Page 1

May 2009

MICA(P) 107/10/2008 | ISSN 0219/5615 | PPS 1561/06/2009 (028033)

Spotlight On

Oil& Gas

P45 Sustainability

In Automation


Choosing An

Electrohydraulic Controller





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contents MAY 2009




Firmly In Control

A pulp mill uses a flexible control system to ensure produciton stability and efficiency. By Lena Sjödin, on behalf of ABB



Choose The Right One!


Delivering Under Pressure


Market Report: Pressure Transmitter Market To Reach US$2.8 Billion By 2013

Closed-loop electrohydraulic motion controllers allows production lines to be more precise and repeatable, as well as sophisticated and flexible. By Michael Liedhegener, Bosch Rexroth

Jumping On The ZigBee Wagon

2  industrial automation asia | May 2009

Common types of pressure transducers and factors to consider when selecting one. By Derek Rodriguez


ZigBee wireless technology creates new possibilities and transforms the office environment into truly effective workspaces. By Dr Bob Heile, ZigBee Alliance


Jumping On The ZigBee Wagon

The worldwide market for pressure transmitters is expected to grow at a CAGR of 3.3 percent over the next five years. By Joe Gillespie, Arc Advisory Group




38 Oil & Gas: Change We Need

oil & GAS

India and China have been served well by oil and gas. Now it is time for the two Asian juggernauts to look elsewhere for their growing energy needs. By Abhishek Mehrotra

Change We Need


Firmly In Control

Dynamic Control Performance Multifunctional Application Easy Maintenance Environmental Adaptation

Fuji Electric Asia Pacific Pte Ltd

171 Chin Swee Road #12-01, San Centre, Singapore 169877 Tel: (65) 6533 0014 Fax: (65) 6533 0021 Email: Website:


contents MAY 2009



Remanufacturing: Old Parts, New Life

8 News 16 Profibus Association S E Asia 18 CAN in Automation 20 Fieldbus Foundation 21 EtherCAT Technology Group 52 Products & Services 63 Calendar of Events 64 Advertising Index / Ad Sales Office 64A Product Enquiry Card

Refer to pg




The Pursuit Of Green-ness

for Advertisers’ Enquiry Numbers

Manufacturers can achieve cost savings in addition to environmental benefits by integrating their Lean and Green initiatives. By Ash Khalek, Oracle

Industrial Automation Asia (IAA) is published 8 issues per year by Eastern Trade Media Pte Ltd 1100 Lower Delta Road #04-02 EPL Building Singapore 169206. Tel: (65) 6379 2888 • Fax: (65) 6379 2805 Website: Email:

When Sustainability Meets Automation

The automation industry has been a major mover in sustainable practices. By Augustine Quek


Remanufacturing: Old Parts, New Life

Subscription Rates: IAA is available to readers on subscription in Singapore at S$60.00 per annum. Subscription by airmail to readers in Malaysia is also at S$60.00 per annum; and Asia Pacific, America, Europe and other regions at S$100. Refer to the subscription card in each issue for further details.

Often misunderstood, the concept of remanufacturing brings crystal clear benefits. By William C Gager, Automotive Parts Remanufacturers Association



For more subscription information Fax: (65) 6379 2806 Email:

Market Report: MRO To Maintain Steady Growth As Global Meltdown Eases

Copyright. Eastern Trade Media Pte Ltd. All rights reserved. No portion of this publication covered by the copyright herein may be reproduced in any form or means – graphic, electronic, mechanical, photocopying, recording, taping, etc – without

The MRO industry remains bullish despite the current economic situation. By Nagib Ramli, Frost & Sullivan

the written consent of the publisher. Opinions expressed by contributors and advertisers are not necessarily those of the publisher and editor.



When Effort ≠ Work Done

Honda, ATR and Shimadzu jointly develop brain-machine interface technology enabling control of a robot by human thought alone.

4  industrial automation asia | May 2009


When Effort ≠ Work Done


The circulation of this magazine is audited by bpa world wide. The advertisers’ association recommend that advertisers should place their advertisements only in audited publications.



double, double,

Published by:


(A fully owned subsidiary of Eastern Holdings Ltd)

Oil& Trouble

Managing Director

Kenneth Tan Managing Editor

Eileen Chan assistant editor

Derek Rodriguez Editorial Assistant

Sharifah Atikah Senior Art Director/Studio Manager

According to the Energy Information Administration (EIA), the world energy consumption is projected to expand by 50 percent from 2005 to 2030. Even with the emergence of alternative energy sources and the negative sentiments attached to the effects of oil consumption on the environment, oil is expected to remain an important source of energy throughout the projection. Despite the economic gloom that seems to be enveloping the world, Oil and Gas Asia 2009, which will be taking place in midJune, is expecting to play host to 1,000 companies, providing a healthy number for more than just the optimistic (pg 58). Statistics or not, there is no doubt that oil is a major part of civilisation, and more so in World energy developing and first world countries. China consumption and India, both countries with enormous is projected to growth inertia and potential, are predicted contribute 45 percent of the increase in expand by 50 to energy needs from 2005 to 2030. To add to percent from this, this rise in demand will have to be met 2005 to 2030 by oil and natural gas (pg 38). Environmental arguments against oil and gas often cite these two giants as areas of debate, and with evidence backing them up, many of their points have been validated. The good news is the general public and the governments have shown a willingness to spare a green thought and more crucially, to act upon it. The Beijing Olympics, or at least the efforts to convert the usually smog-ridden city into a global-sports-eventconducive one was a relative success, with citizens experiencing a brief respite from the normal pollution. The worldwide attention that was generated because of this has had a positive effect, not in the least waking the authorities up to the possibilities of what can be. Although alternative energy sources can be a solution, another answer can be awareness and control. If restraint is practiced on a global level, on a national level and on an individual level, well, there can only be clear skies ahead.

Lawrence Lee Graphic Designer

Katherine Ching advertising sales Manager


Irene Tow Contributors

Lena Sjödin, Hans-Juergen Oertel, Michael Liedhegener, Dr Bob Heile, Joe Gillespie, Abhishek Mehrotra, Ash Khalek, Augustine Quek, William C Gager, Nagib Ramli Editorial Consultants

Jim Pinto Industry Analyst

Alastair Ross Director, Codexx Associates Ltd

supported by:

EASTERN HOLDINGS LTD executive Board Chairman


Kenneth Tan Financial Controller

Robbin Lim



Trade Media Pte Ltd an Eastern Holdings Ltd company

Head Office & Mailing Address: Eastern Trade Media Pte Ltd 1100 Lower Delta Road #04-02 EPL Building Singapore 169206 Tel: (65) 6379 2888 • Fax: (65) 6379 2805 Website: Email: MICA (P) No. 107/10/2008 ISSN 0219/5615 PPS 1561/06/2009 (028033) Co Reg No. 199908196C

Derek Rodriguez Assistant Editor

6  industrial automation asia | May 2009

Printer: Fabulous Printers Pte Ltd



Industry News ABB Wins Order For Hybrid Integrated Solar Power Plant

Zurich, Switzerland: ABB has won an order worth US$14 million to provide a complete electrical balance of plant (eBoP) solution for a 150-megawatt (MW) integrated, combined-cycle solar power plant under construction in Algeria. The order was placed by the Spanish company UTE Aberer Hassi R’Mel Construction and the plant will be set up at the Hassi R’Mel natural gas field in northern Algeria. It will have two 40 MW gas turbines, one 80 MW steam turbine and two parabolic trough solar fields with a generating capacity of 25 MW. The power plant will be fired by a combination of natural gas from the gas field and solar energy collected by the parabolic troughs. This is a pioneering hybrid project in terms of integrating solar and combined cycle power generation in a single facility. 8  industrial automation asia | May 2009

ABB’s project scope includes design, engineering, supply, erection and commissioning of the complete electrical balance of plant. The main equipment to be supplied includes mediumand low-voltage switchgear, auxiliary transformers, generator circuit breakers, isolated bus-ducts and emergency diesel generators. The project is expected to be completed by August 2010. “We are pleased to be associated with this pioneering initiative,” said Franz-Josef Mengede, head of ABB’s global Power Generation business in the Power Systems division. The company is presently executing several photovoltaic and thermo-solar power projects in Europe, the United States, Australia and the Middle East. ENQUIRY NO. 3101

Singapore & US Institutes Collaborate In Sustainable Manufacturing Technologies Singapore: Singapore Institute of Manufacturing Technology (SIMTech) has signed a Memorandum of Understanding with the Golisano Institute for Sustainability (GIS) of the Rochester Institute of Technology (RIT), USA, to advance the development of sustainable manufacturing technologies. The two-year collaboration between the institutes will build on the collective and complementary research capabilities in sustainable manufacturing technologies in SIMTech, and expertise in the areas of sustainable development and design combining real world experience with a strong academic and research background in GIS. Specific research collaboration areas include joint R&D in sustainable manufacturing technologies, renewable energy and fuel cells, clean production process technologies, clean technologies, reverse logistics and green supply chains, intelligent testing and diagnostics and sustainable design for remanufacturing. Sustainable manufacturing technologies will shape future living as they open up manufacturing possibilities to create new environmentally friendly products. These products can be produced cost-effectively to improve quality of life minimising or minus the costly repercussions of pollution, damage to the environment and depletion of resources among others. Sustainable manufacturing technologies can be used in multiple industries for clean production and services. ENQUIRY NO. 3102

Industry News

Honeywell Wins Award For Automation & Software Solutions

IPS Receives Safety Systems Award

Singapore: Honeywell’s Process Solutions business in Southeast Asia was awarded the Frost & Sullivan 2009 Customer Service Leadership Award for Automation and Software solutions in the Southeast Asian Chemical and Petrochemical Industry. To choose the recipient of this award, the analyst team at Frost & Sullivan tracks industry participants and monitors their customer service methods on an ongoing basis. The award recipient is selected based upon extensive research collected from key market participants, secondary Jon Lippin, VP & GM, Honeywell (R) and technology sources, and customer receiving the award from Benny Yeo, interviews. CEO of IA Community Collected data is then cross tabulated to identify the number one ranking company. Selection criteria includes product quality, after sales service and technical support, training, delivery time, brand awareness and overall company rating for customer service.

Singapore: Invensys Process Systems (IPS) has received the 2009 Frost & Sullivan South East Asia Industrial Technologies Award for ‘Customer Service Leadership for Safety Systems’ at a ceremony in Kuala Lumpur, Malaysia. The company will host its annual Safety & Critical Control Forum in Prague, Czech Republic, April 20 - 22, 2009. The forum will focus on improving plant safety, reliability and efficiency and the role that people, process, technology and support play in sustainable safety assurance. The Frost & Sullivan awards recognise outstanding performances by companies across the RFID and securities, electronics, industrial automation and process control, energy and power systems, environment and building technologies, and emerging technologies fields.


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May 2009 | industrial automation asia  9

Industry News

Largest Gas Transmission Project For GE Oil & Gas

Florence, Italy: GE Oil & Gas technology has been selected for one of the largest gas transmission projects in the world. The company will be the primary supplier of compression equipment for the western section of China’s second West-to-East gas pipeline. The second West-to-East pipeline will be part of the ongoing natural gas pipeline infrastructure in China that, when completed over the course of the next five to six years, will total approximately 20,000 km. This second pipeline, 8,700 km in length, will be 2,000 km longer than the Great Wall.

This pipeline will snake through 13 provinces and autonomous regions, and will play a role in supporting the country’s energy security and economic development. Existing Chinese natural gas pipelines total 30,000 km in length. PetroChina is the developer and owner of the West-to-East pipeline in China. The second West-to-East project features pipes with 48-inch diameters, some of the largest in the industry. When completed, it will add 30 billion cubic metres of capacity of natural gas transmission per year, half of China’s annual total natural gas production,

FedEx Opens US$150m Facility Guangzhou, China: Located on the grounds of the Baiyun International Airport at Guangzhou, China, FedEx will make it the centre of its operations in the Asian-Pacific area for the next 30 years. The Guangzhou facility replaces the one at Subic Bay. Although that will be decommissioned, FedEx maintains presence in the Philippines where Manila and Cebu are integral components in its AsiaOne network. A first for an international air express cargo carrier is the Guangzhou facility’s ramp control tower that permits FedEx to manage and control movements of aircraft. The facility also offers dedicated customs clearance. As it begins operations, the facility’s package and sorting systems can handle 24,000 packages per hour. Some 136 weekly flights will move into and out of the new hub, connecting it to the 220 countries and territories served by the company. ENQUIRY NO. 3106

10  industrial automation asia | May 2009

allowing 400 million people access to natural gas. This will bring China’s primary energy consumption rate of natural gas to five percent, up from 3.5 percent. The compression stations in phase two of the second West-to-East Gas Pipeline are expected to go into commercial operation between the second half of 2010 and the end of 2011. Since 2005, GE has been awarded bids by PetroChina worth over US$600 million. ENQUIRY NO. 3105

Siemens Sets Up Centre Of Competence In India Mumbai, India: Siemens Building Technologies has set up a Graphics and Engineering Centre of Competence (GECC) in Chennai. This is the first competence centre of Siemens building technologies in the Asia Pacific region. The GECC will provide engineering design services for the Indian market and also for the Asia Pacific Region. The centre will also have capabilities to provide need based, on-site support. In the initial phase, the GECC will have about 30 engineers and the employee strength will be ramped up in line with business demands. ENQUIRY NO. 3107

Industry News

Tokyo, Japan: Fuji Electric Systems (FES) has set up Photovoltaic Power Business Project Group which takes care of the entire process of engineering, producing and marketing solar cells. By integrating all internal solar cell resources, FES will strengthen the organisation of its photovoltaic power business and reinforce its marketing capabilities. The Ministry of the Environment of the government of Japan estimates that a total of up to 37 million kW can be generated annually by photovoltaic power generation systems in Japan before 2020, by implementing measures to encourage the construction of such power generation systems. This is 26 times the amount of solar power generated in Japan in 2005. The shipment of solar cells in Japan in 2008 increased 36 percent over the previous year to a total of 1.15 million kW. That figure is expected to grow even larger in the future with the resumption of a government subsidy scheme this spring. In the weeks and months ahead FES will strengthen its product portfolio by introducing the high-efficiency power conditioners which use newly developed power semiconductors and secondary cells, in addition to solar cells.



Maverick Technologies Opens Regional Headquarters Illinois, USA: Maverick Technologies, a global engineering, systems integration and operational consulting firm, has begun operations in Singapore. The business will operate as Maverick Technologies (Singapore). The operation is located at the heart of ASEAN, allowing Maverick to support US based companies with locations in Singapore and throughout the Asia Pacific Paul J Galeski, CEO and founder of Maverick market. Paul J Galeski, PE, CAP, the company’s CEO and founder, and Mark Hall, the company’s VP of global business, will oversee the Asia Pacific operations. Further support for the global expansion effort will come from existing Global System Integrators Alliance (GSIA) member operations, including Zi-Argus, in Thailand, the Philippines, Indonesia and Australia. Mr Galeski expects the company to be especially active in the Asia Pacific market with projects in oil and gas, chemical, food and beverage, and life sciences. ENQUIRY NO. 3109


Fuji Electric Systems Strengthens Photovoltaic Power System Business

May 2009 | industrial automation asia  11

Industry News

Digi Int’l Introduces M2M Solution

Minnesota, USA: Digi International has introduced iDigi Energy, a wireless M2M solution bundle optimised for energy services providers. It includes the hardware, hosted software and services necessary to quickly and easily integrate meters, load control modules, displays, relays, thermostats and other energy assets commonly required for demand response, AMI, and other Smart Grid offerings. Energy service applications connect to the hosted software component of iDigi Energy via a simple Web Services interface. This dramatically simplifies developing and deploying energy management services. Utilities have long been in the forefront with regards to investments in remote monitoring technology, originally with SCADA and now with AMI and Smart Grids. In Aberdeen Group's recent research survey, responding utility organisations indicate that 36 percent of connected assets are remote versus 27 percent a year ago. However, these organisations also indicate that 74 percent of its assets would benefit from remote connectivity. At the heart of iDigi Energy is the iDigi Platform, a Platform as a Service (PaaS) that quickly and easily connects remote assets to a customer's applications. ENQUIRY NO. 3110

Boeing Opens Research Centre Bengaluru, India: To help sustain the company’s competitive technological edge while enhancing India’s aerospace capabilities, Boeing has opened its Research & Technology-India centre. The centre marks another milestone of the company’s long term relationship with India. This centre will carry out continued collaboration with Indian R&D organisations, including government agencies and private sector R&D providers, universities and other companies. Boeing’s research in India involves aero structures, aerodynamics and electronic networks with a team of senior researchers, scientists and engineers. This is the company’s third advanced research centre outside the US, the others being in Europe and Australia. The centre will also coordinate the work of more than 1,500 technologists, including 100 advanced technology researchers, from across India on projects that will help define the future of aerospace. ENQUIRY NO. 3111

12  industrial automation asia | May 2009

Boeing, Coca-Cola & General Mills Say Energy-Efficient Practices Are A Necessity Wisconsin, USA: Rockwell Automation has released a white paper that explores how The Boeing Company, Coca-Cola and General Mills, use sustainable production practices to help manage today’s economic challenges. The paper, ‘Perspectives on Sustainable Production: Delivering Economic Value and Serving Greater Good,’ features viewpoints from sustainability executives at Rockwell Automation and its customers, all of whom consider sustainable production practices a necessity during the current economic downturn. “Sustainability is just good business. Energy efficiency, improvement in recycling, and eliminating waste are things we’ve been doing since the 1990s,” CocaCola’s Mark Lee, director, commercial products supply engineering/ELSP, says in the paper. “Rising prices and shortages of resources, whether of talent, dollars, energy or materials, have rewritten the economics of manufacturing,” comments Bob Ruff, senior VP, control products and solutions, Rockwell Automation. “Sustainable production practices deliver economic value. They provide a long-term solution to volatile energy, scarce raw materials, costly workers’ compensation, lost worker productivity, and product liability costs.” “In times of economic trouble, sustainable companies become survivable companies because they’ve driven inefficiencies out of their system,” adds Boeing’s James W Fonda, advanced technologist, networked systems. “Any responsible company will continue to try to drive their bottom line home, so they become survivable in times when oil becomes more expensive and other economic problems bubble to the surface and cause havoc.” ENQUIRY NO. 3112

Industry News

Tokyo, Japan: Mitsubishi Electric Corporation has announced the launch of four new models of photovoltaic (PV) modules for the worldwide market, suitable for use in standalone solar power generation systems in the midlands of the USA and in regions where the local electrification infrastructure is insufficient or nonexistent, such as in remote areas of developing countries. Shipment will begin on April 10, 2009. The PV systems market has been rapidly expanding globally due to increasing environmental concerns, as seen in worldwide efforts to reduce carbon dioxide emissions to prevent global warming. The PV market of the USA, in particular, has been gaining greater momentum with the introduction of environmental initiatives within the new stimulus plan, and enhancements in government subsidies. Meanwhile, countries in Asia and Africa with areas that lack power plants, power lines, and other infrastructure are promoting projects to install standalone PV systems in order to meet electricity needs. The lineup of PV modules for stand-alone systems consists of models with outputs from 115W to 130W. Compared to the company’s previous models, the new models have specifications more suitable for offgrid installation environments in the midlands of the USA and remote areas in developing countries. The company plans to expand its annual production capacity to 600 megawatts in fiscal 2012 (April 1, 2011-March 31, 2012). The company has also enhanced its PV business by forming a new division, the Photovoltaic Systems Division, in the Living Environment & Digital Media Equipment Group as of April 1, 2009. ENQUIRY NO. 3113

Emerson Acquires Epro Texas, USA: Emerson has acquired Epro GmbH of Gronau, Germany. The deal expands Emerson’s online machinery monitoring capability with a full API 670-compliant protection offering. It is also expected to speed availability of next generation solutions. “This acquisition extends Emerson’s leadership in machinery monitoring and expands our Smart Machinery Health Management offerings. All of this is tightly integrated in the PlantWeb digital plant architecture,” said Craig Llewellyn, president Asset Optimisation division of Emerson Process Management. ENQUIRY NO. 3114

Now Offering Industrial Wireless with 802.11n

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IEEE 802.11 a,b,g,n with Data Rates up to 300Mb/s 2.4GHz or 5.8GHz Frequencies IP67 Model Provides Protection Against Dust and Water 20-49VDC or Power over Ethernet -40ºC to 70ºC Operating Temperature Configurable as Station or Access Point in Bridge or Router Modes • Web Browser Management • Secure WPA2 Encryption Shanghai: +86 021 6133 7770 Beijing: +86 (0) 139 1029 0271 e-mail: web:


Mitsubishi Electric Announces PV Modules

May 2009 | industrial automation asia  13

Industry News

Omron, IBM To Collaborate On Green Solutions Tokyo, Japan: Omron and IBM will work together to provide ‘smart’ solutions that lower energy use, reduce carbon dioxide emissions and increase efficiency in transportation operations. The solutions will help clients decide which types of shipping and transportation to use and the best travel routes for reducing costs and CO2 emissions in the delivery of packages, parts, supplies and finished goods. The two companies will work together to assist clients in addressing anticipated regulatory restrictions and penalties for CO2 emissions. The collaboration is consistent with IBM's ‘smarter planet’ initiative, which envisions a world where everything is instrumented, interconnected and intelligent. This can provide greater understanding that allows better decision making, leading to increased efficiency, improved performance, lower costs and reduced environmental impact. The companies will provide these solutions initially for Japanese clients, primarily in the manufacturing and transportation industries-globally, those industries account for more than half of all energy use and corresponding CO2 emissions. The solutions could later be expanded for additional countries and industries. ENQUIRY NO. 3115

Applied Materials & Disco Collaborate On Wafer Thinning Technology

California, USA: Applied Materials and Disco Corporation have announced a joint effort to develop wafer thinning processes for fabricating throughsilicon vias (TSVs) in 3-dimensional (3-D) semiconductors. The two companies will be working together to develop integrated, high-performance process flows intended to lower the cost, reduce the risk and accelerate time to market for customers’ next generation chips. Through-silicon via technology is a method that enables higher density, lower-power devices in a smaller footprint by vertically stacking chips. To make this 3-D stack, each chip or wafer layer must be reduced in thickness by up to 90 percent and bonded to a temporary carrier in order to maintain

structural integrity during the thermal and mechanical stresses of semiconductor processing. Combining Disco’s precision grinding equipment with Applied’s etch, dielectric deposition, physical vapour deposition and chemical mechanical planarisation systems, the two companies expect to develop wafer thinning and post-thinning processes of wafers bonded to silicon and glass carriers. Some of the key technical requirements in developing manufacturing-worthy equipment and process solutions are wafer structural and edge integrity, handling, dimensional control, particle control, stress management and thermal profile control. ENQUIRY NO. 3116

Volkswagen Opens Plant In India Pune, India: With a total financial commitment in India amounting to €580 million (US$782 million), the plant represents the largest investment to date by a German company in the country. The facility has a maximum annual production capacity of 110,000 vehicles destined for delivery to the Indian market. Despite the impact of the financial and economic crisis the desire for individual mobility in India remains high. Experts predict that the Indian automobile market will grow from the present 14  industrial automation asia | May 2009

1.2 million vehicles to over 2 million vehicles by 2014. The Pune plant will begin building the Skoda Fabia compact car in May 2009. Production of a hatchback version of the Volkswagen Polo developed for the Indian market will be added from 2010. The plant has a high level of vertical integration and a large share of local suppliers. The facility covers the entire production process from press shop through body shop and paint shop to final assembly. ENQUIRY NO. 3117

Industry News

Standards For Safe Machinery & Plants Updated

FCI To License Harting’s Solutions

Waldkirch, Germany: Sick offers safety expertise from practicians for practicians in its 120-page manual ‘Safe Machinery – six steps to a safe machine’. The guidelines are based on the updated Machinery Directive 2006/42/EG and the EN ISO 13849-1 and EN 62061 safety standards. In addition to the guidelines, the company supports producers and users of machinery and plant with a wide range of safety activities. Safe machines create legal security for producers and users; machine users expect producers to only offer safe machinery or devices. With its ‘Safe Machinery Guidelines’, Sick offers a manual for the daily work of all producers, users, engineers, plant designers and those responsible for machine safety.

Las Vegas, USA: FCI and Harting have partnered to introduce a standard in PushPull technology for Telecom outdoor solutions. This technology includes a PushPull locking mechanism which provides the smallest size family of IP 67 rated connections on the market for data, power and signal over copper and fibre. They reached the agreement for FCI to become a certified second source for Harting’s Outdoor PushPull I/O connector family. The outdoor I/O design will eliminate the need to inventory costly cable assemblies. These solutions are a viable choice for WiMAX and LTE base stations as well as other outdoor applications.

Regional Network Hitachi Asia Ltd Hitachi Asia (Thailand) Co. Ltd Hitachi Asia (Malaysia) Sdn. Bhd

The guidelines start by describing the legislative and standards-based principles for machines in Europe valid from 29 December, 2009. Among other things, the scope of application, definition of a machine, conformity process, EC Declaration of Conformity, operating instructions and labelling of machines are new or have been amended. Partly completed machinery is now subject to special description. Among other aspects, use of the safety standards and distance measurements, for instance, are explained in six steps, structured in the Risk Assessment – Safe Design – Technical Protective Measures – User Information on Residual Risks – Overall Machine Validation – Placing the Machine on the Market. ENQUIRY NO. 3118

As a regional headquarter, Hitachi Asia Ltd (HAS) markets electric motors, air compressors and digitalized inverters. It is also responsible for the marketing of various industrial products such as programmable logic controllers, ink jet printers, hoists, vortex blowers, contactors and circuit breakers.

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May 2009 | industrial automation asia  15

Industry Updates ‘Meet The Experts’ Seminars For Automation Professionals Profibus Association Southeast Asia hosted a free technology knowledge sharing seminar, named ‘Meet The Experts’ for automation professionals in Southeast Asia. They have completed the seminars in Kuala Lumpur, Malaysia, Singapore and Bangkok, Thailand with overwhelming response of more than 200 participants. In the seminar, experts shared the latest news about Profibus and Profinet technologies, and discussed on the wide range of applications in multiple industries

In which industry do you work? Cement 1% Paper 2%

Others 5%

Chemical 6% Oil & Gas 19%

Offshore 10% Water & Waste Water 8% erage & Bev d Foo 5%

Power 7% Petrochemical 10%

Marine 12%

Steel 1% Automotive 1%

Logistics 1%

Pharmaceutical 12%

such as oil and gas, chemical and petrochemical, offshore and marine, food and beverage, power, water and many more. This event is designed for automation professionals, system integrators and engineering contractors who like to learn more about Profibus technology, and want to meet up with experts. ENQUIRY NO. 3120

Profibus/Profinet Node Growth In 2008, Profinet experienced growth of 40 percent compared with 2007, with 1.6 million nodes installed by year end. PI believes that the total will rise to three million by the end of 2010. In 2008 alone, five million Profibus devices were sold - higher even than the previous year’s 4.5 million, and representing an increase of 11 percent. The Profibus total rose to 28.3 million. PI believes that the 50 million node mark will be passed by the end of 2012. Process automation use of Profibus also rose. By the end of 2008, 880,000 Profibus PA devices had been installed, a 20 percent increase over 2007. The total number of Profibus (DP and PA) nodes in the process industry is now 4.8 million. Further success was experienced in functional safety. By the end of 2008, the number of Profisafe systems reached 66,000 and the number of devices was 630,000. A study by Arc Advisory sees the total market of bus-capable safety devices at 700,000. 16  industrial automation asia | May 2009

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Additional Application Functions Users can design complex and sophisticated network systems with the additional functions defined in the CiA 302 specification set. By Hans-Juergen Oertel, technical director, CiA This mechanism is controlled by four different protocols described in CiA 302-2. There may be more than two NMT master capable devices in the network. The system designer assigns different priorities to the NMT master capable devices. Always the highest prior NMT master device will be the actual NMT master.

CANopen is the standardised communication system for decentralised and distributed embedded control systems. It provides basic communication services such as transmitting in real-time message containing process data (PDO communication). This broad- or multicast service is not confirmed. To read or write to a parameter list (object dictionary) of another device the confirmed SDO client/server service is used. The application layer also provides network management (NMT) functionality. The device with the NMT master functions controls the NMT state machine of all networked devices. As an add-on, the CANopen NMT slave devices may request the NMT master to start or to stop other devices. This function as well as self-starting CANopen devices are 18  industrial automation asia | May 2009

described in the recently released CiA 302 series of specifications (version 4.0). Specification Redefined The CiA 302 specification has been completely re-chaptered. Part 1 contains some general definitions. Part 2 defines in detail the NMT boot-up procedure and the flying NMT master concept. F l y i n g N M T m a s t e r s a re required in mission- or safetycritical network applications, where single failure should not lead to a complete network shutdown. In case that the NMT master device fails, another NMT master capable device takes over. If the original NMT master device recovers from the failure situation, the actual redundant NMT master device gives the NMT master functions back to the original one.

Download & Configuration Manager Part 3 of CiA 302 specifies the p ro g r a m m e d o w n l o a d a n d configuration manager. These additional functions are used in decentralised control systems, where one entity – the CANopen manager device – configures all devices after power-on. In extreme, the CANopen manager downloads always the entire application into the connected devices. This guarantees that all application programmes are compliant to each other. Otherwise it may happen that one substituted device use a software version, which is not consistent to the software running in some other devices. The software download is performed by means of segmented SDO communication. There are special object dictionary entries reserved for up to 254 application programmes. Other entries in the object dictionary provide optionally information of the software version, date, etc.

Network Variables In part 4, the use of network variables is described. Programmable devices have no pre-defined process data. For that reason, the object dictionary provides in the address range from A000h und AFFFh network variables. After device programming, they have a specific meaning and may be mapped into PDOs are accessed by means of SDO communication. Network variables are the process image of programmable devices. In CANopen networks, there may be installed several programmable devices. They may even share simple preprogrammed I/O modules, sensors, or actuators. This is than a real distributed control system with several application masters. SDO Manager Part 5 specifies the SDO manager, an additional function for NMT master devices. The SDO manager is necessary, if a simple CANopen device with just the SDO default server should be configured on-line by an external tool. In this case, the tool rents the correspondent SDO

client from the NMT master device. This avoids that two devices access the simple device using the very same CAN-IDs. Many of the more sophisticated CANopen manager devices support increasingly the SDO manager function. Bus-line Redundancy Bus-line redundancy as requested in marine and other mission-critical application fields is defined in part 6 of the CiA 302 specification set. There is a default bus-line and a redundant bus-line. If the default bus-line is corrupted, all connected devices will automatically switch to the redundant bus-line. An additional PDO error counter is used to decide, when to activate the redundant bus-line. First companies have combined busline redundancy and safety-related communication as specified in CiA 304 (CANopen safety protocol) for train applications. Router & Bridge Functions Part 7 describes the CANopento-CANopen router and bridge functions. The original request

In sophisticated embedded machine controllers, configuration or SDO manager are used to configure the networked CANopen devices in order to avoid parameter consistency problems

comes from companies that have cascaded several CANopen networks for example in mining machinery. Regarding SDO and Emergency communication it is a router function. PDOs are forwarded with the bridge functionality; this means the content of the PDOs are not changed at all. Only the CAN-ID may be changed. The SDO router function requires an additional SDO command, which is send before the normal or expedited SDO. This SDO router command indicates, which device in which network shall be addressed by the following SDO. Of course, the system designer must configure the router by means of router tables. The same has to be done for remote Emergencies, which are forwarded by the router to another network. The number of networks in hierarchical or meshed network systems is limited to 127. The configuration of router/bridges devices can be locked in order to avoid accidentally configuration failures. With the additional functions defined in the CiA 302 specification set, users can design very complex and sophisticated network systems also for mission-critical applications. Some of these functions are required in rail-vehicle applications, an application domain that gains importance. That is why CANopen will be internationally standardised as invehicle network for locomotives, coaches, and train-sets (IEC CD 61375-3-3). The additional CANopen application layer functions are also suitable for industrial automation applications, eg in distributed embedded machine control systems. ENQUIRY NO. 3122 May 2009 | industrial automation asia  19

Updated FF Host Test Kit The Fieldbus Foundation has released its updated Foundation fieldbus Host Test Kit (HTK) DD Application Module (Version 1.1.0). This powerful test kit, driven by the foundation’s End User Advisory Council (EUAC), includes hardware and software for testing the functionality of a fieldbus host and its conformance with the Foundation host profile specifications. The Foundation fieldbus Host Test Kit is designed to validate host applications implementing DD Services, files for persistent storage of functional parameter data, and grids for vector data visualisation and manipulation. Under the new host registration programme, hosts successfully completing the test requirements will be authorised to bear the official Foundation fieldbus

product registration symbol. According to the Fieldbus Foundation’s manager, fieldbus products, Stephen Mitschke, the updated HTK will streamline the process for automation suppliers to test and validate their fieldbus hosts prior to formal registration. For end users, the enhanced testing capabilities will provide greater assurance of seamless integration and interoperability within a Foundation fieldbus system. T h e H o s t Te s t K i t D D Application Module Version 1.1.0 has been updated with enhanced performance features. The most significant additions include support for device-level menus, enabling visualisation of multiple blocks and significantly improving the device integration experience; and support for Unicode, providing device and system suppliers with

an expanded ability to write and visualise DDs using local languages (including Asian languages). The updated test kit also includes crossblock built-ins and references, as well as testing for enhanced DD support. Thanks to the Host Test Kit DD Application Test Module, end users benefit from significantly improved host-to-device integration. Foundation fieldbus host suppliers benefit from standardised test requirements and test cases for all hosts within a profile tested to the same requirements; standardised DD and CF files assuring hosts can parse files; and standardised test devices for all basic I/O function blocks and specialised test transducer blocks. ENQUIRY NO. 3123

Educational Institutions To Offer Fieldbus Training STC Brielle and the Fieldbus Center at Lee College are the first educational institutions worldwide to offer fieldbus training courses certified under its Foundation Certified Training Program (FCTP). This programme establishes uniform standards for fieldbus educational curriculum around the globe, and defines acceptable levels of learning for students of the technology. The FCTP is intended to raise the visibility and prestige of institutions offering certified Foundation fieldbus training to a new and exclusive level. Educational facilities successfully completing a multistage certification process can issue certificates showing the Fieldbus Foundation accredits their courses.

20  industrial automation asia | May 2009

The FCTP is a comprehensive initiative benefiting the entire industrial automation community— particularly in today’s challenging economy and employment market. The programme currently offers three levels of certification. Beginning automation students are able to identify colleges, universities and other facilities offering a certified Foundation educational curriculum. After graduating, they will be able to present official FCTP certificates to potential employers. Existing automation professionals completing certified courses can expand their job skills and employment value within their companies. ENQUIRY NO. 3124

Asia Milestone Reached: The 1,000th Member Since its introduction in November 2003, the EtherCAT Technology Group (ETG) has seen 1,000 member companies joining them. The 1,000th member of is Multivac, a packaging machine technology company headquar tered in Bavaria, Germany. Today, the ETG has members in 45 countries, runs offices in Germany, the United States, China, Japan and South Korea, and keeps its growing team of 15 quite busy. For two consecutive years, the ETG has grown by an average of one new member every business day. Near the beginning of the group’s existence, 70 percent of members came from Germany; today, over 65 percent of the membership hails from other countries. The second largest member group by country is the United States, closely followed by Japan, then Italy, Switzerland and China. In Asia alone, there are 220 member companies. ENQUIRY NO. 3125


The ETG expanded its presence in China with an information booth at the China International Factory Automation & Instrumentation Exhibition in Guangzhou. The booth was well accepted since EtherCAT is already used in many

applications in China and end users such as machine builders and system integrators as well as device vendors welcomed the opportunity to learn more about the technology and its implementation. ENQUIRY NO. 3126

Test Tool To Include CANopen Drive Profile The ETG is expanding the organisation’s Conformance Test Tool to include the CANopen drive profile, CiA402. This step supports the consistent implementation of this profile and further facilitates the hassle-free commissioning of EtherCAT drives. The first version of the expanded test will be released in a few weeks. The CANopen profile, CiA402, as well as its mapping on EtherCAT, are standardised in IEC 61800-7. It contains three modes for cyclic, synchronous motion control, which were introduced in 2005 by ETG members with EtherCAT in mind. The test tool enhancement checks the object dictionary entries and the state machines for conformance with the standard and helps avoid

vendor-specific efforts to commission the drives. The conformance working group within the EtherCAT Technology Group is in charge of the EtherCAT test cases as well as the test enhancement to cover this device profile. “The commissioning of EtherCAT communication itself is very simple. The application interface, which is specified by the device profile, sometimes needs more work – in particular with drives. We expect from the profile test a further unification of implementations and even shorter commissioning times,” says ETG board member Dr Peter Heidrich, R&D manager at the drive vendor Baumüller. ENQUIRY NO. 3127 May 2009 | industrial automation asia  21

issues & insights


ith an annual production of 500,000 tonnes of pulp – including 420,000 tonnes of kraft pulp and 80,000 tonnes of CTMP pulp – SCA’s plant in Östrand, Sweden, is high on the list of Europe’s largest pulp mills. Operating 24 hours a day all year round, wood from the forests in Northern Sweden is processed into chlorine-free bleached kraft pulp and semi-chemical pulp that is eventually used in everyday products such as magazine paper, tissue paper, hygiene products and packaging. Both the recovery boiler and the water treatment system are controlled using ABB’s Industrial Extended Automation System 800xA. A requirement of the integrated control system was that it should unite electrical generation and instrument operations in the most advantageous way possible.




A pulp mill uses a flexible control system to ensure produciton stability and efficiency. By Lena Sjödin, on behalf of ABB 22  industrial automation asia | May 2009

In Search Of Integration The decision to purchase an integrated control system was reached at the same time the company decided to buy a new recovery boiler. One of the most important criteria the system had to meet was that it should unite electrical generation and instrument operations – which previously had separate control systems – in the most advantageous way possible. This was desirable partly to overcome the drawbacks in terms of production quality that come with having distinct departmental divisions, and partly because it takes both time and resources to maintain functioning communications between two separate systems. “Having everything governed by the same system definitely provides us with superior control,” adds Alf Eriksson, who now oversees

Control room at the pulp mill complex

‘Green’ Power The soda recovery boiler is a combined recycling facility and steam boiler. Its raw materials are the used chemicals and wood waste from the kraft mill. The chemicals are recycled and reused while the wood scrap is burned to

fuel the boiler. Steam is produced at a pressure of 105 bar and a temperature of 515°C, higher than in any other comparable facility in the world. The recovery boiler and the turbine enable a doubling o f p re s e n t b i o m a s s - b a s e d

electricity-production to 500 gigawatt hours per year. As a result external electricity requirements will be drastically reduced thus putting the Östrand pulp mill complex at the cutting edge of what is currently possible. E v e n a t t o d a y ’s p ro d u c t i o n l e v e l o f 420,000 tonnes of pulp per year, the kraft mill will actually make a net contribution of ‘green’ power to the electricity grid. This can be increased when, at some time in the future, the new boiler is expanded to its full capacity of about 800,000 tonnes. Simulation Is Key The system comprises nine operator stations and seven AC


a comprehensively integrated department. “The advantages of the new arrangement will manifest themselves over time. But we are already seeing advantages in terms of simplified work routines for switching between maintenance and production modes, and the dialogue between the electrical-generation and instrument disciplines has become more natural.”

May 2009 | industrial automation asia  23

issues & insights

A typical configuration of electrical integration

800 M processing stations for control of the recovery boiler and the water treatment plant. It also includes a control system simulator for the boiler with two operator stations and a smaller training system. The simulator is based on a mathematical model of the recovery boiler, which is a complex process involving both combustion and chemical reactions. There are pre-programmed scenarios such as basin leaks, electrical failure, dry-content problems and furnace leaks. These scenarios can be combined with a number of socalled ‘snapshots’, each of which represent a different operational state of the recovery boiler. Old Way, New Way The basic ideas and the thematic approach to the old way of working have been translated into a new way of thinking and related to a different process. The goal throughout has been to provide information in a way that is immediately accessible and easily comprehended even by occasional operators. To achieve this result the 8 0 0 x A’s g r a p h i c a l f u n c t i o n design has been a useful tool. Presenting information related 24  industrial automation asia | May 2009

to each function as a diagram rather than in text form facilitates a deeper understanding of the underlying process. The graphical function serves as an interpreter that translates the programme language into something familiar. “With graphical function design, you can easily access your application translated to a universal language,” explains Mr Eriksson. “This gives you a useful overview and facilitates troubleshooting, for example.”

Fieldbus Capability Another important criterion was that the system should interface advantageously with databus technology and be able to handle an increased volume of information related to preventive maintenance. The mill has a practice of using Advanced Switching Interconnect (ASI) Profibuses, and great weight was attached to finding a control system for water treatment that was compatible with existing fieldbuses. With the new recovery boiler, all frequency converters and approximately 90 percent of switchboxes are controlled via Profibuses. Digital signals for everything from shut-off valves to alert systems are controlled by ASI. The analogue signals are distributed to fieldboxes. “We make extensive use of HART-I/O and have now begun to work towards managing the increased data in developing ro u t i n e s t h a t w i l l m a k e i t possible for us to predict the need for maintenance more accurately than we can today,” says Mr Eriksson.

Controllers at the Östrand mill


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control point


achine builders and factory operators may have misconceptions about hydraulic-based motion. Although valued for its ability to move, crush or lift heavy loads, it has not been thought of as exceptionally precise, or able to support highly complex, synchronised multi-axis applications. The advent of closed-loop electrohydraulic motion controllers has changed the equation, allowing production lines to be more precise and repeatable, as well as sophisticated and flexible.

Choose The

A range of electrohydraulic controller platforms are available. Choosing the right one is based on assessing several factors, starting with the application requirements and including motion complexity, the number of axes to be controlled, and machine design and operational factors. Closed-loop Hydraulic Control Hydraulic motion control is the coordinated control of the acceleration, velocity and position as well as force or pressure of a

Closed-loop electrohydraulic motion controllers allows production lines to be more precise and repeatable, as well as sophisticated and flexible. By Michael Liedhegener, application engineer, machine tool group, Bosch Rexroth

Right ONE!

26  industrial automation asia | May 2009

machine axis or actuator such as a cylinder or hydraulic motor. Previous generation machines typically used open-loop control, sending a simple signal to a directional or proportional valve to control only one of these factors — thus limiting the precision and sophistication of motion control. In addition, open-loop control often required manual fine-tuning, adding time and costs to machine commissioning or updating. Closed-loop hydraulic control adds feedback to the hydraulic circuit by adding position and

Force Command Valve Output Load Cell

Force Loop

Pressure Feedback Pressure Loop

Active Damping

The ability to cascade control loops gives formidable processing power

pressure sensors to the system, providing real-time data on system states like position, its derivatives and forces. This enables rapid, precise, repeatable, and (most importantly) automated position and force control of hydraulic actuators. A number of simple applications can be configured using open-loop control, but quality requirements and high-throughput demands make closed-loop motion control and electrohydraulic controllers the preferred approach. Going with a digital controller offers significant advantages. For the machine builder, the complexity and time of machine start up will be reduced. For series machines, once a digital control project template is created it can be applied to multiple machines with little extra effort or expense. For the end-user, process monitoring and machine diagnosis is built into the controller at no extra cost. Points Of Decision To choose the best controller for an application, start with four key decision points to assess and define during machine development. The key decision criteria include: • Accuracy of the hydraulic axis stroke and positioning • Need for single, combination or multi-axis control

• Preference for configuration or programming of motion sequences • Bus architecture and I/O support Accuracy Of Stroke & Positioning Most closed-loop hydraulic controller product lines offer low-cost analogue controllers to support basic motion requirements such as simple position or flow control. However, since these controllers don’t incorporate digital feedback and processing, they generally do not provide accurate positioning at the endpoint. If you need stroke accuracy greater than 0.1 percent of the total stroke — for example, no more than a tenth of an inch deviation over a ten-inch stroke, you need the precise accuracy and stability provided by digital feedback and control. Even if the motion is very simple and the path of travel does not require high accuracy, if fine positioning at the endpoint is required, such as micron-levels of accuracy for the machine tool or plastic industr y, then analogue controllers would be eliminated from the decision-making process.

Define Number Of Axes Most digital electrohydraulic controller manufacturers offer a range of systems, with options based on application complexity. The next decision point is driven by how many axes you need the controller to support: • Single axis • Combination (2-4) axis • Multi-axis (from 2 to 32) Single-axis controllers are commonly used to replace analogue controllers and are suited to a wide range of applications such as clamping, presses, materials handling, testing technology, steelworks and machine tools. A common misconception is that single-axis controllers are ‘simple’ devices, supporting less than the full range of motion control. Most single-axis controllers support position, pressure, velocity and force control, as well as position or flow control with bumpless transfer to pressure control, and

A closed-loop control system May 2009 | industrial automation asia  27

control point

active damping for improved dynamics. Single-axis controllers can perform complex operations. For example: a honing tool conducting a complex oscillating single-axis motion, working a cylinder cavity in an engine block. The axis of motion has an extremely precise endpoint and very precise control during the honing. If increasing friction or some other material factor is affecting the operation, the electrohydraulic controller adjusts velocity or force (or both) in real time to keep the actuator within microns of the target. If an application has multiple axes with machine footprint space limitations, or requirements for more cost-effective control architecture, then you should consider using ‘combination axis’ controllers. Combination axis controllers — controlling up to four axes of motion — provide a cost-effective option and provide the full range of position, pressure, velocity and force as well as ‘master-slave’ architecture.

For analogue and digital I/O, make sure the controller you select is equipped with enough I/O to support your application 28  industrial automation asia | May 2009

This avoids redundancies such as multiple bus interfaces, I/Os or space-consuming enclosures. It can also enhance the communication between axes for coordination, synchronisation or safety purposes. A master controller card handles bus communications and power distribution, with four other cards controlled by the master. This provides several efficiencies: • Only a single power supply and bus communications link to the master card is needed • Less equipment equals lower machine costs and better use of space • Axis changes or updates can be uploaded to the master card instead of connecting and updating each controller Multi-axis controllers are the top-of-the-line systems, capable of handling up to 32 interpolatable axes. Controller ‘Programming’ Once you determine whether you need a single-axis, combinationaxis or multi-axis electrohydraulic controller, you need to evaluate the controller’s ‘programming’ tools according to the best fit for your application and operational requirements. Most product lines offer three controller ‘programming’ options, with ascending levels of programming complexity. Choosing the most suitable will often be based on the sophistication, skills and experience of the programming and machine operator resources. Single-axis controllers often use a menu-driven ‘ladder-logic’ configuration system that’s very easy to learn and use, and supports fast implementation of most standard single-axis motion sequences. If you have an application that calls for bumpless transfer

Single-axis controllers often use menu-driven ‘ladder-logic’ that’s very easy to learn and use, and supports fast implementation of most standard single-axis motion sequences

from velocity control to pressure control during a motion loop — in a plastics injection molding machine, for example — that kind of sequence is typically configurable, and can be easily and precisely implemented using pre-stored commands. Motion sequence complexity at this level is limited to what the controller supplier provides in the configuration system. If more complex sequences are required, such as NC level functionality where the precision of either position or force through the motion loop requires real-time processing of algorithms in response to feedback, then you may need to choose a more powerful controller (either single or combination axis) that supports ‘G-code’ programming. Unlike the configuration platform, this will require handson experience using a BASIC-type programming language. G-code commands are an industr y standard machine language that lets users define motion sequences of the axes using freely programmable NC programmes.

Besides standard commands, the best electrohydraulic controller platforms in this category support special NC commands tailored to the particular features of hydraulic axes, such as fields of closed-loop force/pressure control and limitation, transitions from closed-loop position to pressure control, and adaptive controller functions. If your application calls for multi-axis synchronisation and ver y complex control loops, the most effective and flexible controller is one that supports C-level programming. Applications requiring active synchronism with force limitation, or dynamically adding or withdrawing axes from a synchronised group during operation, call for advanced algorithms that need to be written in higher-level languages. This programming approach also facilitates controller-level processing of complex motion sequences for more efficient machine control. For example, in a CNC machine, if a cam profile is being machined, the controller accesses a look-up table with extremely fine variations in command values, guiding the actuator through a complex series of motions to complete the machining of the cam. When an application such as this demands millisecond sampling and processing of feedback devices in the control loop, it is more efficient and more reliable to process motion control sequences at the controller level, rather than constantly communicating back and forth to a machine-level PLC. Therefore, choose a controller engineered to support both C-level programming of sequences, and powerful enough to handle onemillisecond sampling and loop sequence processing. Bus Architecture As you identify the optimum

To help evaluate different controller platforms, look at factors such as accuracy requirements for stroke and positioning, the need for single, combination or multi-axis control, your preference for configuration or programming of motion sequences, and requirements for bus architecture and I/O support

controller platform, you must ensure the communications and power interfaces you need are fully supported. There are a number of bus architectures that electrohydraulic platforms support, including • CanOpen Field Bus • DeviceNet • Profibus • Interbus-S • SERCOS Drive bus • Ethernet Most electrohydraulic controller product lines support several of these buses on each product, so the choice is often dependent on the communications backbone of the machine you’re building or upgrading. For analogue and digital I/O, make sure the controller you select is equipped with enough I/O to support your application.

Finding The Right Support Electrohydraulic controllers provide more options, and much more flexibility for implementing the precise, repeatable automation control architectures demanded by today’s global manufacturing infrastructure. It makes sense to look for a supplier that has in-depth experience engineering a wide range of motion control platforms across multiple technologies, combined with extensive experience in open and closed-loop hydraulics systems. Suppliers that have overall system understanding and the capability to perform computer simulation of the static and dynamic behavior of the machine axes will be able to help you select the right electrohydraulic platform to meet all your performance requirements. ENQUIRY NO. 3301 May 2009 | industrial automation asia  29

software & Networks

any technology and original equipment manufacturers (OEMs) adopt and embed ZigBee technology in a wide range of products. These companies’ collective efforts to develop flexible, mobile and easy-to-use products and to install solutions based on its wireless intelligence capabilities into commercial and industrial buildings deliver on the promise to revolutionise how humans interact with their environments. The net effect simplifies and dramatically reduces the cost of construction, operations and building upgrades through

On The

reduction of manpower or wiring needed to add new control capabilities. At the same time, it enhances energy conservation, safety, lighting control, HVAC and other building operations. ZigBee: The Technology ZigBee has become the standard of choice among other wireless technologies by overcoming speed limitations found in other wireless commercial automation technologies and by allowing for more devices on a single network. It uses the universally available 2.4GHz band to provide low data rate wireless applications and offers a

published specification set of high level communication protocols designed to use small, low-power digital radios based on the IEEE 802.15.4 standard for wireless personal area networks. The 802.15.4 radio technology allows for near instantaneous communication between devices without the need for network synchronisation delays as required by Bluetooth and Wi-Fi. This enables lighting systems to utilise wireless control. IEEE 802.15.4 defines a robust radio PHY (physical layer) and MAC (medium access control) layer. ZigBee defines the network,

ZigBee Wagon ZigBee wireless technology creates new possibilities and transforms the office environment into truly effective workspaces. By Dr Bob Heile, chairman, ZigBee Alliance

30  industrial automation asia | May 2009

Stephan Hempelmann, Wolfenb¸ttel, Germany

Wireless systems reduce wiring and labour costs in building automation technologies, enhance power efficiency and the range of the wireless digital signal transmission

security and application framework for an IEEE 802.15.4-based system. These capabilities facilitate speeds to enable a network to have thousands of devices on a single wireless network. ZigBee also defines the solution to create self-forming, self-healing mesh networks. The mesh network helps sensors and controllers establish reliable wireless communication networks. Wireless mesh networks mean

all devices have communication capabilities to ‘talk to one another’, and act as repeaters transferring data to other radios that might be out of communication range of a particular device. Mesh networking also means ZigBee networks do not require a central control point. Mesh networks automatically adjust to network topology changes. Nodes can be added, removed, replaced or relocated without the need for traditional network administration. Mesh networks can optimise or increase the visibility into dynamic systems, such as the environmental conditions inside of a commercial building or the condition of machinery in a manufacturing plant, without the cost and administration of a wired network.

ZigBee In Business Wireless building wireless technologies began to progressively emerge on the market in 2005. Many major technology-related companies announced new wireless applications or stated their intention to develop and release new technologies in late 2006 and 2007. The adoption of ZigBee has played a pivotal role in driving wireless building automation in this profitable market sector. The technology enables cost benefits, ease of deployment, retrofitting applications and network scalability — all of which spur broader market adoption. Whether used in new construction or retrofit, flexibility offers the ultimate benefit in deploying a wireless system as opposed to a wired network.

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software & Networks

ZigBee chips can be embedded in devices such as controllers, switches and sensors for light, heat or moisture

The adoption rate of general wireless usage in the private sector also provides positive economic indicators for the future of wireless building automation. Most technology adoption tends to start in the business sector. One could theorise that general wireless technology adoption by businesses will also likely act as a catalyst to enhance interest by the overall business sector to move toward this application. For example, enterprises and small and medium-size businesses (SMBs) ranked setting wireless policy and centralising management of mobile devices as the top two telecom initiatives for 2006. Budgets reflect these priorities: In 2006, SMBs plan to spend closer to 33 percent more on both mobile voice and mobile data services than in 2005. The trend continues with 56 percent of enterprises expect spending on mobile voice to increase, and 63 percent expect mobile data spending to increase, according to Forrester Research. Case For ZigBee ZigBee-enabled facilities allow everyone to customise and control their own space while allowing business owners to receive substantial technology benefits and cost advantages for their investments. Wireless-based systems offer building owners and facility 32  industrial automation asia | May 2009

managers more choices and fewer constraints, including simpler more flexible system design, faster, less disruptive installations and retrofits, and smoother, less costly migrations staged to accommodate budgets and schedules. Wireless systems reduce wiring

optimised HVAC management and enables allocation of utility costs equitably based on actual consumption. • Flexibility that allows reconfiguration of lighting systems to quickly create adaptable workspaces and extends to allow upgrades of building infrastructure with minimal effort. • Safety enhanced through a network where integrated data from multiple access points enables capabilities such as a fire extinguisher that indicates blockages, etc., or a wireless monitoring system that enhances perimeter protection to secure the building. ZigBee chips can be embedded in devices such as controllers, switches and sensors for light, heat or moisture. The devices can

Since 20 to 80 percent of system installation costs are consumed by wiring, wireless systems can reduce initial costs as well as recurring utility costs and labour costs in building automation technologies, enhance power efficiency and the range of the wireless digital signal transmission. Wireless mesh networking technology improves wireless signals attenuation and offers improved wireless signals. Also, consider the value of these key ZigBee advantages: • Building system control that enables integrated and centralised management of lighting, heating, cooling and security. • Automation control of multiple systems to improve energy conservation, flexibility and security. • Conservation that reduces energy expenses through

be inexpensive, but the savings for commercial facilities are substantial by avoiding cabling/wire pulling costs. With no wiring required, peel-and-stick battery-powered devices like these can be added anywhere and moved easily. Even greater is the cost savings associated with more efficient control of a building’s HVAC and lighting systems, an improvement that often requires the addition of many controllers and sensors. For example, a room senses when a person leaves and automatically turns down the heat, lights, air conditioner and other energyconsuming devices. ENQUIRY NO. 3401

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instrumentation & Measurement




Common types of pressure transducers and factors to consider when selecting one. By Derek Rodriguez

he pressure transducer is a device that is able to produce a varying electrical signal from a change in pressure. In other words, it converts a change in physical force (pressure) into another form of energy: an analogue electrical signal, which can then be measured or controlled. Strain Gauge One common type of pressure sensing technology is the strain gauge pressure transducer. The basic principle this technology is based upon is the fact that the electrical resistance of some wires varies according to the tensile strain that the wires are subjected to: it increases under tensile strains and decreases when it is in compression. 34  industrial automation asia | May 2009

The sensing element of a strain gauge pressure transducer is usually a diaphragm or a tube. The conversion of pressure into an electrical signal is accomplished by bonding the foil strain gauges in a wheatstone bridge configuration on the sensing diaphragm. This deformation of the diaphragm produces strain to the gauge which will in turn, produce an electrical resistance charge that is in proportion to the pressure. The bonded foil strain gauge has several advantages including: • It is able to operate with high accuracy over a wide temperature range • It can be used with both AC and DC systems • It is relatively cheap and easy to find • It is resistant to shock • It is able to sustain a long

lifecycle without the need for maintenance • It functions across a wide frequency range Capacitance Pressure Transducer A n o t h e r t y p e o r p re s s u re transducer is the capacitance pressure transducer. The principle behind this is that the capacitance between two metal plates will change if there is a change in the distance between the plates. When there is a change in capacitance, it is converted into a frequency oscillation that has an output that is in turn, converted into an electrical output electronically. Although more complicated to set up than most other pressure sensors, these transducers are popular because of their stability and linearity and their ability to facilitate the measurement of extremely low pressure ranges. Three Outputs Generally, pressure transducers have three different kinds of output: • millivolt (mV) • voltage (Vdc) • milliampere (mA) Millivolt Pressure Transducers These pressure transducers have low voltage signals which are directly proportional to the pressure transducer input supply power or excitation. If the level of excitation fluctuates, the output will also change along with it. Typically, they have a 20 mV, 30 mV, 33 mV or 100 mV output signal when supplied by a 10 Vdc input. Because the output signal is low, it would not be advisable for the transducer to be installed in an electrically noisy environment. In addition, the distance from the transducer to the output screen (or vice versa) should not be too long.

Voltage Pressure Transducers An amplified voltage output pressure transducer is used where a high level of voltage output is needed. The wide range of high voltage outputs includes: 5 V, 1-5 V, 1-6 V, 0-10 V, 1-10 V etc. The outputs of these pressure transducers do not usually have a direct relationship with the level of excitation. The implication of this is that unlike millivolt pressure transducers, unregulated power supplies can be used so long as they fall within a specified range of power. Also, due to their higher output, these pressure transducers are not as susceptible to electrical noise as millivolt pressure transducers and can be utilised in more industrial environments. Milliampere Pressure Transducers Also termed as pressure transmitters in the industry, these pressure transducers are variable current devices with internal signal conditioning to provide an industry standard 4-20 mA output signal. Because a 4-20 mA signal is least influenced by electrical noise and resistance in the signal wires, these pressure transducers can be used when the transmission of the signal over long distances is required. In some cases, this type of pressure transducers can be found in applications where the lead wire is over 1,000 feet in length.

The industrial environment should be considered when selecting a transducer

Selecting A Pressure Transducer The ideal pressure transducer for an application might not necessarily be the right fit for another. When selecting a pressure transducer, there are many factors to consider: • Pressure Requirements Many hydraulic and pneumatic systems experience pressure spikes, short duration (microsecond to millisecond) bursts of pressure. These pressure spikes might be caused by a change in the equilibrium of the system due to compressors, pumps, pistons, valves etc. Because pressure transducers are vulnerable to these pressure spikes, care must be taken when choosing one for applications where this phenomenon occurs. In such cases, a transducer with a higher pressure rating can be used. This will provide a safety margin in the event of overpressure. For example, a pressure transducer with a pressure range of 125 percent the normal working pressure can be an option. • Temperature Range A change in temperature causes the expansion or contraction of different materials. This then creates stresses within the structure that can have an effect on the output of the transducer (ie: measurement error). Manufacturers usually specify the compensated and operating t e m p e r a t u re r a n g e s t h a t a transducer is able to function in. The compensated temperature range falls within the operating temperature range and is the temperature range wherein the transducer will meet its published performance specifications. The operating temperature range is the temperature range

The sensing element of a strain gauge pressure transducer is usually a diaphragm or a tube

that, although the transducer is able to work without suffering damage, it might not meet the published performance specifications. • Accuracy The accuracy of a transducer describes the level of uncertainty in the transducer’s output. Although accuracy is generally a desirable quality, more accurate transducers normally cost more and in some cases, the extra cost is not justified by the requirements of the system. • Output Signal The output signal is dependent on the distance between the transducer and the controller and the presence of interferences that may exist. For a short distance, a more cost effective millivolt output might be sufficient. For longer distances or noisier environments, an amplified output or even a milliampere output might be required. • Ruggedness There are several operating parameters in an industrial environment that can affect a transducer’s performance. Some examples are vibration/shock effects, temperature, moisture etc. All this should be considered when selecting a housing for the transducer. ENQUIRY NO. 3501 May 2009 | industrial automation asia  35

product HighlightS Ashcroft: Pressure Transducer

Danfoss: Heavy Duty Pressure Transmitter

With the Ashcroft T2’s static accuracy of ±0.25 percent FS at 21°C, modern digital temperature compensation ensures a Total Error Band better than ±1 percent between –20ºC and +85ºC. An advanced sensor and electronics equip the T2 for maximum stability and long life in the presence of overpressure, shock, vibration, and extreme pressure cycling. The T2 pressure transducer can be configured from a long list of process connections, output signals and electrical termination options. It is available in ranges from vacuum through 0/20,000 psi. Enquiry no. 3502

The compact heavy duty pressure transmitter MBS 3050 is designed for use in hydraulic applications with severe medium influences like cavitation, liquid hammer or pressure peaks and offers a reliable pressure measurement, even under harsh environmental conditions. The flexible pressure transmitter programme covers a 4-20 mA output signal, absolute and gauge (relative) versions, measuring ranges from 0-1 to 0-600 bar and a wide range of pressure- and electrical connections. E xcellent vibr ation s t abilit y, robust construction, and a high degree of EMC/EMI protection equip the pressure transmitter to meet industrial requirements. Enquiry no. 3504

Baumer: Submersible Pressure Transmitter

Stellar: High Pressure Range Transducer

The ED 752 is a pressure transmitter available in 4-20 mA current loop or in voltage output signal versions. The sensor is isolated from the process by a stainless steel diaphragm (1.4435 / 316L) and a filling liquid. The electronics is located within the hermetically sealed transmitter housing. The electronics is a signal processing unit fitted with a fast micro-controller allowing the compensation of drift effects due to temperature on the sensor signal, over a wide temperature range with a fast response time. The ED 752 is a submersible pressure transmitter completely made of stainless steel. It is also available in hastelloy C.

Stellar Technology’s GT3200 high range pressure transducer is designed to handle ranges from 0-30,000 psi through 0-100,000 psig /a. The GT3200 family delivers a static accuracy of ±0.25 percent (BFSL), and voltage, current and/or digital output. These units perform over a temperature range of -65° to +250°F (compensated: -30° to +170°F). This sensor is shock and vibration protected. Burst pressure is 2X FSO or 150,000, whichever is less. The GT32X X integrates with a standard ‘bayonet’ style electrical connector and installation is via an AE F250C f i t t ing up t o 6 0,0 0 0 p si a nd AE F312-C fitting from 750,000 to 100,000 psi.

Enquiry no. 3503 36  industrial automation asia | May 2009

Enquiry no. 3505

Market Report

Pressure Transmitter Market To Reach US$2.8 Billion By 2013 The worldwide market for pressure transmitters is expected to grow at a CAGR of 3.3 percent over the next five years. By Joe Gillespie, analyst, Arc Advisory Group

Pressure Transmitter Business Worldwide ($Millions)








Driven by a stronger emphasis on plant asset management (PAM) and safety applications, the worldwide market for pressure transmitters is expected to grow at a compounded annual growth rate (CAGR) of 3.3 percent over the next five years. The market was US$2.38 billion in 2008 and is forecasted to be approximately US$2.798 billion in 2013. Led by a strong automation market and healthy capital expenditures, the pressure transmitter market has seen strong growth in recent years. Increased adoption of smart transmitters, continued emphasis on PAM systems, multivariable t e c h n o l o g y, a n d w i re l e s s communication protocols have been the primary contributors to growth in the market. Going forward, the market is not expected to sustain its current level of growth. The looming economic recession will adversely impact the market in the near term, extenuating the factors that have been responsible for recent above average growth rates.   Economic Landscape Several economic trends threaten to adversely affect shipments of pressure transmitters over the forecast period. The severity

of these factors combined with the length of the impending economic downturn will have a large impact on the performance of the pressure transmitter market. However, sustained emphasis on PAM systems, plant safety, and multivariable sensing will continue to drive sales of intelligent pressure transmitters. ARC believes these factors will largely cancel each other out and the market will grow at rates close to historical averages. Multivariable Technology Sales of multivariable pressure transmitters, one unit that measure two or more process variables, have doubled since 2004, resulting from increased accuracy and the ability to be used in a wide range of applications.

The most popular multivariable transmitters utilise an embedded temperature sensor. This allows the transmitter to calculate the density and mass of the process, which significantly increases the application scope of these devices. Users gravitate towards multivariable units because fewer insertion points need to be cut into the process piping, and more accurate density and mass flow calculations are generated because temperature and pressure measurements are taken from the same point in the pipe. Asia & The Middle East Regionally, suppliers can expect to see the largest growth in the Middle East, due to its high concentration of oil and gas activities, and in Asia, where heavy investment in new plant construction continues in core sectors. In the mature North American and Western European markets, suppliers will largely rely on replacement business. Latin America will see above average growth, but remain a relatively small market for pressure transmitter suppliers. ENQUIRY NO. 3506

May 2009 | industrial automation asia  37

sector spotlight


ur appetite for energy is increasing at a phenomenal rate. As more villages in developing countries are connected to electricity grids, more cars ply the roads, manufacturing is cranked up to meet voracious consumer appetites and more malls go up, the demand for energy has already gone through the roof. Over the next two decades, this demand will rocket into the stratosphere. As is obvious, it is extremely difficult, if not impossible, to talk about energy without indulging in an orgy of superlatives, so let’s use some numbers to illustrate the point.

Stefanie L, Germany

The Hungry Giants In the first half of this decade from 2000 –2005, the world's energy consumption grew between 14–16 percent, depending on which organisation's statistics one looks at. Unsurprisingly, more than 50 percent of this growth has come from India and China. The two giants may have arrived late at the energy buffet, but they've been helping themselves to large quantities of fossil fuels as well as renewable sources ever since. Between 2000 and 2005, China saw an 80 percent spurt in energy usage while India swallowed 20 percent more in 2005 than in 2000.

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This trend of exponential increases in energy demand and consumption looks set to continue into the foreseeable future. World Energy Outlook, the annual report published by the International Energy Agency (IEA), an autonomous body that operates within the framework of the Organization for Economic Co-operation and Development (OECD), predicted in 2007 that energy needs would grow by 55 percent between 2005 and 2030 with India and China contributing 45 percent to this increase.

Worryingly the report also asserts that a majority of this demand will have to be met by oil and natural gas, if enough time and money is not invested in alternate sources of energy. In this case, greenhouse gas emissions will rise by 57 percent - an increase which could have catastrophic consequences for the world. Oil and gas, along with the third member of fossil fuel troika, coal, have been critical in driving human progress. Vast swathes of people in India, China and elsewhere in the developing world would not

Oil & Gas:

Change We Need India and China have been served well by oil and gas. Now it is time for the two Asian juggernauts to look elsewhere for their growing energy needs. By Abhishek Mehrotra

H Yao, US

have been able to jump to a higher societal stratum were it not for economies that boomed with the help of these much maligned energy sources. But this progress has come at a price - harmful effects on the environment. Now, the world and especially the developed countries are hoping that both these nations will prove that ‘progress or the environment’ is a false dichotomy. The Dirt On Oil & Gas However, a popular sentiment in both India and China is that the West has no right to try and dictate energy policy. The feeling is that in the early stages in industrialisation, the West did harm to the environment as well and thus it is not right to expect developing countries to curb

中 国

China was the first developing country to unveil a national plan that addressed climate change

economic development in favour of the environment. Consequently, dinner table conversations centring around the environment favour rhetoric over intellectual rigour and honesty. The harsh reality is that while India and China are on solid moral ground, global warming is just that - global. It does not discriminate based on statistics (the US per capita emission of greenhouses gases was nearly four times that of China and twenty times that of India in 2005. In 2030, the corresponding numbers are expected to two and eight). Given the vast coastlines that both nations possess, unchecked global warming could become an existential threat if oil and gas

continue to play a central role in meeting energy demand. The local environment in both countries is also a major problem as evidenced by the drastic measures the Chinese Government had to take to make Beijing a feasible venue for the summer Olympics in 2008. In fact, currently China could be in the throes of an environmental crisis. In 2007, according to the World Bank, twenty of the thirty most polluted cities in the world were in China. India too is reeling under pollution's chokehold. A World Bank report states that by 2020 India's air, water, soil and forest resources will be under more human pressure than any other

countr y. Causation between fossil fuels and these fearful problems has been established by international institutions like the Asian Development Banks as well as by domestic organisations like the Ministry of Environment and Forests. While coal is the main source of energy in both the countries, th e con ti nui ng i ncreas e in dependence on oil and gas has greatly exacerbated the situation. The Story So Far The environmental issues finally seem to be causing ripples in the public's collective consciousness, with polls showing that a majority of people in both countries now consider the environment to be a major problem. Perhaps this is the reason why both countries are also waking up to the gravity of the situation. Both countries are signatories of the Kyoto Protocol. May 2009 | industrial automation asia  39

sector spotlight

Although there is a rider attached to the signatures which prevents any numerical limitations on greenhouse emissions for developing nations, there is still a sense of common responsibility to reduce pollution. T h e re c e n t n u c l e a r d e a l between India and the US also bodes well for the future of clean energy in the country. With access of US technology, India aims to quadruple nuclear power generation within the next decade. While this may be ambitious, there is still a sense that things are moving in the right direction as far as clean energy is concerned. In March 2009, India became

down the cost of solar energy as well as ‘find ways to effectively convert plant and animal wastes into energy’. Other promising steps include the establishment of the Bureau of Energy Efficiency, modernisation of power plants to reduce electricity losses and introduction of energy efficiency standards for all buildings. In 2007, China became the first developing countr y to unveil a national plan that would address climate change. Xinhua, a Chinese News Agency, claimed that if all the stated objectives of the National Climate Change Program, ranging from hydro

In March 2009, India became a member of the International Renewable Energy Agency (IRENA)

Subhadip Mukherjee, Calcutta, India

a member of the International Renewable Energy Agency (IRENA), a recently formed organisation that aims to ‘become the main driving force for promoting a rapid transition towards the widespread and sustainable use of renewable energy on a global scale’. According to a press release leaders hope that IRENA will be able to assist India in bringing 40  industrial automation asia | May 2009

and nuclear power generation to use of renewable energy sources such as wind and solar power, the country would emit 1.5 billion tonnes less of carbon dioxide without compromising the pace of its economic development. In keeping with a part of its pledge China was the leading wind energy capacity installer in the world behind the US and nearly doubled its capacity from 2007. If both the countries can stay on the road to green energy while continuing to cooperate with the global community, dependence on oil and gas, especially from the Middle East, might finally lessen. And that would be cause for celebration, not merely because of

the environment, but also because this reduced dependence will go a long way in increasing the energy security of the two countries. Security Issues The Middle East is a political quagmire. An unstable region that houses the majority of the world's oil and gas supplies. Since the 1960s there have been seven major oil supply disruptions due to conflicts in the area. In addition, IEA notes that oil and gas will increasingly be concentrated in a small group of countries, most notably in Middle East and Russia. If India and China do not lessen their dependence on these fuels, their energy security will come under increasing threat. An IEA report states that ‘the faster the increase in the call on oil and gas from the leading exporters, the more likely it will be that they (oil producing nations) will seek to extract a higher rent from their exports in the future’. Add to this the terrorist threat that seems to hang over the region, it makes good sense to diversify the fuel mix as much as possible. A healthy combination of fossil fuels and renewable energy would go a long way in easing security concerns. Taken piecemeal, the steps taken by the world's future superpowers might seem inadequate, but gradually a more optimistic picture seems to be emerging. Undoubtedly, huge challenges remain. Powerful lobbies, poverty ridden people and the difficulty in coming up with solutions that are acceptable to a majority are hurdles in the race to save the planet. Governments will have to stay focused and people resilient if two of the biggest success stories are not to have a tragic twist right at the end. ENQUIRY NO. 3601 2701

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anufacturers today are under pressure to adopt Lean and Green and to create an environmental stance that is a driver for reduced costs and risks, increased revenues, and improved brand image. Environmental regulations, however, are not new to the manufacturing sector. The Restriction of Hazardous Substances (RoHS) directive, the Waste Electrical a n d E l e c t ro n i c E q u i p m e n t (WEEE) directive, the Restriction, Evaluation, and Authorisation of Chemicals (REACH) regulation, and the California Green Chemistry initiative have forced manufacturers to re-examine the entire lifecycle and environmental impact of their products. Such compl iance ef for ts have already resulted in cleaner, safer operations, reduced use and acceptable substitutions for

hazardous substances, increased product recyclability and recovery, and improved transparency of information available to suppliers, trading partners, employees, and customers. The good news is that existing Lean and Six Sigma programmes can be leveraged in developing sustainable Green practices, particularly in the area of waste reduction. Green opportunities for identifying and reducing waste in the lean supply chain can be found in various places: Material costs, consumption of energy and natural resources, equipment efficiency, and education of key stakeholders. Manufacturers must be concerned with controlling pollution and environmental waste at its source in order to address the


rising cost of energy and natural resources and the negative impact on climate change and global warming. In fact, manufacturers can still achieve cost savings in addition to environmental benefits by integrating their Lean and Green initiatives. Green Supply Chain Lean and Green create their ‘ecoadvantage’ in three ways: Ecoefficiency – cutting out waste, using resources productively, and minimising the carbon footprint; Eco-innovation – improving product and service designs so they’re based on green processes, such as minimising waste byproducts and designing for recycling; Eco-transparency – gaining and sharing full visibility into the value chain so that your business can promote its green brand and enhance and protect its overall brand.

Manufacturers can achieve cost savings in addition to environmental benefits by integrating their Lean and Green initiatives. By Ash Khalek, group VP, manufacturing, retail & distribution, Asia Pacific, Oracle

42  industrial automation asia | May 2009

BSK, Indonesia

Pursuit Of Green-ness

Designing For Green Lean in the product development stage is a fore-runner for achieving the benefits from going green – using less materials and chemicals; yielding less scrap; and reducing the consumption of energy and natural resources. Product compliance begins during the product development stage. Product teams utilise, re-use or source components, parts, materials and suppliers that comply with ever-evolving environmental requirements and standards. The new best practice is to make environmental compliance a design constraint throughout the entire product lifecycle, from concept though launch and into retirement; by integrating compliance into their product development lifecycle processes, checklists and design gates. Companies that don’t risk regulatory and product compliance breakdowns can suffer costly business interruptions including product re-designs, delayed market launches, product recalls and some can even be blocked from selling a product in a certain country or region. Successful Product Lifecycle Management (PLM) solutions enable organisations to manage and optimise the compliance of their products and programmes with the standards and regulations of the government and industry. These solutions should merge compliance activities with product development and introduction processes, allowing companies to more reliably comply with environmental standards, create policy documentation and design compliant products from the start – in a repeatable audit-ready system. Effective PLM offerings that include design-for-environment functionality allow manufacturers to:

• Collect information about resources, substances, materials and components with limits set by government standards and regulations. • Analyse new product designs for environmental compliance and conduct what-if analysis to ensure they meet requirements at all levels. • Track the ‘as-designed’ waste that will be generated to manufacture the product. • Track material declarations, certificates of compliance, and standard operating procedures – linking that to the product record, process record and signatures. • Perform related risk analysis and supply reports to customers or regulatory agencies. Reducing Production Waste The adoption of Lean and Green strategies in manufacturing organisations has resulted in processes becoming more flexible, responsive, and competitive. With this improved responsiveness, organisations can quickly adapt to the increasingly complex demands of global manufacturing – demands that require more connectivity and more effective communication among suppliers, shop-floor systems, and back-office Enterprise Resource Planning (ERP). Greening the supply chain generates environmental benefits as well as financial results by: • Reducing risk by managing a product’s environmental compliance in its design rather than making any necessary costly corrections later in its lifecycle. • Optimising supply networks for production cost and time, as well as environmental cost and risks by using strategic network optimisation tools. • Reducing manufacturing costs and environmental impacts by applying lean manufacturing

Green initiatives can be driven by a combination of things – corporate citizenship, environmental protection, and economic opportunity

principles to environmentally sensitive components and production operations. • R e d u c i n g t r a n s p o r t a t i o n costs while also reducing emissions using transportation management tools. • Reducing energy costs and extending the life of assets by managing them more efficiently by utilising Enterprise Asset Management software applications and intelligent device monitoring. • Increasing reverse supply chain efficiencies while addressing increasing product take-back requirements using warehouse management and depot repair solutions. Eliminating activities that do not add value to the customer is the real key to shop-floor effectiveness and enhancing green initiatives within the organisation. Software capabilities such as F l o w M a n u f a c t u r i n g , Va l u e Stream Mapping, and Inventory Optimisation contribute to reduced inventories and lead times, thereby May 2009 | industrial automation asia  43


significantly increasing the factory throughput and freeing up working capital for more productive and valuable activities. Business process automation and paperwork reduction are also critical transformations in enabling g re e n m a n u f a c t u r i n g . F l o w Manufacturing and Manufacturing Execution Systems for Discrete Manufacturing and Process Manufacturing can deliver intuitive, configurable workbenches that guide operators through paperless, task-driven material movements and transactions integral to the production process. These workbenches streamline shopfloor transaction reporting by performing multiple transactions in one pass, thereby allowing for other value-adding activities. To help ensure the smooth flow of information, Lean principles, and clean environment considerations throughout the enterprise and extended supply chain, companies should look for software offerings

The adoption of Lean and Green strategies in manufacturing organisations has resulted in processes becoming more flexible, responsive, and competitive 44  industrial automation asia | May 2009

that enable users to leverage a single source of data to easily share information across all applications. Specifically built-in business flows such as demandto-build, build-to-deliver, and forecast-to-plan, equip companies with streamlined and effective business flows. Tracking Energy Consumption With the turn of the century there is now a focus on energy costs. The first level of cost efficiency and reducing environmental impact is monitoring and controlling commodity consumption. So the first basic requirement is to track consumption of energy commodities aka WAGES (water, air, gas, electric, and steam). This would require tracking consumption at the equipment level with value roll-up through the equipment hierarchy model. There are several business benefits associated with tracking energy consumption. These include better control over the profitability by ensuring that the volatility in energy prices is kept under constant check. The very activities that provide energy efficiency also provide better control over plant assets and inputs. Also, energy efficiency is not just about reducing utility bills. It’s also about boosting revenue through greater productivity. Industry surveys indicate that the average plant can reduce its energy consumption by 10–20 percent, and a lot of that is from procedural and behavioural changes. The cost of sustaining an energy management programme (operations and maintenance costs only, omitting capital expense) is around 1–2 percent of total energy expenditure. Investment in innovative technologies to achieve energy efficiencies can achieve substantial additional benefits not only to the financial bottom line

but also to corporate image and community relations. Optimising Resource Utilisation A manufacturer commonly has in place PLC, PAC and SCADA systems to collect data about asset performance. However, this existing grid of sensor information is commonly not integrated to the business system. To support green initiatives a manufacturer must take advantage of the existing grid of sensor information. The challenge that the maintenance supervisor will face as sensoww r information is collected is similar to the challenge that individuals face in sorting through e-mails, phone and text messages on a daily basis. Analytics and rules-based programmes allow a maintenance technician to filter, sort, and respond to a stream of readings and alarms and events can assist in determining what is significant. Effectively responding to data collected will provide the basis for the movement from interval-based maintenance to condition-based maintenance. Condition-based maintenance bases maintenance requirements on the actual condition of the asset. The Federal Energy Management Program has estimated that conditionbased maintenance results in an estimated 8–12 percent cost savings over a conventional preventive maintenance programme. Recent academic research and surveys find the most compelling reason for organisations adopting lean is the economic and environmental benefits of going green. Leading organisations go beyond the basics of cutting waste and operating efficiently. They embed environmental considerations into all aspects of their operations. ENQUIRY NO. 3701


Sustainability meets

Automati n The automation industry has been a major mover in sustainable practices. By Augustine Quek

ustainability, in a broad sense, is the ability to maintain a certain process or state. The popularisation of the word started with the publication of Our Common Future in 1987, by the United Nations World Commission on Environment and Development (also known as the Brundtland commission). That report defined sustainable development as ‘development that meets the needs of the present without compromising the ability of future generations to meet their own needs.’ In modern manufacturing, sustainability refers to production processes and technologies that use minimal energy and resources, create minimal waste and allows for future production capabilities to be developed. Concerns about global climate change, soaring energy prices, and increased government legislation are driving the demand for all things ‘green,’ including more environmentally friendly products and technologies. The automation industry has been a major mover in sustainable practices, including automated May 2009 | industrial automation asia  45


design, energy efficiency, waste minimisation and reduced product environmental impact.

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Sustainable Technologies The cornerstone of automation has been to increase efficiency and reduce wastage in production processes. Modern automation technologies have reached new heights and complexity that also targets green production. Many products exist for automation technologies in the energy management area, including

Michael, US

Automated Design It’s no doubt that environmental impact can be reduced with well-designed products. In fact, it is easiest to build sustainable features into products and services at the initial design stage, when any changes in production plans, market forces and consumer demands can be accounted for without expensive modifications. This has led to increased popularity with using sustainable designs. An annual sustainable designtrend watch survey jointly commissioned by the American Society Mechanical Engineers (ASME) and Autodesk found that two-thirds of respondents have worked on designing sustainable products. A key trend highlighted by the survey is that more than half of the practicing engineers reported they expect to increase their use of sustainable design practices in the next year. Additionally, a separate survey of ASME student members found that half of the respondents have encountered sustainable design practices in their studies and are extremely interested in green and sustainable information and causes. Thus, designing with a sustainable focus is now no longer the exception. For example, IBM and Dassault Systèmes have recently announced BMW’s use of a single digital software environment for the design of all BMW engines across its fuel and diesel-powered cars, motorcycles, and its newest line of eco-friendly, hybrid cars including the industry’s first hydrogenpowered vehicle. Working with IBM and Dassault Systèmes, BMW has developed a series of software design initiatives aimed at equipping new cars with fuel-saving technologies. From

designing smaller engines to increasing piston and cylinder performance for better ignition and fuel performance, product lifecycle management software continues to play a key role in the intelligent design of new products. Through the CATIA software, BMW product designers can use multiple engineering applications to significantly enhance a manufacturer’s ability to share master versions of an engine design before signing off on production and manufacturing plans.

Automation allows producers to make optimal use of resources, improve their environmental performance and ultimately improve their bottom line

variable-frequency drives and intelligent motor control, energy management solutions, and engine control modules. Controlling variable frequency drives with precise speed and motor torque helps motors run efficiently, while power management solutions help manufacturers determine the most strategic use of energy, reduce emissions and improve productivity. E n e rg y m a n a g e m e n t h a s even gone wireless. Adaptive Wireless Solutions (AWS) has added the WaveLink range from Spinwave Systems to its wireless products. The company said that WaveLink cuts energy costs and reduces carbon emissions in far less time than with hard-wired technologies. The systems monitor and automatically control energy c o n s u m p t i o n , re s u l t i n g i n significant energy savings of over 40 percent from the day of installation, claims AWS. Bosch Rexroth is another example in sustainable application of hydraulics, electric drives, controls, pneumatics, and linear motion technologies. It offers a class of special conveyors for solar cell manufacturing, The company’s TSsolar transfer system can directly transport photovoltaic modules in thin-film and silicon cell technology. Automated Monitoring The effect of automation technologies on sustainable production has been to optimise client operations for maximum visibility, efficiency and safety. With the convergence of factory controls and information technology, the intelligent use of plant-floor data collected from automation systems is more important than ever. The right data gathered at the right time, coupled with process improvement strategies allows

producers to make optimal use of resources, improve their environmental performance and ultimately improve their bottom line. An emerging area of data gathering is environmental monitoring, which helps reduces pollution and wastage. Many Product Lifecycle Management and Enterprise Resource Management companies have diverse offerings for sustainable manufacturing. IFS has launched a fullyintegrated Eco-footprint Management tool as part of an enterprise standard applications suite. The tool provides organisations with a high degree of control and transparency on the environmental impact of their operations, and

The cornerstone of automation has been to increase efficiency and reduce wastage in production processes offers an enterprise standard methodology to help control costs and meet compliance with environmental legislation.

A Gdula, Poland

Concerns about global climate change, soaring energy prices, and increased government legislation are driving the demand for green products and technologies

Sustainable Outlook However, the most important change in the industry is its mindset towards sustainability. Organisations throughout the world are facing increasing local, regional and global regulation; a challenging economic situation; increased consumer awareness to social and environmental issues; resource scarcity; and highly networked business operations. These factors put brands, market share and even market cap at significant risk, but also represent new business opportunities. Sustainability is about increasing the profitability of businesses by holistically managing economic, social and environmental risks and opportunities. For example, SAP AG has announced a long-term strategic focus on sustainability, covering both its own operations and customer solutions for more sustainable business practices. In addition to delivering sustainable business processes through, for example, its SAP EHS Management application, SAP is helping its customers practice ‘Green IT’ by enabling them to reduce the energy footprint of SAP solutions in their data centers through consolidation, virtualisation and

other landscape optimisation services. At Invensys Process Systems, not only are environmental performance carefully monitored, an annual Environmental Per formance Questionnaire (EPQ) is also conducted within its manufacturing operations t o m e a s u re e n v i ro n m e n t a l performance in eleven key areas. According to a report by IBM Global Business Services titled ‘Lighting the Way: Understanding the smart energy consumer,’ consumers around the globe are willing to become more involved with managing their energy use. The study revealed that now, major changes are evident in the ways consumers learn about companies and products, what they value and what they will pay for, as well as how they communicate with each other and the companies with which they do business. Therefore, the trend towards environmental sustainability is now entrenched in the minds of the consumer. Sustainability already is influencing infrastructure investments around the world, transforming energy grids, supply chains, water management and ultimately, society’s way of life. Automation companies must not only embrace this change, but also leverage on it to provide information, influence behaviour, and teach consumers new ways to meet their goals. ENQUIRY NO. 3702 May 2009 | industrial automation asia  47


ld OParts, New Remanufacturing:

Often misunderstood, the concept of remanufacturing brings crystal clear benefits. By William C Gager, president, Automotive Parts Remanufacturers Association emanufacturing is the disassembly of products during which time parts are cleaned, repaired or replaced then reassembled to sound working condition. A product is considered remanufactured if its primary components come from a used product. There are also other instances whereby a product is deemed remanufactured. When a product is dismantled to the extent necessary to determine the condition of its components, when its components are thoroughly cleaned (made free from rust and corrosion), when all missing, defective, broken or substantially worn parts are either restored to sound, functionally good condition, or they are replaced with new, remanufactured, or sound, functionally good used parts. Remanufacturing puts the product in sound working condition – such machining, rewinding, refinishing or other operations are performed as necessary. They are reassembled and determined that it will operate like a similar new product. Other terms may be used 48  industrial automation asia | May 2009

S Petit


interchangeably with remanufacturing in certain specific industry segments. One such term is rebuilt. Rebuilt is synonymous with remanufacturing when used in connection with motor vehicle parts and systems but not the entire vehicle. Recharged is synonymous with remanufacturing when used in connection with imaging products, such as laser toner cartridges. Dispelling The Fallacy The definition of what remanufacturing is describes a process. If a product goes through this process it can be considered remanufactured. There are many terms, which may be confused with remanufacturing; including the following: • Recycled – A 'recycled' product may ver y well meet the minimum remanufacturing re q u i re m e n t s ; a n d m a n y legitimate remanufacturers use this term to describe their product. However, many times a recycled product may be, as in the automotive sector, removed from a scrap vehicle

and resold with little or no work performed on it. Some recycled products are superficially cleaned, boxed and sold. Obviously, as described, recycled would not be considered remanufactured and its reliability is questionable. • Repair ed – This is not a precise term. Essentially it means that the product has had enough work done to it to make it operational again, but this would probably not be considered remanufactured. A holistic root cause analysis is generally not performed in the repair process, which means the product may not perform like a new product. • Restored/Reconditioned – These are generic terms generally applied to antique or classic goods as opposed to a mass market consumer product. • Used – Generally, this is a product that has been subjected to previous use and is not new. Nothing has been done to repair it or correct any problems it may have. Therefore, its useful life is unknown.

In summary, when determining i f a p ro d u c t i s o r i s n o t remanufactured, it is imperative to consider first and foremost the process utilised. Some products are remanufactured more than others. They are motor vehicle parts, compressors, robots and aircraft parts. Ultimate Recycling Inherently, remanufacturing has positive environmental ramifications. In fact, many organisations are now using the concept of remanufacturing, if not the term, in their environmental literature. But why is remanufacturing considered the ultimate form of recycling? First, one must consider the definition of recycling. The term recycling is generally applied to consumable goods: such as newspapers, glass bottles and aluminium cans. However, recycling can also apply to durable goods – such as an engine. Once these goods are consumed, they may be recycled, meaning they are removed from the waste disposal stream, returned to their original raw material form and serve as raw materials for a manufacturing process. The environmental benefits of recycling are easy to comprehend; recycling reduces the quantity of waste headed for landfill space. If

an engine were to be recycled, the steel from the item would be saved from the landfill space and could be used to produce another item requiring steel. However, remanufacturing offers a better alternative. According to an entry by professor Robert T Lund of Boston University in the book, ‘The American Edge: Leveraging Manufacturing’s Hidden Assets’, remanufacturing differs from recycling because remanufacturing ‘recycles’ the value originally added to the raw material. According to professor Lund: "Remanufacturing differs from recycling also, most importantly because it makes a much greater economic contribution per unit of product than does recycling. The essential difference arises in the recapture of value added. Value added is the cost of labour, energy, and manufacturing operations that are added to the basic cost of raw materials in the manufacture of a product. For all but the most simple durable goods, value added is by far the largest element of cost.” He went on to say: “Even in a product as simple as a beer bottle, the cost of the basic raw materials (sand, soda, and lime) is much less than 5 percent of the cost of a finished bottle. The rest is value added. For a product such as an Durable goods such as engines can be remanufactured as well

automobile, the value of the raw materials that can be recovered by recycling is only in the order of 1.5 percent of the market value of the new car.” “Value added is embodied in the product. Recycling destroys that value added, reducing a product to its elemental value - its recoverable raw material constituents. Further, recycling requires added labour, energy, and processing capital to recover the raw materials. When all of the costs of segregation, collection, processing, and refining are taken into account, recycling has significant societal cost. Society undertakes recycling only because, for all nondurable and many durable products, the societal cost of any other disposal alternative is even greater," he concluded. Other Environmental Benefits According to studies performed at the Fraunhofer Institute in Stuttgart, Germany, energy savings by remanufacturing worldwide in a year equals the electricity generated by 5 nuclear power plants or 10,744,000 barrels of crude oil which corresponds to a fleet of 233 oil tankers. They also determined that raw materials saved by remanufacturing worldwide in a year would fill 155,000 railroad cars forming a train 1,100 miles (1,770 km) long. Because products that are remanufactured are kept out of the waste stream longer, landfill space is preserved and air pollution is reduced from products that would have had to be resmelted or otherwise reprocessed. A product can always be recycled. Extending product life through remanufacturing though, is the key to leveraging the earth’s natural resources. ENQUIRY NO. 3703

May 2009 | industrial automation asia  49


Market Report

MRO To Maintain Steady Growth As Global Meltdown Eases The maintenance, repair and overhaul (MRO) industry remains bullish despite the current economic situation. By Nagib Ramli, associate, Asia Pacific Aerospace & Defense Practice, Frost & Sullivan here has been a positive response around the world which has put an unprecedented worldwide focus on addressing the economic situation, driven primarily by massive government fiscal stimulus packages. Current sentiment on the crisis that has reached its lowest ebb and thus provides for a full fledged rebound within the first half of 2009 will continue to spur growth. Strong demand from emerging nations will be a factor in reviving the global economy. Going Strong For the MRO industry coming out of a tumultuous year in 2008, its economic outlook in 2009 in the short term and long term remains bullish. We expect that investments on MRO activity in the interim will hinge on a case by case basis, while our studies suggest that Asia Pacific MRO revenue forecast would decrease by 3 percent due to slowdown in air traffic. Relative to its counterpart in most regions however, Asia Pacific would still record a comparatively higher growth stemming from all maintenance segments, the bulk of which will be driven by the engine segment. This is in part due to long term demand emanating from major economies in the Asia Pacific region that is expecting new aircraft deliveries from major OEMs such as Boeing and Airbus.

50  industrial automation asia | May 2009

However, expected growth may very well differ by countries. We expect that deliveries in 2009 would be close to some 500, adding backlog from 2008 with 450 aircraft that is scheduled for delivery in 2009. Looking To Asia On a different note, since MRO operators in Asia are typically involved in the maintenance of wide body aircraft coming from its western neighbours, we estimate that more long term MRO contracts will be put in place adding to the drifting trend of maintenance provisions onto Asia. We maintain that in the long run, MRO activity will shift toward the Asia Pacific region, as China, India and the region at large are slated to establish its importance as MRO centres. A new engine MRO facility is being established in Shanghai, a joint venture between Pratt & Whitney and China Eastern Airline, and is expected to open its doors within the first half of this year. The facility will be designed to handle CFM International CFM56 engines and the carrier’s fleet includes CFM56- powered Airbus A320 family aircraft and Boeing 737s. MRO Hub In addition, helping to spur this growth is the continued MRO infrastructure development in Singapore, which is the largest MRO hub in the Asia Pacific region.

Aerospace MRO Revenue Forecasts (Global), 2000–2030 $200.00 $180.00 $160.00 Revenue, US$ Billion

As noted by its respective Senior Minister of State for Trade and Industry, the country remains committed to developing the aerospace industry. Currently, Singapore is developing the 300 hectors Seletar Aerospace Park as an integrated aerospace facility which, besides MRO, will play host to manufacturing and other business activities. Companies such as Rolls Royce, Pratt and Whitney and ST Aerospace are among those that have put forth their commitment to invest. Similarly, MAS Engineering & Maintenance and GMR Hyderabad International Airport have also entered into a joint venture. A world class MRO facility is currently under construction at the Greenfield Rajiv Gandhi International Airport in Shamshabad, Hyderabad. This investment worth between US$50 million and US$70 million that will include training, maintenance services for both narrow and wide body aircraft is due to open by the end of the third quarter.

$140.00 $120.00 $100.00 $80.00 $60.00 $40.00 $20.00 $ 2000







in MRO activities. Furthermore, labour cost in the region is relative cheaper and as the MRO industry adopts cost-cutting measures to minimise operational and maintenance expenditure to provide the necessar y cash flow for sustainability and growth, the labour aspects of the business on a whole should not be discounted. The establishments of MRO facilities across Asia will also bolster standard competencies of aircraft technicians and hence produce a strong demand for engineering talents. Despite reports of a global economic slowdown, we remain bullish that worldwide sentiment on the economy is beginning to taper and recovery will soon start to set in. MRO outlook in 2009 would be positive on grounds mainly due to macro influences which will be dictating industry’s trajectory in the short term.

In the long run, MRO activity will

shift toward the Asia Pacific region Steady Growth Forecasted The global commercial MRO market is experiencing a steady annual growth at a circa 4 percent range with its market value that is expected to exceed US$65 billion within the next decade. And over the next few years, We estimate that North America will see a decrease in its market share. There are several factors contributing to the shift. Reasonable growth in the Low Cost Carrier (LCC) passenger traffic within Asia Pacific on short flights and even in the long haul segment could potentially provide stimulus for increase


May 2009 | industrial automation asia  51

products & Services Carlo Gavazzi: DC Energy Analyser

Cognex: Vision Systems

Carlo Gavazzi’s energy analyser for DC applications composes of a measuring unit (VMU-E) and a power supply and digital output unit (VMU-X). It allows measurement, control and retransmission of variables – such as current, voltage, power and energy – in those applications where the electrical system is based on DC type. The energy analyser measures direct current up to 20A and, if connected to an external shunt, up to 1000A. The VMU-E measurement unit is combined with the VMU-X unit that can be either an RS485 communication port – to integrate the meter in a complex energy management system – or a digital output.

Cognex’s entry level In-Sight Micro 1100C model provides a standard (640 x 480) resolution colour vision system. The InSight 1400C model doubles the processor performance for more demanding applications. And, the In-Sight 1403C model is a two megapixel (1600 x 1200 resolution) system that enables high resolution inspection for a wide variety of colour applications. Cognex has also released the In-Sight Explorer version 4.3 software. This introduces two colour tools to the library of vision tools. The Colour Match tool is a high speed colour sortation tool that brings the power of 24-bit colour resolution.

Enquiry no. 3801

Enquiry no. 3803

CEJN: Expanded Hydraulic Range

Contec: Isolated Digital I/O Modules

CEJN’s hydraulic range has expanded from featuring CEJN original classic couplings and Nordic standards to also include quick connect series compatible with a number of ISO Standards. Several of the products meet the demands of the ISO 16028 standard and are available in many versions and sizes, including couplings in steel and stainless steel with a working pressure up to 500 bar. ISO 7241-1 A standard couplings in different sizes are offered in steel and ISO 7241-1 B Standard couplings in several sizes are available in both steel and stainless steel. Some series also feature a pressure eliminator that solves problems with residual pressure on the nipple side.

The GDIO-3232LX-USB and GDIO-1616LX-USB are USB2.0compliant isolated digital I/O modules that provide 12 – 24VDC digital input / output signals through a computer’s USB ports. These modules measure 180mm (w) ×140mm (d) ×34mm (h), provide 32/16 channels of optocoupler isolated digital input (compatible with current sink output) and 32/16 channels of optocoupler isolated open-collector outputs (current sink) with a maximum response time of 200μsec. These modules have a 1port USB hub function. Using a daisy chain style connection, up to 4 of the company’s USB modules can be connected through a single USB port on the host PC.

Enquiry no. 3802 52  industrial automation asia | May 2009

Enquiry no. 3804

products & Services

Emerson: Rotary Valve

GE Fanuc: Remote Telemetry Unit

Emerson Process Management’s Fisher Posi-Seal A81 rotary valve’s tight shutoff and the long seal life capability of the A81 make it ideal for on/off applications. Complete shutoff is made possible by the pressureassisting action of the valve seal ring. The opening and closing path of the eccentric valve disk minimises contact with the seal ring, thereby reducing seal wear. Interchangeable sealing technology allows the A81 valve body to accept both soft and metal seals. The valve can be used in most process on/off applications; it installs easily in either a horizontal or vertical orientation with no detriment to performance or cycle life.

GE Fanuc Intelligent Platforms’ QuickPanel Remote Telemetry Unit (RTU) applied solution enables water/wastewater companies to monitor, diagnose and maintain water assets and processes through flexible communication architectures. QuickPanel integrates with existing PLC hardware locally and other RTUs throughout the system, delivering connectivity across operations. A visual interface for local operators allows site equipment to be operated manually. The integrated controller keeps automatic equipment running through an outage. QuickPanel RTU can range from simple, low I/O count applications through complex automation solutions that require the support of large numbers of I/O.

Enquiry no. 3805

Enquiry no. 3807

Exact Flow: Dual-Rotor Turbine Flow Meter

Hardy Instruments: Weight Controller

Exact Flow’s Exact dual-rotor subsea turbine flow meter is for subsea hydraulic pod valve actuation and topside flow applications in the offshore oil industry. In hydraulic fluid applications, it is packaged in a high-pressure, manifold-mounted system with built-in redundancy. The flow meter is calibrated to account for the entire range of temperature and pressure conditions. It includes internal temperature and pressure sensors to correct for these effects and provide the best possible system accuracy. With the Exact Dual-rotor Subsea Flow Meter, bearing diagnostics can be determined by monitoring the ratio of the rotors to detect wear or cleanliness.

H ardy I ns t r ument s’ H I 4050 weight controller is available factory installed in a stainless steel (Nema 4x) enclosure. A load cell summing board or intrinsic barrier assembly can be added. The controller comes standard with EtherNet and optional EtherNet/IP, DeviceNet, Allen-Bradley Remote I/O, Profibus or Modbus TCP/IP networks. It includes Waversaver to eliminate the effects of surrounding vibration, C2 electronic calibration without test weights, a Secure Digital (SD) based secure memory module card, a built-in web server for internet access, and Integrated Technician for system diagnostics and troubleshooting.

Enquiry no. 3806

Enquiry no. 3808 May 2009 | industrial automation asia  53

products & Services

Jumo: Pressure Transmitter

Maplesoft: Connectivity Toolbox

Jumo’s dTrans p20 transmitter series’ stainless steel housing makes the transmitters ideal for all areas of application where they need to be easy to clean, as well as having optimum corrosion resistance. Electrical connection is via an M12 connector, instead of the conventional cable gland. The rotary knob replaces the traditional keys. At the display level, you can switch between six different images, each showing different measurement variables. The transmitters cover the full industry range from 5 mbar to 1000 bar and has a linearity error of max 0.07 percent.

M a ple s o f t ’s M a ple S im Connectivity Toolbox enables users to expor t highper formance MapleSim models into Simulink, thus taking advantage of the intuitive, multi-domain physical modeling environment of MapleSim as part of their toolchain. Using this toolbox MapleSim models are automatically converted to S-Function blocks for inclusion in Simulink diagrams. In addition, this toolbox allows engineers to better understand and more easily reuse their models with the help of MapleSim’s analysis tools and design documentation abilities.

Enquiry no. 3809

Enquiry no. 3811

Korenix: Networking Computer

Mitsubishi Electric: Safety Relays

Korenix’s JetBox 9310 PoE networking computer combines router, managed Ethernet switch, PoE, a 4-port serial device server and digital I/O controller into one box. It features a RISC-based embedded computer with built-in Linux OS, one WAN port and four LAN ports by default, and a 5-port 10 /10 0T X managed Ethernet switch. I t supports IEEE 802.3af PoE technology, deliver power and data to IP camera, RFID reader, barcode reader and wireless AP. It also features a digital I/O control, carrying four DI and four DO channels for the use to integrate alarms, indicators and sensors into their security system.

Mitsubishi Electric has added a line of safety relays that are designed for standard applications in smaller systems without their own safety controllers. They are available in two versions: as a plug-in module for the Melsec System Q automation platform and as a network module for the industrial fieldbus system CCLink (Control and Communication Link). The safety relays allow modular expansion and conform to the most exacting safety standards. The safety switching devices from Mitsubishi Electric are designed for basic safety functions in mechanical and plant engineering applications like emergency off devices, light grids and safety door monitoring systems.

Enquiry no. 3810 54  industrial automation asia | May 2009

Enquiry no. 3812

products & Services products & Services

Omron: Micro Programmable Controllers

RTK Instruments: Alarm Annunciator

Omron’s CP1E CPU Units can be used to build low-cost micro PLCs. Manufacturers that produce compact equipment place importance on keeping manufacturing costs down without spending a lot of time on design and system implementation. The CP1E CPU units feature simplified programming and wiring verification. There are two types of CPU Units: the E-type Basic CPU Units, which provide a low cost with minimal functionality, and the N-type Application CPU Units, which incorporate a serial port for connection with Programmable Terminals and a pulse I/O function for position control. The N-type CPU Units can control compact devices efficiently.

RTK Instruments’ 725B Annunciator, a solution for monitoring critical alarms, uses Canbus communication technology. The multi-redundant design removes the need for common CPU or a common service module and provides no single point of system failure. All alarm cards in the system are automatically able to act as the master controller. It can be supplied as a stand alone annunciator or with an integrated 1 ms event recorder, allowing the user to analyse the exact sequence of events following a plant breakdown. It can be supplied with integral, universal power supplies to connect directly to 85-264 VAC or 88-360 VDC.

Enquiry no. 3813

Enquiry no. 3815

Portescap: Magneto Resistive Encoder

Vega: Suspension Pressure Transmitter

Portescap’s MR2 incremental encoders deliver accurate positioning at a controlled speed with factory-programmable resolution from four to 512 lines in discrete steps, in a compact package. The encoder eliminates the rigorous test cycle qualifications for qualifying OEM machine parts, as the encoder package remains the same regardless of the desired resolution. The MR2’s reduced jitter delivers a cleaner signal for faster signal processing with improved positioning and speed control. The encoders are compatible with brush DC, brushless slotless DC and brushless slotted DC motors of various sizes and ratios. They are manufactured in an ISO certified facility, and are RoHS compliant.

VegaWell 52 instruments are used for hydrost atic level measurements in water/ waste water, deep wells and shipbuilding industry.  Mounting is accomplished by means of a straining clamp or a G1.5 A threaded fitting. The  measuring ranges  is available from  0.1 and 10 bar (absolute / gauge), the application temperatures between -40 and 80°C. A signal output of 4 ... 20 mA is standard for voltage supply 9.6 ... 36 V DC; HART signal + PT100 is also available on request. Calibration is carried out on a PC with the adjustment software PACTware or via a HART handheld. Transmitter material ranges from Duplex to PVDF (for high chemical resistance).

Enquiry no. 3814

Enquiry no. 3816 May 2009 | industrial automation asia  55


ProPak Asia 2009 The region’s leading trade exhibition highlights innovations that boost cost reduction and energy efficiency.

Additional activities this year, such as lectures, seminars and workshops will be held in cooperation with national organisations and technology institutions.

Exhibition Areas Visitors to the event will be able to find out more about the specific areas in processing, filling and packaging technology by going to the different exhibition areas that cater to their needs. Following is a list of exhibitions within ProPak:

ProPak Asia will take place at Bangkok’s BITEC, in Thailand, from June 17 – 20 this year. Organised by Bangkok Exhibition Services (BES), the trade exhibition will focus on cost reduction and energy efficiency for food processing, packaging and other related industries. More than 800 international exhibitors will be participating, and up to 30,000 visitors from around the world are expected at the event. They represent food and drink processing, pharmaceuticals, cosmetics, consumer products, etc. Processing & Packaging ProPak Asia 2008 saw more than 700 leading processing and packaging machine manufacturers from 56  industrial automation asia | May 2009

Japan, Germany, China, Singapore, UK, South Korea, Taiwan, Italy, India, USA, Australia, Spain, France. The four-day show also attracted a record number of more than 27,000 local and international visitors. David Aitken, MD of BES, said: “Highlights of this year’s event include the biggest assembly of processing and packaging machines and materials as well as more comprehensive updates on food & drink processing, filling, food testing and pharmaceuticals. Moreover, trade exhibition space for laboratory equipment will be expanding its space to meet the increasing international demand for product R&D and quality assurance.”

• P h a r m a T e c h A s i a – Pharmaceutical & Cosmetics P a c k a g i n g & P ro c e s s i n g Technology • DrinkTech Asia – Beverage and Brewing Processing and Packaging Technology • PlasTech Asia – PET & Plastics Packaging Technology & Materials • CanTech Asia – Canmaking & Canning Technology • SeafoodTech Asia – Seafood Processing, Packaging and Related Technology • Lab & Test Asia – Laboratory Equipment, Instrumentation, Test and Measurement and Quality Control BITEC Bangkok, Thailand June 17 – 20, 2009 ENQUIRY NO. 3901

CommunicAsia 2009 CommunicAsia 2009 will focus on the latest hot technologies for applications, solutions and hardware. CommunicAsia2009 and BroadcastAsia2009 are expected to feature about 2,000 exhibiting companies from 65 countries and regions from across the globe. The shows are set to return from June 16 –19, 2009 at the Singapore Expo. The infocomm industr y’s strength is still evident despite the unpredictable conditions in the global economy. IDC has projected that the combined telecom services market of Indonesia, Malaysia, the Philippines, Singapore and Thailand to reach US$35.7 billion in 2009, which is 10 percent higher than its 2008 performance. “The global gloom has accentuated the gleaming potential in Asia and increased the urgency in which international companies are moving into the continent,” said Stephen Tan, chief executive at show organiser Singapore Exhibition Services.

As companies are turning to cutting edge technologies to meet the challenges posed by today’s tough economic climate, CommunicAsia 2009 will focus on the latest hot technologies for applications, solutions and hardware. These key technologies, which are already starting to have a huge impact on the way we live, work and play, include IPTV, Mobile Entertainment, WiMAX, Navigation & LBS, Satellite , Femtocell, e-Government, Green IT, and Mobile Internet. In response to the buzzing media industry development in Asia, BroadcastAsia 2009 will again feature key technologies that draw huge interest and demand from the

market. These include Broadcastto-Handheld/Mobile TV, Digital Media Asset Management, HighDefinition Technology, IPTV, Mobile Broadcasting and Professional Audio Technology. Singapore Expo June 16 – 19, 2009



May 2009 | industrial automation asia  57


Oil and Gas Asia 2009 (OGA 2009) is opening its doors for the 12th time in June this year with a space of 17,000 sq m which will span across six exhibition halls at the KL Convention Centre. The event will be held from June 10–12, 2009. There will be over 1,000 participating companies from over 40 countries exhibiting. It is expected to attract more than 18,000 trade visitors and decision makers from the oil and gas industry. Amongst the leading national oil companies and leaders of industries that will participate are Aker Solutions, Cameron, Delcom, ExxonMobil, Global Process Systems, M3nergy, Neural Oilfield, Olio Resources, Sapura Crest, Scomi, Shell, Siemens, Sime Darby,

Tanjung Offshore, Technip, UMW Oil & Gas, and Weatherford. Ten country groups will be joining as national pavilions. It will showcase world class technology and services in the oil and gas industry and create networking channels between exhibitors and trade visitors, providing opportunity for establishing new

Returning in mid-June, OGA 2009 is poised to showcase leading technology and services in the oil and gas industry.

partnerships. It is a platform for all the professionals, experts and industry specialists of the oil and gas industry to discuss and gather information on the current technology and innovation. KL Convention Centre Kuala Lumpur, Malaysia June 10 – 12, 2009


2009 ENQUIRY NO. 3903

58  industrial automation asia | May 2009

June 10 – 12, 2009 Kuala Lumpur Convention Centre, Malaysia

Arinex: LED Lighting Systems Peterson Manufacturing’s (PM) Safety LED lighting systems with 100,000 hour LEDs are vapourtight, and especially suitable for road-tankers or vehicles operating at chemicals and petroleum terminals, which are subjected to flammable liquids or vapour. It is compliant to international standards in brightness, providing maximum road safety for important vehicles such as school-bus and ambulance, marine vessels etc. Some advantages of the PM work lamp are its ease to clean, better swiveling effects, two wire connection for safety and performance, a weight of 1.3 kg and its user friendliness.

BW Technologies: Multi-Gas Detector BW Technologies’ GasAlertMax XT portable and multi-gas detector simultaneously monitors and displays up to four gases including hydrogen sulfide (H2S), carbon monoxide (CO), oxygen (O2) and combustibles (percent LEL). The compact and field tough GasAlertMax XT features a non-intrusive integrated sampling pump designed for performance, reliability and ease-of-use. SmartSample pump technology improves remote sampling result accuracy and ensures a consistent, uniform flow. One-button operation guarantees ease of use even while wearing gloves. Tamper-proof, user adjustable options enable the instrument to be customised to suit your specific application.

Centek: Internal Drill String Fill Sub Centek’s Itsfu Internal Drill String Fill Sub controls drill string filling and prevent spillage of well drilling fluids onto the rig floor with resulting downtime. The tool screws quickly and directly onto the drill string; it is a closed system for filling but with a telltale that ensures there is no over displacement or pressurisation of the string fluid and no overspill. It also allows the driller to pump at a higher controlled speed. In addition, the top drive saver sub threads are protected and need only be exposed for drilling.

Crowcon: Infrared Gas Detector The Irex is designed to enable pellistor based gas detection systems to be upgraded to infrared technology without changing the original control system, junction boxes or cables. It is a sinter-free, fully featured infrared gas detector that produces a mV Wheatstone Bridge output as used on conventional pellistor based systems. It replaces old pellistor heads by simply mounting on the original junction box, and connecting to the original cable. The concept enables upgrade to dualwavelength IR gas detector technology without incurring the very significant costs associated with replacing the control system and re-installation.

May 2009 | industrial automation asia  59


CTC: Rock Trencher The RT-1 Rock Trencher is a 2.35MW pipeline trencher designed for trenching pipelines and pre-trenching for umbilical installations in hard ground regions. The machine is designed to operate in soil conditions of up to 40MPa, and offers benefits for hard ground stabilisation. The pipe is raised by the grab lifters at the front and rear of the machine, allowing an arrangement of three heavy duty cutters to excavate a trench beneath the pipeline, defining a wide, sloping ‘V’ shaped trench into which the pipe is then lowered. The cutters are arranged in a diagonally oriented, overlapping configuration, allowing the entire trench face to be attacked with minimal pipe lift.

DK Jones: Piping Products DK Jones is able to provide an increased range of pipes, fittings and flanges in various grades of carbon, alloys and stainless steels and sizes up to 24”. Materials supplied include carbon steels, low temperature steels, chrome molybdenum steels, high yield steels, stainless steels, duplex stainless steels, nickel alloys, copper alloys, aluminium alloys and plastics. Other products include butt weld fittings, forged flanges, forged fittings, outlet fittings, seamless and welded pipe and tube, valves and accessories, flat products, bar products, stud bolts and nuts, gaskets and specially fabricated items.

First Marine Services: Personnel Transfer Device The Toro is designed to provide protection against heavy impacts, collisions, falls and immersion. Passengers can exit rapidly when required. It is a rugged offshore tool designed to provide fast and efficient transfers, quick exit with high visibility and awareness and passenger control and peace of mind. The Toro is also suitable for medical evacuations in the event of an emergency. It can accommodate a critically ill or injured person in a stretcher, along with up to two other passengers, providing a protective transfer environment.

Kermel: Protective Clothing Kermel manufactures meta-aramid fibres for flame and heat resistant protective clothing. Protective coveralls made of Kermel fibres are used in petrochemicals, refineries, electrical utilities etc. For example, the non flammable Kermel Alpha ,meets the EN 531 A, B1, C1, E1 standard for workers who are exposed to heat and has been designed for ease of cleaning and maintenance. The flame resistant fabric also benefits from protection from electric arcing as it meets the ENV 50354 Class 1 standard. It also provides protection against chemical agents.

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June 10 – 12, 2009 Kuala Lumpur Convention Centre, Malaysia

Misi Setia Oil & Gas: Tube Meters Vacuum brazing is used for the final assembly of GE Sensing-Rheonik Omega tube meters. Each meter is closely inspected to ensure all joints are sound and defect free. Smaller meters with removable cases are sealed with an O-ring, creating an IP65/NEMA 4X joint preventing the ingress of foreign material into the housing. Process connections can be either a removable manifold style or welded directly to the Omega form tubing to create a sealless meter, ideal for processes with hazardous materials. The pick-up coils and drive coils installed in the meter are constructed of polyamide insulated wire, encapsulated in epoxy resin.

Mustang: Laser Scanning Laser scanning is a means of obtaining a 360-degree data capture within x, y and z axes that provides a three dimensional view of a facility. It collects up to 500,000 individual surface geometry measurements per second and creates a ‘point cloud’ that can be viewed with specialised software. Mustang utilises the two principal scanning camera technologies, time-of-flightbased, best suited for medium to long range scanning by capturing approximately 5,000 data points per second. It has a range of about 300 yards. Phase-based, for shorter range projects, can collect data about 10 times faster.

PT Mitratata Citragraha: PM Certification With the goal of bringing effective project management (PM) to Southeast Asia, this organisation provides courses in Asset Management, where Dr Paul D Giammalvo discusses the strategies that are applicable to proper management of physical assets; Certified Cost Engineer/Certified Cost Consultant (CCC/E) Credential, which includes cost management disciplines like cost estimating, cost control, business planning, management science, project management, planning and scheduling and profitability analysis. Other certifications offered are Certified Professional, Planning & Schedule (PSP) Credential, Certified Earned Value Management (EVM) Credential and Certified Cost Estimating Professional (CEP) Credential.

Wepuko: Pump Skid Wepuko pumps are designed for high working pressures. The materials for the fluid end and the design of the piston seals are dependent on the pumping medium. If necessary, the fluid end is equipped with cooling, heating or flushing. The drive parts are automatically supplied with oil by a forced or wiper lubrication system that is integrated as a standard feature. The API 674 pump skid DP 412-160 for HC condensate has a flowrate of 667 l/min, a discharge pressure of 163 bar and a suction pressure of 43-110 bar. May 2009 | industrial automation asia  61

Parting Shot... ment such as pressing buttons. This technology will be further developed for the application to human-friendly products in the future by integrating it with intelligent technologies and/or robotic technologies.

effort ≠ work done


Honda, ATR and Shimadzu jointly develop brain-machine interface technology enabling control of a robot by human thought alone.

onda Research Institute Japan, a s u b s i d i a r y o f Honda R&D, Advanced Telecommunications Research Institute International (ATR) and Shimadzu Corporation have collaboratively developed the world’s first Brain Machine 62  industrial automation asia | May 2009

Interface (BMI) technology that uses electroencephalography (EEG) and near-infrared spectroscopy (NIRS) along with newly developed information extraction technology to enable control of a robot by human thought alone. It does not require any physical move-

That’s Telekinesis! During the human thought process, slight electrical current and blood flow change occur in the brain. The most important factor in the development of the BMI technology is the accuracy of measuring and analysing these changes. The BMI technology uses EEG, which measures changes in electrical potential on the scalp, and NIRS, which measures changes in cerebral blood flow, with a newly developed information extraction technology which enables statistical processing of the complex information from these two types of sensors. As a result, it became possible to distinguish brain activities with high precision without any physical motion, but just human thought alone. Test Procedures First, EEG and NIRS sensors are placed on the head of the user. Then, one of four pre-determined body part options is provided to the user. The user imagines moving that body part without making any physical movement. Changes in both brain waves and cerebral blood flow triggered by the brain activity are measured simultaneously. The data obtained are analysed on a real-time basis to distinguish what the user imagined. Upon receiving the result, Honda’s ASIMO humanoid robot makes corresponding movements such as raising its arm or leg. An accuracy rate of more than 90 percent was achieved in the tests. ENQUIRY NO. 3904

CalendarOf Events2009 May 6 – 10 MetalTech 2009

PWTC Kuala Lumpur, Malaysia Trade-Link Exhibition Services Email: Web:

6 – 10 Automex 2009

PWTC Kuala Lumpur, Malaysia Premier Exhibition Services Email: Web:

6 – 10 MTA Malaysia 2009

PWTC Kuala Lumpur, Malaysia Malaysian Exhibition Services Email: Web:

12 – 13 World Engineering Congress 2009

Bangkok, Thailand Marcus Evans Email: Web: www.worldengineeringcongress. com

13 – 17 Intermach 2009

BITEC Bangkok, Thailand CMP Media (Thailand) Email: Web:

20 – 22 Semicon Singapore 2009

Suntec, Singapore Semi Email: Web:

20 – 23 Renewable Energy Asia

BITEC Bangkok, Thailand CMP Media (Thailand) Email: Web:

26 – 27 Malaysian Power 2009

Crowne Plaza Mutlara Kuala Lumpur, Malaysia The Asia Business Forum Email: Web:

JUNE 10 – 12 OGA 2009

KLCC Kuala Lumpur, Malaysia Malaysian Exhibition Services Email: Web:

16 – 19 Communicasia 2009

Singapore Expo Singapore Exhibition Services Email: Web:

17 – 20 ProPak Asia 2009

BITEC Bangkok, Thailand Bangkok Exhibition Services Email: Web:

18 – 20 E5 The Engineering Series BITEC Bangkok, Thailand Bangkok Exhibition Services Email: Web:

25 – 28 Assembly Technology

BITEC Bangkok, Thailand Reed Tradex Email: assemblytech@reedtradex. Web:

july 8 – 10 Wind Power Asia

China International Exhibition Centre Beijing, China Koelnmesse Email: marcowang@windpowerasia. com Web:

15 – 18 Industrial Automation 2009

Kuala Lumpur Convention Centre Kuala Lumpur, Malaysia Malaysian Exhibition Services Email: Web:

September 16 – 18 Industrial Automation Vietnam 2009

Saigon Exhibition & Convention Centre Ho Chi Minh City, Vietnam Hong Kong Exhibition Services Email: Web:

16 – 18 Clean Energy Expo Asia

Suntec Singapore Koelnmesse Email: Web:

october 7 – 10 Manufacturing Technology World SMX Convention Center Pasay City, Philippines Global-Link MP Email: Web:

December 1 – 4 CIA 2009

Suntec Singapore Singapore Exhibition Services Email: Web:

NOTES To be considered for inclusion in the Calendar of Events, send details of event (name, date, venue, organiser contact) to: The Assistant Editor IAA. Eastern Trade Media Pte Ltd. 1100 Lower Delta Road, EPL Building #04-02, Singapore 169206 Tel: (65) 6379 2888 Fax: (65) 6379 2805 Email:

May 2009 | industrial automation asia  63

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Ted Asoshina Echo Japan Corporation Tel: 81-3-32635065 Fax: 81-3-32342064






















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Asean CC-Link Promotion Centre 307 Alexandra Road #05-01/02 Mitsubishi Electric Building Singapore 159943 Tel: (65) 6473 2308 • Fax: (65) 6476 7439 • Did: (65) 6470 2480 • E-mail:


From control to optimization of your system in each network level. A new integrated industrial Ethernet network concept with Gigabit.


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