PACE - Process & Control Engineering - August 2014

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AUGUST 2014 | VOL.67 NO.7

INSIDE PACE

Operations

Motors

Control

Peak Gold Mine cuts costs and boosts efficiencies with APC

Integrally-geared centrifugal compressors compared to other options

Effectively manage the pneumatic control specification process

Mining Automation

Post Print Approved PP100008186

IT and operational technologies converge

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CONTENTS

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

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Graphic Designer: Dave Ashley Email: david.ashley@cirrusmedia.com.au Production Co-ordinator: Tracy Engle Tel: (02) 8484 0707 Fax: (02) 8484 0722 Email: tracy.engle@cirrusmedia.com.au

12 News 6

SUBSCRIPTION: $99 pa incl GST OVERSEAS SUBSCRIPTIONS: NZ: $A109 pa & OS: $A119 pa CUSTOMER SERVICE: 1300 360 126

Industry roundup Fieldbus Foundation joins HART; Sydney company’s graphene solutions; Engineering student teaching others a lesson; MES and productivity Insight 10

Energy management Harvesting technologies make it easier to maintain wireless devices Application Update 12

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, 2014 OFFICIAL MAGAZINE OF:

Materials handling Next generation minerals handling technology lifts failing coal and ore chute systems out of the past Technology Management 15

Advanced Process Control Peak Gold Mine was challenged to deliver an APC solution that increased production and improved environmental efficiencies Cover Story 19

Mining automation Mining is currently seeing the start of what

will be the great convergence of IT and operational technologies Engineering 22

Compressor selection Integrally-geared centrifugal compressors provide the nearest possible operation to isotherm compression compared to many other options Case Study 26

Motors & Drives By choosing integrated and flexible motors and drives from a single supplier Contech’s design team had the best of both worlds Insight 30

Safety An innovative measurement system determines the filling level in the oil tank together with a GSM modem to transmit the filling levels Viewpoint 34

Pneumatics How to effectively manage the pneumatic control specification process

ON THE COVER PA0 8 1 4 _ 0 0 1

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Making the new mining factory

AUGUST 2014 | VOL.67 NO.7

INSIDE PACE

Operations Peak Gold Mine cuts costs and boosts efficiencies with APC

Motors

Control

Integrally-geared centrifugal compressors compared to other options

Effectively manage the pneumatic control specification process

Mining Automation

Post Print Approved PP100008186

IT and operational technologies converge

Average Net Distribution Period ending Mar ’14 5,709

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THE global resources industry is a constantly evolving beast, and it is now entering a new age of development. Mining is currently seeing the start of what will be the great convergence of IT and operational technologies.

Many pundits have touted it as the foundation for the industry’s next technological step change, which will be focused on an effort to facilitate productivity gains and reverse much of the loss in productivity the mining industry - particularly in Australia - has seen over the run of the boom.

The mining industry’s productivity has dropped over the last ten years with a 9.8 percent dip in productivity from 2001 through to 2011.

(See page 19.)

AUGUST 2014 www.pacetoday.com.au 3

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COMMENT

EDITOR’S MESSAGE

WHAT’S ON

Education starts in school

Synergy 2014 26-28 August 2014, Surfers Paradise www.schneider-electric.com.au Human Factors in Health and Safety: Organisational Issues 3, 4 September 2014, Brisbane www.icheme.org/humanfactors Chemeca 2014 28 Sep-1 Oct 2014, Perth austcourses@icheme.org

Kevin Gomez Editor

HAZOP Study for Team Leaders and Team Members 21-23 October 2014, Perth www.icheme.org/hazopperth

For daily updates visit www.pacetoday.com.au

Next Issue

• Water & Wastewater • HMIs & Rugged Systems • Sensors & Analysers • Process Control in Building Automation

WE have long bemoaned the lack of skills in Australia. The government’s push for the unemployed to apply for 40 jobs each month has come in for some criticism. It is indeed ironic as there are industries which simply cannot get enough skilled resources.

It is time to look past band-aid solutions and address the root cause of the problem.

STEM. Australia simply does not see the need to encourage enough of our young people to take up science and mathematics. The US and UK have realised the problem and are taking aggressive steps to confront this issue.

In fact, the UK has implemented an innovative campaign to increase the number of boys and girls taking A-level physics by 50 percent in three years. That’s not an easy task, by any means. It’s interesting to note that one of the key objectives of the UK programme, called Your Life, is to see more women in the engineering profession.

It is time for our industry associations and companies to step up, lobby the government and spread the word. We need a national programme to take engineering to every school and especially engage those in the 11 to 14 year age group.

That’s when many children start thinking about career choices and subject selection.

Educators, government and industry can play a part in conveying the message that physics and maths skils are key drivers in the global economy with brighter job prospects.

Right now, our pipeline of tomorrow’s engineers is running low.

We are interested to hear your opinion. Email us, follow us on twitter and sound off on Facebook. kevin.gomez@cirrusmedia.com.au

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

ANALYSIS

Gas prices adversely affecting Australian industry IN alliance with five industry gap. While we have known that prices associations, the Plastics and Chemicals have been rising, it has not been clear Industries Association (PACIA) has what this will mean for our industry and released the first comprehensive analysis the broader manufacturing sector,” said into the impact on industry of the PACIA CEO, Samantha Read. unprecedented changes in Australia’s gas The report brings to light market. major impacts on the Australian The report is an independent manufacturing sector from LNG export study undertaken by Deloitte Access growth. It forecasts a loss of national Economics. It reveals the implications manufacturing output of approximately of forecast Australian domestic gas price $118 billion by 2021 in net present increases and supply tightness, and the value terms. severe side effects on the Australian Job losses for the same period are P 1 -e 0 4 - 0 AA D0 _ 4 P1 A4 C_ E0 M0 E0 T_ AM PE RT _ 2 1 2 -. p forecast df 2 0 Pto1 abe4 g 14,600.

2 7 0 T / 1 0 0 3 :/ 4 1 2 :, economy.

“This analysis fills a major evidence “The impact on the chemicals

and plastics industry is significant, with forecast losses of $13.7 billion in manufacturing output and 4,000 jobs by 2021. This would represent a devastating loss of highly skilled jobs,” said Read.

“The projected hit to revenue would be a serious blow to businesses already operating in very challenging business conditions.

“Many in the Australian chemistry industry are significantly trade-exposed with limited ability to pass on cost 3 7 5 + : 1 0 1 : 0 P0 M increases.

“Revenue loss limits investment for

future growth and employment. This is at a time when the Australian economy needs the strength and resilience that comes from diversification and improved competitiveness.

“There is no reason for Australia’s natural wealth to be spread so unevenly in the economy, given Australia’s abundant gas reserves.

“With smart reform and increased supply, Australia can support both strong energy exports and a thriving domestic manufacturing sector that adds value to its natural resources. www.pacia.org.au

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Call Wonderware Australia on 1300 138 825 or visit our website www.wonderware.com.au 4 www.pacetoday.com.au AUGUST 2014

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NEWS

RESEARCH

EDUCATION

Sydney company to provide graphene solutions NANOCARBON has closed a commercial patent licensing agreement with the University of Wollongong, with plans to develop industrial processes and products using graphene.

The company, established this year, will use a process developed at the Australian Research Council Centre of Excellence for Electromaterials, which has patents in Australia, Japan, USA and the EU. NanoCarbon announced plans today to Chris Gilbey is be producing CEO of Sydneybased NanoCarbon. graphene in Sydney in 2015.

Graphene was discovered only a decade ago and is an atom-thick layer removed from graphite. It is thought to offer exciting possibilities due to properties including being stronger than steel and more conductive of electricity than silver.

It plans to use graphene technology in applications to impact high barrier films, lithium ion batteries, and water purification.

“We believe that now is the time when the unique benefits delivered by graphene will start to be truly realised in products,” said Chris Gilbey, NanoCarbon’s CEO. “This patent represents the first major step for NanoCarbon in being able to develop proprietary technologies that will have global implications in advanced manufacturing.”

The CEO said he believed that NanoCarbon had begun negotiations with several global manufacturers on “high performance graphene-based composite materials”, and that his company had entered the global market for grapheme technologies early enough to be globally relevant.

NanoCarbon will initially source its material from the University of Wollongong. www.nanocarbon.com.au 6 www.pacetoday.com.au AUGUST 2014

Engineering student teaching others a lesson SEW Leng Puah, a former engineering student at the Challenger Institute of Technology has re-joined the Engineering program at the institute, this time as a teacher.

The Bull Creek-based Sew LengPuah had completed the Challenger Institute and Chevron Australia Women in Engineering program at Challenger’s Australian Centre for Energy and Process Training (ACEPT) in 2011. Having topped the course, the mother-of-two was presented with the 2011 Chevron Way Award in recognition of her outstanding achievements.

Sew Leng explains that completing the program gave her both the confidence and skills to consider teaching as a meaningful career pathway. After sharing her positive training experiences with the ACEPT program manager, she was encouraged to apply for a teaching position at the centre. Sew Leng is currently taking classes in process plant operations, technology and engineering.

About her experience as a teacher at ACEPT, Sew Leng says that she loves meeting students from different educational and cultural backgrounds, in addition to promoting engineering to women as a unique and rewarding pathway into the resources sector.

Sew Leng aspires to be involved in developing new training programs for ACEPT in partnership with industry based on the success of the Challenger-Chevron Women in Engineering

Sew Leng is currently taking classes in process plant operations, technology and engineering. model. She observes that the training experience at ACEPT is very relevant to the oil and gas industry because of the centre’s unique simulation and plant facilities, where students are exposed to real life work scenarios. challenger.wa.edu.au

COMMUNICATIONS

Fieldbus Foundation joins HART THE Boards of Directors of the Fieldbus Foundation and the HART Communication Foundation have approved unifying the two Foundations into a new industry organization. The combined power of both organizations will serve to protect the investments that end users in Process Automation have made in HART and FOUNDATION fieldbus communication technologies.

The mission of the combined organization will be to develop, manage, and promote global standards for integrating devices into automationsystem architectures, providing functional solutions for process automation suppliers and end users.

Suppliers will also profit from the increased efficiencies in resource utilisation, procedure consistency, and member service and support improvements.

The Fieldbus Foundation and HART Communication Foundation worked together to develop common

The new organization will eventually serve as the sole integration tool for HART and FOUNDATION fieldbus technologies. international standards, such as EDDL specifications and FDI technology.

Combining the organizations offers significant potential for harmonizing the procedures and efforts supporting the two protocols, as well as simplifying each technology’s implementation while better delivering their full benefits in plant operation and maintenance.

The FOUNDATION fieldbus and HART specifications will continue to exist individually, and to evolve into the

future. Each protocol will retain its own brand name, trademarks, patents, and copyrights. The new organization will continue development, support, and promotion of the two existing protocols, and will direct the development, incorporation, and implementation of new and overlapping technologies.

Thus, the new organization will eventually serve as the single source for FDI, the sole integration tool for HART and FOUNDATION fieldbus technologies. The name of the proposed organization is not yet finalised. The next step will be to complete the membership ballot by the end of summer 2014.

Following a successful membership vote, legal filings for the creation of a new not-for-profit entity will take place in September 2014. As a final step, it is expected that the new organization offices will be consolidated and located near Austin, Texas, in early 2015. www.hartcomm.org www.fieldbus.org

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NEWS ANALYSIS

MES

Enhanced visibility can increase efficiencies

BY ALAN JOHNSON “That’s the problem in terms of MOST Australian companies understand getting the most out of the experts that to remain competitive they need across their business, and getting the to continually raise the efficiency levels information they need in real time to of their production processes, however control the business better and faster. in many cases a lack of visibility is “If companies don’t have good preventing major improvements. control of that, it is not possible to Stewart Johnston, Enterprise get the most efficiency out of their Solutions Manager with Schneider production facilities,” he warned.

Electric, says that while people want to However Johnston says get more information from their plant manufacturers who have implemented floor, many of them are still using Excel a MES system are seeing 10 to 25% spreadsheets to run their operations. productivity improvements.

“This is a very common problem, “Unfortunately, many manufacturers with a lot of the production information still have an OEE (Overall Equipment not binary, not validated, and containing Effectiveness) of only 50 to 60 percent, many mistakes. Plus the information where best practice should be up around is not able to be shared across the the 85% mark.” enterprise,” Johnston told PACE. Johnston admits OEE has “Many companies have gone through traditionally been a lag indicator where the process of installing an ERP system, companies collect the data and do the so they have an enterprise wide view analysis and generate the results the of their not from day.

A D _financials, P A C Ebut AM SF E Ban_ 1 3 . p following df Pa ge 1 9 / 0 1 / 1 3 , operational perspective.

“But by providing this information

to the operators via a MES in real time they can see what their targets are, what they are trying to achieve, what is the maximum sustainable rate, and how to operate accordingly.

“With MES, if there is a problem on the production line, there is no delay in understanding what the problem is, so the operators can quickly manage that production line a lot faster and reduce the losses associated with the problem in a timely fashion,” Johnston said.

Johnston says MES offers manufacturers several important advantages including velocity, visibility and product variety.

“By velocity I mean speed to market.

Companies need visibility of their production information to have control.

“Today manufacturers are producing a lot more SKUs, often it’s the same product, 1 0 : 0 but 0 with A Mdifferent packaging.

So companies need the visibility to

generate the variety and velocity to be able to be competitive in the market.”

Johnston says the key to production efficiency is to push that visibility down to the operational guys, the guys who are actually running the plant, so they can see what is actually going on.

“In many instances, the operations of a company are like a black box. They know the amount of raw materials going in, because the ERP system will tell you that, and the number of products coming out, but not much else.

“We are working with a number of manufacturers to install an integrated solution so that they have visibility across all their operations.”

Johnston explained that Schneider has moved to third generation software for the company’s two MES products, Wonderware and Ampla, which are enterprise wide, object based and model driven.

“Both the MES products can provide

AUGUST 2014 www.pacetoday.com.au 7

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NEWS ANALYSIS

plant information to users at all levels within an organisation. By that I mean, enterprise wide like an ERP system, where companies have a solution that can sit across all their operations, and being object based they have the ability to template those objects, which can be a piece of equipment, or a number of pieces of equipment within a process stream, such as a packaging line.

“It’s all defined within an object, with those objects able to be reused for similar operations or plants, enabling companies to roll the system out much faster, and is model driven,” he said.

“We build a lot of our functionality around the workflow, the process, and we are seeing more and more companies moving down this path.”

Johnston says he is also seeing the workforce getting younger, saying that by 2020, it is estimated that 40% of the workforce will be Gen Y, with mobility very important.

“The transferring of expertise and knowledge across the enterprise will become even more important in terms of mobility and virtual environments.

“We are working closely with Microsoft and already have a number of apps out there, which will pop up on an iphone or ipad.”

Johnston says people working in operations are far more mobile these days, with many people working from home.

“With the latest MES systems, they can now see what the production performance is and be notified of any problems. We are also working on a cloud-based solution with software as a service,” Johnston said.

Johnston admits MES implementation can be time consuming and expensive, similar to an ERP system, but says there are many different ways it can be installed.

“We are finding that a lot of companies are quite happy to grow the system. By that I mean implement the modules they want to address their immediate pain points.”

Johnston says firstly companies need to be able to consolidate the information together in an object-based platform.

“That allows companies to connect to any data source, including PLCs, plant and equipment and engineering, control and management systems. It doesn’t matter what it is or where it might be.

“Our platform system becomes the bedrock to build the MES on 8 www.pacetoday.com.au AUGUST 2014

Companies that have implemented an MES system are seeing 10 to 20 percent productivity improvements. top of, because that will bring all the information, in context, to the user.

And we can use that to build our MES solution set.

“If OEE is a pain point for example, we can install our downtime delay accounting system, but if it’s inventory we can install our inventory management solution.”

Johnston says that by providing the operators with the production information in real time, and also capturing any underlying causes of any delays, they can do root cause analysis and continuous improvement, and fix any problems in a timely fashion.

“The system can be used to focus on all the different types of products being produced that day, which could be a dozen or more.

“It is very difficult to manage the production process if the operation guys don’t have the visibility to see what has

been planned or scheduled and then executing it.

“And when things go wrong, or something breaks down, or a shortfall of raw material, how are they expected to quickly adjust so they don’t lose production time, keep their OEE up, and maximise output,” Johnston said.

Despite the rising cost of energy, Johnston says there are many manufacturers who are not aware that software is available which can help reduce these costs.

“The immediate focus is on trying to get more out of their operations, with the cost of energy often a secondary requirement.

“However, we are finding the more mature operations, those with a stable operation and operating at their maximum sustainable rate, are now starting to look at how they can get more out of their assets by reducing

energy usage, which includes water, electricity and gas.

“This information is readily available from the shop floor. We can see in real time how much energy the production facilities are consuming, and can notify the operators if they are suddenly using more than normal.

“We can also do some smart things in managing and reducing that energy consumption with our supervisory systems.”

However, Johnston admits the low hanging fruit for most companies is improving their operational efficiency.

“But if they can get the benefits of lower energy costs at the same time, that’s a benefit as well.

“We look at it two ways. We look at the productivity being up and the energy consumption being down. Doing more with less,” Johnston concluded. www.schneider-electric.com.au

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OPINION

ENERGY

Increase device connectivity Harvesting technologies make it easier to maintain wireless devices, writes Inderpreet Shoker.

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ODAY’s industrial wireless networks are far more robust and reliable than ever before and sensor prices have gone down, while the capabilities have gone up.

While improvements such as these have encouraged many end users to deploy wider networking of previously “stranded” sensors and wireless devices, some remain reluctant to do so because they fear the maintenance and replacement costs associated with deploying large numbers of batterypowered devices.

In a plant with hundreds (or even thousands) of wireless devices, maintaining large numbers of batteries could certainly become a future pain point. However, energy-harvesting technologies are evolving to offer a possible solution.

Several suppliers have commercialised harvesting technologies in recent years to make it easier and less expensive for end users to maintain their industrial wireless devices and sensors.

harvesting captures energy from sources in the surrounding environment and stores it for use by wireless or electronic devices.

Energy harvesting devices convert various forms of energy (mechanical, thermal, light, electromechanical, etc.) to electrical energy to power devices for the installed lifetime of those devices.

A number of energy harvesting technologies are available at a commercial scale today. Energy harvesting can liberate devices and sensors from batteries and, in turn, from

Finite battery life

Solar photovoltaic

For manufacturing end users, the road to an Industrial Internet of Things starts at the connected device and sensor level. Advances in wireless and sensor technologies have made it possible to deploy more wireless sensor networks in the field. However, users have to be able to supply power to these devices.

Typically, this involves batteries.

While battery suppliers have significantly improved battery life, they still cannot last indefinitely.

Although some models claim a life of up to 10 years, in reality, several factors can reduce battery life in a plant environment. If a plant has hundreds and thousands of wireless devices, this means hundreds or even thousands of man-hours will eventually be required to replace these batteries.

Energy harvesting

Energy harvesting technologies offer a possible long-term solution. Energy 10 www.pacetoday.com.au AUGUST 2014

with battery storage, solar PV systems provide a common power solution for remote field locations without utility service.

Electromagnetic

Electromagnetic (or electrodynamic) energy harvesting uses the movement of a magnet across a wire coil to generate electric power. While the movement of the magnet can be induced by various means, vibration is turning out to be the most popular method.

The technology is now used in the

Energy harvesting captures energy from sources in the surrounding environment and stores it for use by wireless or electronic devices the associated reliability, replacement cost, transportation, safety, and disposal issues. Not only do devices using energy harvesting require less maintenance, they are often also easier to install.

Solar is currently the most popular and commonly harvested energy.

From powering calculators to satellites, photovoltaic power generation is used for numerous applications. The global push toward sustainable and renewable energy sources drives the widespread adoption of solar energy.

Impressively, Germany can now meet almost six percent of its electricity demands with solar PV energy.

Although solar is appropriate for many applications, it is not yet commercialised to directly power field devices and sensor networks in the industrial world. In an industrial plant, integrating photovoltaic module onto the device poses two big challenges.

One, it is almost impossible to guarantee that enough sunlight or ambient light will reach the device.

Second, embedding PV cells can reduce device ruggedness and reliability and increase size. However, when combined

building automation space to power wireless switches, sensors, and controls.

A number of products using electromagnetic energy harvesting are also available in the industrial sector.

Perpetuum, the technology spin-off from the University of Southampton, has commercialised electromagnetic harvesting in vibration-sensing applications.

Electromagnetic energy harvesters are usually referred to as vibration energy harvesters (VEHs), since these utilise vibrations from industrial equipment to wobble the magnet of the harvester and generate power.

These harvesters can power the wireless sensors networks for condition monitoring measuring process parameters.

Several leading process automation suppliers – including Emerson, Honeywell, and GE - have collaborated with Perpetuum to offer wireless condition monitoring and field devices with energy harvesting capabilities.

Thermal

The temperature gradient between two dissimilar conductors can be used to harvest energy. The temperature

difference causes a flow of charge carriers between the two conductors, which creates a small voltage difference that can be used to power certain devices.

Thermal energy harvesting has already been commercialised in the building and industrial sector.

ABB partnered with Micropelt, a German venture firm, to develop a wireless temperature transmitter with thermal energy harvesting.

The transmitter uses a microthermoelectric generator (micro-TEG) that harvests the temperature difference between process fluids and the ambient environment.

To supply enough power for the transmitter, the micro-TEG requires a minimum difference of about 30°C between the process and ambient temperatures, which is usually easily available in a process plant.

Piezoelectric

Piezoelectric energy harvesting is another technology that has gained a lot of popularity in recent times. Piezoelectric harvesters utilise material that converts mechanical stress to electric power.

Ceramic lead zirconate titanate, also known as PZT, is the most popular piezoelectric material currently used for energy harvesting applications. While earlier technology was only suitable for applications requiring very low power, ongoing research and improvements have addressed this limitation.

In industrial environments, piezoelectric energy harvesters could be used to harvest vibration energy from rotating machinery such as motors, fans, and pumps to power wireless sensors.

While in its infancy for industrial applications, ARC has started to see innovations in the space. Many startup firms, as well as industry giants such as Siemens, are exploring various applications of the piezoelectric energy harvesting technology.

[Inderpreet Shoker (IShoker@arcweb. com) is an Analyst at ARC Advisory Group.] www.arcweb.com

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Are you in Contact with your Future?

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SIMOCODE pro V You ask: How can faults in automated processes and costly plant downtimes be prevented? What is the best way to avoid faults in your system or detect pending errors at an early stage?

We answer: Smart motor management with SIMOCODE pro – a reliable partner since 1986 and now with the aid of an Internet browser you can access all diagnostic and service data relating to your motor feeders from anywhere via network connection and the web server. What’s more, it’s easily integrated into your automation solution using TIA Portal, an extremely user-friendly software providing one integrated engineering framework.

To find out how SIMOCODE pro can help your business switch on to the future, call 137 222 or email manufacturing.au@siemens.com

Answers for industry.

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BEHIND THE SCENES

Eliminating blocked chutes Next generation minerals handling technology lifts failing coal and ore chute systems out of the past.

A

NEW generation of coal and ore materials handling technology is being introduced to Australasian and international markets by a group that engineers chutes and complementary systems to permit faster conveyor belt speeds, greater throughputs, fewer breakdowns and enhanced safety.

The Chute Technology engineering group targets problems common to many coal and ore plants and loading systems by addressing them with a combination of three skill sets, including advanced engineering analysis of flow, followed by upscaleable 3D Discrete Element Method (DEM) design processes and finally custom

Chute Technology brings together three proven skill sets that are vital to solving typical mineral processing issues

manufacturing to individual plant needs.

The combined technologies – which are applicable to existing as well as new projects – are complemented by the practical experience of each of the three Principal Partners in Chute Technology, who have combined experience of more than 80 years in a wide variety

Blocked chutes pose a downtime and safety hazard. This spillage was the result of a design failure in a transfer chute. A loss of production, clean-up cost and material handling hazard resulted.

12 www.pacetoday.com.au AUGUST 2014

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BEHIND THE SCENES

of resource industries including coal, iron ore, alumina and limestone across A principal aim will be Australia, the USA, South America and to eliminate reliability South Africa. The technologies are also applicable to gold, nickel and other bulk problems and production minerals and ores. obstacles so as to bring Major benefits of the chute design technologies have already been handling systems up to demonstrated in service with a West their full potential Australian iron ore producer which increased production by several million tons, or 50 percent.

Stuck in the past Several Hunter Valley coal mines, “Existing chute designs have meanwhile, are also benefitting from less fundamentally been stuck in the past, wear and fewer breakdowns because of because few companies have seen the practical individualised designs produced need to take advantage of innovations by one of the partners in Chute now available with advancing technology Technology, long-established Hunter and knowledge. But under the impact Valley mining industry supplier T.W. of steeply rising 21st century volumes, Woods. existing designs are breaking down Chute Technology combines the incessantly – wearing out in weeks, local and international manufacturing sometimes – and always slowing up experience of T.W. Woods, represented production with downtime and repairs,”

by Director Tom Woods, with the says Woods. similarly broad engineering and “As Australian and international technology experience of Engineering producers set out to double and treble Consultant Dennis Pomfret of Dennis outputs, the underlying problems are Pomfret Engineering, and Design becoming starkly apparent through Engineer Gary Telford of McKajj breakdowns, downtime, problems with Services, which contributes extensive sticky material throughput, and spillage project management, engineering and creating cleanup and safety issues. drafting experience.

“Supervisors on sites or on loading “We believe Chute Technology facilities often are painfully aware that brings together a combination of skills they have got the problem, but these is unique in the marketplace, in that issues have become so prevalent that it brings three proven skill sets that they sometimes think of it as inevitable. are vital to solving typical mineral It’s not inevitable, just inefficient and processing issues,” says Woods. These a matter of rectifying the problem issues include reducing wear, removing with focused design and smarter bottlenecks caused by clogging, manufacturing,” said Woods, who has minimising damaging impacts on belts more than 30 years practical experience and optimising operational safety and efficiency and PA0 8 4 0 0 _ SYM 0 7 4 1 0 0 2 :5 0 1 by 2 1curbing 3 _ 0 breakdowns M -E T 1 R with Y 2 producing - 1 4 1 - 0 2better 0 -1 2 3coal - T 1chutes - :2that 1 5 T :1 1 8 Dennis : + 5 1 0 : Pomfret, 5 0 + 1 Gary 1 : 0Telford 0 and Tom Woods bring practical hands-on last longer. cleanups. experience as well as technological expertise to their designs.

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BEHIND THE SCENES

Design skills

Through their specialist company focused on the design, manufacture and optimisation of materials handling systems, Chute Technology’s partners aim to deliver benefits by applying rigorous design skills and practical knowhow gained by experience in mines, ports and industrial plants.

In addition to a proven capability to design new chutes, the new Chute Technology organisation will specialise also in the retrofit of existing plants.

“A principal aim will be to eliminate reliability problems and production obstacles so as to bring handling systems up to their full potential,” says Dennis Pomfret, who holds patents on proven materials handling technologies.

Value-adding services focussed on by Chute Technology include: • Increased tonnes per hour, more product delivered in a shorter time at lower OPEX • Reduced wear rates, reduced consumables, labour and downtime • Control of spillage, dust and clean-up, for a safer and safety compliant workplace • Debottlenecking of conveyor systems by applying new technology to upgrades “The three parties involved in Chute Technology have already worked together on transfer chutes and have identified an opportunity to combine resources to form a company that

Coal Prep Plant Transfer Chute DEM Modelling – introduction of sticky material. and FEA structural analysis for chute platework.

• McKajj Services – A multi-disciplined design and drawing office which has an associated field services group for project management and construction supervision.

• TW Woods Construction – Delivers transfer chutes fit for purpose and the versatility of the fabrication skills allows the designer scope to create the most appropriate chute geometry for the application without undue constraints imposed by manufacturing techniques.

The three parties involved in Chute Technology have already worked together on transfer chutes and have identified an opportunity to combine resources to form a company that focuses on transfer chutes focuses on transfer chutes. We are focusing our capabilities to provide a superior service, and product, that can be delivered to the customers by dedicated effort rather than a generalised engineering approach,” says Pomfret.

All companies are based in Newcastle and have an established business base.

Partner skills include: • Dennis Pomfret Engineering – Their driving philosophy is to combine field observations and theory to evolve new concepts. Designs are supported by the application of DEM (Discrete Element Method) modelling for transfer design 14 www.pacetoday.com.au AUGUST 2014

The company’s services include specialised shaping, fabrication and welding technology for metals including carbon steel, stainless steel and aluminium.

These services are used by organizations such as Delta Energy, Incitec Pivot, water and waste water authorities, Integra Coal, Laing O’Rourke, Glencore and surface and underground mining companies throughout Australia including iron ore producers in the Pilbara and coal companies in Queensland. www.twwoods.com.au

The aim is to bring production systems up to their full potential.

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BEHIND THE SCENES

Gold mine benefits from APC Peak Gold Mine was challenged to deliver an APC solution that not only increased production and cost savings but also improved environmental efficiencies.

M

INING companies around the world continue to face the challenge of increasing their productivity. Streamlining operations and optimising automation and control processes provides mining companies with a way to meet their production goals in the current global market.

New Gold’s Peak Gold Mine is a gold and copper underground mining operation located in the Cobar Gold Field of Central West New South Wales, Australia. The mine produces gold dore for sale at the Perth mint and copper which P A concentrate 0 8 1 4 _ 0 0 0 is _ sold D E to L markets in Asia.

The site comprises of five commercially active mines and a copperA standard off the shelf gold processing plant. Peak Gold Mines control system would are committed to investing in the latest technology with a key focus on not be enough to effectively safety, productivity and environmental improve throughput protection.

To optimise the Peak Gold mine and control for this processing plant to improve throughput processing plant rates and process control, Peak Gold called on Rockwell Automation and mineral processing solution provider, Manta Controls to increase productivity upgraded by the Rockwell Automation and cost savings while also improving Systems and Solutions Business team. environmental outcomes.

The 814kW winder at Peak is Prior to the work on the processing utilised to transport personnel and it was 1 plant, 2 0the 1 4drive - 0and 7 -control 1 0 T system 1 0 : of 2 9 : 3 materials 5 + 1 0 so : 0 0 important to ensure the winder at Peak Gold Mine was the safety and reliability of the winder.

According to Michael Graves, solutions consultant, Rockwell Automation, “We provided a tailored solution based on our proven mine winder safety, control and drive systems.

All phases of the engineered solution were completed by our Local Drive Systems Engineering and Production facility based in Lane Cove in New South Wales in association with Peak Gold.”

Latest safety standards

The winder upgrade ensures that the winder conforms to the latest safety standards and provides ease of maintenance by using common control and communication platforms. The next stage of the project was to optimise the

EtherNet/IP

AUGUST 2014 www.pacetoday.com.au 15 Delta industrial automation (122H x 210W).indd 1

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BEHIND THE SCENES

The Peak Gold Mine site comprises of five commercially active mines and a copper-gold processing plant.

Peak Gold processing plant to increase productivity of the mine.

SAG mills are a critical component in mineral processing operations; at the same time, they are a difficult process to control. There are a large number of variables involved in the process but the main objective is to maximise throughput. According to Vivian Beehan, Mill Manager at Peak Gold, “We set out to optimise the Peak Gold Mine processing plant to improve throughput rates and process control.”

Ore from the Peak, Perseverance and New Occidental ore bodies is crushed underground and hoisted to a surface stockpile and ultimately to the SAG mill feed conveyor. While ore from New Cobar and Chesney is hauled to Peak where it is fed into the SAG mill feed conveyor via a separate bin.

“A standard ‘off the shelf’ control system would not be enough to effectively improve throughput and control for this processing plant,” said Sean Smith, NSW state sales manager, Rockwell Automation.

16 www.pacetoday.com.au AUGUST 2014

The solution provided utilised the advanced control and programming capabilities of ControlLogix from Rockwell Automation integrated with the Manta Cube – the advanced control system from Manta Controls.

“The Manta Cube took more than 18 years to perfect but now provides a clever control system that can leverage the advanced process control functionality of the ControlLogix platform to take process control to the next level,” said John Karageorgos, managing director, Manta Controls.

As a result of the advanced control and process optimisation solution, Peak Gold was able to increase throughput by two percent which equates to an extra 18,000 tonnes per year, adding an extra 2000 ounces of gold per year.

“The life of our mill lining system has also been extended allowing us to push more tonnage through the mill.

We’ve been able to push our relines out so we’re now doing three a year instead of four which is also providing a significant cost saving.”

The Smart Diver as installed on-site at Peak Gold on the Tails Thickener.

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BEHIND THE SCENES

We went from using roughly around 1.8kg of cyanide per tonne to roughly 1.45kg per tonne in a period from the beginning of January 2013 to December 2013 considering that each tonne of cyanide costs about $4000. Additionally, as a result of cyanide reduction, recovery from the leach circuit has increased by an extra 1800 ounces of gold.”

Sustainable production

The SAG Cube graphic at Peak Gold.

Reducing cyanide consumption

Once the ore has been through the SAG-mill, gold and silver are recovered in a gravity circuit with Knelson concentrators, further concentrated in an intensive leach reactor, electrowon and sludge smelted in a gas-fired furnace to produce gold dore bars. A third method of gold and silver recovery is by cyanidation in a tank leach circuit. The resulting sludge is then smelted into gold dore bars.

To reduce costs and improve environmental outcomes, the control

around the cyanide system in the leaching circuit was optimised by incorporating Manta’s Cyanide Leach Cube into the ControlLogix control system.

This allowed for advanced process control of the leaching circuit and the amount of cyanide used was significantly reduced.

“We went from using roughly around 1.8kg of cyanide per tonne to roughly 1.45kg per tonne in a period from the beginning of January 2013 to December 2013,” said Beehan.

“That’s a significant cost saving

Gold, silver and copper from Peak are also recovered as a copper concentrate in a conventional flotation circuit.

The flotation concentrate is thickened, dewatered and stockpiled prior to being transported to the smelter.

The Manta Thickener Cube with a Smart Diver was implemented on the Tailings Thickener to improve the settling rates, rake torque, the underflow density and ultimately increase P A the 0 6efficiency 1 4 _ 0 of 0 the 0 _thickening CON process.

According to Beehan, “We’ve seen that our Tailings Thickener is better controlled and we are getting higher densities out of it. An additional bonus is that we used to spend a lot more time ‘babysitting’ or looking after the Tailings Thickener prior to installing the Thickener Cube with a Smart Diver but now we can dedicate that time to other tasks. We’ve also seen an increase in the density of our tailings system which helps us to meet our environmental commitment.”

“The project has been a huge success from a production, cost saving and environmental point of view and to top it off there was no significant downtime with very little interruption to 1processing,” 2 0 1 4 concluded - 0 5 - 1Beehan.

3 T1 5 : 0 9 : 5 5 + 1 0 : 0 0 www.rockwellautomation.com.au

The Cyanide Leach Cube graphics at Peak Gold showing all three Cube systems.

AUGUST 2014 www.pacetoday.com.au 17

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NEW PRODUCTS

Low Phase Noise RF reference The 96270A and 96040A Low Phase Noise RF reference sources simplify RF and microwave calibration systems by replacing many instruments and accessories in existing systems. Designed as user-friendly instruments for calibrating spectrum analysers, RF power sensors, and other devices, these reference sources replace multiple instruments used for the same task, cutting the cost of RF calibration systems by up to 50 percent. The 96270A and 96040A RF reference sources are designed specifically for RF calibration, and feature a calibrationoriented user interface for simple learning and use, as well as accurate signal delivery direct to the UUT

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input (up to 27 GHz in the 96270A). The integrated frequency counter (300 MHz in the 96270A; 50 MHz in the 96040A) and dual power meter readout in the 96270A eliminate the need for additional instruments.

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PROFIBUS-PA valve controller A new range of digital valve controllers from Fisher is designed to maintain performance and reliability in harsh environment applications. The Fisher FIELDVUE DVC6200p series digital valve controllers are recommended for applications in which accessibility, extreme temperatures (up to 120°C), extreme vibration or confined space make integral mounting difficult or impractical. For instance, pulp and paper and metal and mining industries have typically preferred to isolate valve mounted instruments from harsh environments. The remote mount version of the DVC6200p series features the valve position feedback 18 www.pacetoday.com.au AUGUST 2014

mounted on the control valve, while the remainder of the digital valve controller can be mounted over 300 feet away in a less severe or more accessible environment. The remote valve mounted feedback unit utilises the patented FIELDVUE linkageless, non-contact feedback technology where there is no physical contact between the valve stem and the instrument. With no linkage to wear, loosen, corrode or vibrate, the feedback unit can withstand a plant’s operating extremes.

Emerson Process Management 03 9721 0200 www.emersonprocess.com

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IN FOCUS

Making the mining factory Mining is currently seeing the start of what will be the great convergence of IT and operational technologies, writes Cole Latimer.

T

HE global resources industry is a constantly evolving beast, and it is now entering a new age of development. Mining is currently seeing the start of what will be the great convergence of IT and operational technologies.

Many pundits have touted it as the foundation for the industry’s next technological step change, which will be focused on an effort to facilitate productivity gains and reverse much of the loss in productivity the mining industry (particularly in Australia) has seen over the run of the boom.

A study by consultancy firm McKinsey showed that multi-factor productivity was growing up until 2005; but it dropped 0.7 percent per year until 2011, when the study was carried out.

A report by the Mineral Council of Australia also highlighted that the mining industry last delivered a productivity increase in 2003, but since then overall productivity in the minerals sector has fallen by 30 percent.

According to a recent report by Ernst & Young mining labour productivity has declined by about 50 per cent since 2001.

IBISWorld chairman Phil Ruthven explained that the mining boom, or more specifically a pricing boom, protected the industry from the worst of the productivity slumps, but stated that the sector “desperately needs transformation as it is one of the most inefficient industries right now”.

Ruthven explained that mining’s productivity has dropped over the last ten years, and seen “a 9.8 per cent dip in productivity from 2001 through to 2011”.

Tipping point

Late last year IBM, as part of its Smarter Planet initiative signalled that the industry is reaching the tipping point for productivity and must innovate.

“This right now is the tipping point, we believe, where the risk of inaction outweighs the risk of action,” Andrew Stevens, IBM Australia and New

There are opportunities to eliminate risks normally associated with certain mining activities

The merging of automation technology and computer hardware in to existing processes is increasing mobility on and off site in regards to information and operational control.

Zealand’s managing director, said.

The Reinventing Australian Enterprises for the Digital Economy report considered what the year 2025 might look like for those companies operating in a range of industries.

It found that the future relied on how well they adopted to new technology and used it to “deliver unique value to customers and citizens with the speed, efficiency and ubiquity they demand.”

Yet despite this slower productivity backdrop there are 26 projects under $500 million at the committed stage, with a combined value of $4.8 billion, 16 mining projects with a value of over $500 million and six projects with a value of over $2 billion, showing that miners are still pursuing growth regardless of productivity.

So how can the industry push through this productivity slump and make mining more efficient?

Flicking the swtich

It is a critical time for miners as the investment cycle switches from capital expenditure to capital efficiency.

“The size of the problem is too large

for conventional solutions to work,” Ernst & Young’s global mining and metals advisory leader Paul Mitchell said.

“Making productivity gains isn’t as simple as further cost reduction efforts. The length of the super-cycle and the pursuit of growth led to the subversive change to the organisational DNA of many mining companies.

Their M structures, M 0 4 1 4processes, _ 0 0 0 performance _ I ND measures and culture have all drifted to

favour growth over productivity,” he explained.

However real productivity gains will only come from whole-of-business end-to-end transformations.

A narrow focus on point solutions or continuous improvement won’t solve the problem and could even be counterproductive.

The NIEIR’s executive director, Dr Peter Brain, told Australian Mining “the major point about the mining sector is that it’s going to come under more difficult times as commodity prices decline and their profitability is going to come under threat,” he said.

“What the leaders will do is invest heavily in new technology to integrate the front, middle and back office; much more remote control from remote operations, and looking across the entire supply chain, integrating not just simply pit-to-port, but pit-to-customer.”

Rio Tinto has been a major implementation 1proponent 2 0 1 4of -this 0 3 - 1 3 T1 2 : 3 3 : 1 4 + 1 1 : 0 0 of technology throughout an entire

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AUGUST 2014 www.pacetoday.com.au 19

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IN FOCUS

operating chain, demonstrating it with the Mine of the Future remote operations centre in Perth.

Identify trends for greater productivity

According to Deloitte miners need to go beyond traditional cost cutting measures and re-evaluate their entire operational models, cost structures and company culture that became ingrained during the boom.

“Reducing costs over the long term requires mining companies to prepare for a hard campaign of changing the way they do work.

This, in turn, should spur them to look closely at their culture to determine if that needs changing too,” managing director of Venmyn Deloitte South Africa, Andy Clay, said.

The firm explained that implementing new technology including automation, using analytics and big data processes to identify trends for greater productivity, rationalising supply chains through six sigma processes, right sizing capital projects and transitioning to modular plants and projects are all strategies which can drive continuous improvements.

This merging of automation technology and computer hardware in to existing processes is increasing mobility on and off site in regards to information and operational control, and giving miners a sharper edge.

This is part of what has been touted as the fourth industrial revolution, which is gaining ground with forecasts of its complete implementation within the next decade.

The new industrial revolution

This next evolution of industry is essentially the computerisation and automation of many traditional industries such as mining and manufacturing.

GE’s notion of an industrial internet and what others have dubbed “The Internet of Things” (IoT) is about this wider convergence of IT and OT in the workplace, and life in general.

These, coupled with existing technology advances such as cloud computing, ‘Big Data’, 20 www.pacetoday.com.au AUGUST 2014

as well as machine-to-machine communications already being brought about on many mine sites globally, are making headway in the resources sector.

This convergence is allowing for technology and process improvements to support more automation and operations visibility in mining.

Superfast broadband will play a very important function in logistics, virtual operations (including robotics), ore grade use optimisation, and exploration analyses.

“This will become much more important as mineral prices pause and fall after the current cycle peaks in the 2020s, if not earlier,” Ruthven stated.

The proliferation of remote control centres (such as those developed by BHP, Rio Tinto, and Hancock Prospecting for its Roy Hill mine) will be seen, as well as increased levels of tele-remote operations on- and off-site.

“The ultimate success of these

anywhere if they so choose”.

Speaking previously to Schneider Electric’s solutions vice president for mining, minerals and metals (MMM) Diego Areces, he told PACE the industry is starting to prepare for this next great leap forward, which will be focused “less on the capital equipment itself and more on the technology progression side, seeing the full integration of Informational Technology and Operational Technology, more simple plug and play process, and most remarkably, augmented reality”.

The opportunity for developing mining, and in turn, productivity levels in Australia lies in optimisation which is supported by increased automation.

“It will be more pragmatic, as it moves to a more sustainable mining model and miners use sustainability as a yard stick to measure their operations,” Areces said.

In essence, developing a ‘mining factory’ that provides operators with clear, sustainable outcomes that

It is a critical time for miners as the investment cycle switches from capital expenditure to capital efficiency remote operations centres lies in their ability to control and automate processes on-site,” Ventyx’s John Jessop and ABB’s Eduardo Gallestey said.

boasts more integration, visibility and operational intelligence within their production chain.

This is being implemented both underground and on the surface.

Highly collaborative enterprise

Automated fleets

This requires a synergistic convergence of IT and OT systems across the mining value chain to create a unified, highly collaborative enterprise able to be controlled remotely, either in these remote operations centre or via tele-remote machinery on site.

“Teleworking will continue as a key trend, with possibly one in four people in the workforce working at least partially from home if not full time by the middle of the century,” Ruthven said.

“This would also address some of the major fly-in fly-out issues currently plaguing the industry, as skilled workers will be able to live

Fortescue recently signed an agreement with Caterpillar for automated fleets that are aimed at cutting fuel usage, increasing safety, and precise haulage across its Pilbara operations As part of the second phase of automation implementation, following the installation of the technology and vehicles at the Firetail mine, Fortescue will have the same system running at its 40 million tonne per annum Kings mine.

Eight ‘Command for Hauling’ Cat 793F CMD trucks have already been commissioned and started operations.

However while much focus has

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IN FOCUS

The ultimate success of these remote operations centres lies in their ability to control and automate processes on-site been on the surface, it is in underground operations that major strides forward have been made, particularly in the development of block caving operations which have utilised automated processes to essentially turn the system in to a rock factory.

Industry leaders will invest heavily in new technology to integrate the front, A survey conducted by Timetric middle and back office; much more remote control from remote operations. found the share of underground mines using autonomous vehicles is expected to performance by examining in real time increase from 32 per cent to 45 per cent “For instance, miners are unable processing data from several Rio Tinto in Australia over the next decade. to connect information on relative operations spread across the globe”.

“While there has been much press product pricing, data on feed material Known by some colloquially as ‘the focus on the use of autonomous vehicles and information from sales contracts, excellent centre for excellent excellence’, at surface mining in iron ore operations, because this information is stored in it will provide processing solutions and the real use of automation has been in disparate systems – often in a completely initiatives to mine sites in Mongolia at underground operations where LHD different department than the control Oyu Tolgoi, in the US at Kennecott, loaders have been operating since 1990,” room operators. and across Australia (at five different Trimetric lead analyst Cliff Smee said.

“With the convergence of these IT sites).

According to Ventyx’s John systems and the process control OT, A massive interactive screen will Jessop and ABB’s Eduardo Gallestey the APC can refine the set points to show and analyse technical data production line processes are another maximise returns for the current feed in real time, “allowing processing sector of the industry where progression material and product pricing based on improvements to be immediately has been made. information from the sales system driven introduced and operational performance “Take, for example, the optimisation by the global pricing index.” to be optimised,” the miner said. of dosing and flow rates,” Jessop and Processing Centre of Early trials have already led to Gallestey stated.

Excellence improvements such as adjusting the “While many miners already have Rio Tinto has taken major steps on flotation process for gold and copper Advanced Process Control (APC) this front, earlier this year unveiling its recovery at Oyu Tolgoi. solutions automating the management P A 0 and 8 1 flow 4 _ rates 0 0 0in _real-time, I C H E M - Processing 1 2 0Centre 1 4 - of0 Excellence.

7 - 2 5 T 1 5 : 2 6 : 0In7terms + 1 0of :vehicle 0 0 optimisation, of dosing Based in Brisbane, Rio says this “is a this has been advanced with systems most are unable to easily align this data world first, state-of-the-art facility that such as Caterpillar’s Minestar, Sandvik’s with the real time conditions out in the enhances monitoring and operational Automine, Komatsu’s automated market.

system, Atlas Copco’s Rig Control System and many others seeing increased take-up.

Miners now “know what they want from automation, which is good,” Atlas Copco’s blast hole technology project manager Tyler Berens said.

“They’ve obviously accepted the technology and they are ready to push forward and go autonomous where it makes sense to do so.

“I think it’s [automation technology] appealing to any stakeholder in the mining environment – whether that’s an operator, a safety officer, a mine manager, or even a mining investor.

“There are opportunities to eliminate risks normally associated with certain mining activities; there’s the prospect of better efficiencies and lower operating costs; and, on a broader scale, there’s the opportunity to build a greater quality of life for the workforce,” he stated.

Berens went on to state that “I don’t see the industry’s embrace of automation slowing down in the foreseeable future”.

“In fact, I think peoples’ concept of automation is certainly maturing greatly.

Just in the past year that I’ve been with the company I’ve seen it mature rapidly.”

Core enabling communication technologies combined with real-time input from sensors and logical devices will deliver connectivity and data from the heart of the operations.

The future of mining is bright, but that may be mostly from the backlight of a computer screen as it runs a site’s operation.

[Cole Latimer (cole.latimer@ cirrusmedia.com.au) is Managing Editor, Australian Mining, an associated publication of PACE.]

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AUGUST 2014 www.pacetoday.com.au 21

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IN FOCUS

Control of geared compressors Integrally-geared centrifugal compressors currently provide the nearest possible operation to isotherm compression compared to many other compression options, writes Amin Almasi.

A

N INTEGRALLY-geared centrifugal compressor is a multi-shaft compressor where each stage is a 3D impeller operated at its optimum speed; such a compressor consists of a gear unit with a central bull-gear and different gear pinions which drives many impeller stages (often up to ten 3D impellers).

Integrally-geared compressors with high discharge pressures up to 300 Barg and capacities up to 500,000 m3/h have been offered by different vendors. There have also been machines of combining compression stages and expansion turbine stages.

Such a machine might have one or several turbine stages which are used for enhance power supply. A medium- to high-temperature (or low-temperature) gas steam can be used for energy recover and such gas stream(s) can be employed to help drive the package.

Integrally-geared centrifugal compressors have provided many advantages such as advanced high-speed 3D impeller technologies, relatively low costs (compared to conventional compressors) and higher efficiencies compared to other turbo-machine types.

They can also offer nearly isotherm compression with an intercooler after one or two impellers (each stage or sometimes each two stages).

In other words, currently they can provide the nearest possible operation to isotherm compression compared to many other compression options, therefore a really high efficiency could be provided by them. The high efficiency is because all stages are intercooled (isotherm compression), and the speed increasing gear allows all stages to operate in a higher specific speed.

Another advantage of an integral geared compressor is the reduced number of stages required and higher efficiency. To determine the number of stages, process requirements, optimum efficiency and many other technical and commercial conditions should be respected. Many modern designs 22 www.pacetoday.com.au AUGUST 2014

The flow inside each 3D impeller is highly three-dimensional (3D) and complex. The flow depends on the interactions between various geometrical parameters and aerodynamics factors.

The flow conditions could be responsible for flow non-uniformity, large portion of energy losses, and sometimes system instability.

Inlet Guide Vane

An example of an integrally-geared compressor (Source: Siemens). allow rotor removal without having to disconnect the connected piping.

Operation

For integrally-geared centrifugal compressors like many other types of centrifugal compressors, the sectional head-capacity characteristic curve of each compressor section should rise continuously from the rated point to the predicted surge. The compressor, without the use of a bypass, should be suitable for continuous operation at any capacity at least 8 percent greater than the predicted surge capacity.

Thrust loads from impellers and gears should be absorbed by individual thrust bearings on pinions, or transmitted to the bull-gear thrust bearing by means of thrust rider rings fixed to the pinions and bull gear. All specified operating conditions and start-up conditions should be evaluated for residual thrust loads. Balance pistons are normally not used. Thrust balancing may be achieved by helix thrust force direction of the gearing and offsetting impeller aerodynamic thrust forces.

The bearing design and operation in an integrally-geared compressor needs

great attention. The speed is usually very high, often above 40,000 rpm for the final stages. Specially designed bearings are needed which should be tightly controlled in the manufacturing, installation and operation.

As a design criterion, bearing metal temperatures should not exceed 100°C at all specified operating conditions.

The oil inlet temperature range should be adjusted with great care. Often the minimum oil inlet temperature could be above 30°C, sometimes above 35°C. Most often the maximum oil inlet temperature could be 50°C. The geometry and the design of advanced 3D impellers have significant effects on the overall performance and operation of an integrally-geared centrifugal compressor because the flow development inside each 3D impeller not only determines the aerodynamic performance and efficiency of the 3D impeller itself, but it also strongly affects the performance, operation and efficiency of the downstream and upstream systems and piping such as IGV (inlet guide vanes), diffuser (volute), integrate facilities and complex piping systems of each stage.

Integrally-geared centrifugal compressors are constant-speed machines because complex dynamic situations (rotordynamics, lateral, torsional, etc) do not allow variable-speed operation of these machines. Inlet Guide Vane (IGV) is the selected control (and capacity control) method for many integrallygeared compressors.

IGVs usually consist of a row of aerodynamically-shaped blades placed at the inlet of impeller. The blades can rotate around their aerodynamic centre in order to give the suction flow a pre-swirl that provides an optimum incidence angle with the impeller’s leading edge even at reduced flows.

In an integrally-geared compressor, impellers should achieve high pressure ratios with good efficiency together with a (relatively) broad operating range. An important aspect is the suppression of surge so that the compressor can operate safely and efficiently at reduced flowrates. IGVs which generate a swirling flow in the direction of rotation of the impeller can enhance the underlying stability. In compressors with IGV, the surge usually commences at the peak of pressure-ratio/mass-flow characteristic.

The distance between the surge and the BEP (Best Efficient Point) could also be relatively small.

It is possible to install an IGV for each 3D impeller of an integrally-geared centrifugal compressor. There are compressors designed with IGV systems at the first two stages or more. However, a common design is an IGV only on the first stage.

The operating range of a typical integrally-geared compressor might

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IN FOCUS

be increased by using variable diffuser guide vane, but this can increase cost, complexity and maintenance. This also reduces reliability. This solution is not recommended.

The IGV pre-swirl angle has a notable influence on the integrallygeared compressor performance and operation. Negative IGV pre-swirl angles may be adopted for a flow-rate that is slightly larger than the design (rated) flow-rate, and positive pre-swirl angles under a smaller flow-rate or part-loads.

There is sometimes confusion about negative and positive IGV angles. A negative IGV pre-swirl angle is an IGV angle in the opposite direction of IGV angles that are used for part-load (low flow) operation.

The efficiency map usually only slightly differs when a negative pre-swirl angle is adopted (for example, in 0 to -10° range). The pressure ratio map most often (slightly) shifts up when the negative pre-swirl angle is increased.

The performance map of the machine has often a trend of shifting to a slightly larger flow-rate and a slightly lower efficiency for negative pre-swirl angles compared to zero IGV angle.

The performance map shifts to a smaller flow-rate when a positive pre-swirl angle is adopted, and the amplitude of its shift could be much larger than it is under negative pre-swirl angles. For large positive IGV pre-swirl angles (say around +45° for instance), the flow from the IGV inlet to the impeller inlet could be partially blocked due to the quite large pre-swirl angle, and the flow separation may also occur on the suction surface of the impeller.

In these cases, the corresponding efficiency and pressure ratio can decrease significantly. In general, moderate positive IGV angles (say +10°, +20°, or +30°) can improve compressor work conditions at low flow-rates. Large positive IGV angles may introduce low performance, poor operation, low efficiency and sometimes instabilities.

IGV pre-swirl angles should be adjusted appropriately under different low flowrates.

Operation and reliability

Old-fashion multistage integrally-geared compressors were used in the plant and instrument air services and inert gas compression units such as nitrogen or similar service. They used in these services for several decades.

24 www.pacetoday.com.au AUGUST 2014

Compressors in process plants do not ususlly have a ‘spare’, and they are considered critical equipment items.

Records of reliability and availability of many integrally-geared centrifugal compressors have usually shown that they present a relatively lower reliability compared to conventional centrifugal compressors.

Integrally-geared machines use multiple bearings, seals, gear meshes and operate at high speeds. Many compression services in process applications are un-spare and it is not feasible to provide two machines instead of one. In other words, the cost of two

designed and manufactured in a compact and cost-effective manner with minimum margins and expenses.

They could present some operational problems, control difficulties and performance issues.

The non-API manufacturer’s standard integrally-geared compressors are typically supplied with only an overall surge protection system and not individual impeller stage protection.

They are prone to surging if intercoolers do not attain design heat removal requirements. Many operational issues have been recorded for these integrallygeared compressors.

Another example of an integrally-geared machine. This is a machine that has integrally geared process-gas radial turbines which enhance power supply. A medium- to high-temperature gas steam can be used for energy recover and such a stream can be used to help drive a compressor package (Source: Siemens). integrally-geared centrifugal compressors would be considerably more than one conventional API machine in a way that two integrally-geared centrifugal compressors cannot be feasible.

Non-API un-spared integrallygeared compressors should not be used for un-spared process duty because in most cases they are based on original designs used previously for the plant and instrumental air services which would use spared compressors. The non-API manufacturer’s standard integrally-geared compressors are usually maintenance intensive and present low reliability.

In addition because the gas is cooled after each impeller stage, their performance characteristics and reliability are dependent on intercooler conditions. Many intercoolers are

As a very rough indication, non-API manufacturer standard integrally-geared compressors could offer around 95 percent of availability. Properly-designed API integrally-geared compressors and API conventional (between-bearings) centrifugal compressors might offer about 98.5 to 99 percent and above 99.6 percent of availability, respectively.

All the above-mentioned figures are very rough values, but they give an idea what could be expected during operation.

3D impellers

The flow inside an integrally geared compressor package is 3D and complicated. The blade angle distributions in each 3D impeller have significant influence on the impeller flow characteristics and overall integrally-

geared compressor performance, stability, efficiency and operation.

The blade angle distributions can affect compressor performance, loss generation, operating range, and surge/ stall limits. The variations of hub meridional blade angle distribution have usually greater effects on operation and efficiency than varying the shroud meridional blade angle distribution. The efficiency, operation and performance vary with the blade angle distribution.

The comparison of the wall skin friction, blade loading, and hub-toshroud loading losses should be done for different operating scenarios such as design (rated) mass flow-rate, reduced flow-rates, etc. The wall skin friction loss usually increases as the variation of blade angle increases because the increase in the blade surface area.

The impeller blades which have relatively small variations of blade angle and are relatively radial, have been found to exhibit relatively small wall skin friction loss due to relatively small surface area but a relatively high blade loading loss.

In contrast, the blades which have large variations of blade angle exhibits relatively large wall skin friction and hub-to-shroud loading losses, but they represent relatively low blade loading loss because the flow from the inlet to the outlet is usually well guided.

As the flow coefficient increases, the performance of such blades (blades with large variations of blade angle) could steeply decrease.

The blade distribution angles and meridional contours of a 3D impeller should be properly optimised. Finding the optimum blade angle distribution is the best approach to the design, control and operation of 3D impellers.

Gear system

The gear system is one of the key systems in an integrally-geared centrifugal compressor. The complex configuration, high accuracy demand, and high-load operating conditions of gear systems in integrally-gear compressor require very stringent design and manufacturing criteria.

[Amin Almasi (amin.almasi@ymail. com) is a rotating machine consultant in Australia. He specialises in rotating machines including centrifugal, screw and reciprocating compressors, gas turbines, steam turbines, engines, pumps, condition monitoring and reliability.]

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BEHIND THE SCENES

The layout of the snack food plant called for a complex system of conveyor lines.

The drive to integrate By choosing integrated and flexible motors and drives from a single supplier that was able to meet the technical requirements for the entire system, Contech’s design team had the best of both worlds.

T

HE choice between fully integrated systems or a mix and match approach can be a difficult one for engineers seeking to optimise drives and control systems. By selecting from different suppliers, they can match each component in the system to their overall design. Alternatively, integration offers simplicity, guaranteed compatibility and the advantages of dealing with a single supplier. In a recently installed snack food conveyor system, an integrated system of MOVIFIT drives was implemented without compromising the design objectives.

A quick check of the local supermarket shelves gives a clue as to the complexity of the snack food 26 www.pacetoday.com.au AUGUST 2014

manufacturing process. The variety on display is enormous. Everything from high-energy breakfast alternatives and morning pick-me-ups to chips and party foods is readily available.

Imagine then, the logistical exercise

must be boxed in their various manufacturing zones and moved along sophisticated conveyor lines to the appropriate packing and despatch areas.

Design of the conveyor systems and the motors and drives that power them is

We wanted simple drive operation and decentralised installation to save on space and cabling costs of continuously moving all these different snack foods through a clean manufacturing plant, where hygiene, energy efficiency and reliability are the priorities. To achieve the tight production schedules, all these items

of critical importance in this environment.

According to Jason Thompson, Director of Contech Engineering, there was no need for compromise when designing the drive system for a recently

installed snack food conveyor system in Sydney.

By choosing integrated and flexible motors and drives from a single supplier that was able to meet the technical requirements for the entire system, his design team had the best of both worlds. While the mix and match approach had worked well in the past, the opportunity to source suitable drives and electronics from a single supplier, SEW-EURODRIVE, produced the optimal result at the snack food manufacturing plant.

The layout of the snack food plant called for a complex set of conveyor lines, feeding into the despatch area like a multitude of tributaries flowing into a major river. From the manufacturing

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BEHIND THE SCENES

line, each snack food carton is placed on a conveyor that joins other lines before moving at a steady rate to an upper level in the manufacturing plant.

To achieve this, and to keep the snack food production targets on track, the design incorporated a number of high grip and inclining conveyors. At the upper level, these lines feed into a single conveyor that carries the cartons to the distribution area.

that was where we made most of the space savings,” he says. This reduced the design complexity and overall costs, while allowing for easy diagnostics and maintenance. The simplified design also reduced possible sources of errors in the wiring-up stage.

The use of these standardised, industry-specific components for the conveyor system allowed Thompson and his team to minimise the amount of time spent on planning and reduce costs Investment and planning accordingly.

Thompson had a clear goal in mind The decision to close couple the when planning the project. “We were gear motors to SEW-EURODRIVE looking for a reliable and integrated decentralised motor controllers was a system of drives to keep the conveyor significant step says John Gattellari, belts moving,” says Thompson. “We National Industry Specialist Food & wanted simple drive operation and Beverage, with SEW-EURODRIVE. decentralised installation, to save on “The inclusion of our MOVIFIT space and cabling costs.” system, particularly suited for food-grade To accomplish this goal, Thompson environments, provided a perfect match deployed 34 SEW-EURODRIVE in terms of compatibility, and reduced MOVIFIT FC, 0.75 kW variable speed the time required for installation and drives. “The decentralised control units setup. We provided some initial training of the drive systems required less cable and theyPdid the rest. The system has A D _ P A C E P L A MA R _ 1 2 . p d f a ge 1 1 5 / 0 2 / 1 2 , and fewer cabinets in the field, and run like clockwork ever since,” he says.

1 1 : 2 9 : 5 2

AM

AEDT

The decentralised control units of the MOVIFIT drive systems required less cable and fewer cabinets in the field, saving valuable space.

Gattellari says that the MOVIFIT solution allows for flexible topology, which simplified the design process for the snack food conveyor system. This was aided by built-in local intelligence and local control functions.

Isolators are also local, providing an important safety feature. Additional protection devices were not required for the snack food application. This is typical of such projects and applies to wet areas as well.

components required in the system design. A decentralised electronics unit enables control of several drives, which reduces the number of units required in the system.

The three versions of the unit available afforded his team the options they sought for the snack food project.

A flexible communication system was a major requirement. The designers selected DeviceNet for this project, and also had the choice of other

The opportunity to source suitable drives and electronics from a single supplier produced the optimal result Energy efficiency was another important consideration in the design of the snack food conveyor system. “The energy efficiency of the drives reduces costs, while also complying with new energy efficiency laws,” says Thompson.

Decentralised

Being modular and flexible, the MOVIFIT drive control fulfilled Thompson’s important criteria for decentralised drive systems, with fewer 28 www.pacetoday.com.au AUGUST 2014

commercially available fieldbuses such as Ethernet, PROFINET, PROFIsafe and PROFIBUS. Looking to the future, the system offers easy diagnostics and maintenance, for example when the electronics are replaced. Expansion of the system can be carried out with minimal disruption due to the modular, decentralised design concept.

Furthermore, the modules can be reused, reducing project planning time

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BEHIND THE SCENES

A decentralised electronics unit enables control of several drives which reduces the number of units required in the system and costs. Gattellari says that the units have been designed with installation in mind. The inside of the robust housing is large enough for electricians to comfortably work in, so that any wiring that may be required can be completed quickly and efficiently.

Minimal training

The connection technology enabled quick installation and commissioning. With SEW-EURODRIVE providing training from its Drive Academy, Contech Engineering only required two half-day sessions for one of their engineers in order to complete the project. Following this training, the installation and commissioning of the drives was carried out by their own staff.

“All we required was updates on the new technology to assist with the design,” says Thompson. “The process was straightforward and we are familiar with SEW-EURODRIVE equipment as we have used it since our inception 17 years ago. The robust housings of the

MOVIFIT drives add to the reliability of the conveyor system. The drives are excellent – second to none.”

After the conveyors were built and tested they were disassembled in preparation for shipping to site. The entire project took eight weeks to complete, with the locally assembled drive units delivered within three weeks of the order being placed.

Despite the complexity of the conveyor system, Thompson says that because of the system design and the equipment chosen, disassembly and reassembly on site were easily implemented.

The integrated design approach, with all drives sourced from a single supplier, allowed Thompson’s team to reduce the complexity of the conveyor system by minimising the number of different components.

At all phases of the project – planning, design and implementation – this approach proved to be cost effective and fulfilled all technical requirements.

For the snack food conveyor system, integration of the drives was achieved without compromising the design objectives.

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AUGUST 2014 www.pacetoday.com.au 29

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BEHIND THE SCENES

Making empty tanks a thing of the past An innovative measurement system determines the filling level in the oil tank together with a GSM modem to transmit the filling levels via the mobile telephone network once they have been ascertained, writes Marcel Gautschi.

A

VIA Osterwalder St. Gallen AG (AVIA) operates more than 120 filling stations in eastern Switzerland. This company also sells and distributes motor vehicle and other fuels to corporate and private customers. For many years now, AVIA Osterwalder St. Gallen AG has deployed the EasyOil system to offer its customers a practical method for remote monitoring of filling levels in oil and gasoline tanks.

To assist with the recent relaunch of the EasyOil system, AVIA Osterwalder St. Gallen AG called on the measurement technology expertise offered by KELLER AG fĂźr Druckmesstechnik.

In essence, EasyOil comprises a measurement system that determines the filling level in the oil tank, together with a GSM modem to transmit the filling levels via the mobile telephone network once they have been ascertained. In collaboration with an IT solutions provider, AVIA has developed software that enables contracting customers to call up current filling levels and previous purchase orders for making empty tanks a thing of the past Remote monitoring of tank filling levels their tank installations.

Customers are also alerted via SMS or email if the filling level falls below a certain limit (which can be freely defined). By replying to these messages, customers can immediately trigger purchase orders to AVIA. Because they can call up data anywhere and at any time, customers are able to plan their purchasing efficiently. For example, stocks of fuel can be bought in when the price of oil is low, or when a tank truck is nearby.

Win-win model

The system offers economic benefits to facility managers in companies, and for real estate managers who have to coordinate fuel supplies for multiple properties. Gas station operators and their suppliers 30 www.pacetoday.com.au AUGUST 2014

The system offers economic benefits to facility managers who have to coordinate fuel supplies for multiple properties (i.e. large oil corporations) can also benefit from a system such as EasyOil. EasyOil has therefore proven to be a win-win model in the ten or so years since the system was launched on the market: customers appreciate its convenience and transparency, while AVIA Osterwalder St. Gallen AG benefits from long-term customer loyalty in the fiercely contested fuel market. So from 2013 onwards, the company will offer its customers updated contract models that are even more transparent and easier to manage than those in place at present.

The technology behind the EasyOil system had already been relaunched prior to this redesign.

As AVIA searched for a suitable supplier who could deliver the measuring probes as well as the GSM transmission module, their attention was drawn to KELLER. KELLER operates across the globe and earns some 10 percent of its sales revenue from applications that use pressure probes to measure filling levels. This is technically possible because the pressure at a specified point in a tank rises in proportion to the filling level.

The measured pressure can therefore be used to perform a very accurate electronic calculation of the corresponding filling level. The current content can be determined in liters, taking account of the tank shape.

The benefits of using EasyOil are derived from the combination of measurement and remote transmission.

The GSM-3 comprises a modem and what is known as the SB box, to which as many as three KELLER pressure transmitters (with voltage outputs of 0.5‌4.5V) can be connected.

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Helping to put you in Control

Ethernet Serial Server

While developing the proposed solution for AVIA Osterwalder St. Gallen AG, KELLER’s pressure measurement experts were able to draw on experience garnered from customers in the water management sector, where similar concepts are used to monitor groundwater and river water levels.

Supports data exchange

The underlying technology is developed by KELLER in-house, so special solutions of this sort can be developed for customers with great flexibility and speed.

For customers in the water management sector – to take one example – KELLER has developed a GSM modem that supports data exchange via email, SMS and FTP. Now, for AVIA, KELLER is producing the GSM-3 variant (modified at the customer’s request) which also offers the option of SMS communication with consumers.

“Customer surveys have confirmed that this is the most reliable version, and the one that customers prefer,” according to AVIA. More so than email, SMS messages guarantee that customers are informed promptly; they are spam proof and can be clearly personalised. “Especially in offices, emails could be called up by different individuals who might not all be authorised to make a purchase decision. And that could waste valuable time.”

The GSM-3 comprises the modem itself and what is known as the SB box, to which as many as three KELLER pressure transmitters (with voltage outputs of 0.5…4.5V) can be connected. The box contains three built-in safety barriers (SBs). These circuits also make it possible to process the electrical measurement signals to gas stations, where an electrical spark could cause an explosion due to the gases contained in the atmosphere.

This is why any pressure transmitter that performs measurements in an environment of this sort must be intrinsically safe. The safety barrier limits the electrical power produced by the measurement system within the area subject to explosion hazards (EX area).

For EasyOil systems at gas stations, KELLER uses its intrinsically safe piezoresistive Series 26 Y Ei level sensors, which are suitable for environments subject to a high explosion hazard.

Because they can call up data anywhere and at any time customers are able to plan their purchasing efficiently The GSM-3 itself may only be installed outside of the EX area. As part of the complete package, KELLER also supplies the level sensor cables used to transmit the measurement signals.

To ensure that purchasing is planned efficiently, the software enables visualization of current tank filling levels as well as consumption and order histories via a web portal. Different graphic display options guarantee a transparent overview for users.

Silicon measuring cell

For EasyOil systems at gas stations, KELLER uses its intrinsically safe piezoresistive Series 26 Y Ei level sensors, which are suitable for environments subject to a high explosion hazard.

KELLER uses its intrinsically safe 26 Y Ei level sensor for EasyOil systems at gas stations, whereas the conventional version is used for heating oil tanks in locations not classified as EX areas. Like all of KELLER’s pressure measurement equipment, the transmitters in these devices are based on the piezoresistive silicon measuring cell invented by the company’s founder and CEO, Hannes W. Keller, at the end of the 1960s.

Nowadays, KELLER is one of the world’s leading manufacturers of piezoresistive pressure sensors. The slight mechanical deformation caused by the pressure on a piezoresistive element in the sensor triggers a change in resistance which, in turn, produces the electrical voltage that is used as the measurement signal. In Series 26 Y, which includes the level sensor, the temperature error is compensated electronically.

Depending on the location where each EasyOil system is deployed, AVIA Osterwalder St. Gallen AG now purchases either the conventional 26 Y level sensor or the intrinsically safe 26 Y Ei version from KELLER, together with the GSM-3 transmission unit and the cables (whose lengths vary according to on-site conditions).

Final assembly and installation of the systems at the customer’s premises and software configuration are handled by AVIA. KELLER info@keller-druck.com www.keller-druck.com

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PID temperature controller features: autotuning PID function, dual display, full range universal & ramps soak function. 240 VAC powered with 3 relay output & 1 pulse output.

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Pushbutton Control Station 22 mm twist release pushbutton enclosed in an emergency stop labelled plastic housing. Comes with 2 x 20 mm dia cable entries that suits PG13.5 cable gland.

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Large Matrix Display

Large 5 digit universal process indicator accepts 4 to 20 mA signal.

Features include: 24 VDC excitation for powering 4 to 20 mA transmitters and 2 alarm relays.

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H685 Series Cellular Router H685W cellular Router is designed to establish a 2G/3G cellular and Wi-Fi wireless network and share a cellular broadband internet connection. 2 to 40 VDC powered.

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NEMA23 Stepper Motor IP65 single shaft bipolar stepper motor with 19.3 kg·cm holding torque. The motor is fitted with a 300 mm, 4-core shielded cable.

It is ideal for driving moderate loads in outdoor, wet and dusty condition.

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3-Axis Stepper Controller

The new MX3660 3 axis drive stepper system provides excellent low-tohigh speed performance with high precision, extra low motor heating, smooth movement, and low motor noise. It features anti resonance, multi stepping, digital smoothing options of different configuration for each axis & a 25 pin PC interface. 20 to 60 VDC powered and output current of 1.45 to 6 A. SKU: SMC-040 Price: $449 ea + GST

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

AUGUST 2014 www.pacetoday.com.au 31

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SPOTLIGHT

Economical nitrogen tank blanketing Process engineers in search of a flow measurement solution to support accurate, safe and economical nitrogen tank blanketing operations will find the ST Series Family of Flow Meters from Fluid Components International (FCI) provides a range of choices designed to accommodate various tank and line sizes. Storage tank blanketing or padding by pumping inert nitrogen or other gases into the vapour space of a tank is designed to protect the contents. The ST100 Series Flow Meter is suitable for mass flow measurement of nitrogen gas in tank blanketing processes. Communication options include 4-20 mA analog, frequency/pulse, or certified digital bus communications such as HART, Foundation Fieldbus, Profibus PA or Modbus RS485. For the small tanks and line sizes required by specialised processes, the ST75 Flow Meter is an accurate, no moving parts, direct mass flow measurement and monitoring solution. It is suitable for measuring nitrogen tank blanketing, as well as measuring compressed air, fuel gases and other gas flows within industrial processes. The ST75 Flow Meter supports small line sizes ranging from 6 to 51 millimeters.

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

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

ProfiHub B5+RD monitors PROFIBUS DP installations In partnership with PROCENTEC, I S Systems releasing the ProfiHub B5+RD. The ProfiHub B5+RD is a member of the ProfiHub family. It is a network component providing a solution for spur lines and starshaped structures in PROFIBUS DP networks. Its salient feature is the built-in PROFIBUS DP Slave which allows transferring of diagnostic data to a PLC. With this function, the ProfiHub B5+RD is able to permanently monitor PROFIBUS DP installations - which is the key when it comes to maintaining PROFIBUS networks. Technicians and engineers can now access detailed diagnostic information about communication failures and details of retries. In addition, the ProfiHub B5+RD generates a live list of all connected PROFIBUS devices. The ProfiHub B5+RD has been provided with five galvanically separated transparent channels. Each channel comes with dropout protection to ensure the rest of the PROFIBUS network remains flawless. The redundancy feature caters for the creation of a redundant PROFIBUS DP connection between two ProfiHubs which – in combination with the new redundant 24V power supply connection – increases network availability. Information about the redundancy status of the PROFIBUS channels as well as the power supply is also available via the built-in PROFIBUS DP Slave.

I S Systems 02 4964 8548 sales@issystems.com.au 32 www.pacetoday.com.au AUGUST 2014

Solenoid interlock The Schmersal AZM 300 solenoid interlock features an interlocking system in the form of a Maltese cross. The interlock can be actuated from three sides, which provides for universal application possibilities. The user does not need any additional add-on parts such as a door stop or a latching element, considering that these functions have been integrated in the interlock. The AZM 300 integrates another practical function, namely the adjustable latching force, i.e. the non-safety-related interlocking function when the safety guard is unlocked.

Because of this feature, the interlocking system can be smoothly adjusted to suit individual requirements. An integrated RFID sensor detects the identification and the coding of the actuator allowing the user to choose three different types of coding. In the basic version, the sensor accepts any suitable target. A second – coded – version only reacts onto an individually assigned target. The teaching procedure can be repeated an arbitrary number of times. Finally, a third variant is available, which only accepts the target that was taught upon the first activation.

The new solenoid interlock meets the requirements of Cat 4, Performance Level e or Safety Integrity Level 3. Because of its protection class IP 69K, it is also suitable for use in hygiene-sensitive areas.

Control Logic 1800 557 705 www.control-logic.com.au

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

Decentralized servo drive system Kollmorgen’s AKD-N is a distributed servo drive solution that reduces cabinet space and cabling hassle, simplifying machine design, set-up and operation. This drive system leverages IP67-rated drives positioned next to the motor and supplied by a central power module located in the switchgear cabinet. An 11mm diameter hybrid cable delivers power and fieldbus communication to the AKDN servo drives. As a result, the drives operate directly in series, supplying up to 4 kW per axis. Safe Torque Off functionality is also included. Typical applications include packaging machines and production systems in the food and beverage industry. With AKD-N Kollmorgen provides users the flexibility to utilise any Kollmorgen motor technology, while still implementing a system that decentralises the drives into the machine chassis. Because the AKD-N is able to connect to all types of Kollmorgen motor technologies, the solution enables the machine designer to select for environment and load requirements. This modular approach also optimises the thermal properties of the drives and the cabinet, and by being mounted directly on the machine, distributed AKD-N servo drives significantly reduce cabinet volumes and cabling effort. In certain applications, savings of over 80% can be achieved.

Motion Technologies 02 9524 4782 www.motiontech.com.au

Drive technology at the tip of a finger The NORD Drivesystems website has been relaunched with a fresh look and enhanced usability on mobile devices. At www.nord. com, users from all industry sectors will find the suitable drive solution for any task.

Product details, reference projects, and the download section are arranged for PCs, tablets, and smartphones. Navigation is equally simple and comfortable via mouse and touchscreen. The product section provides information on all available gearboxes, motors, and drive electronics units as well as a special focus on energyefficient motors. The individual product feature pages contain detailed characteristics data and include the relevant links to documentation and software. Users can quickly generate CAD files and 3D models.

In addition to standard drives, NORD supplies application-specific concepts and solutions, even for special applications, for example with energy-saving drives or explosion-protected systems.

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

Variable speed drive with embedded services Schneider Electric has releaseed Altivar Process â&#x20AC;&#x201C; a range of drives for process applications. It is the first variable speed drive on the market with embedded intelligent services. Due to a convergence of IT and operational technologies, Altivar Process drives deliver added value services in the water, oil & gas, mining metals and minerals, and food & beverage industries that enable business and process optimisation through improved life-cycle asset management and optimised energy consumption. Through advanced system and equipment condition monitoring, Altivar Process ensures that applications are performing at optimum efficiency at all times. Compared to conventional drives, Altivar Process delivers an additional eight percent cost reduction due to its ability to instantly detect efficiency drifts and to monitor motor power with a high level of accuracy (< five percent). This enables the automation system to immediately make adjustments, thereby minimising a negative impact on the bottom line. In contrast to conventional drives, Altivar Process is also able to reduce downtime by another twenty percent due to predictive, condition-based maintenance and an innovative user-interface with easy-to-understand graphs.

Schneider Electric 1300 369 233 www.schneider-electric.com

Determine the quality of bore holes Bestech Australia has introduced the boreCONTROL LAB, a benchtop device designed for laboratory use. It provides high precision statements about the quality of bore holes or cavities in the diameter range from 4mm up to 16mm.

The measurement system from Bestech Australia offers non-contact measurement using a small light spot, high resolution in radial and axial directions and a high sampling rate of up to 10kHz. The optical measurement principle is applicable on many materials. A granite table enables temperature-resistant and vibration-free measurements.

The sensor consists of a fast exchangeable sensor lance with rotary drive and is moved via a high-precision traversing unit in the axial direction (z-direction). Delivery includes two sensor lances for diameters 4 to 10mm, as well as from 10 to 16mm. Measurement objects can be mounted using a chuck and precisely positioned with a manual x-/y- table.

Handling and evaluation take place with an industrial tablet PC (delivery includes PC and software).

Bestech Australia 03 9540 5100 www.bestech.com.au AUGUST 2014 www.pacetoday.com.au 33

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ANALYSIS

CONTROL

Effectively manage the pneumatic control specification process Whether installing a new system or making alterations to an existing system, access to a wide range of reliable connectors with the necessary approvals is crucial.

M

ANY processing plants have adopted pneumatic process control system methodologies. However as the complexity of these control systems has grown, reliability and integrity has become more critical – as has the need for appropriate specification.

Not every system requires large format valves, or fieldbus communication, to achieve the required level of automation.

Pneumatic control has been in use for many years, especially in the pharmaceutical and food and beverage industries where hygienic conditions must be maintained.

Pneumatics have many advantages, including simplicity of design, low maintenance requirements, and excellent reliability due (in part) to the use of compressed air as the power source. In addition, these systems are intrinsically safe and so can also be used in hazardous atmospheres, such as those in the petrochemical industries.

Modern control systems can be divided into two groups, centralised and decentralised. As the names suggest the main control functions will either be grouped at a central point or located at the point of control, such as a process control valve.

impacting profitability, and being reported on the ‘triple bottom line.’

The first step is to clean and regulate the compressed air supply to the control system using air preparation units which filter and regulate the air supply. These units remove water and oil aerosols while also controlling the system air pressure all of which makes them crucial to ensuring correct operation of the system as well as reducing wear and corrosion of the components.

Explosive environment

Integral control

A centralised control solution is the more traditional solution and will usually involve a control panel containing a bank of control solenoids which are connected to the process control valves using air lines alone.

In a decentralised system, the air supply is fed direct to the control valve and the integral control head uses control signals to determine what action is required.

The choice of system is dependent on the application since both have 34 www.pacetoday.com.au AUGUST 2014

Smart Panel with air preparation units. their advantages depending on the circumstances. The crucial point is to ensure that the system is properly designed and installed to ensure efficient and reliable operation.

Once the design scope is agreed, even for the simplest of installations, it is important to ensure the proposed design will produce an effective and efficient control system which will be easy to

maintain, expand, and (if necessary) clean to the required standard.

Although many of the components used in a pneumatic control system are relatively inexpensive, the cost of generating the compressed air is not and so it is crucial that the air is used in the most efficient way.

This also impacts the ‘green rating’ of your process line, which is increasingly

Air preparation units are available with a range of filter sizes, down to 0.01µm, as well having the option of an activated carbon filter which can remove oil aerosols to a level of less than 0.005 mg/m3. In addition, a range of connection sizes is available, plus explosive environment certification to comply with regulations when operating in hazardous atmospheres.

As the system starts to take shape, so there is a need for flow restrictors, one-way valves and check valves to ensure that the air pressure and flow direction is correct for the equipment it is supplying.

These need to be matched to the application with regard to construction material, sealing properties and connection sizes, to ensure reliable and efficient service.

An example is the type TRG001, from Bürkert, which contains a complete range of restrictor valves, check valves and flow control valves, with non-standard versions, materials and seals also available.

All of this equipment will need to be connected together and this requires careful selection of connectors, threaded, push-in or a combination of both. In all cases the application is the deciding factor when determining the correct design of connector. www.burkert.com.au

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Safely Monitor Pressure in Hazardous Areas with the Rosemount® Wireless Pressure Gauge Do you have limited labour resources?

Struggling to add new measurement points?

Lacking the visibility of your process to improve plant operations?

The Rosemount Wireless Pressure Gauge allows you to efficiently see process conditions and gather data reliably and safely. With accuracy rated at Grade 4A of ASME B40.7 and a power module life of 5 years, you have a solution to achieve accurate and reliable measurements in hazardous areas. *Intrinsically Safe for Class 1, Division 1 – Groups A, B, C, D*

www.emersonprocess.com.au emersonprocess.australia@emerson.com

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