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19

Norgren’s new IVAC cylinder.

04

Balluff Smart Light instead of stack light.

Magazine

Industry Asia Pacific The industry magazine for Asia Pacific

April 2013 - Issue 02

20

Reliable cleaning of New York’s iconic Beekman

Tower ensured by NORD

25

WIDIA, higher turning productivity, lower costs

across wide range of materials

De Dietrich® offers a complete range of

06

23

Seco adds 8xD option to Crownloc® Plus family of

advanced and dedicated solutions.

exchangeable-tip drills

08

Canadian Natural resources automates oil

and gas operations using PcVue


table of

06

CONTENTS

04 05 08 10 14 16 17 19 22 25

BALLUFF

DE DIETRICH

First signal lamp with IO-Link

PolyAluminium Chloride

EPLAN

EPLAN Data Portal on the up on an in-ternational...

ARC INFORMATIQUE

Canadian Natural resources automates oil and gas operations using PcVue Solutions...

SECO TOOLS

TATA STEEL

Modular platforms

Tooling up for mould machining...

12

KENNAMETAL

Latest Tooling and Surfacing Technology Advance Ganassi and Kennametal Partnership...

KEPWARE

KEPServerEX Version 5.11

NORD

Compact, durable, robust: New worm gear unit series SMI from NORD.

Pepperl+Fuchs

18

Small, high-performance sensors for tight spaces.

NORGREN

Norgren’s new IVAC cylinder offers OEMs and end users dramatic reduction in...

Pepperl+Fuchs

Solutions for Process Interfaces.

WIDIA

Victory portfolio means higher turning productivity, lower costs across wide range...

HMS

Reducing operating costs of telecom base stations...

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Balluff Smart Light instead of stack light The new IO-Link Smart Light from Balluff is equipped with all features for fundamentally revolutionizing the signal light sector. It is the first light that can be flexibly adapted to nearly every requirement without complex configuration via hardware. The otherwise typical costly combination of different-colored modules to form a light is no longer needed as this device can also be adapted to its new task ad hoc on-the fly via the controller. Even solutions that can be set by means of DIP switches are not much of an alternative as they cannot be changed during running operation.

Temperature states, fill levels of systems or even the position of a carriage via a position sensor system can be visualized on the column, which may be up to 20 LEDs tall. For connection and installation, just one simple, unshielded, three-wire sensor cable – as is typical for IO-Link – is needed, and already the LED signal column offers maximum functionality and previously unimagined possibilities with its three operating modes “Stacklight”, “Level” and “Run”.

The Balluff Smart Light is a true multi-talent, as it can do much more than signal the system operator certain predefined operating states with just three colors. Even tendencies, developments and trends of physical values can be represented. 4

Industry Asia-Pacific 2-2013

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EPLAN Data Portal on the up on an in-ternational scale: now 48 manufacturers, 43,000 users and 225,000 units of data The Eplan Data Portal has grown massively since its launch in 2008. The number of manufacturers has in-creased to 48 - with component manufacturers Sick and Saia-Burgess among the new additions. Data and mac-ros relating to more than 225,000 parts can be simply imported into the project by means of Drag & Drop. This saves the time-consuming independent development of device macros. Users can benefit from standardized, up-to-date data and efficient configuration with no changes in media format. The Eplan Data Portal is a web-based portal which provides Eplan users with component data from numerous manufac-turers. The constantly expanding parts database now incor-porates more than 225,000 parts from 48 manufacturers. Sick, with around 800 records for reflector light sensors and light barriers, is one of the latest additions. Swiss manufacturer Saia-Burgess is also represented with 260 records and macros in the portal. The controllers, modules and energy meters are an addition to the portal, as is the data from Aus-trian company Mersen, which has now incorporated its NH fuse circuit breakers. In 2012, the Eplan Data Portal has added

around 12,000 new parts and 14,000 macros to the portfolio. This component database guarantees users time-saving configuration and standardized, high-quality, up-to-date data. On the up on an international scale For a few years, component manufacturers and Eplan have been working together to produce solutions to make engi-neering easier for customers. The Eplan Data Portal has now become a fixed part of configuration using Eplan solutions even beyond Europe. Solution provider Eplan sees one of the reasons in the data format, which incorporates not only order information and technical details on the components but also graphical and logical aspects for configuration purposes. This provides integrated data for product development. On its route towards internationalization, Eplan has collected over 43,000 registered users at more than 30,000 customers around the world. The portal is also increasing in popularity in North and South America, where it now has a significant market share. Expansion eastwards is also in full swing, going via Russia into Central Asia, where Eplan is hoping to provide a sus-tainable increase in quality in terms of norm-compliant data. More Information

Industry Asia-Pacific 2-2013

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PolyAluminium Chloride (PAC): Effective technology for water purification De Dietrich速 offers a complete range of advanced and dedicated solutions for PAC Producers South East Asia Polyaluminium Chloride, usually called PAC, is a fast growing coagulant used in water treatment. PAC is highly-efficient for the treatment of drinking water, swimming pool water, sewage and industrial effluents, as well as for paper processing. PAC offers numerous advantages in comparison to other mineral coagulants, including lower dosage requirement, less flocculent needed, reduction of sludge and sulfate concentration, effective at low temperatures, and a wide range of PH.

manufacturers. They produce all critical components related PAC and are not simply a manufacturer but also an engineering firm that has extensive knowledge on all aspects of this complicated process. The firm provides turn-key units which have been optimized to reduce maintenance and operation expenses and improve safety and productivity. In addition, De Dietrich offers a complete range of advanced and dedicated solutions for the Polyaluminium Chloride synthesis and its derivatives for different PAC productions: PAC 14%, PAC 18%, PACS 10%.

De Dietrich速, leveraging decades of experience Depending on the market requirement units as a leader in the water treatment industry, can be sized from minimum 2,000kT per year offers a wide range of solutions to PAC 6

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to up to 50,000 kT per year. If needed, the units can also be designed so aluminum sulfate can be produced so as to cover a wider range of coagulants. Die Dietrich offers a comprehensive service and product portfolio. They can offer basic and detailed engineering, supervision and assistance throughout all steps of the manufacturing process, and can procure glass-lined reactors, equipment, process control and automation, and valves and instrumentation. In addition they provide process optimisation through the use of the adapted Impeller Agitator and the D.e.Co.S. SystemThe return on investment of such units is around 2 years. The investment is particularly interesting when serving an area where PAC is not yet available or only transported from far away in solid form (Liquid PAC is significantly more efficient and easy to use for water treatment than solid PAC). With the expansion into the Southeast Asian Market, De Dietrich is the optimal solution for PAC manufacturers since all units can produced locally and do not need to imported from China or India.

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Industry Asia-Pacific 2-2013

7


Canadian Natural resources automates oil and gas operations using PcVue Solutions from Arc Informatique. CNRL is measuring millions of tags and an approximate 800,000 I/O points within its primary operations. GE and Allen-Bradley PLCs, Fisher and Bristol Babcock RTUs are the major brands used throughout production. The pcVue SCADA is monitoring and providing pertinent data used by some 2,500 employees who need to access the information in some shape or form – i.e., monitoring, reviewing, or maintaining data in real-time. Canadian Natural Resources Limited (CNRL), founded in 1989 and headquartered in Calgary, Canada, possesses a diversified combination of assets in North America, the North Sea and Offshore Africa and today is the largest independent crude oil and natural gas producer in the Canada. Delivering a balanced mix of 8

Industry Asia-Pacific 2-2013

natural gas, light oil, heavy oil, in situ oil sands production, oil sands mining and associated upgrading facilities, CNRL engages in the exploration and development of geographic areas for the production of natural gas and crude oil. The company operates its business through three primary reportable segments: Horizon oil sands production, thermal heavy oil, and conventional oil and gas. Within the last year, CNRL invested in a large scale automation project that primarily impacts the conventional oil and gas business that deals with the exploration, development, production and marketing of crude oil, natural gas liquids and natural gas. Canadian Natural Resources needed a better way to manage the process control and


monitoring of its 300 gathering stations, 800 compressor stations, and 150 gas processing facilities. CNRL’s SCADA Specialist, Kurtis Jackson, spearheaded the company’s automation project to replace its FactoryLink SCADA systems with the pcVue’s SCADA and FrontVue solutions.

to prevent fires, explosions, and ecological disasters,” said Jackson. Characterized by remote and widespread operations, CNRL wanted to have each automated activity whether in drilling/production, distribution, transportation or refining supervised from several of its control centers.

CNRL has numerous independent automation systems of various brands and Jackson wanted to centralize and achieve consistency by integrating as many of these automation systems as possible on pcVue. In addition, CNRL wanted to leverage pcVue’s ability to support multi-station architectures for networking and currently runs Modbus Roc, Roc Talk, and BSAP.

A solid and securely designed SCADA system must be able to control such critical factors as: flooding, leakage, fire, ESD, oil and gas flow rate and accumulated flow, line pressure, wellhead pressure, pump status, tank level, and gathering station equipment status, among others. Due to the nature of the product, which must be transported from the well to final consumer, and the potential adverse environmental effects of oil/petroleum accidents, SCADA systems are a necessity.

In addition, CNRL uses CTH Systems’ IMSCADA™ , a multiprotocol measurement and communication software. It allows the wells that are equipped with different automation devices, such as RTUs (remote terminal units) or pump on/off controllers, to talk over a single radio channel in order to bring the data back to pcVue SCADA. CTH Systems supported CNRL with implementing automatic and remote readings of gas compositions from the well, the upload of the corrected gas compositions to each well, and the elimination of variances between the well meter and the IMSCADA™ database. “We couldn’t be happier with how robust and effective the IM-SCADA driver works for us. It helps maximize operational efficiency,” said Jackson. It minimizes the need to physically go to the well sites to download or upload the gas compositions.

“We wanted to leverage SCADA features and benefits that give us the ability to reliably gather more data and achieve more control,” said Jackson. CNRL is looking forward to reaping the benefits of upgrading its automation systems and is really happy thus far with how well it has been working optimize their processes. “From the first FactoryLink conversion to pcVue, it has been about eight months now that pcVue has been up and running. We are really glad we chose pcVue and IM-SCADA for our SCADA solution and that the configuration process has been very straightforward to implement, especially in consideration that most of our applications are mission critical and work around the clock,” said Jackson.

The pcVue SCADA collects such I/Os from PLCs and RTUS used in production fields and gathering stations such as gas/oil pressures, (ESD), pump start/stop, remote/local pump control, pump speed, pump run/stop, motor operated valves and motor operated valve shut down, choke setpoints/positions,temperature, emergency shutdown and fire alarms etc. “One of the most important factors in our industry is safety. At every stage of the process, pcVue monitors our mission critical operations and maintains all of our safety measures

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Industry Asia-Pacific 2-2013

9


Tooling up for mould machining As milling techniques and tooling technology continue to advance, more mould manufacturers are taking advantage of the developments for optimising machining operations, reducing cycle times and producing far superior mould surface finishes. However, factors such as machine tool capability, intended milling techniques, programming, workholding and toolholding are a necessary part of the equation during cutting tool selection. Equally critical is the ability to analyse worn cutting inserts in an effort to maximise tool life and predict tool usage in mould machining applications.

Milling techniques High-speed (or dynamic) milling techniques are becoming increasingly popular. They are also particularly effective when using solid carbide cutting tools. This milling method is an optimised roughing approach that combines large cutting depths with relatively small radial engagements when cutting steel. This technique is also effective when machining materials 60 HRC and harder.

For high-feed milling, large indexable insert cutters designed for that purpose are recommended to remove the majority of material. Essentially, the process starts with Today’s fast and powerful machine tools relatively large indexable insert cutters for with increased programming capabilities are roughing, and works down to essential when it comes to taking full advantage smaller-diameter indexable ball nose cutters of the latest cutting tools and incorporating and solid carbide cutters as the mould highly effective milling techniques. approaches near net shape.Appropriate cutter diameters are determined based on mould High-feed milling and high-speed milling are two features—such as corner radii. High-feed indexable insert cutter diameters popular milling techniques that require certain are usually 15 mm (0.62�) and larger. If smaller types of cutters for operational success. 10

Industry Asia-Pacific 2-2013


cutters are needed, solid carbide end mills should be used. Inserts for high-feed indexable cutters can vary depending on workpiece material, but most applications will dictate a PVD-coated or CBNcoated insert. As for insert geometry, Trigonstyle inserts provide the lowest possible lead angle over round or square inserts. Low lead angles produce a much thinner chip, which in turn requires higher feed rates to maintain proper chip thickness for the insert geometry. The lower lead angle also directs the cutting forces in the axial direction, pushing up into the spindle, which is more stable and easier on the machine. Higher lead angles create thicker chips requiring less adjustment in feed rate. They also produce more radial force, causing vibration and stress on the spindle bearings. While high-feed mills with long overhangs are effective, used in high-speed operations they cannot be run as fast as tools with shorter overhangs -unless specialized vibration dampening tool holders are used or cutting speeds are reduced significantly. When a tool with long overhang operates faster than recommended, vibration increases causing insert chipping and premature insert failure. Insert-wear analysis Maximum tool life and predictable tool usage to maintain part accuracies and reduce machine tool deterioration are critical in optimising mould machining operations. Yo assist in the insert examination process, a stereoscope - with good optics, adequate lighting and a magnification of at least 20X - can pay great dividends in identifying failure modes that contribute to premature insert wear. Cutter grades, geometries, materials and sizes Most cutting tool manufacturers develop cutting tool grades and geometries for specific materials. In mould machining, those materials are typically P20 steels, CPMV 10 and powdered metals. It is critical to select the right grades and geometries according to the particular material being machined to avoid premature tool failures. Additionally, matching cutting tool to material increases performance and predictability, which results in fewer tool changes, less rejects and less reworking. If a material is 52 HRC or softer,

general-purpose solid carbide tools work well. For materials harder than that, solid carbide end mills with different geometries and coatings such as aluminium titanium nitrate designed for extremely hard materials should be used. Plus, for solid carbide tooling, there are special blends of coatings unique to individual tooling manufacturers. For indexable insert cutters, insert geometries and coatings for hard milling will work for most extremely hard powder metals. And the different insert grades and chip grooves available on today’s indexable insert cutters make it possible to optimise machining harder mould materials. Cutter paths and programming Mould machining cutter paths should be optimised through proper programming to avoid placing unrealistic demands on cutting tools. For example, when machining a mould and the toolpath initiates a corner, a smooth transition must be programmed for changing direction to prevent creating a large angle of engagement, which can overload the cutting tool. A good rule of thumb is to program an arc that is larger than the cutting tool’s radii. So, if a 50 mm (2”) diameter cutter is used, the program should not encounter 25 mm (1”) radii, but instead use a smoothing radius that is larger. Summary By gaining a better understanding of today’s milling techniques and tooling technologies as well as the various failure modes and failure analysis skills, mould manufacturers can experience increased productivity, reduced cycle times, better tool life and tool life consistency, improved part tolerance and appearance, superior mould surface finishes, and less wear and tear on equipment.

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Industry Asia-Pacific 2-2013

11


New success for Tata Steel modular platforms Tata Steel has installed two new modular platform systems in the UK, one at West Drayton Station, and the other at Langley Station. These modular systems provide a cost efficient, quick way to design and install passenger platforms and can be customised with all types of surfaces and finishes. West Drayton was installed with only a weekend of traffic disruption, and Langley needed no traffic interruption. Tata Steel modular platforms have been used on over 80 new platforms and platform extension projects in Europe, and are unrivalled in their constructability in difficult access conditions and under strict time constraints. At West Drayton Station, Tata Steel faced an extremely challenging environment. The extension was located on the top of a Victorian earth embankment with a raised ground profile due to a previous platform structure and with numerous buried services. Furthermore, there were residential properties 12

Industry Asia-Pacific 2-2013

located right on the vegetated embankment so access was very limited. Therefore, a minimal depth of construction and excavation was required. Despite such difficult working conditions, all twelve units of the ́Long Span ́ platform were able to be delivered to an access point five miles from West Drayton, and the main bulk of the platform structure was installed during a single shift of a weekend blockade. Then Tata Steel Projects ́ installers were able to adjust the platform system to the theoretical gauge, install rear fencing, platform lighting, signage, access stairs and surfacing all during traffic hours. ́Long Span ́ is one of Tata Steel ́s innovative modular platform structures. It features the same flexibility and future adjustability as the standard platform structure, but replaces the frequent legs with a spanning ladder beam that connects the 7.32 metre gap between pairs of piles, although other spans can be developed.


Langley Station was another another successful platform extension project carried out by Tata Steel. The components utilized in the extension were installed without any mechanical lifting. Also, the bulk of the installation took place behind blue safety fencing while the line was still open so there was no traffic disruption. Tata Steel received a STAR award from Crossrail in recognition of an excellent Health and Safety record and good site management for their projects at West Drayton and Langley Station.Modular Platforms are sustainable solutions since installation incorporates steel that consists of a high degree of recycled material and offside construction minimises waste and transportation. The use of lightweight components reduces foundation impact and avoids the need for costly and time consuming ground treatment measures. In addidition, the structure has a 75 year life span. Tata Steel フ《 patented state-of-the-art software allows a quick customised design, starting from standard modules, whatever the width, length or curvature (convex, concave or reverse). Structural resistance, shape and weight are automatically computed. Thanks to the low weight of the individual components, installation can even be manually assembled. Each component requires only a one or two person lift. Pre-surfaced modular deck panels can also be proposed or a bespoke finish can be used to enable extensions to fit in aesthetically with existing structures.

Industry Asia-Pacific 2-2013

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Latest Tooling and Surfacing Technology Advance Ganassi and Kennametal Partnership for Indy Carsnology Advance Ganassi and Kennametal Partnership for Indy Cars mould machining In the wake of Dario Franchitti and Scott Dixon’s dramatic first and second-place finish at the 2012 Indianapolis 500, Chip Ganassi Racing Teams (CGRT) announced a multi-year renewal of its machining technology partnership with tooling and engineering services leader Kennametal Inc. “We’ve been in business for 23 years and for 19-plus of those, Kennametal has been a partner,” said Chip Ganassi, owner of Chip Ganassi Racing Teams. “We are a 100-percent Kennametal-tooled shop and their logo is on every one of our cars across all our teams and series. But what really makes the partnership even more valuable to the race team is how their expertise helps us perform, even on race day. They come to us with many solutions for different mechanical challenges we face. It is 14

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great when you have a partner that can do that.” Right People, Right Equipment, Right Tools Tour the Target Ganassi machine shop in Indianapolis and you’ll find a concentrated hive of activity consisting in part of four CNC machines (two multi-axis machining centers and two CNC turning centers, one with live tooling and a sub-spindle). “Ninety-nine percent of our necessary machine work is done right here in-house,” says John Huffman, machine shop supervisor in his 14th season with the team. He points out a steel tripod cover formerly purchased as a factory part now made in house out of titanium for extra strength at reduced weight. “Because of our tooling and machines, it’s actually cheaper to make titanium parts in house than to purchase ready-made steel components,” he says. High-tolerance parts,


too, down to 0.0002” on average. The nature of part production at the Ganassi Indy shop is low-volume, requiring high variety and tight time constraints, or “different parts in a hurry,” as Huffman puts it. His team readily points to the various Kennametal tools providing process advantages, such as PCB tooling for hard turning, resulting in high-tolerance finishes that eliminate the need for grinding, or new five-flute HARVI II™ solid-carbide end mills for roughing and finishing titanium. “Our engineers are confident in specifying more intricate parts with high tolerances and surface finishes because they know we can meet the numbers in-house,” Huffman says.

Typically, a part is fixed between two opposed media cylinders, and the machine extrudes abrasive media from one cylinder to the other. The tooling works together with the abrasive media and characteristics of size and viscosity to perform the finite honing of the part. When the media is forced through a restricted passage, its viscosity rise and that holds the abrasive material in place. The media abrades only in this restricted state, so once it exits the restrictive passage, viscosity returns to normal and abrasion is suspended to protect threads and seal surfaces. Further research and development in AFM at Extrude Hone has resulted in MicroFlow AFM™, where lower-viscosity media and smaller abrasive particle size allows finishing and edge radiusing of holes down to 50 inches.

Kennametal has expanded its 19-year partnership by providing Ganassi’s Indy machine shop with proprietary Precision Surface Management Technology by Kennametal Fuel-spray nozzles in fuel injectors, for example, Extrude Hone. can have defined edge radiuses that diffuse fuel microspray for better engine performance. Finishing processes like abrasive-flow machining (AFM) have evolved from pure Huffman adds that because titanium represents deburring functions to polishing and radiusing a growing portion of his shop’s work, in addition within very close tolerances. Add new to aluminums and alloy steels, he gleans a developments in machine controls, abrasive number of performance-enhancing ideas from media, and flow targeting, and the results Kennametal’s aerospace-focused “Innovations” continue to get much more precise. catalog, from complex 3D shapes to solutions for deep-hole drills that can reach up to 30 X D. Critical Needs Machined holes, including intersecting holes, “Our capacity to produce parts in-house will in many high-performance applications require only continue to grow because of this ability to surface improvement, usually a lot of polishing hold tighter tolerances on part dimensions and to achieve required tolerances. Any smeared surface finishes.” metal or micro-cracks at the surfaces created in conventional or non-conventional machining processes increase the risk for diminished performance or failure. To eliminate that risk, engineers factor AFM surface finishes into many component designs, especially where laminar flow, boundary layer turbulence, compressive residual stresses and edge conditioning are important factors. Even in inaccessible areas, surface-finish improvements from an original 120μ inch to 16μ inch or better are possible. AFM machines can be operated as standalone stations or integrated into production systems.

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Industry Asia-Pacific 2-2013

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KEPServerEX Version 5.11 New Enhancements to Kepware’s KEPServerEX Platform Improve Connectivity for Power Distribution, Extend OPC Support, and Simplify EFM Configuration Kepware Technologies, a software development company focused on communications for automation, today announced new enhancements to its KEPServerEX platform, offering new solutions to simplify communications management.The new KEPServerEX 5.11 enhancements include support for Windows 8 and Windows Server 2012, in addition to the following new products and features: -IEC 61850 MMS Client Driver: This new driver utilizes the Manufacturing Messaging Specification (MMS) of the IEC 61850 specification for sending data from substation automation devices (like switches and circuit breakers) to SCADA and HMI applications for analysis and reporting. “I’m excited to begin using Kepware’s new IEC 16

Industry Asia-Pacific 2-2013

61850 driver for the solar projects we will be working on in 2013 due to the ease of use and robustness I’ve come to expect with Kepware products,” said Xavier Vallespi, the Technical Information Officer of Green Power Monitor. KEPServerEX is a flexible and scalable platform that connects, manages, monitors, and controls diverse automation devices and software applications. Kepware continues to evolve the platform’s communication abilities to help companies improve their operations and decision-making by ensuring accurate and reliable data. “Kepware realizes that learning new communication protocols or spending time to understand new applications is inconvenient and often slows business processes,” said Tony Paine, President and CEO of Kepware Technologies. “To address this situation, we have developed a single server communications platform that enables customers to simply add multiple drivers as needed. More Information


Compact, durable, robust: New worm gear unit series SMI from NORD

Bargteheide – NORD DRIVESYSTEMS now offers a new range of worm gear units in a robust, one-piece UNICASE housing in five sizes with a maximum torque of 427 Nm. New, larger output bearings allow users to choose increased shaft diameters than the previously available series. In addition, the large bearings ensure a much extended service life. The aluminum permanent mould casting process was optimized for the SMI series, resulting in an especially smooth surface that prevents dirt build-up. Closed SMI worm gear versions are washdown-capable, and can therefore be easily cleaned along with other systems during plant cleaning processes. If required, these gear units are available with NORD’s NSD tupH surface conversion treatment which transforms their durability with up to seven times the hardness of the base aluminum material, providing excellent protection against acids and alkaline solutions.

A synthetic long-life lubricant makes the worm gears maintenance-free during their entire service life. Equipped with oil gauge screws, the gear units are now also suitable for use in hazardous areas. The worm gear units provide transmission ratios between i=5:1 and i=3000:1. Thanks to the modular design, they are easily configured according to application requirements. Users can optionally select the field-proven and extensive SI series modular worm gear unit program which is flange-compatible to the SMI series, allowing for very versatile configuration. On the drive side, several standard IEC interfaces (B5/B14) are available for every gear unit size. The worm gear units can be foot- or flange-mounted and equipped with solid or hollow shafts, and as closed or open frame versions. More Information

Industry Asia-Pacific 2-2013

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Small, high-performance sensors for tight spaces Pushing the limits of physical possibility is the greatest challenge facing technology. In addition to technical excellence, the economic aspect is taking on an increasingly important role. The machine construction market is continuously aiming for more compact, faster machines with higher capacity. Special packaging machines or machines for manufacturing PCBs are being constantly optimized to enhance their overall power density. In addition to mechanical components, electronic components that control the systems must also be consistently adapted. There is an increasing demand for smaller sensors that offer the performance, speed, and precision of larger sensors. In addition to functionality, it should also be possible to integrate these sensors discretely into the machine. Inductive sensors for metals Sensors that operate according to the inductive functional principle detect metallic objects without contact and are therefore wear-free. Advantages of inductive proximity switches include a complete absence of maintenance and outstanding resistance to sources 18

Industry Asia-Pacific 2-2013

of interference in the direct vicinity of the application. Dust, dirt, vibration, and moisture do not influence the capability of these sensors to detect, count, and control processes in numerous applications. Ultrasound solves material issues The new ultrasonic generation of the F77 series with a compact design can accurately detect objects made of the most problematic materials, such as reflective or transparent objects. The narrow projection cone and extremely small blind zone of 10 mm enable the detection of objects through extremely dense clusters of machine components. The F77 series offers an impressively high degree of immunity to plant noise and can be easily integrated in machines with limited space. Optical precision The latest development in the miniature housing category is the R2 series. The special features of the ultra-small series include extreme robustness, user-friendliness, and ease of installation. The extremely small housing with 45째 cable outlet allows for spacesaving installation in the plant. Due to the flat, scratchproof glass front, the R2 can be mounted close to the moving object. More Information


Norgren’s new IVAC cylinder offers OEMs and end users dramatic reduction in energy and operating costs. This integrated platform lowers costs for users in many ways. Because it is easier to install, maintain and replace a single unit, scheduled and unplanned installation, commissioning and maintenance time and costs are reduced. Less downtime for maintenance also means higher productivity. Meanwhile, eliminating air piping between valves and actuators minimises ‘dead’ volume, reducing air consumption by up to 50 per cent, significantly cutting cost per mm of stroke when compared with conventional pneumatic systems. Norgren, an international market leader in pneumatic motion and fluid control technologies, has announced the launch of an innovative, high-performance range of cylinders, designed to significantly reduce energy usage and operating costs for OEMs and end users in a range of processing applications. Conventional pneumatic control involves an arrangement of valves or valve islands, actuators, flow controls and sensors, along with connectors and accessories. In typical applications, up to 13 different components can be required for each actuator function. This complexity presents some intrinsic disadvantages and performance constraints. Following close collaboration with customers to offer a solution which would overcome these shortcomings and satisfy individual requirements, Norgren has develop ed IVAC (integrated valve and actuator control) - an integrated unit which delivers Engineering Advantage by combining the valve, flow controls, cushioning and sensors in a single actuator package. IVAC is a weight and space optimised actuator, suitable for a range of bore sizes from 40mm to 80mm, featuring integrated valve and magnetically operated switches for complete actuator control. Able to be retrofitted or integrated within new systems, each unit requires only one pneumatic and one electrical connection, eliminating the need for multiple valve islands, components, tubing and accessories.

For a machine operating at two million cycles per year, this results in enough energy savings to pay back the cost of an IVAC product within one year. In addition the IVAC presents improved machine aesthetics. A sharp, uncluttered appearance reveals a more sophisticated look and, for end users, it makes plants look cleaner and more advanced. A number of options and varieties are available including cleanline versions for industrial cylinders, industrial slave cylinders and easy washdown, helping OEMs comply more easily and cost effectively with hygiene regulations. OEMs can take advantage of all of these benefits without any mechanical design changes, as IVAC products conform to the latest ISO VDMA dimensions. Its single M12 connection for input and output can be hardwired or plugged into a fieldbus system no matter which protocol is being used. Richard Bull of Norgren explains: “When designing the IVAC range of cylinders, our key aim was to offer a unique and innovative sustainable energy improvement, via a singleunit solution. The IVAC unit has been devised to provide OEMs and end-users with a high-performance, innovative and high-specification engineered product. It will help cut energy costs, installation costs, and air consumption, while reducing downtime for cleaning and maintenance. More Information

Industry Asia-Pacific 2-2013

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Developing a cleaning gondola to handle the undulating bays and folds of Manhattan’s Beekman Tower – designed by the prestigious architect Frank Gehry – was a challenge which has been successfully met by NORD DRIVESYSTEMS and the Spanish firm GinD. NORD supplied the geared motors and frequency inverters used in the gondola, working closely with GinD, a company specializing in the design, manufacture, and installation of custom systems for maintaining building façades.

the course of the day. Completely asymmetric, with no two sections the same, it is undoubtedly one of the most complex façades ever constructed.

The many curves and folds make it very difficult to access the windows by gondola. Long-time drive supplier GinD (Góndolas in Design), a Spanish company with its headquarters in Madrid, designed the gondola for the Beekman Tower with the specific purpose of enabling access to all parts of the building’s façade. NORD is GinD’s regular At 265 meters, the Beekman Tower is the tallest supplier of geared residential building in the western hemisphere. motors and frequency inverters, this project However, what really makes it stand out is its being no exception. “We work with NORD on design – the waves of stainless steel on the all our projects, since we have the greatest outside that, by reflecting the changing light, transform the appearance of the building during confidence in them at a technical level, the 20

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Reliable cleaning of New York’s iconic Beekman Tower ensured by NORD DRIVESYSTEMS gearbox with a brake motor which turns the gondola’s cable drum. An SK 500E frequency inverter smooths out the gondola’s stops and starts. It also maintains the gondola’s position with respect to the building’s façade when the telescope arm is in use. The counterbalance mechanism (the box located to the rear of the mast) is of fundamental importance since without it the structure would have to be much stronger and therefore heavier and more expensive. The counterweight is moved forwards and backwards by a helical bevel geared motor as the telescopic arm is extended and retracted. This geared motor also maintains the machine’s centre of gravity in the center of rotation of the whole apparatus. Another SK 500E frequency inverter is responsible for moving the mass of the counterweight, with acceleration and deceleration ramps. For rotation, two helical inline geared motors engage a gear ring in order to turn the whole machine, so that the gondola can be used on any face of the building. Here again, an SK quality is optimum, the post-sales service offers 500E frequency inverter softens the starts and international cover, and the price is competitive stops, and also provides different speeds of rotation, depending on how far the telescopic within this market,” says Hugo Donoso, arm is extended. This is to even out the linear Managing Director of GinD. speed as the gondola turns – if the telescopic arm is retracted, the geared motors will work at Custom-tailored gondola system a higher speed than if it is extended. The project was a significant challenge, given The Beekman Tower project also required a that every aspect of it was custom-made in winch to be mounted, for raising loads such terms of both design and calculations. The as new panes of glass to repair the building’s GinD equipment consists of a telescopic arm, a special system of façade guides, and a multi- façade, or air conditioning equipment, which will telescopic pod for accessing the inward-curving have to be raised up to the building’s flat roof. surfaces of the building. The machinery supplied The gondola cannot be used for this purpose, since it is only rated to carry the cleaning staff by NORD performs various functions, lifting, and their relatively light cleaning materials. In rotating, and counterbalancing the pod. It also this case, NORD again chose a helical bevel drives the winch and the telescopic unit. geared motor. Optimally adapted drive systems More Information For lifting, NORD has supplied a helical bevel Industry Asia-Pacific 2-2013

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Solutions for Process Interfaces standards and best practices.Our world-wide network of explosion protection specialists and engineers as well as more than 60 years of experience form the knowledge data base which makes Pepperl+Fuchs one of the leading companies when dealing with explosion hazardous areas. Our close contact to the plant operators enables us to always be at the leading edge of technology. A recent example was the invention of DART, the next step of intrinsic safety. Within the FieldConnexŽ product line several DART fieldbus modules are readily available, but also with Remote I/O systems and intrinsic safety barriers there are constantly new developments reaching marketability. In order to guide users and engineering consultants through the maze of regulations, requirements and product offerings our specialists offer trainings on explosion protection principles regularly. One step closer to the process our project engineers, based in Solution Engineering Centers all over the world, offer counsel and project support for individual construction projects. In close cooperation with the user the requirements are exhaustively evaluated, followed by detailed specifications as well as design proposals. No matter if it’s an automation system based on IS barriers, signal The complex topic of explosion protection transmission via Remote I/O systems or a for process production plants requires fully digital fieldbus topology, the experienced profound knowledge and experience. project engineers find the best fit to the users’ Pepperl+Fuchs offers all this, along with requirements. reliable, high-class technology products and Installation of the appropriate modules from close support of individual projects, from the comprehensive Pepperl+Fuchs portfolio first evaluation up to delivery of the final into space and cost efficient enclosures as solution to the plant, ready for operation. well as integration of third-party components, if needed, is done by skilled technicians in the Intrinsic safety, increased safety, pressurization, Pepperl+Fuchs assembly workshops. encapsulation, flameproof enclosures or powder filling - when dealing with explosion hazardous After thorough testing, full certification and areas a very deep knowledge of protection documentation the system gets delivered to methods, equipment certifications and the the plant ready for commissioning. If you are relevant standards is mandatory, especially interested in state-of-the-art and since the latter vary from region to region. CAPEX-efficient explosion protection solutions please do not hesitate to contact us. Even operators of process production plants happen to have their specific protection More Information 22

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Seco adds 8xD option to Crownloc® Plus family of exchangeable-tip drills Achieving excellent chip evacuation and wear resistance, Crownloc Plus drills incorporate an exchangeable-tip system that eliminates the need to replace an entire tool. Instead, when the cutting edge becomes worn, the user simply removes and replaces the tip of the tool with the Crownloc Plus wrench. A secure locking interface maintains high stability while allowing the exchange process to be quick and easy. The system’s unique approach minimises tool inventory requirements while offering exceptional cutting performance.

Crownloc Plus drill bodies contain deep and wide flutes that optimise chip evacuation and contribute to a long tool life. The cutting head tips incorporate optimised geometries and a

TiAlN coating to boost performance and wear resistance. Available in diameters ranging from 12.00 19.99 mm (.47’’ – .787’’), Crownloc Plus drills are available in 3xD and 5xD options in addtion to the new 8xD models. The tools can be incorporated with Weldon, hydraulic chuck and shrinkfit toolholders.

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Kennametal Named Again Among World’s Most Ethical Companies Kennametal Inc. (NYSE: KMT) announced today that it has been named for the second year in a row as one of the World’s Most Ethical Companies by The Ethisphere Institute, a leading international think-tank dedicated to the creation, advancement and sharing of best practices in business ethics, corporate social responsibility, anti-corruption and sustainability.

14001 certifications, waste reduction, recycling and management programs across the company’s supply chain worldwide; Information technology, including industryleading execution of standardized enterprise resource systems and processes; and Innovation, including consistently exceeding 40% of sales realized from new products, which offer at least 20% performance improvement.

Kennametal’s global leadership exemplifies a company culture in which employees put ethics into action with consistent investment and performance toward 100% safety, environmental excellence and community engagement, as well as extensive efforts to advance technical education, material science and industrial technologies indispensable to next-generation manufacturing.

Through in-depth research and a multi-step analysis, Ethisphere reviewed nominations from companies in more than 100 countries and 36 industries. Kennametal showcased exemplary standards in its code of ethics, investment in innovation and sustainable business practices as well as its activities designed to improve corporate citizenship.

“To again be recognized as one of the world’s most ethical companies is a great honor and tribute to Kennametal people everywhere, ” said Kennametal Chairman, President and CEO Carlos Cardoso. “Not only are we committed to be our best as corporate citizens; we are compelled to improve our performance continuously. That is what differentiates Kennametal as a leader.” In addition to extensive ethics training and communication with employees, Kennametal’s efforts in the past year included a number of new records for the company in: Employee engagement, achieved at levels exceeding peer comparisons; Talent development, delivering technical training and professional development in record numbers to Kennametal employees, customers and supply chain partners worldwide; Safety, including two consecutive months with zero injuries requiring days away or restricted time (DART), key milestones toward the aim of keeping all employees and visitors 100% safe, 100% of the time; Community stewardship, including employee volunteerism and fundraising, from participation and support for the United Way in North America, to educational programs and service to community organizations worldwide; Environmental performance, including ISO 24

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“Not only did more companies apply for the World’s Most Ethical Companies recognition this year than any year in the past, which demonstrates that ethical activity is an important part of many of these companies’ business models, but we are also seeing more companies be proactive and create new initiatives that expand ethics programs and cultures across entire industries, such as industry-based ethics associations and other activities,” said Alex Brigham, Executive Director of Ethisphere. “We are excited to see the 2013 World’s Most Ethical Companies take these leadership positions, and embrace the correlation between ethical behavior and improved financial performance.”

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WIDIA Victory portfolio means higher turning productivity, lower costs across wide range of materials With overwhelmingly positive feedback from pre-launch customers, new high-performance WIDIA™ Victory™ turning grades deliver increased productivity with improved surface finishes and longer tool life across steel, stainless steel, cast irons, and specialty alloys. “These are significant new turning solutions including 10 different grades and 14 different geometries, including five new chipbreaker designs,” says John Gable, product manager, global turning products for WIDIA. “And in many cases, the results are not just marginal improvements, but more like double the number of parts versus other inserts.” WIDIA’s Victory inserts employ coating technologies to improve wear resistance and allow for higher speed and / or feed capabilities. Additional post-coat treatment provides increased cutting-edge toughness to reduce the depth of cut notching and extend tool life.

WIDIA Victory inserts are ground after coating to provide a secure seating surface, adding to tool reliability. “Whether the task is light or medium turning under favorable conditions or heavy-duty roughing with heavy interrupted cuts, there is a WIDIA Victory insert that will improve your results,” Gable says. “Customers can machine more parts per insert and get higher dependability at elevated cutting speeds. The bottom line is more uptime and higher throughput to get parts out the door faster.”

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REDUCING OPERATING COSTS OF TELECOM BASE STATIONS WITH REMOTE MANAGEMENT As more and more people rely on mobile communications in their daily lives, the pressure on telecom infrastructure is increased. We want telecom base stations to achieve higher performance while decreasing operational costs. This can be a real challenge, especially in rural and scarcely populated areas where we might lack a well-developed power grid and the nearest service technician is miles away. There are many actions that can be taken to improve operations and reduce costs, for example using newer energy-efficient equipment and integrated power management systems to use power more efficiently. These actions may work well when a new site is being built, but the investment may be harder to justify on existing sites as it requires replacing existing, well-functioning equipment with new. 26

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So what can be done to improve operations and reduce operating costs on our existing sites? These are some of the questions we will answer in this whitepaper. Five ways to cut operating expenses on telecom infrastructure. There are many things that can be done to improve the operation of existing telecom sites, but the key factor to successfully be able to reduce operational costs is information. By understanding when, how and if equipment is operating, we are able to make better decisions regarding site maintenance and take actions when necessary. Below are five examples of how access to information helps us make better decisions and reduce operating costs.


1) Energy metering – the key to making the right decisions By adding intelligent energy meters (sometimes referred to as smart meters) at strategic locations in your site, you will get a detailed overview of how much energy each part of your BTS is consuming. For example, with an AC meter installed directly after the mains, and DC meters which measure the consumption of the telecom load, you can easily calculate the site’s Energy Efficiency Ratio (EER). Additionally, energy meters can be added to individual equipment (the air-conditioning for example) to see how it is performing and when it is time to do maintenance. The results will help you identify what kind of energy efficiency measures to take.

that has not been properly shut, will affect the temperature at the site and thereby generate unnecessary energy consumption. By recording the temperature at each site and monitoring and configuring temperature set-points remotely, we can assure an optimal climate inside the BTS and extend battery lifetime.

2) Perform service when needed A lot of the equipment used within a telecom site (for example air-conditioning units, diesel power generators, etc.) requires regular service to operate reliably. Telecom sites are often serviced according to a pre-determined service schedule. As site visits are costly, we may be able to reduce the service costs if we only send the service team to sites that actually need service. The challenge is to know when service is needed at each individual site. By analyzing the operation of equipment remotely, we are able to understand equipment health and more efficiently schedule service visits in the field.

A great percentage of generator failures can be avoided by simply analyzing the basic operational parameters, such as fuel levels, battery levels, oil-pressure and coolant temperatures.

4) Improve reliability and operation of diesel power generators. Diesel power generators are often used for back-up power at telecom sites. In rural areas, the luxury of a reliable power grid might not be present, and in such cases the diesel power generator acts as the main source of power, occasionally combined with renewable energy sources, such as wind- or solar-power.

Service of a power generator is normally carried out at certain intervals, for example after operating the generator for a certain number of hours. By being able to see the operating hours remotely, we are able to make a decision of when to send a service engineer to the site. Like a car that has been parked for an extended period, a generator engine that has not run in a long time is likely to have start-up problems. For back-up power generators that are not operated very often, it is important to regularly perform test starts. Remote test starts can be made with a remote monitoring solution that has control capabilities and is connected to the generator controller.

3) Increase lifetime of batteries. Batteries have a limited lifetime which depends greatly on how they are operated as well as the surrounding temperature. With a temperature that is just a couple of degrees higher or lower than the optimal operating temperature, the lifetime of batteries is significantly reduced. And since batteries are expensive, this can generate With a simple action such as a remote test substantial savings. run, we are able to increase the likelihood of the generator working the day there is a power Normally, an FCU in combination with an airoutage and the generator needs to perform. conditioning unit is installed to regulate the A well-maintained generator operates better temperature on site. Outdoor temperature and with lower costs as unplanned operating fluctuations, equipment failure or even a door disturbances often means substantial expenses. Industry Asia-Pacific 2-2013

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5) Minimize fuel theft. Fuel theft can be a significant problem and reports have suggested that in certain regions, as much as 40% of the fuel disappear before it is used. Avoiding fuel theft completely might be difficult since it is often stolen a bit at a time; during transportation, at fill-up, or at the telecom base station. However, a remote monitoring system that connects to a fuel sensor can be used to ensure that the right amount of fuel is delivered at a refill. By using an intelligent level sensor, it is possible to track the fuel level of the tank. The fuel sensor can be calibrated to sense a full tank and by knowing this we can verify that the tank is properly refilled. A good fuel level sensor is able to detect variations down to 3-5 liters. An abnormal decrease in content may be detected and indicate that the fuel is being stolen. With a remote monitoring system that supports alarms, a notification is sent immediately as the theft occurs. Even if it might be hard to catch the thieves, we are at least aware that the fuel has been stolen and we can schedule a refill to ensure the generators have 28

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the fuel needed to operate. Tracking the level of fuel in a tank remotely increases our awareness of what happens to the fuel on site and helps us understand when theft occurs. In some cases, where organized theft is common, this may help detect patterns and take action. Remote monitoring puts you ahead of the game Modern remote monitoring technology enables us to get instant access to data from equipment in the field and take action based on the information. This enables us to have full control 24/7 and creates instant awareness of any operational issues. To get this information, we need to gather it from the field equipment to a data center where it can be stored and accessed. The next chapter describes how this process works 2. How remote management works There are three main elements to a modern remote monitoring solution. The first is the physical layer that comprises of a communication gateway that links to


your equipment, acquires the data, and communicates it to the remote server. The second is the remote server that collects and stores the data, and the third is software services that provide secure access to the data through a user interface. a. Communication gateways Communication gateways are devices that handle the connection to the device or equipment being monitored. The connection is generally through serial or Ethernet based communication link using protocols such as Modbus RTU, Modbus TCP, SNMP, etc. A common challenge to solve is access to the remote sites as many solutions require open ports in firewalls or VPN based connections to the field installations. It is normally better to avoid such solutions as open ports in a firewall reduces the protection of the site and VPN based access may give access to other components that what the connection may be intended for. A more secure method is to use a solution where the communication gateway initiates the communication to the remote server (only outgoing TCP/IP connections need to be open) and also uses communication protocols that only map selected data from selected devices to the remote server instead of open transparent access to the field site. It may also be a good decision to use a solution which allows communication gateways to be pre-configured for the intended application. Such solutions make installation simple and require no programming or IT expertise at the time of installation and makes solutions are easier to deploy in the field. Remote monitoring offer secure access to field data from remote sites b. Central server Acquired data as well as information regarding events occurring in the field are sent to the management server by the communication gateway at selected logging intervals as demanded by the application.

To communicate with the server, gateways generally use either quad-band GSM/GPRS, 3G or Ethernet based communication using TCP/IP based protocols. Information held on this server can be displayed graphically in the form of customized dashboards (see below), or downloaded into the customer’s businesses management system for analysis and reporting.

c. Graphical dashboards Information stored on the remote server can be presented using a standard web browser or integrated with other applications used for monitoring the field sites or applications handling logistics. There are normally several different tools and functions available at the server to simplify configuration of a graphical display, customize reports or functions to provide access to the data stored on the server. A configuration can be packaged as a pre-configured profile that can be deployed to sites in the field and present a common user interface with information presented in the same way for each site. 4. What information can you get from your telecom base stations? Remote monitoring can be used to monitor and control all the equipment that supports the operation of a telecom site (often referred to as passive equipment). There are normally three different applications of the remote management solution: Industry Asia-Pacific 2-2013

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Fault management – the ability to detect a critical event at the site and use the information to take action. Configuration management – the ability to adjust equipment at the site to achieve optimal operation. Performance management – the ability to measure how the system is performing and reduce energy consumption as well as optimize operation. Below are some examples of what can be monitored and managed remotely: Grid power - Grid power - Energy consumption - Status of diesel generator and fuel tank - Battery power -Solar panels -Wind turbines -FCU and air conditioning -Sensors (such as temperature, humidity, door sensor, water leak detection sensor, etc.) In other words, remote monitoring makes it is possible to monitor everything that keeps the base station running. Renewable energy management See how much energy the solar panels or wind 30

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turbines are producing. Access management Detect when doors have been opened and the site has been accessed. FCU/Aircon management Check that temperatures do not exceed certain levels. Control and modify your site’s cooling system. Fuel management Monitor the fuel level in your diesel tanks. Power Metering See exactly how much energy the BTS is consuming. Rectifier/battery management Monitor the health of your batteries. Genset management What to gain with remote monitoring -Ensure that the base station has constant supply of power and measure energy consumption. -Ensure that the back-up power (diesel generator, batteries etc.) is ready to kick in if needed. -Reduce on-site scheduled and emergency service visits. -Receive and direct alarms to service personnel whenever certain thresholds are reached. -Generate reports on how different equipment is performing and analyze over time.


4. What about security? Establishing a secure communication path with a remote monitoring solution requires solving a number of technical challenges (such as secure access through firewalls).

authentication. Multi-level password layers are used to provide permissions to access different functions, and the server authenticates users and ensures their correct access levels. The server may also record all user access as well as attempted access.

Moving data off-site raises concerns over both its security and availability. By using solutions that are “firewall-friendly� and restricts communication to only the intended data, it is possible to limit the amount of information that can be access and reduces the possibilities of misusing the remote access.

5. Costs and conclusion Custom-made remote monitoring systems are often costly to develop and time-consuming to deploy. A ready-made remote solution makes it possible to quickly deploy solutions at a lower cost.

Most remote monitoring solutions also use encrypted communication to avoid eavesdropping on the data exchange.

By using a solution such as Netbiter from HMS Industrial Networks, it is possible to deploy a test installation within a couple of days.

This helps make a quick return on investment (ROI). The cost of a communication gateway is normally less than the average cost of a service visit and by cutting down on travelling, it is also This means that it is not possible to ping or try to possible to reduce a company‘s carbon footprint access the remote site except through any other and only do service visits when really needed. link than the intended connection to the data Remote monitoring may not be the answer to all center. supervision issues at telecom base stations, but its secure performance and potential to reduce Data storage at the remote server also needs operating costs is likely to have a major impact. protection. It is common practice to regularly perform so called penetration tests of the remote server to ensure the security protection is up to date and detect any security holes. Another method to ensure the security of wireless communications over GPRS or 3G, dedicated SIM cards with private APN.

Access to the remote monitoring system is normally centrally controlled and requires

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