder logic with structured text, and merging it with both motion control and safety systems. All programming standards, namely IEC61131-3 and PLCopen. speed and robustness and can connect to SQL
is assured by all NJ CPUs supporting separate RJ45 ports for EtherNet/IP and EtherCAT. Both enjoy widespread usage and are open-vendor meaning users have the flexibility of selecting the ‘best-of’ technology from a wide range of devices. EtherNet/IP interconnects HMIs, other controllers and computers. EtherCAT’s high performance and low cost make it the ideal remote I/O network. Its FSoE protocol allows safety I/O (rated to PLe) to be mixed with standard I/O, and distributed around the plant. EtherCAT’s distributed clock reduces jitter to under 1 µs, making it ideal for tight time synchronising applications. OMRON supplies a large variety of devices for EtherCAT, such as I/O blocks, vision systems, VSDs, servos (rotary and linear) and even Delta robots. All programming is via SYSMAC Studio, OMRON’s single, integrated development package. It supports the entire SYSMAC product range and provides extensive simulation facilities to help you achieve your goals faster, more efficiently and with greater safety. For more information: 1300 766 766 www.omron.com.au
NOW in DIGITAL! Your copy of What's New in Process Technology is now available as an online eMag.
http://www.processonline.com.au/latest_issues
FLOWMETER CALIBRATION MANAGEMENT UNDERSTANDING WHEN AND WHY YOUR FLOWMETERS NEED CALIBRATION Ben Keizers and Kyle Shipps*, Endress+Hauser USA
4 WHAT'S NEW IN PROCESS TECHNOLOGY - SEPTEMBER 2014
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Failure to calibrate flowmeters can negatively impact performance, while calibrating too frequently can result in excessive costs without providing any benefits. So, the question is, how do you determine if calibration is needed and what the frequency should be?
The importance of instrument assessment The first step in a calibration plan is to perform a plant-wide assessment of all your instrumentation, including flowmeters. To do this, you must first identify and make a list of all the equipment parts and all instrument-related systems. This list should also include details such as description, location information, operating conditions, working range and history, and any other points that provide a better understanding of the part’s function.
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The first stage in analysing this data is to identify which instruments are critical to the application, the environment and operator safety. To start, the head of metrology (quality) and head of maintenance - or similar professionals who have the most in-depth knowledge of the process and related instruments - should together determine their knowledge of the process environment, the condition of the installed instruments, the type of maintenance work carried out and, finally, any limitations imposed by the plant in terms of servicing. After this information is compiled, it is important to start from the finished product - and the tolerance permitted in relation to its quality - and go back through the various stages in the production process. At each stage it is important to assess each instrument and flowmeter in place and ask, does this instrument have an impact on the quality of the product (or intermediary product) on process functioning, or operator safety? The total installed base will determine how frequently to calibrate flowmeters. The next step will be to then set up a calibration plan depending on these factors.
Prioritise your flowmeters After an installed base audit has been performed, it is important to categorise all flowmeters by critical importance. Flowmeters fall into one of four categories, ranging from critical to noncritical importance. The first category - flowmeters critical for the product - are those that affect product quality. We start here, because these flowmeters have a direct link to company profits, whether it involves measurement of ingredients in food processing, mixing of chemicals or custody-transfer applications. The next category - flowmeters critical to the process - are those that can upset the overall plant or other processes (shutting down the entire process) and thus cause inefficiencies and production losses, but have no direct effect on product quality or safety. Flowmeters critical for safety have a direct impact
SEPTEMBER 2014 - WHAT'S NEW IN PROCESS TECHNOLOGY 5
Š iStockphoto.com/Christian Lagereek
A
flowmeter that is not measuring properly can cause many problems. In a custody-transfer application involving crude oil or natural gas, even the smallest error can cost a customer millions of dollars a year. In a food processing plant, a similar error can adversely affect the quality and safety of food products, resulting in the costs that go along with such failures. Because flow measurements are so critical to many processes, the industry standard is to calibrate annually, even though that might not be necessary. In many cases, this is done in an attempt to demonstrate to a quality auditor that instruments within the process are under control. For most companies, annual calibration is performed as a traditional ritual with no scientific basis behind it, other than it being the longest duration of time they are willing to risk before finding a potential problem. In many instances, yearly calibrations are not necessary, as some flowmeters require calibration only once every three or four years depending on the process fluid, operation and criticality. In other cases, a flowmeter may require calibration much more frequently, possibly on a monthly basis, to maintain a safe, efficient or regulatory compliant operation. It’s also important to realise that calibration intervals are not always fixed, meaning that they might fluctuate based on usage or historical performance. How do you determine when to calibrate a flowmeter? By setting up a calibration plan that follows best practices for flow calibration.
Instrumentation
Figure 1: A technician manages a flowmeter’s calibration data via a software system, such as Endress+Hauser’s CompuCal calibration management system.
on operator safety, equipment protection and/or the environment. These flowmeters do not necessarily have to be extremely accurate, but they certainly have to work properly and reliably. Finally, non-critical flowmeters have no impact on product quality, the overall process, safety or the environment. After all flowmeters have been identified and classified into these four categories, a maximum permissible error (MPE) is assigned to each device. MPEs define the tolerance for each function being measured. A critical flowmeter will usually have a more stringent MPE than a non-critical flowmeter.
Asset management software Flowmeter data from the audit should be stored in an asset management, maintenance management or instrumentation management program. One of the major advances in recent years has been the development of instrumentation management software. These systems provide information such as spare parts lists, drawings specific to the flowmeter and original calibration data and certificates (Figure 1). Most flowmeters are calibrated by each manufacturer prior to delivery to the customer, and the calibration data is easily entered into asset management software. Afterwards, when a flowmeter is recalibrated, the device’s calibration history is updated and can potentially be automatically loaded via an electronic calibrator connected to the asset management system. Diagnostic data from each flowmeter can be read by the automation system or by the asset management system.
Figure 2: At a certified flow calibration rig, flowmeters are calibrated to meet applicable standards.
For example, diagnostic data for a Coriolis flowmeter includes empty pipe detection, sensor drift, sensor error, electronics error, inhomogeneous mixture error, ambient and process temperature errors, and other information. This data can be used to optimise calibration, to diagnose problems and to detect minor issues before they grow into substantial problems. All flowmeter vendors provide this kind of information in real time, typically via fieldbus. Depending on the fieldbus, flowmeters can also provide diagnostic data directly to technicians in the field. EtherNet/IP, for example, lets devices be polled by a condition monitoring or automation system to determine if there are any diagnostic messages that need to be sent to maintenance personnel as an alert.
Deciding when to calibrate Setting up a flow calibration plan for individual instruments often requires assistance from the flowmeter manufacturer and a qualified calibration company with industry experience, as they are best qualified to advise on how often a flowmeter should be calibrated in a typical installation. The end user must then use this advice and apply it based on particular service conditions, functions of the meter and their experience. Calibration frequency depends on the criticality and MPE, as well as the nature of the product being measured, the continuity of the process (continuous use or intermittent use), the need for clean-in-place (CIP) operations, the severity of process impacts, the type of flowmeter (contact or non-contact) and how easy it is to access and remove the flowmeter for calibration.
6 WHAT'S NEW IN PROCESS TECHNOLOGY - SEPTEMBER 2014
In some cases, it may only be possible to access a flowmeter during a complete process shutdown; in other cases, a flowmeter might be completely accessible for calibration. In a new plant, setting the flowmeter calibration frequency is usually based on expected operational parameters and advice from the flowmeter manufacturer and qualified calibration team. But in an existing plant, the frequency of calibration can be based on actual historical experience and previous documented calibration performance with the flowmeters and processes that yield better results. It is important to note that in either case quality, regulatory or safety requirements may dictate a specific calibration interval regardless of the advice from the flowmeter manufacturer or historical data from previous calibrations. Once a calibration plan has been in effect for a few years, the instrument management software takes on a bigger role. When a calibration is done on a flowmeter, new data is recorded and stored in the database. This data shows the status of the flowmeter before and after calibration, and it may very well indicate that the flowmeter does not require calibration as often as expected.
Where to calibrate? Depending on the application and the standards involved, flowmeters can require calibration, proving or verification. For calibration, flowmeters are removed from the process and shipped to a calibration facility (Figure 2). Accredited calibration labs must meet the requirements of ISO/IEC 17025 (an international standard that defines the quality
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Instrumentation
Figure 3: A portable flow calibration rig performs on-site flowmeter calibration.
and technical requirements for calibration laboratories) to ensure traceability to the governing national metrology institute in your country. Accreditation of a calibration laboratory’s proficiency is performed by third-party accrediting bodies. Laboratories that have achieved ISO/IEC 17025 accreditation have published defined scopes of accreditation, which illustrates their range of calibration capability. Calibration can also be done at the user site, using a portable flow rig (Figure 3). A portable rig does not provide the same accuracy as a calibration lab, but it can calibrate instruments to within ±0.25% or better, depending on the specifics of the flowmeter under calibration. Portable flow calibration rigs offer convenience and speed. Depending on plant topology, many measuring points can be quickly calibrated with minimal interruption to a process. This helps to minimise downtime or shutdown of the process, especially when fast turnaround and keeping production up and running is most crucial. Portable flow rigs can handle flowmeters up to a maximum of DN50 (5 cm) with results traceable to recognised standards, and the turnaround time is reduced to hours versus days or weeks when the meter is removed from site and sent to a calibration laboratory.
Flow proving Portable calibrations can also include flow proving. Flow proving is typically performed by the oil and gas industry on devices used for hydrocarbon custody transfer. In proving, a transfer standard is installed inline
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Figure 4: On-site flow verification performed with a test and simulation device - removal of the instrument from the pipe is not required.
with the flowmeter under test on process fluid under process conditions. Specific requirements for test methods and for documented results are required in the oil and gas industry. Transfer standards can be master meters, piston, small volume, ball or bidirectional provers. During proving, the flowmeter under test is compared to the transfer standard and an external meter factor is determined, based on the unit under test’s repeatability. Proving differs from calibration in that it’s typically in situ testing under process conditions.
Verification It is important to distinguish that unlike calibration, verification aims to provide evidence that a flowmeter fulfils certain technical requirements of functionality as defined by the manufacturer. It is usually a very detailed functional test to confirm sensor or transmitter stability and produces a qualitative outcome. Electronic verification consists of the flowmeter and a verification system (Figure 4). A verification system acquires a number of flowmeter parameters related to the flowmeter response. These values are evaluated by a dedicated algorithm in the verification system and the system parameter reference values. The result will deliver the current status of flowmeter functionality. The final outcome is a qualitative assessment report based on a pass-fail criterion such as process impacts, drift or hardware failures. The concept of verification must define the long-term stability of the test system, the stability of internal references and metrological traceable factory references for user confidence. In many cases, verification can be
performed on less critical meters or as a means to extend the calibration frequency. A clamp-on ultrasonic flowmeter can also be used to check a flowmeter’s operation. While a clamp-on ultrasonic flowmeter typically has only 2-5% accuracy, comparing the ultrasonic flow measurement to that of the installed flowmeter can provide some level of confidence that the meter being tested is operating properly. Such a test is often performed in concert with verification on very large flowmeters in water and wastewater applications, or on other flowmeters that are difficult to remove for full calibration testing.
Conclusion Thanks to advances in flowmeter diagnostics and instrument management software, the increasing availability of nearby calibration labs and portable calibration rigs, and the willingness of instrument vendors to help users with calibration, setting up a flow calibration plan based on best practices is much easier than in the past. Once set up, the flow calibration plan will improve operations and save money by making sure all flowmeters are calibrated only when necessary.
*About the authors Ben Keizers is the Product Business Manager for Services and has worked for Endress+Hauser USA for over six years. Kyle Shipps is the Calibration Manager for Endress+Hauser USA and has worked in the Service Department for 13 years. Endress+Hauser Australia Pty Ltd www.au.endress.com
SEPTEMBER 2014 - WHAT'S NEW IN PROCESS TECHNOLOGY 7
NEW PRODUCTS
HIGH-RESOLUTION LIGHT GRID Balluff has developed a high-resolution light grid for optical object detection with a width of 50 mm and a range of up to 2 m. Comprising a transmitter with a redlight laser and a receiver, the device is self-sufficient, working without additional accessories such as PC or special software. All settings can be made via a display in the receiver. The device evaluates not only the light quantity of the homogeneous red laser light, but also the location and position within the light grid. In addition,
RIGHT-ANGLE GEARBOXES
the emitter and receiver are encased in a rugged industrial housing and can
Wittenstein has announced its alpha SC+, SPC+
be easily aligned using the live graphic display on the integrated multifunction
and TPC+ right-angle gearbox range.
display. Users can teach-in up to six different objects using the buttons and can
The SC+ uses a high-speed bevel design with
hide obstructions in the measuring field (blanking). In this way, different objects
reduced output friction to achieve speed increases
can reliably detected, compared and sorted based on minimal differences in
of up to 30% for enhanced throughput. Using the
size, the company says. Other applications include presence and height checks.
2:1 ratio offers designers increased output speed
The result of the inspection is available at two analog and three digital outputs.
while maintaining inertia reduction.
Balluff Pty Ltd www.balluff.com.au
PIPE DEPOSIT INSTRUMENT Flowrox has released Deposition Watch, an instrument designed to enhance the monitoring of pipelines and related flow-process equipment affected by paraffin wax and asphaltene deposits. The Flowrox Deposition Watch is a predictive device, allowing
Using new materials, innovative gearing designs
its operators to address deposition issues well before these reach
and improved lubrication, the SC+, SPC+, and
critical levels that can cause downtime or costly damage. Crude oil
TPC+ operate cooler, leading to longer lifetime and
contains a variety of molecular substances that challenge the oil and
increased speed.
gas companies with the build-up of paraffin wax when it crystallises
The range offers an improved synchronous running
into a solid deposition on the pipe wall - along with the accumulation
accuracy, delivering the highest results in printing
of asphaletene - which can altogether reduce the fluid flow or plug
and imaging systems. Enhanced drivetrain accuracy
pipes and valves.
delivers the best resolution for vision scanning and
The Deposition Watch utilises electrical capacitance tomography (ECT)
3D imaging systems.
to create real-time images of the inside of the piping and to detect
The SC+, SPC+, and TPC+ gearbox family is
the differences in permittivity of the various substances found in the
based on a newly designed right-angle spiral bevel
piping system. It uses a patented algorithm that creates a 3D image
gearset. The family is intended to be a modular set
of the process fluid in the piping and generates trend data to show
to provide different ratios and output configurations.
free volume inside the pipe and the growth
The SC+ contains the spiral gearset in a single stage
rate of the deposition growth over time.
design with output shaft configuration, and is avail-
Ultimately, the Deposition Watch can
able in 1:1 and 2:1 ratios, while the SPC+ contains
show its operators the deposition thickness,
the spiral bevel gearset, but is also equipped with
deposition profile, growth rates over time,
an SP+ shaft-style planetary output stage, providing
composition and free flow volume - all of
ratios to 20:1.
which allow engineers to understand areas
The TPC+ contains the spiral bevel gearset, but
where pipes are prone to these damaging
is also equipped with a TP+ flange-style planetary
deposits.
output stage, providing ratios to 20:1.
Flowrox Pty Ltd
Treotham Automation Pty Ltd
www.flowrox.com
8 WHAT'S NEW IN PROCESS TECHNOLOGY - SEPTEMBER 2014
www.treotham.com.au
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HOT PRODUCTS
ON WWW.PROCESSONLINE.COM.AU THIS MONTH
> POWER SUPPLY DECOUPLING DIODE
>
WIRELESS REMOTE CONTROL FOR HOISTING
The Phoenix Contact Uno Power diode decouples power supplies connected in parallel, thereby increasing operational reliability. Phoenix Contact Pty Ltd
http://bit.ly/YSvSdL
The Harmony eXLhoist range of wireless remote control systems is designed for operator control of cranes and other materials handling equipment. Schneider Electric Industry Business
http://bit.ly/1sOByC3
>
COMPRESSORS Atlas Copco’s GA and GA VSD compressors, with 90 kW VSD drive and above, provide high-quality compressed air at ambient temperatures up to 55°C. Atlas Copco Compressors Australia
http://bit.ly/1pwIiSa
DIGITAL VALVE CONTROLLERS
>
The DVC6200p series is a suitable solution for applications in which application extremes or confined space make integral mounting difficult or impractical. Emerson Process Management
http://bit.ly/1pvKpGr
10 WHAT'S NEW IN PROCESS TECHNOLOGY - SEPTEMBER 2014
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Ari control vAlves… •regulating •open-close •3 way
NEW PRODUCTS
PUSH-BUTTON SWITCHES APEM has released the IA series push-button switches designed for harsh environments. The push-buttons are highly resistant to salt spray, frost, sand and hydrocarbons, and are rated at IP67 above panel. The polyurethane membrane is UV resistant and is press fitted onto the bushing ensuring the high resistance to ingress.
ARI ‘STEVI’ Control Valves Electric and Pneumatic 2 and 3 way operation. • Full Variable Flow Control • Mix or Divert designs • Compact ON-OFF model Designed for hot water, steam, gas & refrigerant. Thermal Oil applications. In cast iron, nodular iron, cast steel & stainless steel.
The actuator provides a positive tactile feedback even if the operator is wearing gloves. The maximum current and voltage rating into a resistive load is 2 A and 24 VDC with an electrical life at full load tested to 1 million operations. The total travel of the actuator is 1.5 mm with a typical operating force of 7 N. Electrical functions are N/O or changeover and flying leads are supplied as standard. The case is supplied only in black but the actuator colours can be blue, black, green, yellow, red, white or orange. Control Devices Australia www.controldevices.net
DISTRIBUTED SERVO DRIVE SYSTEM The Kollmorgen AKD-N is a distributed servo drive solution that is claimed to significantly reduce cabinet space and cabling hassle, simplifying machine design, set-up and operation. The drive system leverages robust industry IP67-rated drives positioned next to the motor and supplied by a central power module located in the switchgear cabinet. An 11 mm diameter hybrid cable delivers power and fieldbus communication to the AKDN servo drives. As a result, the drives operate directly in series, supplying up to 4 kW per axis. Safe Torque Off functionality is also included. Typical applications include packaging machines and production systems in the food and beverage industry. With the system, the company provides the flexibility to use any Kollmorgen motor technology, while still implementing a system that decentralises the drives into the machine chassis. Because the system is able to connect to all types of the company’s motor technologies, the solution enables the machine designer to select for environment and load requirements, like the IP69K-rated stainless steel AKMH or the Kollmorgen direct drive platform of motors. This modular approach also optimises the thermal properties of the drives and the cabinet, and by being mounted directly on the machine, distributed AKD-N servo drives significantly reduce cabinet volume and cabling effort. Drives are quickly and easily installed by making three screw-lock connections, as compared with traditional panel-mount systems that involve cable chasing, panel
ARI stevI contRol vAlves
wiring, tagging and crimping.
DIN and ANSI models with ARI’s unique Actuators. New Boiler Blow Down model.
Motion Technologies Pty Ltd
Large range of safety and process vaLves in stock for immediate deLivery. austraLian agent & stockist
www.motiontech.com.au
SENSORS WITH HART PROTOCOL HYDAC Electronic has further developed its sensor portfolio to include pressure, temperature and flow rate transmitters available with HART protocol. The pressure transmitters HDA 4700, the temperature transmitters ETS 4500 and the flow rate transmitters HFT 3100 with HART protocol are available for both standard applications and with various approvals for applications in explosive atmospheres. The intrinsically safe device types have ATEX and IECEx approvals. The device types of the ignition protection class “explosion proof” and “flameproof enclosure” have triple certification (ATEX, IECEx and CSA). Benefits include: according to standard HART specifications, option of additional zero point/range setting, versions available - standard
Tel: (03) 9699 7355 www.pressureandsafetysystems.com.au 9193p&ss-Wnipt3
applications, explosion-proof enclosure and intrinsically safe. HYDAC International www.hydac.com.au
12 WHAT'S NEW IN PROCESS TECHNOLOGY - SEPTEMBER 2014
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NEW PRODUCTS
SIMULATION SOFTWARE UPDATE CD-adapco has released STAR-CCM+ v9.04, the second release in 2014 of its simulation tool. Customers will see reductions in overall time-to-solution and dramatic gains in productivity using its workflow improvements, parallel meshing models allows users to perform increasingly realistic CFD and
PRP REDUNDANCY MODULES
CAE simulations that more closely represent the real-world
Phoenix Contact’s PRP redun-
conditions under which the product will operate.
dancy modules enable parallel
and optimisation capabilities. The addition of new physics
Concurrent per part meshing allows users to mesh large
network redundancy without
and complex assemblies by assigning each part to a separate
switchover times and thereby
parallel processor. This allows users to leverage as much
increase the fault tolerance in
computing power as they have available to wrap and mesh
energy networks.
(or remesh) the geometry.
Using Parallel Redundancy
STAR-CCM+ v9.04 and Optimate have the option to perform
Protocol (PRP), a standard-
a CAD robustness study. This study, performed before the
ised protocol according to
full analysis, allows users to quickly check the robustness of
IEC 62439-3, the modules enable the easy
their design ensuring that computational time will be spent
design of a parallel, high-availability network, without any configu-
performing simulations on viable geometry configurations.
ration at all. At start-up, the components must be connected according to
The new expression cost function available for adjoint prob-
the colour designation on the device. Diagnostic functions via LEDs as well
lems in STAR-CCM+ allows users to mathematically combine
as a potential-free signal contact also support the design and operation of
cost functions into arbitrary formulas. Both individual and
the parallel network. In order to be used in energy systems, components
combined sensitivities can then be used to more precisely
must be able to meet the demands of extreme electromagnetic, electrostatic,
guide the improvement of the design.
and climatic conditions. These are described in the IEC 61850-3 and IEEE
A contact coupling feature has been added to DFBI to model the contact and collision between moving bodies and boundaries, while Field Function editing is made easier
1613 standards, which the redundancy modules also fulfil. A power supply with a wide supply range ensures reliable operation even in the event of a fluctuating supply voltage in the system.
- syntax highlighting and parenthesis matching will provide
Up to now, high system availability was either achieved using conventional
users with immediate feedback on whether expressions are
processes with RSTP or by using proprietary processes with reconfiguration
constructed correctly. In addition, the filtering feature is now
times of just a few milliseconds. For applications in the energy field, however,
capable of supporting queries and conditional expressions
not even short switchover times are sufficient - here, network availability is
to group entities.
required completely without switchover times.
CD-adapco Australia
Phoenix Contact Pty Ltd
www.cd-adapco.com.au
www.phoenixcontact.com.au
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SEPTEMBER 2014 - WHAT'S NEW IN PROCESS TECHNOLOGY 13
CASE STUDY
SCADA upgrade for Lake Como aqueduct system
Lake Como, in northern Italy, is served by nearly 60 km of aqueducts. The aqueducts draw water directly from the lake and pump it to storage tanks. The water flows from the tanks via more aqueducts serving businesses around the lake, so the reliability of the water system is paramount, because water disruption leads to lost production for manufacturers in Como. After 30 years of service, the SCADA system was in need of modernisation, and energy costs in the region have risen significantly during the last 30 years. The geography of the lake, set in mountainous terrain, is also particularly challenging to water management, so the modernisation of the SCADA system created the opportunity to not only take advantage of technology advances, but also to review water management concepts and to introduce energy profile management. Pumping forms the greatest percentage of energy consumed. Energy profile management involves analysing daily consumption and comparing to lake levels, which allows projection of the storage required. The setpoints for the pumps are managed such that the tanks are filled at night when electricity is less expensive. Operating the pumps during the day is possible, but minimised to reduce costs. The SCADA collects other relevant operational data from the system, including the continuous recording of pressure, level, flow rates and volumetric meter readings. The telecommunications were evaluated in the early phases of the project, and the decision was made to move to an Ethernetbased network. Existing landlines interconnect the PLCs and the SCADA host, so HDSL was used to provide the Ethernet network over the telecommunication system. The Ethernet-based network provides multiple advantages over a fieldbus architecture, including the potential for future revenue sources. For example, other Lake Como utilities may lease bandwidth for their own industrial protocols or other applications such as surveillance and telephony may be hosted. The design also made the telecommunications independent of PLC and SCADA technology. A client-server architecture was chosen for the SCADA system. The simplified design is based on commercially available hardware with a modular open architecture for easier maintainability. PcVue, from ARC Informatique, was chosen for
14 WHAT'S NEW IN PROCESS TECHNOLOGY - SEPTEMBER 2014
versatility and ease of maintenance. The graphics provides a very lean display, thanks to modern symbols for visualisation and animation. Using a branching structure, the tags in PcVue minimise the number of screens to be developed. The client station deployment is essentially automatic - clients are enabled by simply sharing the project file, therefore any modification for the project can be made on the server and copied to the clients. The system has about a thousand alarms, which are divided into priority levels. All of the alarms are stored and are available in both textual forms and with graphic animations. When alarms are raised, the SCADA uses contextual logic to determine the appropriate course of action. For high-priority alarms, SMS text messages are sent to the operator based on the concept that the operator can connect to the network and acknowledge the alarm. If the operator does not respond within a designated time, the system will resend the SMS message until the alarm is acknowledged. Even the choice of the contractor was strategic. Only qualified system integrators capable of design and implementation of the entire system with full autonomy were considered. A critical aspect was to bring the new system online with minimal disruption. It was not easy to manually operate the system and only possible for short times during emergencies. To replace the SCADA, a total halt of the waterworks was required, so well organised and coordinated teams worked simultaneously on all sites to keep disruption during installation and commissioning minimised. The selected system integrator, TSA, provided a careful analysis of the state of the art in existing similar systems. TSA formed a partnership with Borghi, which had previously been responsible for the design and installation of new electrical switchgear and control. The synergy between the two partners (TSA-Borghi) allowed for a competitive proposal with a substantial savings in cost. More importantly, the team had all the necessary areas of expertise to be able to execute all stages from design to commissioning without depending on third-party subcontractors. Itech Corporation Pty Ltd www.itechcorp.com.au
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NEW PRODUCTS
PROFISAFE CONTROLLER MODULES Phoenix Contact’s Axioline F I/O system now includes Profisafe modules to enable the implementation of safety applications. Based on Profinet and Profibus, the modules enable the acquisition and output of safety-related signals in the control cabinet. The devices are characterised by their low-stress, delayed switchoff irrespective of bus faults due to integrated stop category 1. The channel-based diagnostic messages ensure high system availability. Their resistance to interference is due to their coordinated switching behaviour
HIGH-TORQUE ETHERNET SERVO DRIVES
under capacitive and inductive loads. Being completely integrated with the controller manufacturer’s engineering tool, the devices speed up the engineering process and simplify start-up.
ABB has enhanced its ranges of servomotor
The Profisafe modules are compliant with specification V2 and possess
drives for the Ethernet-based motion control
outputs with capacitive loads of up to 10 µF and 2 A rated current. They
systems market with variants that can sub-
meet safety integrity requirements up to SIL CL 3 and offer a performance
stantially increase the speed of machinery
level of up to PL e.
and automation systems while also reducing bill-of-materials costs. Due to a redesign of the drives’ power
Phoenix Contact Pty Ltd www.phoenixcontact.com.au
stage, the latest iteration of ABB’s MicroFlex e100 and e150 servo motor drives can now deliver peak current levels that are three times the continuous rated current, and sustain that
DOUBLE SENSOR DP TRANSMITTER
peak output for up to 3 s. This provides the
The Keller PRD-33X series differential pressure
torque to substantially increase the speed
transmitter includes a double sensor for measuring the
of moves and machine cycle times. In some
differential and line pressure independently, highly ac-
cases, ABB expects that the generous 3 s
curate measurements and a high overload resistance.
overcurrent capability will allow motion system
Due to calibration over its entire pressure and tem-
builders to use a smaller size of drive - reduc-
perature range, the PRD-33X achieves a high accuracy
ing system building costs dramatically and
level up to ±0.05% FS. A floating assembly of the sensor
potentially the footprint of systems as well.
unit provides protection from external forces during installation.
A higher overcurrent capability can be par-
Pressure tanks impose particular requirements on pressure transmitters. The closed
ticularly relevant for system builders employing
systems require two measurements to determine the level: one for the tank pressure and
new generations of high-performance servo
one for the liquid pressure. The PRD-33X having two independent sensors can achieve
motors with neodymium magnets, as these
this in one measurement process. All transmitter parts contacting with the medium are
tend to offer a peak current capability that
made from high-quality materials such as stainless steel AISI 316L, silicone, gold and
is at least three times the continuous rated
silicon. The PRD-33X is therefore suitable for use with (liquid) oxygen, argon, nitrogen,
current level. The 3 s overcurrent capability of
helium and carbon dioxide.
the drives may then be exploited to increase the acceleration of movements.
When it comes to the cryogenic liquefied gases, tanks that are smaller than 3 m can have a differential pressure range of only 200 mbar - with a line pressure of up to 32 bar.
MicroFlex e150 drives are compatible
With line pressure compensation of 0-40 bar, the PRD-33 X can tackle this challenging
with real-time EtherCAT, plus EtherNet/IP,
combination. When the tank is being filled or the valve is being used, the entire tank
Modbus TCP and TCP/IP protocols. Micro-
pressure can hit one side of the differential pressure transmitter. The PRD-33 X also copes
Flex e100 drives are compatible with the
with the resulting 32 bar uneven overloading with its overload resistance of ±35 bar.
real-time Ethernet Powerlink protocol, plus EtherNet/IP, Modbus TCP and TCP/IP.
Bestech Australia Pty Ltd www.bestech.com.au
ABB Australia Pty Ltd www.abbaustralia.com.au
16 WHAT'S NEW IN PROCESS TECHNOLOGY - SEPTEMBER 2014
www.ProcessOnline.com.au
NEW PRODUCTS
FLOW METER FOR COMPRESSED AIR The ST50 flow meter uses FCI’s highly accurate thermal dispersion mass flow sensing technology to provide highly effective direct mass flow measurement at a lower cost. With the ST50, there is no need for the temperature sensors, flow computers or other devices required with orifice plates, Venturis, Vortex shedding and other meters. The ST50’s design also provides built-in temperature compensation for reliable measurement over a wide temperature range with almost no pressure drop. Highly suitable for compressed air flow measurement, the ST50 features a wide flow range from 0.23 to 122 NMPS for air, compressed air or nitrogen. Flow meter accuracy is ±1% of reading, ±0.5% of full scale, with repeatability of ±0.5% of reading. The meter operates at temperatures from 4 to 38°C. The flow meter’s flow range can be field configured in either standard mass flow or volumetric engineering units. It features dual analog outputs, 4-20 mA and 0-10 VDC, which are field assignable as flow rate or temperature, and an RS232C I/O port. A 0-1 kHz pulse output for totalising flow is also available as an option. The flow meter features a rugged stainless steel sensing element with Hastelloy-C tips. Its electronics are housed in an all-aluminium, epoxy-coated enclosure that is NEMA 4X (IP66) rated and it withstands operational pressures up to 34 bar (g). The ST50 is available in three field-adjustable U-length probes, 152, 305, and 457 mm to accommodate pipe sizes 51 to 610 mm. Instrument powering options include both 18-36 VDC and 85-265 VAC. AMS Instrumentation & Calibration Pty Ltd www.ams-ic.com.au
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SEPTEMBER 2014 - WHAT'S NEW IN PROCESS TECHNOLOGY 17
EFFICIENT MULTITASKERS
Erwin Ruppelt, Head Project Engineer and Daniela Koehler, Press Officer, Kaeser Kompressoren SE
Since appearing on the market, master controllers have helped to significantly enhance the efficiency of compressed air stations, but the latest generation of these intelligent systems pushes the boundaries of compressed air efficiency even further.
P
roviding precision monitoring and control, the latest pneumatic system master controllers not only keep an eye on the compressed air system as whole, but also supply data for a range of applications. In short, they provide greater convenience, further enhance reliability, minimise costs and can be applied to an even wider range of uses. The drive towards efficiency, reliability and - most importantly - sustainable resource usage and energy savings is increasingly compelling developers and users to optimise existing solutions ever further. Modern installations are comprehensive systems, including compressors, cooling systems, dryers and filters. Even the individual components have auxiliary systems, such as ventilation or cooling water systems. Moreover, modern compressed air stations are often beneficially incorporated into heat recovery processes in order to achieve best possible use of the available energy. The range and number of individual components comprising a complete compressed air system can therefore be considerable. Complex systems such as these require an organising principle of sorts - this is where master control systems come into play. By monitoring the individual components and optimally coordinating the interaction between them, these controllers transform the
18 WHAT'S NEW IN PROCESS TECHNOLOGY - SEPTEMBER 2014
individual ‘players’ into a truly cohesive team that operates reliably and efficiently. Up until now, use of such systems has yielded a certain degree of optimisation. For instance, master controller systems such as the Kaeser SAM with 3D-Control have for some time been capable of coordinating multiple compressors with different internal control systems, ensuring that they supply the required and set working pressure with maximum energy efficiency.
Better communication among components Even with all this aforementioned optimisation, there are still certain aspects that harbour significant potential for improvement. For example, communications between the components and controllers still presents considerable potential for development and refinement. Some compressors are equipped only with floating contacts that merely signal the basic status of the compressor (running or not running) and do not feature integrated controllers capable of detecting and communicating more detailed status information about the compressor. Furthermore, within the wide range of different bus systems available on the market, many are not compatible with one another
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Pneumatics
able to transfer this data rapidly without limitation to a centralised control system for evaluation. A closed, secure network ensures that the data is secure and cannot be accessed from outside the system without access permission.
Graphical interfaces ensure straightforward operation Once in the system, the data is visually displayed for maximum intelligibility and is easy to access. The components of the compressed air station are represented graphically and can be individually called up with just a few clicks. Once configured, the information can be displayed on the controller itself or on a PC or a centralised control system. Users can select which data they wish to transfer; for security reasons the functions can only be accessed from the controller itself. The collected data then open up a range of monitoring, evaluation and application options.
Optimal energy management of components The primary uses of a management system are to provide compressed air production monitoring and to automatically optimise compressed air system performance. For example, while also ensuring maximum operational reliability and efficiency, the compressors and treatment components are switched on and off as needed, or operate at partial load, so that compressed air quantity and quality always remain in step with actual demand. The new compressed air management systems are available for compressor stations of varying sizes. Currently, systems of up to 16 compressors can be integrated for monitoring and control. at all or can only be made compatible with difficulty. This makes it difficult to communicate all the necessary information regarding a system’s status. Contemporary Ethernet-based bus systems enable more straightforward integration and communication of large data volumes. Systems equipped with modern internal controllers therefore already rely on Ethernet technology in order to communicate with other networked systems.
Latest generation of management systems The latest master controllers are true management systems which act like master controllers, yet are capable of much more. Compressed air management systems are designed to provide energy-optimised management of the compressed air station as a whole. Easy to operate, they also supply data for various output and evaluation forms, and ensure optimal, predictive maintenance and efficiency of the entire compressed air system.
Innovative communications infrastructure The new management systems gather information regarding the connected components and measurement points via the network and are
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An eye on system parameters The management systems additionally monitor all other relevant system parameters, such as the temperature and pressures in the compressor and compressed air treatment system, as well as ambient environmental conditions. This means the control system can also check whether a compressor’s cooling system is performing as required and whether environmental conditions (such as temperature and pressure) are consistent with the relevant requirements. Where heat recovery systems are used, all associated parameters can also be integrated in the management system. Using an integrated, freely programmable control logic module, peripheral devices necessary for compressor station operation can be flexibly programmed, to open inlet or circulating air louvres, for example.
Predictive maintenance However, progress isn’t restricted to system operation alone. Maintenance represents a key area to consider when it comes to maximising cost-effective compressed air production. It goes without saying that poorly maintained systems with contaminated coolers or filters,
SEPTEMBER 2014 - WHAT'S NEW IN PROCESS TECHNOLOGY 19
Pneumatics THE LATEST GENERATION OF COMPRESSED AIR MANAGEMENT SYSTEMS NOT ONLY CONTROL THE COMPRESSORS THEMSELVES, THEY ARE NOW ALSO CAPABLE OF KEEPING AN EYE ON AUXILIARY PARAMETERS SUCH AS THOSE FOR COMPRESSED AIR TREATMENT, ENVIRONMENTAL CONDITIONS AND SYSTEM MAINTENANCE.
Retrofitting only where necessary
Figure 1: The latest compressed air management systems provide a comprehensive range of useful options, including monitoring, analysis and prediction, as well as flexible data evaluation and application. for example, also operate with impaired specific output values. New management systems therefore also take maintenance parameters into account and include them in overall optimisation strategies. Over the long term, preventive maintenance not only reduces both energy consumption and costs, but also helps boost the value retention of the system as a whole. This more complex monitoring also enables the creation of predictive maintenance schedules.
Documentation and management In addition to control of the compressor package itself, the latest generation of management systems also enables the gathering, forwarding and evaluation of important data to produce documentation in accordance with ISO 50001 (ISO 50001:2011 - Energy Management System). The new management systems collect data regarding air consumption and, where applicable, heat recovery. Based on this data, costs are automatically calculated and can be assigned once again to the various individual components within the system. These functions, including visualisation, are accessed via the web using standard browsers without the need for any additional software. Compressed air management systems can therefore determine and collate a range of key metrics, including evaluation and analysis of compressor status, time period comparisons, threshold value evaluations, energy tables, cost tables and capacity.
Integration of older systems Of course, the benefits of monitoring and maintenance are most effective when all the compressed air station components (compressors, filters, dryers, etc) feature the latest technology. But what if the existing system doesn’t correspond to the latest standards? Well, there’s no need for worry, as compressed air management systems also allow integration of older, less advanced systems. Although monitoring is more difficult if the available compressor system is not appropriately technically equipped, it is still possible. Depending on how modern the technology is, integration is accomplished via different types of controller or bus converters.
20 WHAT'S NEW IN PROCESS TECHNOLOGY - SEPTEMBER 2014
Anyone considering retrofitting an existing compressed air installation with a new compressed air management system should be aware that this strategy doesn’t necessarily make sense for every system. The age of the existing machines determines whether a retrofit will actually deliver advantages. If they already feature temperature and pressure sensors and the filters are monitored, retrofitting is relatively straightforward. The signals already being transmitted are usually conditioned locally by signal conditioning devices and can then be retrofitted for use with bus converters that suit the management system. If the existing system has no monitoring points at all and the compressors are relatively old, then it likely doesn’t make sense to equip the systems with additional sensors. This is because technical development over the years has resulted in significant efficiency gains, which, of course, also applies to the world of compressors. In such cases, it is advisable to consider a completely new system ready equipped with modern monitoring and sensor capabilities. The overall potential efficiency gains and energy cost savings can quickly offset the associated investment cost.
Potential savings depend on the current situation The extent to which installation of a new compressed air management system yields energy savings depends on the current situation of each individual operator. In the past, compressed air stations were rarely conceived with a comprehensive energy efficiency concept in mind, and even today this approach is not universal. This being the case, it is older stations in particular that present the greatest potential for improvement. When such stations are updated to the latest technology, the potential savings are considerably higher than for systems that are already optimised. Controllers have been on the market in various forms for several years. The leap from the once common, traditional cascade control to controllers with average target pressure delivered energy cost savings of up to 20%. The next leap to systems with demand pressure control yielded around a further 6% in energy savings. The latest control systems are still new and being tested, but it is already clear that the savings potential will be even greater.
Conclusion New compressed air management systems minimise interface problems and require no additional software to provide valuable cost monitoring information. Compressor station master controllers are increasingly evolving into management systems that not only control the compressors in accordance with compressed air demand requirements, but which also monitor the compressed air system as a whole, as well as associated auxiliary systems. This is performed with optimum efficiency and maximum evaluation potential in mind, which, in turn, delivers improved reliability with more detailed information regarding the system and significantly reduces operating costs. Kaeser Compressors Australia www.kaeser.com
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30 Sept-2 Oct 2014 Melbourne Convention and Exhibition Centre, Melbourne, Australia
Utilities
|
Government
|
Enterprise
|
Transportation
|
Resources
|
Public Safety
COMMS CONNECT RETURNS TO MELBOURNE Now in its 8th year, Comms Connect has become the leading conference and exhibition for combined communications users and industry. With keynotes, workshops and panel sessions, this year will see the launch of a new, dedicated stream focusing on all that is important in the public safety communications sphere.
Keynotes
2014 Training workshops include:
Deputy Chief Eddie Reyes — Alexandria, VA Police Department
• Next Generation Triple Zero (NG000): challenges and opportunities
Next Generation 9-1-1 (0-0-0): Are public safety agencies ready?
• In a converged communications environment, just how secure is your radio system?
Shane Fitzsimmons AFSM — Commissioner NSW Rural Fire Service (RFS)
• Advanced radio over IP
The value of communication networks in a public safety environment
Visit www.comms-connect.com.au for more information on speakers, topics and half-day training workshops.
Digital Partner
•E nsure network migration success with change management •F ibre Optic for the radio technician, a fundamental overview •T ETRA: Advanced systems planning, integration and deployment
Platinum Sponsors
Prize Draw Sponsor
Gold Sponsors
Lanyard Sponsor
Silver Sponsors Magazine Partner
In association with
Supporting associations & media organisations
In conjunction with the ARCIA Industry Gala Dinner — 1 October 2014 — MCEC. Visit www.arcia.org.au to book your tickets.
Register online at www.comms-connect.com.au
NEW PRODUCTS
FLAME-BARRIER CABLES Prysmian Power Cables and Systems has de-
DETECTABLE SPHERICAL BEARINGS
veloped a range of flame-barrier cables that are
The igubal self-aligning bearings line from igus has been
suitable for use with non-barrier type flameproof
extended with spherical detectable bearings. The line
glands and are specifically designed to be
includes a range of lubrication and maintenance-free
used in a variety of hazardous and potentially
rod-end bearings, clevis joints, flanged units, press-fit
explosive applications including mine sites, oil
and pedestal bearings.
and gas platforms, fertiliser plants, chemical
Both the housing and spherical ball are detectable by standard metal-
installations and explosive manufacturers.
detection systems to pick up even the smallest particles of the bearings were failure to occur. The bearings are easy to install, adjust to all angular misalignments, and can replace traditional metal bearings, which can weigh up to 80% more than igubal. The detectable bearings are dry running, unaffected by dirt and dust, operate well in liquids and a variety of chemicals, and are corrosion resistant. They are suited to run in temperatures from -20 to +80°C and are able to absorb very
Prysmian’s flameproof cables cover all
high forces due to their vibration-dampening properties. They also possess
requirements for LV power, LV control and
high levels of compressive strength and elasticity.
ELV instrumentation. They offer a substantially
Treotham Automation Pty Ltd
compact and circular construction, evaluated
www.treotham.com.au
and tested for gas groups IIA and IIB to the requirements of AS/NZS 60079.14-2009 clause 10.4.2 (b) and AS/NZS 60079.1-2007 clause
WIRELESS BATTERY MONITORING SYSTEM
15.2 utilising already certified Exd rated, non-
The Ablerex Enerbatt 3G wireless battery monitoring system is based on short-range radio linking
barrier-type flameproof glands with sealing rings.
of individual battery block monitoring units, allowing battery characterisation and detection of
Armoured cable versions afford wiring protec-
incipient problems. Mature radio data transmission technology avoids cumbersome, problem
tion levels exceeding EPL Gb for non-energy
prone and costly cable harnesses, and provides superior battery bank expansion flexibility.
limited wiring systems in accordance with
The system provides one-second reports on battery impedance, voltage, temperature and
AS/NZS 60079.14-2009 table 6. This protec-
string performance and monitors up to 4000 batteries, transmitting battery data via 2.4 GHz
tion level is generally adequate for Zone 1
radio links with up to 50 m reach. Individual batteries in a string are monitored in one-second
and Zone 2.
intervals by BMK monitoring units suitable for 2, 6 and 12 V. Individual battery voltage and temperature are transmitted by 2.4 GHz radio signal to BMS-RFR receiver.
There is also an option of specific engineering to provide reduced flame propagation exceed-
BMS-HCT Hall-effect CTs monitor individual string currents (from 50 to 2000 A) and feed
ing the requirements of IEC 60332-3 category
this information to BMS-SMK string measuring kits (one per string) measuring string voltage
C bunched vertical test. General market orange
to 150 or 750 V. BMS-RFR receivers pick up the signals from battery voltage BMK monitoring
circular TPS cables do not necessarily comply
units and BMS-SMK string measuring kits (up to 256 nodes).
with this performance - they are required to
The BMS-RFR receivers are daisy-chained to transmit their data to the BMS-DC-LCD data
comply only with single cable burn test to IEC
collector. With a 16 GB flash memory card and 7″ LCD touch screen, the data collector
60332-1-2, which is not considered adequate
provides immediate supervision and can by connected via RS485 to supervisory computers.
performance for bunched cable systems.
Power Parameters Pty Ltd
Prysmian Cables & Systems Australia Pty Ltd
www.parameters.com.au
www.prysmian.com.au
22 WHAT'S NEW IN PROCESS TECHNOLOGY - SEPTEMBER 2014
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NEW PRODUCTS
AIR FLOW METERS FOR HAZARDOUS AREAS Sierra Instruments QuadraTherm 640i and 780i air flow meters have received global approvals for the following standards of safe operation in potentially hazardous environments: cFMus (USA and Canada), ATEX (European Union) and IECEx (International). This signifies that the QuadraTherm is certified as flame-proof and protected from dust ignition sources, and meets all design criteria for electrically powered flow meters used in areas where combustible gases may be present. The IECEx and ATEX certification programs ensure explosion-proof and hazardous area compliance in the European Union and international destinations. The cFMus certification program ensures explosion-proof and hazardous area compliance in the United States and Canada. With approvals, QuadraTherm is approved for applications in hazardous plant areas like facilities management, chemical processing, oil and gas, wastewater, and natural gas throughout the European Union and international communities. The QuadraTherm provides an accuracy of ±0.5% of reading above 50% of full scale for flow meter air measurement and other gases. It also offers built-in flow conditioning (inline version), has multivariable outputs and can measure flow ranges up to 60,000 sfpm (305 smps). It is available in two models: the 640i insertion and 780i inline. The QuadraTherm family has a no-drift sensor with lifetime warranty; has multivariable output for mass flow, temperature and pressure (optional); and measures all inert and all non-condensing clean gases, as well as flammable gases (methane, propane, hydrogen and digester gas). Repeatability for mass flow rate is ±0.15% and gas accuracy is ±1°C. Procon Instrument Technology www.proconit.com.au
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SEPTEMBER 2014 - WHAT'S NEW IN PROCESS TECHNOLOGY 23
NEW PRODUCTS
SECURE DATA ACCESS ACROSS THE DMZ
DIN POWER SUPPLIES The Mean Well EDR-75
The MatrikonOPC DMZ Agent provides a secure, standardised solution for
and NDR-75 series DIN rail
accessing real-time and archived control automation data across DMZs using
fanless power supplies are
off-the-shelf MatrikonOPC products.
designed for those projects
Corporate IT departments implement DMZs to protect network assets by
that require a more efficient
layering and isolating secure zones from those that are considered less secure.
power supply at a lower cost. With
Network traffic is restricted between these layers via multiple firewalls. While
the same dimensions as the SDR-75
DMZs work to secure the automation environment from the dangers present in
series, the EDR-75 and NDR-75 are
the outside world, they prevent necessary operations and business applications
suitable for cabinets with a limited width.
from accessing key data using traditional methods. The MatrikonOPC DMZ Agent
Both the EDR-75 and NDR-75 accept a
overcomes DMZ related control data sharing issues by providing engineers and
full range 90-264 VAC input, and are available
system integrators with two time-tested OPC architectures depending on design
with 12, 24, and 48 VDC outputs. They offer
and corporate security policies.
an efficiency of up to 88.5% (EDR-75) and 89% (NDR-75),
The DMZ Agent Pull solution enables permitted enterprise applications to securely initiate requests for OPC data located within a secure network, while
and have an operating temperature range of -20 to +60°C (EDR-75) and -20 to +70°C (NDR-75) respectively.
the DMZ Agent Push solution allows permitted enterprise applications to receive
Other features include short-circuit protection, overload
secure network data pushed from within a DMZ (one-way firewall configuration).
protection (constant current limiting output), overvoltage
The DMZ Agent eliminates traditional DCOM and firewall issues associated
protection, overtemperature protection, and front-panel DC
with DMZs, while providing secure, controlled access to process data. The Push
voltage adjustment.
architecture provides access to historical data, while the Pull architecture provides
The EDR-75 and NDR-75 series are certified to UL/CUL/
access to real time or historical data. The agent is OPC UA compatible and has
CB/TUV/CE safety regulations and are supplied complete
configurable data encryption.
with C-Tick.
MatrikonOPC
ADM Instrument Engineering Group
www.matrikonopc.com
www.admtech.com.au
Consistent Quality
Specialist
Design I/O Modules for: • Data Acquisition
• Digital and Analog I/O • Temperature Measurement • Thermocouple and RTD’s • PLC I/O Expansion • Point to Point Multiplexing • Ethernet/Serial Converters • Programmable Logic Controllers
phone: fax: email:
+61 2 9624 8376 +61 2 9620 8709 glen@proconel.com
www.proconel.com 24 WHAT'S NEW IN PROCESS TECHNOLOGY - SEPTEMBER 2014
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CASE STUDY
Managing power demand at Gardena At Gardena Manufacturing near the ancient town of Ulm in southern Germany, work proceeds at a brisk pace, and in a high-pressure environment - quite literally. Each year, the site’s 93 injection-moulding machines turn 9400 metric tons of plastic into 500 million parts, such as handles for pruning shears and push lawn mowers. Work proceeds seven days per week, from Monday to Friday at full capacity in three shifts, while weekends are a bit slower with fewer machines and workers on duty. It is a clear pattern, and power demand at the plant follows the same routine. On an average workday, Gardena Manufacturing uses an average of between 2 and 2.3 MW. On Saturdays and Sundays energy demand drops to one or two megawatts, depending on the workload. This regularly repeated p a tt e r n i s s o m e t h i n g t h e power company has adjusted to. It knows how demand will change over the course of the week and can plan its output accordingly. This pattern is reflected in its supply contract g u i d e l i n e s w i t h G a rd e n a Manufacturing. On the one hand, the company must pay for the electrical energy it uses. On the other hand, the power company guarantees that Gardena can always pull up to 2.68 MW of power. But exceeding that amount on even a single occasion would be expensive for the plant. “The power company determines our average power use in fifteen-minute intervals,” explains Jürgen Röck, who shares responsibility for automation and load management at Gardena Manufacturing. “If we are over the contractually agreed maximum during even a single interval, that costs us a lot of money, because then the power company raises the guaranteed maximum value for the rest of the year, and of course we have to pay for that.” A few years ago it happened. When Gardena’s machines were started up after Easter, power demand suddenly rose to 3.2 MW for a short period, because the machines required a particularly large amount of power when starting up in unison. Gardena wanted to prevent that from happening again. As a result, the company decided to use the latest load management technology. In the spring of 2010, engineers installed nine Siemens Sentron PAC 3200 monitoring devices at the plant’s transformers. The devices measure current, voltage, and power. Their measurements are fed into a Simatic S7-400 controller that produces a power demand forecast for the current 15-minute interval. The goal here is clear: average power demand should never exceed the limit of 2.68 megawatts. Röck, an electrical technician, can look at the plant’s current status at any time. All he has to do is to click the Siemens
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Simatic WinCC Powerrate app on his desktop computer. “A green area shows me how much electrical energy we’ve already used,” he says. “An orange-coloured line shows the forecast for the remainder of the 15-minute interval. As a result, we see immediately whether we’re in danger of going over the maximum.” But if the plant gets too close to its limit, the system responds automatically. The controller gradually scales back power use until things are back to the normal range. In 200 kW stages, it reduces the power of the systems that extract heat from the process water that cools off the
moulds in the injection-moulding machines. Here, a shortterm temperature increase is not a problem. Similarly, the drier for the plastic pellets can also respond flexibly to load management needs. Its power can be reduced in four stages by 28 kW each time. The control system has proven to be remarkably effective. Since it was installed, power demand has never exceeded the stipulated maximum. “Since we already use a great deal of Siemens equipment, the installation of the load management system didn’t cost very much. For example, we were able to use the existing S7 communication system for data transfer among the Siemens controllers,” says Röck. “Thanks to its reduction in peak loads, the load management system will pay for itself within a year.” And Gardena Manufacturing plans to further expand its energy monitoring. In the near future, for instance, Röck will be able to use WinCC to keep track of how the compressed air and heating systems are working. Although he won’t be able to influence power demand this way, the readings will provide him with valuable clues regarding possible leaks in pipes or pumps that could be draining energy from the plant. Siemens Ltd www.siemens.com.au
SEPTEMBER 2014 - WHAT'S NEW IN PROCESS TECHNOLOGY 25
NEW PRODUCTS
MINIATURE PRESSURE AND TEMPERATURE TRANSMITTER A fully functional digital combination transmitter for pressure and temperature, claimed to be the smallest available, has been launched by Keller AG für Druckmesstechnik. In the LD series, all the electronic components are accommodated in a laser-welded stainless steel housing filled with silicone oil. Measuring only 11 mm in diameter, the housing contains the sensor technology, the compensation coefficients, the digital signal processing and the I2C interface for simple, loss-free integration into higher-level systems. Made of stainless steel or Hastelloy, the housing not only acts as a Faraday cage but also offers appropriate pro tection against electromagnetic radiation and all potential environmental influences. Due to the chip-in-oil technology, extremely short signal paths with exceptionally high impact and vibration resistance are realised. Six standard measurement ranges extend from 1 to 200 bar abs. with a compensated temperature range of -10°C to +80°C. Accuracy is rated as better than ±0.15%FS, and a total error band of less than ±0.5%FS is attained between 0°C and 50°C. The temperature measurement accuracy is ±2 K. Transmitters in the LD series are optimised for battery-powered applications: during A-to-D conversion, current consumption is ~1.5 mA, dropping to ~0.1 µA in idle mode. The supply voltage range of 1.8-3.6 VDC corresponds to a normal microprocessor environment. With a diameter of 11 mm, the Series 4 LD is the smallest of four versions. Larger models measuring 15 mm, 17 mm and 19 mm in diameter are also available for relative pressure measurements. KELLER AG für Druckmesstechnik www.keller-druck.com
PRESSURE TRANSMITTER The ESI GS4200 pressure transmitter is designed to meet the operational requirements of demanding pressure measurement applications and incorporate ESI’s silicon-on-sapphire sensor technology to give high stability over a wide temperature range. The design of the GS4200 allows the sensor to endure higher overpressures and titanium alloy wetted parts give it high corrosion resistance. The GS4200 exhibits virtually no hysteresis as well as high long-term stability. The sapphire substrate allows the pressure sensor to operate over a wide media temperature range of -50 to +125°C without loss of performance. Accuracy is ±0.25% with a typical overpressure limit of twice the rated pressure range. The electrical output from the GS4200 is the industry standard 4-20 mA and there is easy access for recalibration. All models are supplied with integral 1/4″ BSP process connection, and alternative options are available. There are also versions available offering IP66 sealing. Typical applications for the GS4200 pressure transducer are numerous and include the continuous monitoring of hydraulic systems with oil, gas, water and other process liquids, industrial, medical and aerospace industries. The GS4200 is also suitable for the measurement and control of pressure in refrigeration, pneumatic, compressor, HVAC and engine monitoring systems. An optional IECEx certified version of this pressure transducer is available, approved for explosion protection for flammable gases (Zone 0), dusts (Zone 20) and mining areas (Group I M1). ADM Instrument Engineering Group www.admtech.com.au
26 WHAT'S NEW IN PROCESS TECHNOLOGY - SEPTEMBER 2014
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NEW PRODUCTS
WATER SYSTEM MODELLING SOFTWARE Bentley Systems has announced the availability of its SewerGEMS, SewerCAD, CivilStorm, and StormCAD V8i (SELECTseries 4) products for the analysis and design of wastewater and stormwater systems. The for an increased depth of information modelling that empowers users to
ETHERNET I/O MODULES
evaluate and compare a wider range of network considerations. Users
Acromag has expanded
are able to assess trade-offs across disciplines and systems in terms
its BusWorks XT Series of
of cost, time, and efficiency.
Ethernet I/O modules with
updated releases provide advanced hydraulic and operational capabilities
The SELECTseries 4 release provides users with a number of new or
the XT1210 and XT1220
enhanced capabilities. SewerGEMS users can leverage SCADA systems
models that provide an 8-channel
and data loggers through SCADAConnect, supporting calibration and
interface for analog voltage or cur-
operational efforts; and model hydrogen sulphide formation to decrease
rent input signals and EtherNet/IP,
the risk of pipe damage, prevent odour complaints, and improve safety.
Modbus/TCP, Profinet or peer-to-
SewerGEMS, SewerCAD, CivilStorm, and StormCAD users can conveniently trace and display the surface-water flow direction across any
peer communication. Differential inputs have superior
terrain, ensuring proper location of inlets and other drainage infrastructure
noise rejection for reliable measurements when radiofrequency or
as well as automatically assign elevation data to manhole elements for
electromagnetic interference is present. Internal software helps elimi-
faster model building and updating. They can also import MX drainage
nate the effects of network traffic loads for more reliable messaging.
files easily and efficiently, facilitating ready access to the data, and
The slim design features dual Ethernet ports, removable front-
explicitly model headwalls and endwalls for culverts more efficiently.
facing terminal blocks and DIN rail power bus support. Convenient
SewerGEMS and CivilStorm users can design stormwater ponds more
USB-to-PC connection makes configuration fast and simple with
quickly and easily using PondMaker.
free Windows software. Suitable for use in harsh environments,
Users of any of the SELECTseries 4 releases are said to benefit
all modules operate from -40 to 70°C with high-voltage isolation,
from the products’ support of AutoCAD 2015, giving them the ability
surge protection and CE approval. UL/cUL Class 1 Division 2
to model from within the latest AutoCAD version.
Zone 2 hazardous location approval is pending.
Bentley Systems Pty Ltd
Metromatics Pty Ltd
www.bentley.com/en-AU/ Projekt1 18.07.14 09:06 Seite 1
www.metromatics.com.au
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SEPTEMBER 2014 - WHAT'S NEW IN PROCESS TECHNOLOGY 27
NEW PRODUCTS
SIL3-CERTIFIED LEVEL TRANSMITTER
PHOTOELECTRIC SENSORS
Emerson Process Management’s Rose-
The O6 type photoelectric sensors from
mount 5300 2-wire GWR level transmit-
ifm are now also available in a stable plastic
ters are now certified to IEC 61508 for
housing. The robust diffuse reflection sensor
safety instrumented functions up to SIL3.
features reliable background interference suppres-
Companies in the oil and gas production,
sion. The ranges are set via potentiometer and a rotary
refining, petrochemical, chemical and power
switch which is intuitive and simple (light-on/dark-on selection).
industries can use the level transmitters for
The sensing range is independent of the characteristics and colour of the object being detected.
safety-critical level applications such
With the O6 sensors, highly reflective backgrounds like stainless steel, as well as moving ma-
as overfill prevention and dry-pump
chine parts, do not affect the background suppression. The clearly defined round light spot in the
protection.
operating area ensures a consistent light distribution in the light cone. Scattered light around the
The functional safety assess-
light spot which could potentially disturb other photoelectric sensors due to reflections is completely
ment was performed by the
avoided. This provides additional safety. For the compact unit (13 x 41 x 21 mm) ifm offers vari-
independent global organisa-
ants with PUR connection cable, M12 pigtail or a robust M8 metal connector on the housing. The
tion exida. It covered SIL2-rated
sensors are also available as through-beam and retroreflective systems. A wide range of mounting
safety applications in a single configuration, and SIL3-rated safety applications in redundant mode. The certification means that the level transmitter
accessories allows universal installation without problem. ifm efector pty ltd www.ifmefector.com
is suitable for continuous level measureup to SIL3, as defined in IEC 61511
PROGRAMMABLE LOGIC CONTROLLER
for applications in the process industry.
The Panasonic FP7 Series programmable
Traditionally, fixed-point-level devices
logic controller offers a fast, 32-bit pro-
have been used for overfill prevention
cessor platform with a large adjustable
and dry-pump protection. The Rosemount
memory capacity for program or data and
5300 GWR provides all the benefits of
a high-speed processor capable of 11 ns
continuous level measurement, including
per step. It incorporates all the functional-
the actual product surface location con-
ity and performance of a modular PLC in a
firming that the level sensor is functioning
compact format with a height of 90 mm. Typically the FP7 lends itself to
correctly. The high- and low-level alarms
larger machine or plant control where I/O counts are high and there is more process-oriented
are set up locally or remotely during
control taking place. With 16-bit analog cards offering 25 µs per channel conversion rate and
the installation and configuration process.
an accuracy of 0.05%, precise control can be achieved. An Ethernet communications op-
Proof testing is required at regular
tion allows for field I/O or devices to be integrated via Modbus TCP/IP. Direct connection of
intervals to confirm that the overfill and
24 VDC to the processor eliminates the need for dedicated power supply units, and expan-
empty-tank protection functions result
sion units are clipped together without the need for a backplane, reducing the cost of the
in the desired system response. These
PLC itself and the overall cost of the job due to the reduced footprint.
ment in safety instrumented functions
conditions can be simulated either locally
The PLC programs can be password protected or additionally, different security levels can
using a HART-compliant master, such as
be set, according to application requirements. The CPU unit can also store two programs
a Rosemount Radar Master or Field Com-
so in the event of a fault no SD memory card is needed to return to a previously saved
municator, or remotely using Emerson’s
backup program. The IEC61131-3 compliant programming software has been updated to
AMS Suite software.
FPWIN Pro 7 and is compatible with all Panasonic FP family PLCs.
Emerson Process Management
Control Logic Pty Ltd
www.emersonprocess.com.au
www.control-logic.com.au
28 WHAT'S NEW IN PROCESS TECHNOLOGY - SEPTEMBER 2014
www.ProcessOnline.com.au
NEW PRODUCTS
SUBMERSIBLE DEWATERING PUMPS The Tsurumi LH4110-W is designed to improve the way mining engineers, quarry and construction operators carry out dewatering duties. The LH4110-W can achieve up to a 200 m total head while providing a 1000 L/min maximum flow, but is only 592 mm in diameter. Tsurumi’s LH-W series feature two abrasion-resistant, high chrome closed impellers and a centre-mounted discharge flange that ensures the pump is balanced for lifting. The LH-W range is available with discharge ports of between 50 and 100 mm, and has a slimline design, enabling the pump to be used in bores and wells, with major cost reductions for users. The LH4110-W is a fully lubricated dual silicon carbide mechanical seal enclosed in an oil chamber. This eliminates spring failure caused by corrosion or abrasion and keeps both surfaces of the mechanical seal lubricated and cool. An oil lifter guide vane inside the oil chamber ensures the mechanical seal is lubricated even if the oil level falls. This increases the time between routine pump maintenance and extends operating life. An anti-wicking cable block on the cable entry also prevents water incursion due to capillary wicking should the power cable be damaged or the end submerged. Tsurumi claims this eliminates around 40-50% of submersible pump failures, again delivering lower operating costs and significantly improving reliability. The pump comes with a 2-pole, 415 V motor, driving the impeller through a high-tensile, stainless steel shaft supported by deep groove ball bearings. Australian Pump Industries Pty Ltd www.aussiepumps.com.au
www.ProcessOnline.com.au AUS.indd 1
SEPTEMBER 2014 - WHAT'S NEW IN PROCESS TECHNOLOGY 29 14-8-19 下午6:30
CASE STUDY
Compagnie des Fromages saves energy with Emerson technologies Compagnie des Fromages is part of the Bongrain Group, the world’s fifth-largest milk-processing company. In pursuing a policy to reduce energy consumption and CO2 emissions at its plant in the town of Vire, France, the company engaged Cofely Axima-GDF Suez to perform an energy audit. The audit provided a snapshot of the Vire plant’s consumption levels and suggested replacing its four piston compressors, which provided only cooling, with a thermorefrigerating pump. Chilled water at 1-7°C and 200 m3 of hot water at 60°C are produced daily at the Vire plant. To do this, the old system consumed an average of 820 kW of energy per tonne of production per year. In the system audited, this water was heated by gas, which has a high carbon footprint. In addition, the heat produced was rejected to the atmosphere by a cooling tower instead of being recovered and re-used. This solution was to use a process that heats and cools within a single cycle, recovering and re-using the heat. Its key components were supplied by the Emerson Group: a Vilter singlescrew compressor from Emerson Climate Technologies and a LeroySomer variable-speed drive from Emerson Industrial Automation. The new system now saves 9000 m3 of water a year and has reduced use of the cooling tower, which, with its plumes of steam, always reflects negatively with local residents. A thermorefrigerating pump is a thermodynamic heat-transfer system that can cool and heat at the same time. The refrigeration system makes it possible to provide cooling capacity to the evaporator and heating capacity to the condenser. When chilled water is produced at Vire, 1300 kW of energy is recovered at the same time and combined with just 100 kW of electricity to heat water to +62°C. All the energy produced and used is fully recovered. A 150 m3 buffer storage unit allows energy to be used to produce hot water as needed by the process (particularly cleaning operations). At the heart of the system are a 390 kW motor and a variablespeed drive. Both are made by Leroy-Somer and power a Vilter single-screw compressor with 1000 kW of cooling capacity. The refrigerant circulated in the system is ammonia (NH3). Cooling and heating are simultaneously produced for one-third of the time. To raise the water temperature from 15 to 58°C, the ammonia, after having removed heat from the cold side to produce chilled water, is compressed to achieve the right pressure and temperature. As this temperature is much higher than the usual temperature for a conventional cooling system, the ammonia condenses at 59°C.
30 WHAT'S NEW IN PROCESS TECHNOLOGY - SEPTEMBER 2014
The water is heated by transferring the heat from the ammonia via the condenser and other heat exchangers located at various points in the system for heat-optimisation purposes. During the remaining one-third of the time, chilled water is produced conventionally. Ultimately, the system will recover all the heat extracted during the production of chilled water. The old system for chilling and heating water consumed an average of 820 kW of energy per tonne of production per year. With the new system, this level is now only 560 kW. “As a result, the payback period is particularly short, even when you factor in received aid, which amounts to less than 20% of the funding,” says Patrick Marie, maintenance manager of Compagnie des Fromages. “The process for producing heat with less grid electricity is not the only source of energy savings,” says Jean-Yves Druillennec, sustainable development manager for Cofely Axima-GFD Suez. “The use of much more energy-efficient components is the other source.” Instead of standard twin-screw compressors, Vilter uses a singlescrew compressor. Compression is accomplished by a single screw and two star-shaped gaterotors. The compressor is designed to balance the single screw both radially and axially. This balance ensures that very low loads are placed on the bearings, thus achieving a high level of reliability with considerably reduced vibration and noise levels. This design allows Vilter to offer its exclusive 5/15 warranty (5 years for the compressor and 15 years for the bearings). The key to the single-screw co m p re ss o r ’s h i g h e n e r g y efficiency is Vilter’s exclusive Parallex slide system, which allows the compressor to run at optimum efficiency throughout its capacity range. The capacity and volume slides (with an expanded volume ratio of 1.2 to 7.0) move independently of each other under all operating conditions, eliminating over- or under-compression and saving motor horsepower. Cofely Axima was in charge of managing every aspect of the project, from engineering and installation, to control and supervision (PLC control, instant performance monitoring and traceability of all parameters). Only the electrical wiring was contracted out. Compagnie des Fromages’ process was down for only three hours during the commissioning phase. A slightly longer and more detailed version of this article can be read online at http://bit.ly/1CkUB9L Emerson Industrial Automation www.emersonindustrial.com
www.ProcessOnline.com.au
NEW PRODUCTS
ETHERNET-COMPATIBLE ANGLE TRANSDUCER The Camille Bauer Kinax HW730 is
NON-CONTACT THERMOMETERS
a hollow-shaft angle transducer with
The Ametek Land Cyclops L family of non-
Modbus/TCP and PoE.
contact thermometers includes four
Suitable for incorporation in complex
models measuring across a range from
control schemes, the Kinax HW370 an-
200 to 3000°C. They are designed for
gular position transducers have a Modbus TCP/IP (IEC 61158) 100BaseTX Ethernet (PoE) interface and utilise an 8-pole spring-type terminal
a wide range of applications including liquid metal, steel and glass production, and furnaces.
block or 4-pole solid cable gland to connect to Cat-5 wiring. They are
A high-efficiency Route Manager enables users to
dustproof and waterproof according to IP67/IP69K and are also suitable
identify each location with a description, an emissivity
for marine service applications according to GL (German Lloyd) require-
value, a window correction factor (if applicable) and
ments. They are designed to be used in challenging environments and
a unique identifier. This mode allows for complete
offer high vibration and shock resistance in accordance with IEC 60068-2-6.
repeatability of readings, making the thermometer a
The mechanism for angle measurement is capacitive, utilising an
suitable tool for multiple locations requiring regular
accurately dimensioned rotatable vane from 0 to 360° in clockwise or
and reliable monitoring.
anticlockwise mode, with a 14-bit resolution (absolute precision of ±0.15°),
The thermometer stores up to 9999 temperature meas-
and has a low starting torque of only 0.5 Nm. Parameterisation and data
urements with a 0.1°C measurement resolution. All can be
acquisition is facilitated via Camille Bauer CB PC Manager software,
downloaded to an optional logger to capture, view and
included in the package.
record live temperature readings for further analysis and
The Kinax HW370 transducers are supplied in rugged anodised
comparison. The thermometers have a precise, narrow field
aluminium housings and are capable of accommodating up to
of view and continuously focusable optics with through-the-
30 mm shaft extensions.
lens sighting for accurate sample point selection.
Power Parameters Pty Ltd
OneTemp Pty Ltd
www.parameters.com.au
www.onetemp.com.au
www.ProcessOnline.com.au
SEPTEMBER 2014 - WHAT'S NEW IN PROCESS TECHNOLOGY 31
NEW PRODUCTS
CONFIGURABLE SAFETY RELAY The Allen-Bradley Guardmaster 440C-CR30 is a flexible, cost-effec-
ELECTRONIC SENSORS AND PRESSURE SWITCHES WITH IO-LINK FUNCTIONALITY
tive and easy-to-use configurable safety
HYDAC Electronic has extended its
Workbench (CCW) software - the same programming
product portfolio to provide IO-Link
environment used by the Micro 800 family of controllers,
functionality for the HYDAC 300 sen-
PanelView component HMIs and PowerFlex drives.
relay suitable for applications requiring 4-10 safety circuits and control of up to five zones. The Guardmaster 440C-CR30 is configured through Connected Components
sor series and the EDS 842 pressure
The distinct graphical user interface and drag-and-drop
switch. The products, with IO-Link
capabilities of CCW help guide users through a simple
communication interface according
process of selecting certified safety function blocks for
to specification V1.1.2, are suitable
the 440C-CR30. This means users can create, control and
for use in automation systems.
monitor a safety system in the same software environment
Compared with the standard version, the IO-Link interface enables
as their standard control, resulting in increased productivity and reduced programming time.
bidirectional communication between the device and the control. Thus, a
An embedded Modbus interface allows the Guardmas-
parameterisation and a cyclical transmission of process and service data
ter 440C-CR30 to communicate diagnostic data to an
is possible.
Allen-Bradley Micro 800 PLC and PanelView component.
Typical fields of application are machine tools, handling and assembly automation, intralogistics or packaging industry.
By leveraging the features of CCW and the embedded communication capabilities of the Guardmaster
The HYDAC 3000 sensor series with integrated digital display is suitable
440C-CR30, users can monitor, troubleshoot and modify their
for the measurement of pressure, temperature, fluid level and oil humidity
applications quickly and easily for increased uptime. Five
monitoring.
status and 16 user-configurable LEDs on the Guardmaster
The EDS 842 pressure switch with IO-Link functionality allows utilisation in combination with the HPG or the IO-Link adapter as a flexibly adjustable pressure switch.
440C-CR30 relay’s faceplate provide local diagnostics to further aid in status reporting and troubleshooting. The Guardmaster 440C-CR30 helps optimise panel
Product benefits include: IO-Link interface or PNP transistor switch output;
space with 22 onboard configurable safety I/O points in a
one additional signal output as PNP transistor switching output or configurable
110 mm footprint and provides a flexible solution for ap-
analogue output; parameterisation and a cyclical transmission of process and
plications requiring multiple safety zones. Without increasing
service data; simplified installation and commissioning; reduced maintenance
the footprint, the 440C-CR30 can also be expanded with
time and effort.
two standard Micro 800 plug-in modules to support 16
HYDAC International
additional standard I/O points.
www.hydac.com.au
Rockwell Automation Australia www.rockwellautomation.com.au
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NEW PRODUCTS
MULTISIGNAL CALIBRATOR AMETEK Test & Calibration Instruments has released a portable multisignal calibrator that allows all functions to be controlled from the main screen for ease of use. The intuitive, single-layer interface of the JOFRA ASC-400 allows technicians to use as many as 11 different functions without referring to documentation. It has a highcontrast, full-colour screen and full numeric keyboard. It provides laboratory accuracy for field calibration, process monitoring and maintenance functions. It is compact enough to fit into a tool box and operate with one hand. The instrument meets the calibration demands of modern sensors and transmitters for numerous functions in process control, systems engineering and maintenance. It is capable of sourcing with simultaneous read-back from device-under-test of mA, V, pulsed transmitters, pressure and temperature. The calibrator easily performs time-saving functions such as automatic switch test, leak test, scaling and online percentage error calculation. It performs fast RTD simulation, works with pulsed transmitters and PLCs, and can be used as a high-accuracy thermometer. When paired with the CPF Series pressure modules from AMETEK Crystal Engineering, the ASC-400 beÂcomes a pressure calibrator that can achieve accuracies down to 0.025% of reading unaffected by temperature in the range from -10 to 50°C. The ASC-400 offers simultaneous input and output, which makes it possible to calibrate and adjust a transmitter with no need for additional equipment. Royce Water Technologies Pty Ltd www.roycewater.com.au
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SEPTEMBER 2014 - WHAT'S NEW IN PROCESS TECHNOLOGY 33
AS I SEE IT A.B.N. 22 152 305 336 Head Office Cnr. Fox Valley Road & Kiogle Street, (Locked Bag 1289)
THE SKY’S THE LIMIT FOR CLOUD ENGINEERING
C
loud. It’s a word that’s not just on everyone’s lips at the moment but one that is seeing progressive and practical applications appear in many industries around the world - and ours is the next to be revolutionised. For the process industries, applying engineering disciplines to the traditional application of cloud computing has resulted in a new and significantly more cost-effective approach to project implementation: cloud engineering. In simple terms it’s about designing and testing engineering systems in the cloud that are ultimately used to solve real-world business problems. When the Queensland Mining Expo was held earlier in 2014, the emergence of cloud computing and development of cloud engineering was a headline topic for discussion, as the industry looks to implement the first fully cloud-based and purpose-built engineering management solutions. Similarly, in recent months there has been a flurry of excitement in the IT space, with several cloud service providers awarded lucrative contracts as manufacturers in the process industries wake up to the potential of cloud. But just how does cloud engineering differ from a standard project implementation and what are the benefits? In a typical project rollout, hardware would be sent to the remote (often dangerous) location and set-up, and teams of skilled engineers would be flown in to begin the creation of systems, workflows and, ultimately, the testing of both the software and hardware. This traditional, sequential approach requires automation and controls to be implemented during a specified timeframe before the rest of the plant can be completed. But this approach poses challenges, particularly when managing changes, which can affect all subsequent steps of the implementation and threaten project schedules and budgets. With cloud engineering and the implementation of parallel workflows, core project tasks can start much earlier in the implementation process and be done from any location. What this means is that teams can be mobilised from anywhere in the world to work on a
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
project, and this flexibility allows for latestage changes and faster project completion time. The added benefit to this is that skilled workers don’t have to be transported to a location to commence a project - they can work on it remotely. Adding to this, the use of virtual machines in the control system is also removing dependencies between the functional and physical design, enabling standardised server cabinets, reducing hardware requirements and delivering corresponding savings in space, power, cooling and weight. From a hardware perspective, the creation of universal channel technology is allowing instant, remote configuration of channel types (IO/DI/AO etc), removing the need for marshalling cabinets and cutting down on human error. Cloud engineering also brings about many more additional benefits. With flexible procurement and design allowing for late-stage change, the time of the overall project implementation can be decreased significantly and similarly, the cost of the project can be spread over the duration of the implementation rather than backloaded. Estimates place CAPEX savings at 30%, an increase in schedule flexibility of 25% and an overall decrease in project risk. Honeywell is one organisation already embracing this industry trend. We recently announced LEAP project services - proprietary hardware and software, virtualisation and cloud engineering. The goal behind LEAP is to help manufacturers in the processing industries get their plants up and running faster and at a lower cost.
Garry Mahoney is the Pacific Director of Honeywell Process Solutions. He has over 35 years’ experience in engineering, with a specific focus on instrumentation and process automation. Garry joined Honeywell Process Solutions in 1981 and has held a variety of positions during this time, from support to project delivery and business development.
34 WHAT'S NEW IN PROCESS TECHNOLOGY - SEPTEMBER 2014
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