PACE - Process & Control Engineering - August 2013

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AUGUST 2013 | VOL.66 NO.7

PACE marks 60 years For six decades now, PACE magazine has been an integral part of Australia’s process control and automation community. Tell us your story editor@pacetoday.com.au

AIMEX Preview

INSIDE PACE PA0 8 1 3 _ 0 0 1 _ END

Robotics

Profile

Check out some of the Custom automation delivers products at the show for Electrolux 1 2 0 1 3 - 0 7 - 2 4 T 1 2 : 4 3 : 1 5 + 1 0 :productivity 0 0

Garry Mahoney is Pacific Director with Honeywell Process Solutions

No power?

No problem.

Post Print Approved PP255003/00539

Power and transmit tank levels wirelessly.

www.endress.com.au

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coNtENts

Associate Publisher: Martin Sinclair Email: martin.sinclair@cirrusmedia.com.au Editor: Kevin Gomez Tel: (02) 8484 0976 Fax: (02) 8484 0722 Email: kevin.gomez@cirrusmedia.com.au

iN tHis issUE

Group Sales Manager: Tim Richards Tel: (02) 8484 0829 Mobile: 0420 550 799 Email: tim.richards@cirrusmedia.com.au QLD Sales Manager: Sharon R. Amos PO Box 3136, Bracken Ridge, QLD 4017 Tel: (07) 3261 8857 Fax: (07) 3261 8347 Mobile: 0417 072 625 Email: sharon.amos@cirrusmedia.com.au Graphic Designer: Nicolle Lawson Email: nicolle.lawson@cirrusmedia.com.au

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Production Co-ordinator: Tracy Engle Tel: (02) 8484 0707 Fax: (02) 8484 0722 Email: tracy.engle@cirrusmedia.com.au

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CUSTOMER SERVICE: 1300 360 126

Average Net Distribution Period ending March ‘13

AIMEX 14

Mining 22

Case Study 12

Automation 16

IICA Corner 30

Tunnel Architecture Australian company hExeis improves security and overcomes DCOM challenges

Show Preview A sneak peek at some of the products that will be on display at the show in Sydney Custom Solution Leviathan Design’s automated cell bonds metal trim and plastic columns to a glass panel

Automation Case Study Fortescue upgrades its bulk material handling facilities at Port Hedland to boost exports Commit to Change The Institute should work to raise its profile as well as the image of our industry

oN tHE coVER

OFFICIAL MAGAZINE OF:

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Application 8

Manufacturing How Ethernet and wireless network technologies are enabling IoT or Internet of Things

Cirrus Media Tower 2, Level 3, 475 Victoria Ave, Chatswood, NSW 2067, Australia Locked Bag 4700 Chatswood Delivery Centre, NSW 2067, Australia Phone: 02 8484 0888 Fax: 02 8484 0633 ABN 80 132 719 861 ISSN 1329-6221 www.cirrusmedia.com.au © Copyright Cirrus Media, 2013

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Level measurement in storage tanks may be desirable but not affordable.

The cost of the measuring point, mechanical installation, electrical installation, power and system connection may be too much to justify the information from the storage tank.

The Micropilot M with WirelessHART™ adaptor removes the physical electrical and system connection from the tank top leaving 2 0 1 3 - 0 7 - 1 6 T1 4 : 2 3 : 2 9 + 1 0 : 0 0

only the mechanical installation to be considered on the vessel.

System access to the wireless device is then via the WirelessHART™ gateway SWG70 for PLC, DCS integration or simply by a web browser.

Remote access for configuration is available from Endress+Hauser FieldCare. www.endress.com.au

The Next Generation of Micro PLCs Introducing you to the Allen-Bradley® Micro800™ family of component-class controllers, offering convenience and connectivity, in just the right size.

Find out more, visit:

www.rockwellautomation.com.au Allen-Bradley and Micro800 are trademarks of Rockwell Automation, Inc. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

MicroPLCs-Advert_quarter-pg_July2013.indd 1

12-Jul-13 12:12:49 PM AUGUST 2013 www.pacetoday.com.au 3

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COMMENT

EDITOR’S MESSAGE

WHAT’S ON

NIWeek 2013 5-8 August 2013, Texas www.ni.com/niweek

Wireless can transform plant networks

2013 Honeywell Users Group Asia-Pacific Symposium 25-29 August 2013, Perth apusersgroup@honeywell.com

IT often seems as if our industry has a love-hate relationship with wireless technologies. There is interest and wonderment when it comes to the capabilities of the increasing number of wireless devices hitting the market. Our minds boggle at the immense possibilities that wireless can deliver.

But then comes doubt – is wireless all that it is cut out to be? What about reliability? How will nearby high power equipment affect a wireless set-up? Also, many of us will have heard of a not-so-successful wireless implementation where jitter, metal structures, rogue nodes, dead spots and connectivity

Specialist Industrial Control System Security Training 3-5 September 2013, Melbourne www.sistraining.com.au

Kevin Gomez Editor

HAZOP Study for Team Leaders and Team Members 10-12 September 2013, Perth www.icheme.org/hazopperth

Next Issue For daily updates visit www.pacetoday.com.au

• Water & Wastewater • HMIs & Rugged Systems • Sensors & Analysers • Process Control in Power Generation

issues resulted in more pain than gain.

Still, many say it is futile to fight the wireless onslaught.

With users accustomed to accessing data on smart phones and tablets, there are similar expectations of wireless in the industrial environment.WiFi in particular is increasingly being used to remotely access equipment and devices. Since it is an open standard, WiFi is able to work on devices across manufacturers.

Moreover businesses are pushing for implementation of the IEEE 802.11 standard.

Plants that have installed 802.11n are enjoying speeds of up to 450 Mbits. They are still in a minority, but

802.11n is common in the consumer industry, thus pushing the automation industry to speed up.

Some are holding out for the new 802.11ac 1 Gbit wireless devices, forecast to hit one billion units by 2015.

Devices based on this standard promise several advantages – they are less affected by metallic structures and machinery noise.

That begs the question, how long does one wait for the next best innovation? kevin.gomez@cirrusmedia.com.au

Like us on Facebook and join the conversation facebook.com/PACEtoday

Robotics

Local students prepare for international robotics competition ROBOTS are used across an increasing the final of the NI Autonomous students to showcase their creative array of industries from mining and Robotics Competition in Melbourne on and technical capabilities as they delve defence to manufacturing and healthcare 24 September. into the world of robotics, spurred on to undertake tasks that are unsafe or As a lecturer at the University of by friendly rivalry with their fellow impractical for humans to complete, Texas in Austin for the mechanical engineering and mechatronics students at says Chief Control and Simulation engineering and aerospace engineering other universities,” said Falcon.

Engineer for National Instruments departments, Falcon said the competition Over 20 student teams are tasked (NI), Dr Jeannie Falcon, who toured allows students to demonstrate their with building an autonomous robot for Australia last week. engineering abilities in a fun and the third annual competition designed Falcon’s visit comes as engineering interactive environment and hone their to demonstrate their skills on an and mechatronics students from leading skills to become the robot designers of international platform. With a theme of A D _ Pacross A C EAustralia M E T Aand P RNew _ 1 2 . p the d f future.

P a g e 4 2 0 / 0 3 / 1 2 , ‘Gold 5 : Rush’, 1 1 each P Mrobot will navigate an universities Zealand are preparing to face off in “The competition is a stage for obstacle filled course, identify, pick up

and move objects to designated locations in the shortest possible time.

Participating teams each received a development kit featuring an NI Single Board RIO- board level reconfigurable control system and NI LabVIEW system design software featuring the LabVIEW Robotics Module. All teams have successfully passed two of four milestone tasks in the competition under the guidance of academic supervisors and support of NI Engineers. australia.ni.com

ThinManager’s MultiSession Core THINMANAGER.COM

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Our MultiSession core technology allows multiple sessions running anywhere on the ThinManager network to be viewed through one thin client.

ThinManager can “tile” these screen views based on your settings. You can dictate which tile shows which session. You can set it to run in screensaver mode so that certain “tiles” are constantly updated with different sessions. Multisession allows you to view displays from different applications on the same monitor.

Call Wonderware Australia on 1300 138 825 or visit our website www.wonderware.com.au 4 www.pacetoday.com.au AUGUST 2013

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NEWS

Helping to put you in Control N1500 Flow Rate Indicator

Accepts 4-20 mA, NPN, PNP, dry contact or coil signal input signals. Isolated retransmission 4-20 mA & pulse output. 2 configurable SPDT alarms. RS-485 interface with Modbus RTU protocol. 240 VAC powered SKU: IPI-106 Price: $399.00 each + GST

Frequency to Analog Converter DIN Rail or panel mount NPN (0.01 Hz to 80 kHz) frequency input to 4-20mA output isolated converter. 0-5V(TTL),PNP, 12V input can be selected by jumper. 18-60 VAC/DC powered.

SKU: AXB-002 Price: $159.00 each + GST

GSM Remote Controller It features 8 digital inputs, 1 relay output. Configuration is setup by GSM mobile phone or via RS-232 serial port. 7 to 15 VDC powered. Up to 10 different numbers can be preset in the system.

SKU: LEC-001 Price: $315.00 each+ GST

Serial Converter & Repeater

Converts RS-232/422/485 to RS422/485 through a 2.5 kV optical isolation barrier or use it as an isolated repeater to extend your RS-422/485 network. Female DB-9 for RS-232 & screw terminals for all other connections. 12-36 VAC/DC powered.

SKU: TOD-002 Price: $139.00 each+ GST

Bipolar Stepper Motor

Industrial 6-wire NEMA 23 frame double shaft stepper motor. It features a holding torque of 0.88 Nm. Ideal for CNC projects and robots.

SKU: MOT-1241 Price: $59.00 each+ GST

Engine Start Attempt Relay

An 11 pin plug in engine start attempt relay for use in starting combustion engines connected to generators. Features 8 start attempts, 2 SPCO relay output rated 10A @250 VAC. 9-30 VDC powered.

SKU: NTR-150 Price: $89.95 each+ GST

Multi-function Timer SPCO

Slim DIN rail mount, multi-function timer. Dual LEDs indication. Multiple time range 0.1 s to 100 hours.

SPCO relay output rated to 8A @250 VAC. 12 to 240 VAC/DC powered.

SKU: NTR-101 Price: $59.95 each + GST

Isolated Analog Converter Slim isolated selectable analog input signals with selectable single analog output. 20 to 56 VAC/DC powered. Features LED indicators, span and zero adjustable via potentiometers. Accuracy: ±-0.2% F.S. Also available with dual output SKU: NTB-001 Price: $169.00 each + GST

For OEM/Wholesale prices Contact Ocean Controls Ph: (03) 9782 5882 oceancontrols.com.au

AIMEX

Fully flexible segmented girth gears SEW-Eurodrive will present its segmented girth gear solution for transmitting energy in large, rotating systems at AIMEX. According to SEW-Eurodrive’s National Products Manager for Industrial Gears, Ian Tribe, the design principles of the segmented girth gear solution simplify transportation, assembly and servicing in these applications. “Our girth gears aren’t just single pieces, but rather made up of multiple identical segments whose number depends on the overall diameter,” said Tribe. “Assembling these girth gears using a spring cup or flange is also much easier with this solution.”

SEW-Eurodrive currently produces segmented girth gears with a pitch diameter up to 16m and a width up to 600mm. Due to the segmented design principles even larger diameters and widths are possible. The power range reaches up to 2500 kW per pinion. The use of special ADI cast material means that SEW-Eurodrive girth gears have industry leading material properties providing minimal wear. This enables SEW to offer a smaller tooth width than competing technologies can, allowing customers to save on the overall system.

SEW-Eurodrive provides customer-specific solutions within its existing product range, delivering not only segmented girth gears, but, the entire drive package.

“We can engineer the complete drive solution, providing our customers with ease of ordering and an efficient end system,” said Tribe.

Research

Girth gears are used to drive grinding mills, kilns and rotary dryers. SEW-Eurodrive assists customers find technically and economically optimised solutions for other applications. www.sew-eurodrive.com.au

COMPANY NEWS

CSIRO and DSTO jointly strengthen research

Fyfe purchases Adelaide process control company

AUSTRALIA’s two largest publicly funded research agencies, CSIRO and the Defence Science and Technology Organisation (DSTO), have signed a Strategic Relationship Agreement aimed at high-impact research priorities.

Technologies which will come under the umbrella of the agreement include horizon scanning and emerging technologies, manufacturing technologies, advanced materials, intelligent processing, energy storage, autonomous systems, sensors and bio-technology.

Under the alliance the two organisations will also share professional development training programs for staff, undertake staff exchanges and joint community outreach activities and share infrastructure including participation in each other’s innovation precincts.

“This agreement puts two powerhouses together to support high-tech development for Australia,” CSIRO Chief Executive Dr Megan Clark said. Chief Defence Scientist Dr Alex Zelinsky who leads DSTO said the agreement was a significant step in conducting worldleading collaborative research for dual use technologies.

FYFE has purchased Adelaide automation and process control firm Command Automation. The purchase, for an undisclosed sum, was completed this month and will enable Fyfe to expand its engineering services in the oil and gas sector.

Fyfe’s Managing Director, Mark Dayman, said Command specialised in industrial automation and process control solutions and currently operated in the oil and gas, water and industrial sectors.

“Process control is an area which is increasingly relevant to our operations, particularly in the oil and gas sector, and this acquisition will enable us to further improve the service we offer our clients,” he said. “It also opens up a new area of business for Fyfe – one we believe will play an important role in the future of the company.”

Command will be set up as a separate division within Fyfe’s Energy and Resources business unit.

Command was formed in 2010 by Luke Day. It has a team of three engineers plus support staff and turns over about $1 million a year.

www.csiro.au 06 www.pacetoday.com.au AUGUST 2013

SPECIFIC: SEW-Eurodrive’s girth gears are made up of multiple identical segments whose number depends on the overall diameter.

www.fyfe.com.au

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NEWS

Innovation

Manufacturing

Free glassware app monitors machine tools A US company has released MTConnect + Google Glass, a free Glassware application that monitors machine tools using Google Glass. Every department in a manufacturing facility will be able to use MTConnect + Google Glass – from the shop floor to the management suite.

A new machine operator will be able to watch YouTube training videos while at the machine, supplementing his training program. Getting and sharing information on the machine and its processes would be as intuitive and non-threatening as using his smartphone or playing a video game.

An experienced machine operator sends an email to the maintenance staff as soon as he sees a problem.

The CEO travels the shop floor, getting accurate realtime machine data and comparing it to the company’s accounting, quality control, sales and engineering data.

Project managers evaluate workflow and machine readiness before scheduling future work.

They also access 100% accurate data and share information with their customers to ensure smooth delivery between vendors. The maintenance staff becomes even more astute at monitoring machines and they to Sproblems, A respond D _ P Aquicker CEAM M A R _ while 1 3 .developing pdf Pa g stronger preventative maintenance programs.

With Google Glass, they can “see” instruction manuals overlaid on the equipment when installing or repairing machinery. The sales staff provides guided Google Glass tours, impressing prospects with the capabilities of the facility and helping them visualise the final product.

Data streams from MTConnect Agents directly to Google Glass which recognises the machine tool, grabs appropriate information from MTConnect and parses the MTConnect stream to display it in a userfriendly way for the Google Glass wearer.

The user will be able to view the following information from the MTConnect-compatible equipment: Power Status, Emergency Stop, Alarm/ Messages, Block, Controller Mode, Line, Program, Execution, Path Feed-Rate, Spindle, Axis Positions, Spindle Overrides, Feed-Rate Overrides, Machine Location, Part Location, and Current Part Status.

Also, if there is a camera inside the machine, Google Glass will stream the video to the user and overlay the machine data so the user can compare, analyse and make quick decisions. The user could record and share this data seamlessly with all eappropriate 1 1 2parties. / 0 2 / 1 3 , 5 : 1 0 PM

Advanced fibre centre in Geelong THE Fibre Processing and Carbon Nexus buildings in Geelong have just been opened, having received $38 million in Federal Governemnt funding.

The buildings are part of the $103 million Australian Future Fibres Research and Innovation Centre (AFFRIC), which aims to transform Geelong’s into a global centre for cutting-edge manufacturing.

Advanced fibre manufacturing promises to benefit to the Geelong economy and the country. “New generation fibres, like carbon fibre, smart fibrous materials, and sustainable textiles are revolutionising industries across the economy, including in the aerospace, defence, automotive and textile sectors,” said Innovation Minister Senator Kim Carr when opening the buildings.

Geelong researchers are working directly with industry and said to be building new prototypes and making breakthroughs. Geelong company Carbon Revolution has worked closely with Deakin University, and is now the first in the world to manufacture carbon fibre car wheels, which weigh about half as much as regular wheels. Carbon Revolution are currently exporting worldwide.

Reduce costs and improve quality of calibration Beamex® documenting calibrators and software form an automated paperless calibration system.

www.deakin.edu.au/affric

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AMS AMS INSTRUMENTATION & CALIBRATION PTY LTD Unit 20, 51 Kalman drive Boronia VIC 3155 AUSTRALIA Phone: +61-3-9017 8225 Fax: +61-3-9729 9604 E-mail: sales@ams-ic.com.au Internet: www.ams-ic.com.au

The new Beamex MC6 - more than a calibrator.

Touch-screen, 5.7” color-display. Light-weight, robust (IP65) and long operating time. A meter, calibrator, data logger and full multi-bus field communicator. Pressure, electrical, temperature and frequency signals. HART, Profibus PA, Foundation Fieldbus H1. Seamless communication with calibration software for paperless calibration management.

www.beamex.com info@beamex.com

AUGUST 2013 www.pacetoday.com.au 07

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OPINION

Manufacturing

Ethernet and wireless enable IoT The push to adopt an Internet of Things in manufacturing coincides with a concurrent enabling trend toward use of industrial Ethernet and wireless network technologies within the production environment, writes Chantal Polsonetti.

T

HE concept of an “Internet of Things� (IoT) has morphed from its origins in RFID to one that encompasses all networked devices, both within and external to a manufacturing operation. Along with intelligent sensors and machines, IoT encompasses cloud computing, analytics, Big Data, mobility, and universal visualisation. Improved business performance, production efficiency, and asset optimisation remain the core objectives for manufacturers to implement this technology.

In a manufacturing context, these objectives are achieved by gathering data locally from the myriad of sensors, devices, machines and other entities operating on the plant floor. This data is then made available globally via a cloud or similar infrastructure platform to all sanctioned parties for use in analytics, optimisation, and a variety of other applications.

The push to adopt an Internet of Things in manufacturing coincides with a concurrent enabling trend toward use of industrial Ethernet and wireless network technologies within the production environment. These technolo-gies not only offer incremental benefit over dedicated automation solutions in many applications, they also favorably position manufacturers to support the data transfer requirements inherent in IoT. Industrial Ethernet networks have sustained a continued downward march in the industrial automation hierarchy. Originally viewed primarily as an IT technology best suited for enterprise-level applications, Ethernet’s poten-tial to provide a single network technology for use in vertical and horizontal integration throughout the enterprise, plus its improved industrial performance, make it increasingly popular. The network is now a staple at the control level of the automation hierarchy, with most suppliers offering 08 www.pacetoday.com.au AUGUST 2013

an Ethernet-based control backbone.

Numerous I/O and device- level products are also available.

Both manufacturing engineers and their IT counterparts now have years of experience with the IEEE 802.11 Wi-Fi wireless standards. Most manufac-turers have already established best practices for its usage in their facilities. These COTS-based wireless networks are widely used throughout production operations and the digital oilfield, whether to support mobile devices, in-plant material handling, location tracking, safety, compliance, or multiple other uses.

Manufacturers already recognise the incremental advantages these networks provide compared to dedicated automation networks, particularly for data delivery. Ethernet and wireless both offer bandwidth greater than most dedicated automation networks and largely rely on established standardisation organizations and a large supplier base for continued development. Ethernet in particular has shown its ability to reliably deliver the right data to the right place at the right time, while manufacturers are broadly applying cable-free wireless instrumentation to address business challenges ranging from improved process performance, reliability, and efficiency to conformance with government mandates.

The enabling infrastructure behind the Internet of Things is composed of intelligent sensors and machines, data delivery networks, and cloud or similar platform computing architectures that support analytics, massive data base management systems, and any number of applications. This infrastructure is designed to support the data gathering, analysis, and presentation necessary to improve production efficiency and performance, optimise asset utilisation, ensure safety and compliance, and generate incremental gains in these and other areas that were not previously

achievable. A core concept behind the IoT is that minimal potential currently exists for improvements at the device or machine level.

Instead, this more holistic approach contends that the potential for more robust improvements that incorporate all the potential variables and elements lies at the system level. IoT also promises to support real-time decisionmaking that incorporates real-time information, rather than the typical reliance on historical data.

One of the further lures behind the IoT concept is the promise to enable new innovations in products,

One way to view the IoT is as a progression or step-change in integration that provides multidirectional access to a collaborative environment potentially enabling continued improvements in business performance and innovation. processes, and procedures throughout the enterprise.

IoT data and analysis can be remotely accessed via PCs, laptops, tablets, consoles, handhelds, smartphones, other machines, for both process improvement and sources of innovation. As an extension of this concept, many current and future products and activities will migrate into services offered by both in-house and external providers.

This is already true in areas such as machine or fleet maintenance, where external suppliers provide remote

services reliant on local data.

One way to view the IoT is as a progression or step-change in integration that provides multidirectional access to a massively collaborative environment, potentially enabling continued improvements in business performance and innovation.

Migration toward the IoT will require manufacturers to continue to mandate compatibility with COTSbased networks when specifying new sensors, machines, or systems. Ethernet and wireless networks will form the bedrock of the IoT architecture and, fortunately, many specifiers are already familiar with their use in production equipment. In general, plant floor sensors, devices, machines, and systems will be required to transmit their data to the cloud computing platform for analysis and then be capable of accepting real-time feedback from the analytical engine(s) for performance improvement.

The ability to access production data from within the typically tiered production architecture will be a major consideration. Security of plant floor operation is a major concern when such an integrated, networkdependent concept is raised. Multidirectional access control strategies will be paramount, as will continual monitoring and threat defenses.

Again, many manufacturers have experience with these issues through their adoption of Ethernet and wireless networks and have security provisions in place. Automation suppliers now offer their own firewalls and other security products and more standards are becoming available in this area.

The IEEE 802.1x standard supported in many Ethernet switches, for example, offers port-based network access control.

[Chantal Polsonetti (cpolsonetti@ arcweb.com) is Vice President, ARC Advisory Group.] www.arcweb.com

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Looking for plant-wide profitability?

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I can ensure that my production quotas meet the expected targets.

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Is your plant operating at its full potential? If you don’t have a collaborative architecture for monitoring and control, this question may be difficult to answer. And yet, quick access to precise information is exactly what you need to achieve optimised business performance.

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Produce effectively with PlantStruxure architecture

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PlantStruxure provides you with a global view across your entire plant, closing the gap between the field and enterprise, delivering real time information to users as and when they need it.

Ensuring a safe and sustainable working environment With PlantStruxure architecture, you can finally meet your automation requirements, reduce capital and operating expenses, and optimise energy usage without lowering standards or compromising safety.

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Software Vijeo Citect and Vijeo Historian deliver critical production related material to those who need it, while dedicated configuration software such as Unity Pro, reduces engineering and maintenance time.

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Networking and communication

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Based on Ethernet and with support for standard devices and process buses, the networks help to ensure the high availability and transparency of valuable plant data.

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©2013 Schneider Electric. All Rights Reserved. Schneider Electric and Make the most of your energy are trademarks owned by Schneider Electric Industries SAS or its affiliated companies. www.schneider-electric.com.au

CLIPCOM 26634

Production Manager

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conversation

The future is here now Tim Sowell of Invensys Operations Management talks strategy with Kevin Gomez.

IN A wide-ranging interview, Tim Sowell, VP of System Strategy outlines the key areas of focus for Invensys Operations Management (IOM) and offers key insights into the direction the industry is headed. He also discusses solutions to the modern day challenge of enabling decisions by workers who lack experience.

What is Invensys’ game plan for the next few years?

Our direction is all centered on enabling customers to evolve towards “Operational Excellence” with a strong focus on operational empowerment.

There are three main aspects to operational excellence: one is operational empowerment, that’s people; the second is product performance through asset efficiency, process performance and production management; the third is lifecycle of solutions, and systems across the value supply chain, so they can evolve in functionailty and technology at low cost of ownership.

A project is not just about the project, it’s also about the full end-to-end lifecycle. Companies are buying multiple assets and it is challenge to merge them.

How do you change the architecture without losing the engineering?

Too many of the architectures we’ve implemented in the nineties and early 2000s are good for the project but they’re not good to evolve in today’s environment which is all about agility.

I’m talking about agility of architecture, agility of new products and agility of process. Probably the biggest factor is human capital.

We do a lot of work around physical assets, but we haven’t done a lot of work around how to enable people. Most of the HMI systems that were built are focused on the process, tasks accomplished and navigation information. There was no thought about a team, yet today we’re seeing operational teams come in to play all the time. Moreover by 2020, Gen Y will comprise 42 per cent of the workforce.

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The average tenureship in a job will be 2.4 years. A customer did a survey at one of their locations, checking with operators, maintenance teams and process engineers. In 2001, this group were in their jobs for five years on average. Last year they did the same survey, it’s now just eight months.

How do we increase worker efficiency?

People need to be removed from behind their desks. We see Rio Tinto and others building operational centres.

An operational centre in Perth is now controlling plants like Cape Lambert in the Pilbra, a thousand miles away.

There’s a roaming team, an operational centre team and then the experts. How do they all work and collaborate and access the same data?

new structures of alarming, in terms of being able to manage alarms, severity of alarms, roll up of alarms. Alarms need to be to be effective, and we already have the Abnormal Situation Management (ASM) specs.

Then there’s the way that’s presented to the user. We’re adopting more of a grey background; if there’s something critical, the rest of the information all fades away.

We’re doing a lot of work on object management and building standards.

We’re really about people management.

How can I get you to react to a situation the same way? It’s not just to give you the information, how can you make sure you take these five steps the right way?

That’s why we have developed workflow as a natural extension to the

CHARTED: Mapping out the strategic focus for Invensys Operations Management in the period ahead.

Perhaps the user is dealing with several thousand alarms and functions so the system needs to be self-aware and exception-based, aggregation of alarms, and sitation is key.

Instead of the user monitoring everything, the system should monitor itself and only send up an alarm when there’s an exception or an abnormal situation. Yet most of the systems we have put in place over the years are all about monitoring.

We are spending a lot of time on the

UI environment. So that operational processes, procedures can be embedded into the operational experience, so no longer do we have just information we also have recommended actions and menthods. This goes from the traditional DCS/ Process Control screen, to analysis and reporting, notifications which will all have actions assocaited. That’s a big change.

What’s cooking in your labs now?

We’re spending around 33 per cent of

our software investment on pathfinding development – products which we have not released. We’re spending a lot of money on new generation products at the moment, effectively we want to bring dynamic simulation and design simulation as a natural part of a supervisory system control system, it shouldn’t be an add on.

When we look at trends there is the whole movement to mobility. There were more mobile devices sold last year than PCs and we need to deliver context information, how does this mobile device become an effective companion for the roaming worker to do his job more effectively. At this conference we’ve got at least three or four mobile appliactions we each for different roles in a plant. You can go to SmartGlance now, download our free smart phone application, connect to a demo and you’ll see the alarms and in-formation automatically on your phone.

To us, virtualisation is not a nice to have; you’ve got to be virtualised. We did a lot of work in the last two years with releases focused on high availability and disaster recovery. We’re also making huge investments around Cloud. While our industry may not be ready for the Cloud today; we’re starting to see much wider acceptance.

The other area of focus is dealing with big data? We’re seeing an explosion in data in the industrial market, mainly because de-vices are becoming smarter and more intelligent, resulting in more data. We’re investing a lot of time and effort around the use of big data and the big data concepts to be able to remove the complexity and understanding of all that data and trying to bring it together using information models.

What about concerns related to data security in the Cloud?

Security and data ownership – these are the two questions of relevance. Data is owned by the customer if it goes on the Cloud.

We spent a lot of time with Microsoft – they went through the Cloud security

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conversation

challenge about five years ago and we’re doing the same thing now. All our coders have to go through safe coding practices and we regularly audit them. We’ve changed our software development lifecycle to be very security orientated.

The challenge is to write secure code and don’t leave yourself with any holes. We’re also doing a lot of work around reverse security protocols so that we can pass data back and forward in an extremely secure manner without opening up any holes in the networks and firewalls.

People are running their banking in the cloud, their ERP systems in the cloud, following this acceptance we seeing more and more interest in what potential the cloud provides to plants of all sizes and across plants.

We are releasing an historian in the cloud this year and we will be introducing a number of cloud services over the next year. Already we have three, but core to our approach is how we protect the data, how we protect the access from and ack to plants, it is apart of natural the P A 0 8culture 1 3 _as0we0 architect 0 _ R Ofor C3 cloud. The internet and cloud will be

natural aspect of a hybrid operational/ automation architecture in two years, we building and delivering for it now.

To do that we’ve got change our practices on how we manufacture. We have a philosophy in this country of manufacturing food for the Australian What are the challenges and market not for the world market. The opportunities for Australia? opportunity exists to grow that market From a business point of view the and do it in a highly productive manner. biggest problem is the high Australian To me this market represents a dollar, which is causing problems with mammoth opportunity, but we first manufacturing, oil plants and refining. need to get our practices and processes As a result, there’s a really a big in place, set a bigger vision, so that we drive towards getting more out of what comply and can satisfy the potential they’ve got. We’re starting to see a lot markets. I think the number one of interest in energy, putting systems problem in this country is the vast in place around energy monitoring and shortage of expertise to do projects, energy practices. and run the plants and operations. It is We’re also see local industry going to change the way people have to examining how they can get more with operate their plants. existing assets. They’re tending to align They’re going to have to deal with their assets more, and make them more their plants more remotely and ensure agile, unify the information across the more collaboration between sites with assets to empower more people in the common practices. bussiness with this real time information.

I don’t think we’ve changed the way From an opportunity point of view, we educate engineers, certify and manage this country has got the potential to them in their environment. Why aren’t deliver a lot of the food to the Asian we adopting The Khan Academy’s market. Today, we can supply food philosophy’s in the engineering today 1 2to060 1 million 3 - 0 7people, - 2 5we T should 1 2 : 2 1 : environment 4 3 + 1 0 : and 0 0using small YouTube be able to supply to 200 million people. videos to build knowledge?

To me the opportunity is how we manage people, enable and empower them to do more in their day? Also, how do we absorb the new generation who will want to work very differently? They wish to interact, they want to search.

Nobody looks at a manual or goes to a library any more. You google or get your information out of Wikipedia. Why can’t I do that with data?

On my manufacturing floor I might have 15 Historians, databases and alarms.

Why can’t I search across that data? Why can’t I just type in ‘#pump’, search and get all of the data back and understand it. Maybe it gives out a trend and I see the alarms for the past day. That’s where we need to get.

The opportunity in this country is around people, leverage what we’ve got.

My big concern is getting our engineers to realise the culture change they have to go through, because they have to design the screens and operational practices differently.

[Readers can check out Tim Sowell’s blog at http://invensyssysevolution.blogspot. com] iom.invensys.com

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AUGUST 2013 www.pacetoday.com.au 11

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IN FOCUS

How hExeis improved security This case study looks at how Australian company hExeis used MatrikonOPC Tunneller to improve security and overcome DCOM challenges.

B

ASED in Eagle Farm, Queensland, hExeis applies the theories and principles of mathematics and science to design computerised systems including hardware, networks, software and processes to solve novel engineering problems for operating assets such as machinery, buildings, and processing plants. hExeis uses OPC to establish communications between energy monitoring systems and building management systems.

Using native DCOM presents a number of challenges related to system security, as well as DCOM interoperability between different versions of Microsoft Windows operating systems and computers in different Microsoft security domains and workgroups. OPC Tunneller either eliminates or significantly mitigates security risks and interoperability issues to dramatically reduce setup time and make computers more secure.

The company recognised a significant opportunity to help oil, gas, mining and other resource companies comply with Australia’s stringent greenhouse gas and energy control and reporting requirements. To do so, hExeis needs to integrate energy monitoring systems with its clients’ existing building management systems — that’s where the DCOM challenges began. hExeis has always relied on OPC technology, but the company ran into authentication difficulties as it tried to configure DCOM connections across different domains. Security was also an issue, as DCOM requires that multiple ports be open through firewalls, effectively increasing the systems risk level for cyber-based attacks.

Without the ability to predict how long it would take to establish DCOM connections, hExeis struggled with budgeting. The company was also concerned that at some point a client would simply refuse to allow a DCOM connection because of the vulnerabilities it opens in firewalls.

12 www.pacetoday.com.au AUGUST 2013

INTEROPERABILITY: Architecture Sample of MatrikonOPC Tunneller.

When hExeis heard about OPC Tunneller, the company downloaded the free trial version from the MatrikonOPC website. “We had it up and running within an hour,” said Conrad van Rooyen, Sales and Marketing Director, hExeis. Soon after, the company had made a firm commitment to the OPC Tunneller solution.

With OPC Tunneller, setup —

which was once a weeks-long headache — can now be scheduled for a single half-day. hExeis simply contacts the third-party server owner, gains permission to install and set up OPC Tunneller, and opens a single port in the client’s firewall to establish the connection with the OPC server.

The added security of the single port is a risk-mitigation measure that impresses

both potential and existing clients.

“For those familiar with DCOM, we are able to tell them that we now have an easier and more secure option — that’s a big selling point,” said van Rooyen.

OPC Tunneller has also reduced the need for ongoing support and maintenance. The addition of security patches or other minor changes frequently breaks OPC connections,

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IN FOCUS

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FIGURE 2: Sample of DCOM Setup. but OPC Tunneller provides a far more stable connection that can also be restored much faster than standard DCOM configurations.

“We now use OPC Tunneller exclusively,” said van Rooyen. “It’s easy to set up and it improves the security of our server and the third-party server. It is simply a better solution.”

MatrikonOPC Tunneller provides an effective way to communicate between networked computers. It does away with the challenges typically associated with DCOM configuration. No longer are different protocols, security settings or locations a factor when sharing data

12V

3.75A

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78 × 93 × 56

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78 × 93 × 56

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65.5 × 125.2 × 100

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125.5 × 125.2 × 100 $109.60*

(30W & 75W also available - call for pricing)

between computers. This is achieved by installing MatrikonOPC Tunneller on the OPC client and PC server nodes and then stipulating a computer name or IP address and the port setting.

MatrikonOPC is a vendor neutral connectivity supplier and provides equipment data connectivity software based on the OPC standard.

• Wide power range 30W to 240W • Universal AC input voltage 90-264VAC • Voltage tolerance +/-1% • Adjustable output voltage +/-10% • High efficiency & reliability • 100% full load burn-in

• Cooling by free air convection • LED power indicator for power on • International safety approvals • Local stock • Low cost solution • 2 year warranty

* Price excludes GST and ONLY available to approved business and/or trade customers.

Bulk pricing available on request.

hExeis 07 3260 2946 www.hexeis.com MatrikonOPC info@MatrikonOPC.com www.MatrikonOPC.com

www.soanar.com RANGE - RELIABILITY - STANDARD - CUSTOM

info@soanar.com AU 1300 365 551 NZ 0508 765 956

AUGUST 2013 www.pacetoday.com.au 13

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AIMEX PRODUCTS

AIMEX 2013 Preview

A selection of new products on display at AIMEX 2013 which will showcase the latest technologies for the mining industry.

1. Rugged tagging systems

APC Technology will be exhibiting a range of rugged computing solutions designed to survive in the harshest locations, whether above or below ground. A feature product will be a customised tagging system, which has been designed and manufactured at the Adelaide factory for a large Australian mining company. “This tagging solution met a range of requirements, as specified by the client,” regional sales manager Ken Duldig said.

These included the incorporation of a radio-frequency identification (RFID) card reader system; connectivity and integration from the unit to existing systems on location; plus meeting the budget and additional scope of work as set by the company. Key features include stainless steel construction to maximise durability, dual sealing to prevent dust and liquid getting in, and customised metal work and electrical control panel wiring.

2. Fire safety technology

ARA Group’s FirePass Oxygen Reduction Fire Protection systems produce and use breathable air for fire prevention in protected rooms, preventing any hazard to human occupants and any damage to protected rooms and their contents. The FirePass agent is oxygenreduced air with no chemicals or gases involved so the systems are also environmentally friendly.

ARA Group 0434 077 231 www.aragroup.com.au

3. Racking and shelving

BAC Systems will be unveiling its latest racking and shelving concept, the BAC Series 77 which also includes their dedicated Long Span Shelving system. Customers can incorporate the High Density Drawer system into the same structure as the pallet racking, providing a hybrid P A 0 8 1 3 _ 0 0 0 _ E L E - APC 1 Technology 2 0 1 3 - 0 7 - storage 2 5 T 1solution 2 : 2 to 0 suit : 1requirements 6 + 1 0 : 0from 0 a two-bay parts store all the way up to a large distribution 08 8363 0400 www.apctechnology.com

Untitled-2 1 14 www.pacetoday.com.au AUGUST 2013

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warehouse. Their special integrated dust control feature of the High Density Drawer Storage Modules. Its range of Dust Control Storage Modules complies with the Caterpillar Category 5 Contamination Control, and is used in mines and warehouses to keep dust away from all small-to-medium parts in the warehouse.

BAC Systems 02 9832 2777 www.bacsystems.com.au

4. Mining electronics

Bramco will highlight its b3 range of electronic products for the mining industry. The range includes earth continuity relays; earth leakage relays (fascia and DIN mount); neutral link monitors; module remote interfaces with flameproof buttons; isolation barriers; and combination relays.

Bramco Electronics 02 4014 4444 www.bramco.com.au

5. Solution architecture

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Schneider Electric’s EcoStruxure solution architecture combines the five key business domains of power, process and machine, IT room, building and security management.

It also incorporates StruxureWare software applications and suites, which unify the above can 2 0 1 3 - 0 7 - 1domains 1 T 1 5so: that 5 1users : 4 5 + see, 1 0 measure : 0 0 and manage efficiency across entire processes,

at the enterprise, operations and control levels. The company will also focus on Mine-to-Port logistics, in particular its Integrated Planning and Optimisation System. These include stockpile management, advanced blending, transport scheduling, demand and supply planning, maintenance planning, scenario management and intelligent reporting. Its PlantStruxure PES (Process Expert System) brings together the PLC/ SCADA and DCS worlds, combined with integrated energy management features, to deliver superior value throughout the lifecycle of a plant.

Schneider Electric www.schneider-electric.com

6. Hydraulics and valves

Hawe Hydraulics Australia will showcase directional control seated and spool valves, available with maximum pressures to 700 bar and flows to 300 lit/min, with applications including mining equipment, as well as cranes, lifting and lowering devices; pressure relief/ limiting (safety) valves offer pressures to 700 bar and flows up to 160 lit/min, for general hydraulic, test bench and hydraulic drive tool applications; and flow control valves with pressures to 315 bar and flows to 120 lit/min, for general hydraulic and machine tool applications.

Hawe Hydraulics Australia 02 4225 7255 hhirning@hawe.com.au www.aimex.com.au

AUGUST 2013 www.pacetoday.com.au 15

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BEHIND THE SCENES

Custom automation delivers the goods An innovative custom designed automation system is delivering significant productivity benefits for an Adelaide manufacturer, writes Hartley Henderson.

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Industrial Software & Electronics Tel: (07) 3856 2232 Fax: (07) 3355 1012 Email: info@industrialsoftware.com.au 16 www.pacetoday.com.au AUGUST 2013

1 1 : 5 1

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AM

T a time when Australian manufacturing industry is confronted with substantial challenges, an innovative custom designed automation system is delivering significant productivity benefits for an Adelaide manufacturer.

Leviathan Design, in the Melbourne suburb of Rowville, has designed, manufactured and installed an automated cell to bond metal trim and plastic columns to a glass panel to form a door outer assembly used in free standing household cookers manufactured by Electrolux Home Products in Adelaide.

The Adelaide factory, which

ATTACHED: The glass sheets tend to stick together due to vacuum between the sheets but this issue was solved by gripping the glass stack so that the top sheet can be removed by robot without the second sheet sticking.

employees some 450 people, produces around 1300 cookers per day including Electrolux, Westinghouse and Chef brand names.

Leviathan Design has in-house machining facilities capable of producing all components required for the system. These were designed in 3D CAD and the model was used directly by the company’s CNC machines to produce the components.

This ensured that the company had complete control from design through to the manufacturing process.

Sales engineer at Leviathan Design, Glenn Westonsmith, points out that the automated production cell

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BEHIND THE SCENES

designed for Electrolux is extremely compact, with seven ABB robots all working together in the one cell, which is very unusual.

“A critical requirement of the project was to achieve a cycle time of 14 seconds. A full computer simulation using ABB’s Robot Studio software was used to show the proposed system capability,” he said.

“This simulation was continually updated and tested throughout the project to check the cycle time.”

Automated system

The oven doors are constructed of three parts: painted glass sheets supplied in stacks, plastic injection molded columns provided in trays, and powder coated or stainless trim placed by hand onto the conveyor.

Main elements of the automated production system are the robot oven door bonding cell, overhead link conveyor, and the robot storage buffer.

A key task of the robot oven door bonding cell is glass separation and paper removal. The glass sheets tend to stick together due to vacuum between the sheets, but this issue was solved by gripping the glass stack so that the top sheet can be removed by robot without the second sheet sticking.

Paper removal is provided by a high velocity fan creating a vacuum to suck the paper away to a hopper.

Westonsmith says it is critical that glass and trim is accurately aligned for assembly of the doors, so glass and trim are placed on ‘air tables’ to provide a frictionless surface.

“Small holes release air to provide a flotation cushion so that friction between the glass and the table is reduced to almost zero. This ensures that the glass and trim consistently align to a datum position,” he explained.

“The glass bonded doors are then stored in a curing oven for 20 minutes for accelerated curing of silicon. This double sided oven was designed and manufactured by Leviathan Design to provide redundancy and to ensure that cycle times could be met.

“The oven maintains a controlled temperature and stores 80 doors (40 in each side). The complete system can run at a reduced speed with only one side of the oven operating.

“Glass and trims are inspected by a vision system of Cognex ISM1050

vision cameras to ensure that the correct components have been loaded.”

Seven robots supplied by ABB Australia were required to assemble the doors and tasks are shared between the robots to optimise cycle time.

Tasks undertaken by the robots include: • IRB2600: Robot 1 – Picking trim, placing trim on regrip station.

Picking trim from regrip station and placing on assembly table.

• IRB2600: Robot 2 – Plasma treating trim on regrip stations for better silicon adhesion.

• IRB2600: Robot 3 – Picking glass, confirming correct glass with vision system, applying label, checking label barcode with vision system, placing in regrip station.

• IRB2600: Robot 4 – Picking columns, plasma treating columns for better silicon adhesion, placing columns in regrip station.

• IRB2600: Robot 5 – Picking glass from regrip station, applying silicon bead, placing glass on assembly table.

• IRB2600: Robot 6 – Picking columns from regrip station, applying silicon bead to columns, placing on assembly table.

A unique element in the design of the system is the inclusion of the buffer cell robot which utilises all of its working envelope and physical range to enable maximum storage for the doors.

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• Wide power range 25W to 500W • Universal AC input voltage 85-264 VAC • Voltage tolerance +/- 1% • Adjustable output voltage +/- 10% • High efficiency & reliability • International safety approvals

DIMENSIONS (L x W x H) (MM)

LIST PRICE

98 x 97 x 35

$28.77*

159 x 97 x 38

$38.37*

199 x 98 x 38

$44.77*

215 x 115 x 50

$71.20*

• Safety standards (EN60950-1) • EMC standards (EN55022 Class B) • Low cost solution • Local stock • Local engineering and sales support • 2 year warranty

* Price excludes GST and ONLY available to approved business and/or trade customers.

Bulk pricing available on request.

www.soanar.com RANGE - RELIABILITY - STANDARD - CUSTOM

info@soanar.com AU 1300 365 551 NZ 0508 765 956

AUGUST 2013 www.pacetoday.com.au 17

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BEHIND THE SCENES

• IRB4600: Robot 7 – Picking assembled door from assembly table, place into curing oven. Pick cured door from curing oven and place onto overhead conveyor.

All product conveyors, robot grippers, curing oven, regrip tables and assembly tables were designed and manufactured by Leviathan Design.

Gluing systems are German-made SCA Schucker supplied by Australian distributor H Technologies.

To transfer the doors 45m down the factory to a storage buffer cell, a conveyor was designed and manufactured using tabs to align the doors on a plastic top steel chain.

Westonsmith says this conveyor is 4.5m off the ground to provide access underneath for forklifts and cranes as well as pedestrian access.

“The longer reach IRB4600 can pick the doors from 900mm high in the bonding cell and place them onto the conveyor at 4.5m high. The robot sits A onDa _2m high enable PA C Estand P L to AM A R _this 1 2 . pHARMONY: df P a g The e 1automated 1 5 / 0production 2 / 1 2 , cell 1designed 1 : 2 9for : Electrolux 5 2 A Mis extremely A E D T compact with seven ABB robots all working together in the one cell. reach. “At the end of this conveyor,

It is critical that glass and trim is accurately aligned for assembly of the doors so glass and trim are placed on air tables to provide a frictionless surface.

18 www.pacetoday.com.au AUGUST 2013

a transfer unit lifts and transfers the doors into the buffer cell and rotates them through 90 degrees so that they are oriented for storage. The doors are then lifted by another IRB4600 and loaded into the buffer storage cell.

“At the same time, as doors are required for production, they are picked out of the storage cell by the same robot and loaded onto the out-feed conveyors. The doors are picked on a ‘first in, first out’ basis.”

According to Peter Bradbury, channel manager robotics at ABB Australia, the IRB4600 enables more compact manufacturing cells with increased production output due to its small footprint, slim swing base radius around axis 1, the fine elbow behind axis 3, small lower and upper arms, and the compact wrist.

“The IRB2600 robots are part of an ABB Multi-Move System which offers a number of cost cutting benefits including the ability to keep investment costs low by controlling up to four robots with the one controller. Savings flow on to reduced wiring costs because overall wiring of system controls is greatly simplified,” Bradbury said. Senior manufacturing engineer at Electrolux, Chris Henkens, says the strongly integrated one cell system developed by Leviathan Design

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BEHIND THE SCENES

“ ProTrac measures reliably – even under extreme conditions.”

New from VEGA: the radiation-based instrument series, ProTrac.

RADIUS: The IRB4600 enables more compact manufacturing cells with increased production output due to its small footprint. is ideal for operation in the limited floor space available.

“We were presented with a major challenge to meet the target cycle time of 14 seconds, but achieving that cycle time and combined with the new construction methods for the door outer assembly, our cost reduction targets have been realised,” Henkens said. “A unique element in the design of the system is the inclusion of the IRB4600 buffer cell robot. This robot utilises all of its working envelope and physical range to enable maximum storage for the doors.

“We are now in a much better

position to compete with imports from low cost countries, which has been a significant issue due largely to the high Australian dollar.”

ABB Australia 03 8577 7109 www.abb.com/robotics Electrolux Home Products 08 8401 8401 www.electrolux.com.au

ProTrac delivers reliable measurements for level, density, mass flow or point level.

Using four detector variants, ProTrac can solve the most difficult measuring problems – whether in extreme temperatures, high pressures or aggressive media. The system also provides additional security with integrated asset management. www.vega.com/au/innovation Phone: 1800 817 135

Leviathan Design 03 9544 6444 www.leviathandesign.com.au

AUGUST 2013 www.pacetoday.com.au 19

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NEW PRODUCTS

Calibrate gas analyser on-site

One cable display link CP-Link 4 is the new connection technology for operating panels located up to 100m away from the Industrial PC. The singlecable solution can be used to transfer video signals, USB 2.0 and the power supply in a standard CAT 7 cable, thus reducing cable and installation costs. A further benefit is the use of purely passive displays. The CP-Link 4 technology is supported by the new Beckhoff multi-touch panel series CP29xx0010 (built-in version) and CP39xx-0010 (mounting arm version). The new Beckhoff panel generation with industrial multi-touch display offers a wide range of display sizes and connection options. CP-Link 4 extends the product portfolio with simple, standardsbased connection technology. An advantage of this transmission technology is the use of commercial CAT 7 cables. They are easy to install and are also available as drag chain versions. The standard plug connectors are field-configurable. Alternatively, pre-assembled cables are available as accessories. The plugand-play connection makes commissioning very simple and convenient. CP-Link 4 requires no special software or drivers. The CP-Link 4 technology is directly integrated in the passive panels of the multi-touch series. On the PC side, the connection can be made either via the PCIe module slot in the Industrial PC or via the CU8802 or CU8803 transmitter boxes.

Beckhoff Automation 03 9912 5430 www.beckhoff.com.au

On-site calibrations of gas analysers may be performed with Michell Instruments’ Portable Calibration Rig (PCR).

The PCR is a mobile gas blender utilising premium mass flow controllers housed in a tough transport case that can be used for a huge variety of applications and analysers. It can mix two or three gases from: Air, Oxygen, Nitrogen, Carbon Dioxide, Methane and Hydrogen and is controllable so that the perfect blend can be achieved for the application. Provided the customer has zero or spans gas cylinders available – it is possible to ‘factory’ calibrate an analyser such as Michell’s XTP601. For example, an analyser range 0-10% O2 in N2 could be calibrated with synthetic air and N2. A field calibration of an analyser can be carried out in under 1 hour including set up time. For a complete factory calibration, with multiple calibration points (to change the range/background/both), can be done in four hours. These time-scales represent a minimal downtime compared to the alternative of sending the instrument away for calibration.

Although the unit is designed for field calibrations, it can also be used in a laboratory to mimic changing process gases for research work.

AMS Instrumentation & Calibration 03 9017 8225 www.ams-ic.com.au

Pressure switch reports its own health United Electric Controls has added a differential pressure model to the One Series electronic switch family.

The Differential Pressure Electronic Switch continuously monitors and communicates its own health status. This feature provides piece of mind in critical applications and helps to increase process uptime. The “I Am Working” and “I Have Switched” signals are communicated both locally and remotely. The local digital display and programmability make the One Series simple to install, set up and test. The switch will replace airflow indicators, limit switches, and transmitters combined, on a single process connection. Designed to monitor dry air as well as non-corrosive gases, HVAC as well as fluid density, flow measurement, and fan control.

Pryde Measurement 1800 688 211 www.pryde.com.au

Functional surge logger Weidmuller has released its Varitector Logger 30 to register and document large current pulses as well as the frequency and time of the incidents. The plug and play Varitector Logger 30 counts the current pulses greater than a set threshold value which are discharged by PE conductors on surge protection devices. Any lightning strikes and surge voltages are continuously recorded. Each measurement is issued with a time stamp accurate to the hour and both the time and date of their occurrence are recorded. Using this information, engineers can design appropriate systems as well as tweak existing ones to ensure they are continuously functioning at optimal levels and protected against surges. Maintenance staff can verify installed units and forward plan routine maintenance tasks.

Weidmuller 02 9671 9999 www.weidmuller.com.au

Rugged power supplies for direct mounting A large amount of expensive cabling with large cross sections is required if the field device and the control cabinet for the plant are large distances apart. The use of power supply units with IP67 protection is particularly suitable here, since they provide a 24V power supply directly in the field without any voltage drop. Due to their degree of protection to IP67, the new PSU67 power supply units can also be fitted directly to the machine without any protective measures. The power supply units offer a high level of failsafe performance, due to their no-load and short20 www.pacetoday.com.au AUGUST 2013

circuit protection as well as passive air cooling. The devices also automatically bridge voltage dips of up to 50 ms. They feature a voltage output with a 4-pin 7/8-inch connector. LEDs indicate the actual operating state to the user. TURCK is offering the PSU67 series switched-mode power supply units in four variants: A 2 A, 4 A and an 8 A variant, each with one output, and a variant with two 4 A outputs.

TURCK Australia 1300 132566 www.turck.com.au

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Our safety experts talk safety.

Our operators talk control. But when it comes to keeping our people and plant safe, we all need to speak the same language.

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BEHIND THE SCENES

Train unloaders boost exports Fortescue Metals Group recently upgraded its bulk material handling facilities at Port Hedland that will help the company meet its target export capacity of 155 mtpa.

F

ROM humble beginnings in 2003 Fortescue has grown into the world’s fourthlargest iron ore producer. Its first mining operations started at the Cloudbreak mine in August 2007 with the construction of all mine, rail and port infrastructure reaching completion in 2008.

A critical part of the port infrastructure was the company’s train unloader, which was put into operation in April 2008 when Fortescue unloaded its first train at the Herb Elliott Port, near Port Hedland in North Western Australia.

Since then, the company has fast-tracked its growth by steadily increasing production from its UNLOADER: The tipplers are located in an enclosure which is part of a Cloudbreak mine and then bringing pressurisation and dust extraction system. the Christmas Creek mine on-line in 2009. Recalling that time, Fortescue’s General Manager - Port, Gerhard anyone in the Pilbara is able to unload production to 155mtpa. The US$9 Veldsman said, “At that stage, at that rate. The problem was that billion project not only includes an the mines were running at about we had more mining capacity and expansion of mining operations at 70-75mtpa; car dumper one was shipping capacity than dumping the Chichester Hub and a greenfield running really well, matching the capacity,” he said. development at Solomon but an capacity of our mines.

In 2010, Fortescue approved expansion of the company’s port, PA0 8 1 3 _ 0 0 0 _ PRY 1 2 0 1 3 - 0 7 - 1 9 T1 0 : 5 2 : 5 4 + 1 0 : 0 0 “Even now, I don’t think that an ambitious expansion to triple train unloading capacity and main

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rail network as well as a new line to Solomon. Over the last few years Fortescue Port Shutdowns Supervisor, Brad Stillman has been involved in all aspects of the company’s first train unloader’s maintenance. This has ranged from basic weekly inspections to major change outs. During that time, he has worked closely with Metso’s Service team on the procurement of spare parts, equipment enhancements and services.

For Stillman, TU601 is truly at home in the harsh conditions of the Pilbara due to its sturdy construction and reliability. “We’re not in a pharmaceutical lab – it’s a really rugged environment out here. But even so, the unloader is like a Swiss watch – everything just works. That’s why it’s my favourite piece of the plant. It is a big, heavy, powerful piece of gear that needs to be treated with respect,” he said.

Additional orders

On the back of the reliable performance of their first Metso twin cell, tandem train unloader

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22 www.pacetoday.com.au AUGUST 2013

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BEHIND THE SCENES

HANDLING: Trains arriving from the mine sites are moved through one of the unloaders. commissioned in 2008, Fortescue awarded Metso Mining and Construction a contract to supply two more identical systems.

The first of the two new unloaders (TU602) was commissioned ahead of schedule in mid-September and the second (TU603) in November 2012.

Veldsman P A 0 8 1says 3 _it0was 0 0crucial _ C Othat N TU602 was delivered on or ahead of

schedule and that the ramp up had train unloader resulted in Fortescue to go well, because the business was being able to dump 580,000 tonnes experiencing a “real bottleneck” when of unbudgeted ore in September, it came to unloading trains. said Veldsman. “At $100 a tonne, “It was delivered two weeks early, that’s $58 million in extra revenue which was fantastic. The original that we hadn’t counted on. So the ramp-up schedule was meant to be early delivery helped cover our capital eight weeks, but we shortened that to investment!” he said. he1said.

1six and 2 0 we 1 3did - it 0 in 7 -four,” 1 2 T 0 : 2 8 : 5 6 According + 1 0 : 0 to 0 Operational Readiness The early delivery of the second and Commissioning Manager, Mark Shirley, the company is clearly benefitting from the additional capacity of TU602. Even though it is not yet needed for full time use, TU603 is already playing an important role. As well as catering for future expansion of the company’s production capacity, TU603 provides overall system redundancy in case of any problems occurring with the other unloaders. “Train unloader two is hugely important to the business, taking us to between 110 and 115 million tonnes capacity. TU603 is also one of the critical parts in our supply chain; if you’ve only got two train unloaders and you lose one, you’ve lost 50% of your capability,” said Shirley.

Veldsman agrees, adding that the installation of the two new train unloaders represents a significant part of the company’s move to expand their Herb Elliott Port facility.

From mine to port

Fortescue’s railway is the heaviest haul line in the world, with a 40 tonne axle load capacity. The company’s rail infrastructure operates 24 hoursa-day, seven days-a-week. Each train is around 2.7 km long and carries up to 32,800 tonnes of iron ore in 240 freight cars.

Trains arriving from the mine sites are moved through one of the 24 www.pacetoday.com.au AUGUST 2013

unloaders. During unloading, two wagons are simultaneously unloaded every 90 seconds. The unloader clamps and then inverts the wagons, rotating them through 150 degrees. This is done without uncoupling the wagons as each pair of wagons has a swivel coupling at either end.

Prior to each operation, the wheels of the train are locked in place to prevent the train moving during the rotation cycle. The contents of the wagons are dumped into a chute that feeds an apron feeder which transports the ore onto a conveyor feeding one of the facility’s stackers. The stackers create the port’s stock piles which are later consumed by reclaimers that feed the company’s ship loaders.

Unloader composition

Each unloader consists of three main parts; the indexer, the tippler and the train holding devices. The indexer is a rail-mounted vehicle which is dedicated to advancing the train through the unloader, two wagons at a time. This heavy-duty work-horse moves back and forth along a short, straight rail track, located at the entry to the unloader.

It is moved by 13 vertically-mounted drive units, each powered by a 90kW, three-phase motor that turns a pinion via a gearbox. These pinions engage in the indexer’s rack which is mounted down the middle of the rail section along which the indexer moves. Each pinion is around 400mm in diameter and over 200mm in height. The indexer also incorporates a retractable hydraulic arm that is inserted between the wagons. The arm pushes the train along by two wagons for each cycle, and is retracted at the end of the indexer’s forward travel.

Photoelectric laser sensors are used to locate the gap between wagons, allowing the indexer arm to be precisely positioned before it is extended. The position of the indexer is monitored by a rotary encoder as well as inductive proximity travel limit sensors. This is backed-up by mechanical over travel limit switches which trigger an indexer ‘fast stop’ in case the travel limit sensors fail. The indexer’s drive motors are controlled by variable speed drives that deliver an amazing combined power of 1.1MW to move the train.

The tippler or freight car tipping

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BEHIND THE SCENES

and emptying device is a rotary machine which is made up of two unloading cells. Each cell comprises the main cell structure, a drive unit and support roller assemblies, as well as a braking and lubrication system.

The tipplers are located in an enclosure which is part of a pressurisation and dust extraction system. Each cell is equipped with train rail sections and on-board hydraulic clamps that hold the wagon in place as the cell rotates during the unloading cycle.

the system’s PLC. Both drive units comprise a three-phase 200kW electric motor which drives a pinion in either direction via a gearbox. The pinions act on geared drive racks that are mounted on the outer diameter of the cell end rings.

The motors are controlled via variable-voltage variable-frequency (VVVF) drive units that incorporate closed-loop speed control, ensuring smooth and efficient operation.

Finally, each cell drive has a disc brake with two pairs of brake callipers.

Each calliper has a dedicated hydraulic power pack to operate it independently of the other, providing redundancy in case of brake failure.

Three positions

The clamping system consists of four hooked arms that have three positions: fully raised to allow a locomotive to pass; intermediate position allowing wagons to pass; and engaged position where the wagons are held. The intermediate position is the normal retracted position during unloading, allowing a gap of just 20mm between an ore car and the bottom of the clamp, P A greatly 0 8 1 3reducing _ 0 0 0engagement/ _ CHE retraction time compared to the fully-

SIGNIFICANT: The commissioning of TU602 was a major milestone for Fortescue as it continues its expansion to 155mtpa. raised position, thus allowing for of both cells are connected together optimal unloading times. via a cardan shaft to make sure that Each tippler cell has its own drive they are perfectly co-ordinated. The 1 unit 2 to 0 1rotate 3 - it.

0 7When - 2 5the T train 1 2 : 2 2 : 3 position 0 + 1 0 of : each 0 0 cell is also monitored unloader is tipping, the drive units by its own encoder and fed back to

Plenty of flexibility

Hydraulically-powered train holding devices are located at both the inbound and outbound sections of the unloader.

Four sets of wheel locks are located before the tippler entry and six sets of wheel grippers are located after the tippler exit to prevent movement of

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the two ore cars being unloaded. Each set of holding devices is powered by its own hydraulic power pack.

According to Fortescue’s Shirley, the system provides lots of flexibility, along with failsafe measures to protect staff as well as guarding against downtime and production loss.

“It’s certainly very easy to utilise the redundancy that’s provided by the new train unloaders by simply switching from one to another.

“Each train unloader is able to link with at least two stackers, providing operational flexibility. This is one advantage of having the three up and running,” he said.

“What we want to do is keep train unloader three in a ready state so that within 24 hours we can fire up and run it if we need to. So certainly the arrangement that we have provides a lot of flexibility.”

Safety is a top priority for Fortescue, and the team has worked with Metso to ensure maintenance personnel are kept out of harm’s way.

“Our scheduled shut-down happens every 12 weeks where we’ll go in and do work, which is mainly driven around the conveyor belt maintenance and chutes,” said Shirley.

“We have trialled a new idea with TU602 and 3 where we’ve located the hydraulic power units off-board – on TU601 they’re actually on the tippler cell itself which creates a few maintenance issues. So we’ve taken the power packs off the tipplers and we’ve just got hoses running to them now.

“This means the maintenance technicians no longer have to go on the tippler itself, meaning a couple of the major hazards we had identified in our business are completely removed. With safety our number-one priority, the associated safety benefits are significant.”

System automation

Co-ordinating the three parts of the train unloader with their myriad of sensors, motors and hydraulics has been accomplished through the use of a GE Fanuc RX3i PLC. The motor starters, VVVF equipment and associated I/O are located in the switch room. The field I/O located around the plant is connected back to the PLC by

The problem was that we had more mining capacity and shipping capacity than dumping capacity.

Profibus fibre optic cables. A GE Fanuc Cimplicity SCADA terminal in the unloader’s control room provides SCADA displays of plant status.

While the automation of each train unloader is rather complex and is managed by a standalone system, each

NORD Drivesystems (AU) Pty Ltd 18 Stoney Way, Derrimut, Victoria, 3030 Australia Phone: +61 3 9394 0500, Fax: +61 3 9394 1525, www.nord.com.au Melbourne / Sydney / Brisbane National Customer Service 1300 00 NORD (6673) au-sales@nord.com Member of the NORD DRIVESYSTEMS Group

DRIVESYSTEMS FLIPPED: The contents of the wagons are dumped into a chute that feeds an apron feeder.

26 www.pacetoday.com.au AUGUST 2013 AU_Process and Control_030413.indd 1

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BEHIND THE SCENES

CHECK OUT THE SERIES

LONG: Each train is around 2.7 km long and carries up to 32,800 tonnes of iron ore in 240 freight cars. train unloader also has to co-ordinate with the control of the other port equipment such as apron feeders, conveyors and stackers.

“Our process has to be highly automated because we run very lean structures. The more we can automate the better. We’re certainly on the bleeding edge of that technology. The automation platform is GE and it’s all Ethernet connected, so there’s massive capability there; we can set-up remote condition monitoring at these locations and have it all reporting to a central data centre,” said Shirley.

On-site, Fortescue employs a process control team resourced with a lead, process control engineers, and on-shift technicians. One operator and one electrician together run an entire train unloader asset, while the train circuit itself is controlled from an integrated operations centre in Perth.

Two operators are responsible for inload and outload duties at the operations centre in Perth; this includes managing the activities of the on-site operators, such as directing who attends issues as they arise on the circuit. “Two operators and two electrical technicians are on-site on a 24-hour basis.

Inspections

But essentially the system is all controlled out of Perth, so the role of our site staff is to do inspections and to provide rapid response if there is an issue. We can direct them very quickly

and they can attend to the issue and get it resolved in the shortest possible time,” said Shirley.

Fortescue Director Development Peter Meurs said the commissioning of TU602 was a major milestone for the company as it continues its expansion to 155 mtpa.

“The second train unloader takes our unloading capacity to 120mtpa, which gives us the capacity to reach a run rate of 115mtpa by the end of the March 2013 quarter, comprised of 95mtpa from the Chichester mines and 20mtpa from Firetail,” Meurs said.

“The third train unloader will give us inloading capacity well in excess of the 155mtpa we need for our current expansion project.”

Commenting on the successful deployment thus far, Metso Minerals Vice President of Capital Equipment, Max Wijasuriya, said: “We are delighted to play such a pivotal role in Fortescue Metals Group growth plans.”

“Not only do we supply our clients with a broad range of high quality capital equipment, we can also provide an extensive program of services post commissioning to ensure that our customers enjoy peak performance, as well as many years of trouble free service from their machines.”

Metso Minerals (Australia) 02 8825 1600 www.metso.com Fortescue Metals Group 08 6218 8888 www.fmgl.com.au

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SPOTLIGHT

5best of the

PACE showcase of the best engineering technology releases of the month.

ProfiTrace V2.8 released In partnership with PROCENTEC, I S Systems has released Version 2.8 of ProfiTrace. The salient feature of this latest ProfiTrace version is the introduction of an Overview tab. It contain a new 3-colour traffic light symbol, but also a network summary table to give the user an at a glance view of the health and status of the Profibus Network. Managers and junior technicians who may have limited Profibus skills or experience will thus get a better insight into the condition of the network without getting blurred with too many details. The colours of the traffic light are based on the bus statistics and signal quality. ProfiTrace experts will also find the traffic light useful and use it as a quick check-up during long term logging or commissioning. As with previous releases of ProfiTrace, this version is a free of charge download for registered ProfiTrace users. ProfiTrace is considered the beacon for Profibus commissioning, troubleshooting and maintenance.

AC/DC DIN rail switchmode power supplies

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The output power range of 30W, 45W, 60W, 75W, 120W, and 240W MA 0 8 1 3 _ 0 4 2 _ F E R 1 2 0 1 3 - 0 7 - 1 8 T1 5 : 1 6 : 0 9 + 1 0 : 0 0 I S Systems cover many applications and are 02 4964 8548 sales@issystems.com.au stocked in 12VDC, 24VDC and

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Email your product news to editor@pacetoday.com.au

Wear-free decentralised soft starter

PVDF submersible pressure transducer for harsh liquids The AST4530 PVDF / PTFE is a submersible pressure transducer offering a 0-30psi (0-2.07bar).

The submersible pressure sensor is designed for harsh and corrosive liquids level measurement where even stainless steel and titanium cannot survive. The level sensor is constructed using PVDF cable, cord grip, seal and housing as well as a PTFE diaphragm. All sensor materials are optimised for compatibility for long lifespan and stability. The PTFE diaphragm sensing pressure changes and the integrated ASIC electronics convert mechanical motion into an electronic output signal 1-5V, 4-20mA for long distance transmission or for low current consumption applications a ratio metric output 0.5-4.5V. The AST4530 submersible transducer from Bestech Australia offers liquid and gas compatibility. Compared to ultrasonic and radar level sensors, vapours neither foaming or reflections of the liquids will affect the AST4530 sensing element, therefore, errors and false readings are prevented as the sensor measures liquid pressure based on specific gravity.

These submersible transducers are vented to atmosphere through the cable for optimal accuracy. It features a standard 1” NPT male conduit connection, to be used in turbulent tank installations.

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NORD Drivesystems’ motor-mounted starter offers an extended performance range for the economic distributed implementation of soft start and reversing functions, for motors from 0.25 to 7.5 kW. The compact SK 135E integrates motor overload protection through PTC thermistor monitoring, mains and motor phase failure monitoring, I²t monitoring, and magnetising current monitoring.

The electronic, wear-free switching technology replaces motor circuit breakers, reversing contactors, and brake rectifiers, thus rendering entire control

cabinets unnecessary in large facilities. As PTC thermistor connection cables and brake control cables are not required either, installation becomes generally more cost-effective, space-saving, and faster. When the drives are ordered complete and wired with gearbox, motor, and starter, any assembly effort is reduced to tightening the screws and establishing the electrical connection, which is optionally with plugs.

NORD Drivesystems 03 9394 0500 www.nord.com.au

Linear adjust mechanical vibration switch

IMI Sensors has released a mechanical vibration switch, model 685A09, which features a unique design that claims better sensitivity adjustment compared with traditional designs. This linear adjust mechanical vibration switch is targeted at applications such as cooling towers, fin fans, large exhaust and vent fans, HVAC systems, blowers and motors. The switch’s design claims better trip sensitivity adjustment than traditional designs and allows a user to better control the trip level in the switch and improve protection of their equipment. Due to the design and manufacturing processes to build the switch, it claims to be cost competitive compared with existing mechanical vibration switches on the market. The benefits of this switch includes low cost protection for critical machinery, better 2 0 1 3 - 0 7 - 1 8 T1 5 : 1 6 : 4 6 + 1 0 : 0 0 Bestech Australia sensitivity repeatability on reset, DPDT relay, 10 amp dry contacts and 120, 240 VAC or 24 VDC options.

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AUGUST 2013 www.pacetoday.com.au 29

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CONNECTIONS

5

minutes with...

In the mid 90s I developed an energy dashboard.

Garry Mahoney, Honeywell Process Solutions How did you come to be in this industry?

I began my career in the minerals processing and smelting industries in the early 70s. I have always been in some form of process engineering, primarily in instrumentation and process automation. The majority of my industry experience has been with Honeywell, being in my 33rd year, though I did work for BHP Billiton for over four years prior to Honeywell.

to be process centric rather than people centric in its approach to data capture and presentation. Today, the majority of a person’s time needs to be spent making decisions on quality data, not sourcing and compiling that data. Additionally there is a need for a more concerted effort to encourage a new generation of engineers to pursue careers in the industry, through formal education and training programs.

What do you see are the biggest opportunities for our industry?

The impact of the imminent retirement of the baby boomer generation has been widely discussed. How we can effectively capture the knowledge and skills of these people before they leave the industry?

There are two options for industry.

The first is the development of more intuitive knowledge capture technologies and solutions, which enable an operation

What’s the best business idea you have that you will never use?

In the mid 90s I developed an energy dashboard to measure and report real time energy cost aligned to production quality. A great idea at the time, but it never took off; back then energy cost wasn’t a consideration in the overall cost of production.

What’s the greatest challenge in your job?

As a business, our challenge is ensuring that

we continue to provide solutions that meet the evolving needs of our customers. Today, it’s about being smarter with the way we tailor technology for industry. We recently developed a solution for conveyor belt condition monitoring that took advantage of industry leading technology from our pulp and paper portfolio. Our strong R&D presence in Australia means that with smart thinking, we can remain at the cutting edge of solutions development to meet our customer’s business objectives.

If you could be anything else, what would it be and why?

To be honest, there really isn’t anything else I would want to be doing. This is an incredibly exciting time for the industry and I look forward to what’s next on the horizon.

[Garry Mahoney is Pacific Director, Honeywell Process Solutions.] www.honeywellprocess.com

IICA CORNER

Institute commits to significant change The IICA should raise its profile as well as that of the industry, writes Julie Meynell.

THE IICA Federal Committee was pleased to accept the comprehensive report and feedback presentation from the Focus Group Initiative which was conducted in April and May of this year.

John Immelman, BizBrand Solutions, presented this report at the Federal In-Person Meeting held on the 24 and 25 May in Melbourne.

We believe the instrument, control and automation industry fills a void in the process, engineering, automation and manufacturing environment and that the IICA is the custodian of that industry.

The question is: Are we realistically meeting the expectations of the industry?

Twelve Focus Group meetings were held in Sydney, Adelaide, Melbourne, Brisbane, Gladstone and Perth. Around 120 members and/or industry-related 30 www.pacetoday.com.au AUGUST 2013

associates committed to attending the Focus Group events from roughly 250 people who were contacted. This exercise proved to be an excellent marketing opportunity to illustrate to our members that we are concerned about their interests and to make connections with industry-related companies and individuals that were not aware of the IICA. The events were segmented into categories depending on the membership types of the Branch where the event was to be held. For instance, Vendor, Engineering and End-User category meetings were held in Sydney and Melbourne, while only End User and Engineering category meetings were held in Perth and Brisbane – indicative of the focus of the industries in those regions.

Adelaide and Gladstone were

combined categories due to the nature of their local Branch support. This need for ‘grouping’ is an indication of the vastly different requirements of each of our companies and individual members. Our Branches should concentrate on their local area’s particular interests.

The Focus Group presentation covering our Institute’s current membership was studied in great detail.

While our membership remains healthy, numbers have remained static. There are many companies and individuals that we are not necessarily reaching. We estimate that our membership is only 5 percent of the industry we represent.

Recently we have focused on upgrading our Individual members to Corporate level and, while this has been successful, it was identified that we need

new members from the industries that our Institute represents. To achieve this we need to offer greater addedvalue and additional services. From the 631 feedback comments documented throughout the Focus Group events, one recurring topic was deemed imperative to the IICA’s future: our Institute should raise the profile and image of both our industry – and even more vitally, ourselves. The IICA Federal Committee agreed that there is no single magic bullet, and all have committed to significant change for our Institute and take the feedback from this report to a dedicated Strategic Planning Workshop to deliberate the way forward.

[Julie Meynell is IICA Sydney Branch Secretary.] nsw@iica.org.au www.iica.org.au

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