PACE - Process & Control Engineering - December 2010

www.pacetoday.com.au

PACE PROCESS & CONTROL ENGINEERING Industry Notepad Process Controls - 1800 6330405

Ultrasonic Level Sensors

Automation Direct’s range of Level sensors offfer a wide sensing range, High accuracy, Non-contact measurement, fixed components, Capable of detecting liquids and solids Adopts echo tracking technique to capture the real echo precisely.

Adopts temperature compensation technique (on speed and frequency) to make the measurementmore precise and reliable With both digital and analogical outputs

AutomationDirect.Com.Au DECEMBER 2010

VOL.63 NO.11

INSIDE THIS ISSUE

Opinion 10

What is PAS 55?

An asset lifecycle management program offers benefits.

Integration 12

Boost for baking Software helps plant improve operational flexibility and product consistency.

Process Control 16

Reducing time delay Analyser responses can often be underestimated or even misunderstood.

Wireless 20

Select the right drive voltage Transmit data directly from multiple wireless sensors using a mesh network.

Solar Power 24

Post Print Approved PP255003/00539

Challenge of clean energy Overcoming the solar challenge using thin film photovoltaic panels.

The promise of simulation Working out a favourable return on investment need not be a challenge.

Feature 14

Robots pack a punch Small-footprint IRB robots are able to deliver a raft of productivity gains.

Feature 18

Sunny future for alliance

BY KEVIN GOMEZ TWO Sunshine coast businesses – Auzion, a supplier of solar systems, and Latronics, a local manufacturer of inverters – have announced a strategic alliance to provide the country with greater access to solar systems.

Auzion began operations just over two years ago and have been involved in sustainability research with the University of the Sunshine Coast. “We have developed AuziMax Energy Maximiser which will be fully commercialised in the first quarter of 2011 after the completion of a pilot study,” Auzion managing director, Mark Leckenby, told PACE. For customers with a solar grid connect system, AuziMax can help maximise the amount of power fed into the grid. AuziMax allows users to monitor all of their building’s energy needs (including incoming mains, power circuits, lights, hot water and air conditioning) in conjunction with the solar power generated. Through a secure web portal, users can view an accurate breakdown of their energy usage. The device allows users to establish energy alerts to optimise usage in line with set targets.

Auzion is keen on using Australianmade products wherever possible. This drove Leckenby to develop AuziRack – a solar panel mounting system made from anodised aluminium which is rated for all Australian cyclone zones. He believes locally developed and produced systems are better than available imported products. “We were able to reduce the number of components needed, making the system more streamlined,” he noted. The only component not made in Australia is the solar panel. “And these come with a 25-year performance warranty,” he adds.

ENERGY: Solar power brings Mark Leckenby (L) and Klaus Langer together.

According to Latronics CEO Klaus Langer, their research and development efforts come on the back of 25 years of manufacturing experience.

“We can’t say too much about current projects until they are ready for release to the market but we are collaborating on innovative communications for a complete residential energy management system,” he said.

“We have been working with Auzion for some time,” said Langer. “This new alliance means both companies can work more closely in the booming solar sector.”

In 2009, the Australian Government set an ambitious renewable energy target of 20 per cent by 2020, which means

PowerFlex 750 Series —the NEW flexible AC drive The latest drive technology which offers greater control, communications, safety and supporting hardware options for either general purpose or demanding applications. www.rockwellautomation.com.au

that one-fifth of Australia’s electricity must be supplied by renewable sources such as solar power. Teamed with the implementation of numerous government-based incentive schemes and the anticipated soaring energy prices over the next decade, Auzion and Latronics are gearing up for increasing demand.

“We live in one of the sunniest places in one of the sunniest countries in the world, with an average of seven hours of sun a day, an ideal climate for solar panels,” Leckenby said. “People can make real contributions to the environment and also save money by installing efficient solar grid connect systems.” www.auzion.com

NEWS

EDITOR’S MESSAGE

PACE

Spotlight on solar

PROCESS & CONTROL ENGINEERING

Published monthly by Reed Business Information Pty Ltd Tower 2, 475 Victoria Avenue Chatswood NSW 2067 Locked Bag 2999 Chatswood DC NSW 2067 Tel: (02) 9422 2999 Fax: (02) 9422 2977 ABN 80 132 719 861

Editor: Kevin Gomez Tel: (02) 9422 2976 Fax: (02) 9422 2722 Email: kevin.gomez@reedbusiness.com.au

Kevin Gomez Editor

Editorial Coordinator: Isaac Leung Tel: (02) 9422 2956 Email: isaac.leung@reedbusiness.com.au Accoount Manager: Tim Richards Tel: (02) 9422 2818 Mobile: 0407 948 774 Email: tim.richards@reedbusiness.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@reedbusiness.com.au New Business: Alex Evans Tel: (02) 9422 2890 Email: alex.evans@reedbusiness.com.au Associate Publisher: Michelle Graves Tel: (02) 9422 2391 Email: michelle.graves@reedbusiness.com.au Graphic Designer: Elliott Hind Email: elliott.hind@reedbusiness.com.au Production Co-ordinator: Jennifer Collinson Tel: (02) 9422 2657 Fax: (02) 9422 2722 Email: jennifer.collinson@reedbusiness.com.au

Next Issue ● ● ● ●

Sensors & Analysers Fluid Handling SCADA & MES Water & Wastewater

IT IS again that time of the year when we scour the country seeking out and encouraging entries to the Zenith Awards. Now in its eighth year, the 2011 edition of the Zenith Awards has already begun to generate interest. So if you have worked on a challenging project or know someone who has, please hop over to our website (www.pacetoday.com.au/awards) and download the nomination form. It is really straightforward and you will likely have most of the information readily available.

We can even help you put your entry together – drop me an email if you need our assistance.

A big thank you to our sponsors who have been with us for many years: Rockwell Automation, ifm efector, Endress+Hauser and AMS Instrumentation & Calibration.

A special welcome to NHP who have come on board this year with sponsorship of the Young Achiever Award. This category has just been introduced following feedback from the industry – if you have a young team member who deserves recognition, the entry form is just a click away.

Looking through the visitor traffic on our site, I was pleasantly surprised to see the interest generated by our news and features on solar related products and technologies. This month we have got two interesting pieces: the first is about two entrepreneurs on the Sunshine Coast who hope to capitalise on their location and their fledgling technology. They were reluctant to divulge too many details but if they have got the formula right, we could be hearing a lot more about them in the months ahead.

The other is an interesting techno-travelogue of sorts written by Dave Turner who ventured right to the heart of China to bring us some fundamental lessons on managing green energy. He uncovers solar farms blending into the surroundings and an emphasis on educating the communities they serve. We may own the Sunshine Coast but there is a lot for us to learn.

The team at PACE wishes its readers a wonderful Christmas and a fantastic New Year.

Kevin.Gomez@reedbusiness.com.au

PRODUCT LIFECYCLE MANAGEMENT Printed by: GEON 20 Baker Street, Banksmeadow NSW 2019 Tel: (02) 8333 6555 SUBSCRIPTION: $99 pa incl GST OVERSEAS SUBSCRIPTIONS: NZ: $A109 pa & OS: $A119 pa CUSTOMER SERVICE: 1300 360 126

Copyright © Reed Business Information 2010 All rights reserved. No part of this publication december be reproduced or copied in any form or by any means without the written permission of the publisher.

Average Net Distribution Period ending Mar '10 7,100

64 Tags 128 Tags 256 Tags 500 Tags

FROM

FROM

FROM

FROM

PLM market rebounds strongly in first half of 2010 WHILE the global economic downturn in 2009 impacted revenues for PLM suppliers, revenues for the first two quarters of 2010 reflect a strong rebound in new licenses and overall PLM business.

Demand for increased efficiency and productivity; a continuing need for collaboration across a global manufacturing lifecycle; PLM solutions penetrating new markets such as power and energy; architecture and construction; shipbuilding, and consumer goods; the rapidly growing need for product reinvention and innovation; the emergence of mechatronics and product complexity; the continued growth of

manufacturing in emerging economies; and expanding adoption of a more holistic end-to-end PLM solution set are all contributing to growth in the worldwide PLM market, according to a new ARC Advisory Group study.

The primary influence on the global PLM market for this reporting period (base year 2009) has clearly been the global economy and the direct effect of downturns in certain industrial verticals such as automotive and other discrete manufacturing sectors.

PLM solution providers have been most directly impacted by reductions in new software licenses and engineering

seats. Business in this sector has experienced a general reduction in the range of around 8 to10 percent. For most of the PLM providers, this downturn in business has been offset by services business in the areas of maintenance, implementation and consulting, with reoccurring maintenance providing the bulk of sustaining revenue.

The market leaders in PLM, as well as many of the smaller suppliers, have responded to the broadening adoption of PLM technologies into new markets with strategies and solutions to penetrate these industrial vertical markets. www.arcweb.com

$908

$2,057

Place your order online! visit www.intouchspecials.com.au

$2,420

for pricing, product options and detailed product specifications.

$1,089

DECEMBER 2010 www.pacetoday.com.au 3

NEWS

FROM THE WEB

EMERSON WINS DESAL Emerson Stewart Group has been awarded two desalination plants.

The first award relates to the engineering consultancy for the Collie River salinity recovery project. The project involves a desalination plant and associated piping and pumping infrastructure. The second plant for an undisclosed client is a 10 ML per day RO plant. The scope awarded includes the provision of engineering design, specifications and construction support.

SIEMENS GETS VICTORIA The Victorian Desalination Project has confirmed Siemens as their supplier for process automation and switchgear equipment, in what is considered to be the largest combined automation and energy contract in the company’s history.

Siemens PCS7 will be used to manage the flow, vibration, temperature and pressure among a wide range of other complex functions across the seamless platform.

COUNTERFEIT PRODUCTS The Anti-Counterfeiting and Brand Protection (ABP) market is expected to expand globally between 2010 and 2015, according to a new study by the ARC Advisory Group. The ABP market contains information on technologies being used to deter counterfeit products including human-readable markers (overt), machine- readable markers (covert), printers, applicators, authenticators, track and trace software, serialisation and epedigree software.

LARGEST PROJECT Pearson-Harper has been awarded a $10.3 million contract by Chevron Australia to provide engineering information management services and software solutions for the Gorgon Project. At $43 billion, the Chevron-operated Gorgon Project is the country’s largest single resource project to date. Pearson-Harper will work with the project’s engineering, procurement and construction management teams to collect and manage the vast amounts of data.

For daily updates visit www.pacetoday.com.au 4 www.pacetoday.com.au DECEMBER 2010

WATER MANAGEMENT

FarmConnect a step closer RUBICON is extending its expertise in channel automation technology directly on to the farm. The company has appointed former AquaSpy executive Peter Moller to head its newly established FarmConnect division. Rubicon expects to capitalise on its expanding product range which will offer farmers a better way to optimise crop yield with limited water.

“Essentially we’re miniaturising the automation technology that Rubicon uses in large channels into small bays to make on-farm irrigation automatic, which has never really been done before,” said Moller, general manager FarmConnect.

Once operational, FarmConnect is expected to revolutionise on-farm water efficiency and productivity and allow farmers to maintain crop yield, and therefore their income, with less water.

“What’s traditionally happened is the farmer or irrigator has had to deal with different groups of technologies on different platforms on different software fronts,” Moller said.

“So at the moment farmers have to go and find a radio from one company, a water meter from another company and a sensor from another company, and find a software platform and puzzle and piece it together, and that’s not their core business.

“The beauty of FarmConnect is that it integrates water control, irrigation, performance and demand management in to one single platform making it easier for farmers to benefit from the

UNIFIED: FarmConnect integrates water control, irrigation, performance and demand management into one single platform.

latest technology. Importantly, it allows the farmer to expand the system over time and can readily integrate a wide range of farm devices.

“Real-time feedback of soil conditions dictates when and how much to irrigate, taking the guess work out, minimising wastage and optimising plant health by avoiding conditions which are too dry or too wet. By monitoring plant demand and by precisely controlling the application of water, the plant receives only what is needed and no more.”

According to Moller, FarmConnect is likely to follow suit with Rubicon’s channel automation technology and expand overseas. “There is huge opportunity for this integrated product over-

seas,” he said. “Other countries are going to follow suit, they’re watching what’s happening in Australia as the leaders in water innovation. FarmConnect is currently in the final stages of intensive field testing and we are looking to commercially release the product early in the New Year.” Moller joined Rubicon as General Manager, FarmConnect in October 2010, to establish the on-farm water technology division for company’s Australian, Chinese and US markets.

Rubicon has also recently secured the master distributorship for AquaSpy products in Australia. AquaSpy produces soil moisture sensors and associated technology. www.rubicon.com.au

WINNER

Hawk commended for export effort NUNAWADING-based Hawk Measurement Systems has received a commendation for its services to Small and Medium Manufacturing at the 2010 Governor of Victoria Export Awards. The company designs and manufactures level, positioning and flow measurement systems which are exported to over 30 countries across a range of industries, including mining, water, food, power stations and cement.

Hawk is the only Australian manufac-

turer of level measurement systems.

Hawk Measurement Systems CEO Les Richards (pictured here) said that with export demand for level measurement growing because of the global mining boom and water crisis, Hawk is forging into emerging markets including China, India and South America. The company lists Rio Tinto, BHP Billiton, Xstrata, Outotec and FLSmidth Minerals among its line-up of international customers. www.hawk.com.au

NEWS

RESEARCH

Centre to enhance productivity A NEW centre focusing on process engineering in industries including natural resources, gas and petroleum, food processing and materials fabrications has been launched at Curtin University. The Centre for Process Systems Computations (CPSC) is part of the Department of Chemical Engineering and will concentrate on applied and fundamental research for generating basic and advanced knowledge in chemical engineering, ranging from molecular scale to ecosystem level.

Research will include modelling and simulation, process optimisation and control, nonlinear control system, and computational fluid dynamics. Curtin University’s Dean of Engineering, Moses Tadé, said over the last two decades researchers have been focused on improving the understanding of chemical engineering processes.

“Despite the great differences in products in chemical engineering, the various unit operations can be designed and analysed on the basis of the same fundamental conservation principles such as mass, energy, and momentum balances,” Tade said.

The Centre has several world-renowned experts and strong industry partnerships and members collaborate extensively with researchers worldwide. It will be co-directed by Tadé and Professor of Chemical Engineering, Vishnu Pareek.

“Process system computations are particularly important in unravelling the complexity of dynamic systems and assist novel process designs and optimisations,” Pareek said. “This is key to Australian industries remaining at the forefront in the face of increasing global competition.” cpsc.curtin.edu.au

FOCUS: Academic staff of the CPSC in the new Engineering Pavilion building (L-R) Nicoleta Maynard, Ming Ang, Ranjeet Utikar, Qin Li, Gordon Ingram, Shaobin Wang, Moses Tadé.

DECEMBER 2010 www.pacetoday.com.au 5

NEWS ANALYSIS

DEVELOPMENT

Dassault keeps Australia in the loop PLM software is applied across industries from apparel to defence, writes Hartley Henderson.

AS AN integrated global approach to product development gathers pace, it is imperative that Australian engineering teams are kept in the international design loop.

This has implications on a number of fronts including development of our domestic design expertise, and the ability to exploit opportunities for export development and import replacement.

French-based company, Dassault Systemes (DS), is a supplier of 3D and Product Lifecycle Management (PLM) software that the company says is used to design 80 per cent of the world’s vehicles and 40 per cent of its aircraft, as well as many other products.

The DS portfolio includes CATIA, for integrated collaborative design and engineering across disciplines; SolidWorks, for mechanical design in 3D; SIMULIA, for virtual product simulation; DELMIA, for enabling manufacturers to virtually experience their entire production system; ENOVIA, for allowing global collaborative engineering product development; and 3DVIA, for companies to communicate across the entire enterprise and directly with consumers using 3D as a universal language.

When utilising CATIA for the design of composite parts for example, engineers in different locations can work concurrently on that component before later merging and synchronising separately designed stacks into a single manufactured composite part.

During a recent visit to Australia, DS executive vice president, Etienne Droit, said that as product development activities are increasingly carried out by many diverse teams across geographically dispersed sites, pressures to deliver quality products on time have never been greater.

“Some 80 per cent of all products being invented don’t get to the market, and the reasons are that the product is not right, it is not of good quality, or it is released too early or too late. This is not a sustainable situation, and there is a clear need to 6 www.pacetoday.com.au DECEMBER 2010

COLLABORATION: PLM has enabled an integrated global approach to product development.

bring the voice of the customer inside the development process,” Droit told Manufacturers’ Monthly.

“A car for example must hit the market in the right way, otherwise big losses can occur. The answer is to establish a PLM virtual universe where the product can be developed, because as market cycle times become more compressed, cooperation on global market considerations is critical.

“The key is to establish an on-line collaborative environment that taps into centres of excellence in different countries. Australia for example is good at engineering composite materials, while France has expertise in plastic moulding.

In this way, competent multi-disciplines can be brought together from around the world in a virtual environment to develop products.

“It is important that dispersed team members are all able to see the same 3D on the screen, which helps to avoid mistakes. 3D laptops are on the way and this will further empower multi-national team operations.

“There is a lot of opportunity for

Australia in a range of industries to take the next step and decide whether to develop products in Australia utilising some overseas input, or just buy the original design. With CATIA it is possible to design and build in Australia.

This country has a very strong education system that is producing expertise capable of developing new products here rather just servicing existing products.”

Managing director of DS for Australia and New Zealand, Gilles Cruanes, points out that engineers at Toyota in Australia are part of a global team that includes input from engineers in Japan and the US to produce a Camry specifically for the Australian market. The team is using CATIA and DELMIA to connect live in real time on large screens from country to country,” he said “The fast moving digital capability of PLM has enabled an integrated global approach to product development, simulated testing and lifecycle management to bring goods and services to market faster at lower cost.

“Our PLM software is applied

across most Australian industries from apparel to warship production.

Without this technology, Australian engineering could not continue to contribute to global projects.”

So is the integration of Australian engineering teams in global product development projects likely to be a continuing and escalating trend?

Austrade’s industry leader for auto and advanced manufacturing, Hayden Williams, advises that in the automotive industry this is a growing practice at the motor vehicle producer and major component manufacture levels, as well as the aerospace industry.

“Probably the best recent example was GKN’s participation in the F35 ‘joint strike fighter’.

“As the automotive and aerospace industries are truly global with global supply chains, this is one way Australian-based research and development will be competitive going forward,” Williams said.

Dassault Systemes Australia 02 9238 6312 www.3ds.com

NEWS ANALYSIS

USER CONFERENCE

Invensys pushes real-time results Real-time data integration was the theme at the Invensys OpsManage event, writes Isaac Leung.

THE 2010 Invensys OpsManage Australia and New Zealand user conference took place in Sydney on 8-9 November 2010. The key theme at the event was “Real Collaboration, RealTime Results” and centred on the realtime integration of data from all levels of process-centric companies, from production through to ERP. Attendees had an in-depth look at how InFusion ECS allows Operational Excellence across control, asset, productivity and environment and safety, through sessions across four tracks covering Process Control, SCADA, Safety and Critical Control, and Wonderware Business Intelligence.

Running together with the conference was an exhibition featuring 16 technology booths from Invensys Operations Management and its partners, including Pepperl+Fuchs, Advantech and Efficientia.

Attendees also got the chance to visit the ANSTO, Wrigley’s or Colgate-Palmolive facilities on the third day, or attend additional workshops. Networking events included a cruise around Darling Harbour and recreational activities.

Tony Ho, vice-president of sales and marketing, addressed conference dele-

gates in a presentation titled “Operational excellence: the real time frontier for sustainable value creation”.

“We need to get real time information so that we can get measurable results that link back to the strategy the company is embarking upon,” Ho told the audience.

This real-time information allows contextualising of changes, be it mitigating the risks to clients emanating from changes on the plant floor, or adjusting processes in response to changes in market demand.

He identified a number of key problems with getting real-time information transfer between different levels of control. Business and strategic controls, for example, tend to characterise time in years, quarters and months, while production and process controls on the plant floor operate in hours, minutes, seconds and milliseconds. Synchronising these time units present a real challenge.

Additionally, there are typically 150 different solutions, tools and systems present in the various layers of controls in any given enterprise. Invensys claims integrating these and linking the different layers is the key for real-time solutions. While connecting, measuring, controlling, visualising, modelling and

SOLUTION: The OpsManage conference in Sydney featured technical booths from Invensys and its partners.

scaling are important tasks, Ho says the focus needs to be on managing these within a single instance.

Invensys says the holistic nature of its IOM framework is in response to the convergence in technology and customer demand. IOM is a platform for launching integration and synchronisation efforts. It is agnostic to any vendor, allowing the use of data and devices from different manufacturers.

According to Ho, the industry has reduced capital expenditure investment

over the recent years, but solutions such as those offered by Invensys and its partners provide measurable returns, and operational excellence is based not on a one-time investment, but on a continuous process of investment and returns.

While acknowledging the difficulty of achieving real-time integration, Invensys says it has developed a roadmap and a journey, with demonstrable products and solutions which will achieve the results its customers demand. iom.invensys.com

DESIGN

Intercad debuts SolidWorks 2011 in Australia

LOCALISED: The built-in SolidWorks SustainabilityXpress module now includes data from Australia.

INTERCAD has worked with vendor partner SolidWorks on the inclusion of Australian-specific improvements targeting sustainable design in the latest version of 3D CAD/CAM software, SolidWorks 2011.

The built-in SolidWorks SustainabilityXpress module within SolidWorks 2011 now includes data from Australia on materials, transport and manufacturing processes. Australian designers can use this functionality to not only ensure their products are ecofriendly but also evaluate the environ-

mental impact on parts that are produced in other regions, off shore manufacturing and distribution around the world. In addition to usual parts and materials, customised materials can also be added to the database.

SolidWorks 2011 also includes hundreds of other refinements, many based on feedback from the global SolidWorks community. Headline improvements include a boost to drawing functionality, new technology for thermal simulations, an enhanced user experience through memory and

interface improvements, and new tools for greater collaboration with suppliers, partners and manufacturers.

“We worked closely with SolidWorks on including Australian information in the SustainabilityXpress module for this release,” says Max Piper, CEO, Intercad.

“Our account management and services teams work directly with our customers to help solve their business issues so we know green design is one topic on their minds. We provided that feedback to the SolidWorks engineers for this module.” www.intercad.com.au DECEMBER 2010 www.pacetoday.com.au 7

NEWS ANALYSIS

FIELDBUS

Profibus PA Profile 3.02 simplifies The launch of Profibus PA Device Profile 3.02 addresses the interoperability shortcoming that has plagued the technology since the introduction of the PA protocol in 1998, writes Andrew Dummett.

INTEROPERABILITY describes the ability to exchange a measuring or controlling device from one vendor, with a device from another complying vendor, without disruption to the process. In theory this should have been possible since the inception of Profibus PA, but this has not been successfully implemented so far. The new Profibus PA Device Profile 3.02 resolves this issue.

In spite of the ever increasing complexity of technology, the integration of field devices in control systems should still be as easy as for 4-20 mA technology. While 4-20 mA technology involves transferring only a single piece of information, the process variable (PV), between the device and the system, much more information is transferred on the fieldbus. Examples of data that may be transferred include the status of actuators for predictive maintenance or more precise measured values for intelligent process control.

This information will be critically necessary in the future. The complexity of plants is rising, while the number of employees operating them is falling. At the same time, product quality requirements are becoming more stringent; variations in quality are no longer tolerated.

Analogue devices, although undeniably simple, cannot meet these challenges. Rather, the diagnostic possibilities of an intelligent field device are required. However, the problem of field device integration has proven in recent years to be anything but a selling feature for the introduction of fieldbuses in the process industry. Installation of new patches and service packs and switching to new device versions and control systems during the service life of a plant led to unmanageable situations in terms of device replacement. In particular, the ability of users to manage the life cycle of devices was limited.

“Device failures also happen at inconvenient times, such as at night or on the weekend or when the personnel on-site are not experts in automation systems," described John Immelman, 8 www.pacetoday.com.au DECEMBER 2010

LABORATORY: The testers focused on replacement of an existing device – in this case an actuator – while the process is running. The display of status signals according to NE 107 in the event of an error was also checked.

President of the Profibus Association of Australia. “Nevertheless, it should be possible for a user to replace a field device without any special knowledge about digital communication technology. The new profile really makes life easier in these scenarios,” noted Immelman about the Profibus PA Profile 3.02 introduced this year. The application profile defines vendorneutral device parameters and functions for a wide variety of device types. This creates a basis for ensuring the compatibility of description files (GSD, EDD, DTM) and field devices. For example, it is possible for integration tools to automatically assign a description file to a device, thereby simplifying engineering procedures (such as during initial installation of a field device).

Up to now, the use of manufacturerspecific description files meant that users were encouraged to replace a field device with an identical one. The Device Profile 3.02 bridges this gap, as the new field device now automatically assumes the device version of the old device. To achieve this, the tasks of the predecessor

model are determined and the device assumes its functionalities without any interruption in the process.

The replacement device thus presents itself to the control system as its predecessor, even thought it may contain technology that is 10 years more advanced. Then, during a subsequent planned shutdown, the new functionality can be integrated by updating the description file. The same applies to the integration of an EDD or a DTM during a device replacement. It is also possible in this case for a new device to assume the functionality of several predecessor versions (Device Revision), which is designated by the device manufacturer in a standardised manner and checked during certification.

The profile was scrutinised in the test laboratory of BIS Prozesstechnik in Frankfurt. The laboratory houses one of the world's largest multi-vendor fieldbus installations in which type tests of field devices are performed. The laboratory is also a test centre for EMC and actuator technology (SIL, CE, TA-Luft) and a PI Competence Centre for Profibus.

All test results were clear: the profile proved itself in real-world industrial scenarios and satisfied the user requirements. As Immelman concludes definitively, “We regard the results of the test as very positive, and we view the PA Profile as an important step toward simplified device replacement.”

The main goal behind the development of Profibus PA Device Profile 3.02 was to minimise the additional effort required by users when working with device descriptions on the fieldbus. At the same time, the maintenance effort over the entire life cycle of the device should be reduced.

The manufacturer describes the properties and functions of a field device on the fieldbus in a file (GSD, EDD, FDT/DTM), which the user integrates in an overall control system (for example, process control system and engineering system) using a software tool. The field device functionality is made available in the system and additional information can be generated.

To reduce the maintenance effort throughout the life cycle, a suitable version policy for devices, device files, and software platforms was necessary. It includes provisions for marking the software version on the device, the automatic adaptation to the functionality of predecessor versions in commerce, as well as vendor-neutral guidelines for modifications to device software and their effect on compatibility.

Additional profile specifications include the mandatory mapping of specific diagnostic information of field devices onto standardised categories and faster transfer of field device data, for example, during transmission of parameterised data during device replacement.

The aim of certification is to provide users with an assurance that devices from different manufacturers are capable of fault-free operation when used together. The large quantity of profilecompliant device functions facilitates uniform handling of standard device functions by users. www.profibusaustralia.com.au

OPINION

PINTO’S POINTERS

Automation creativity sleeps Lack of innovation places industrial automation in stagnant backwaters, writes Jim Pinto.

I

NDUSTRIAL automation suppliers regularly put out a stream of "new" product announcements – sensors, signal-conditioners, displays, recorders, controllers, valves, actuators and all the "stuff" in between.

But most are mere extensions and refinements of old products - nothing significant, no new creations.

Creativity is the ability to introduce something new, with value that is significantly greater than anything that already exists. All major automation innovations date back to the 1970s, mostly developed and introduced by small, start-up companies. Each represents an inflection point that generated new growth categories.

The PLC was the brainchild of prolific

inventor Dick Morley, conceived at Bedford Associates, a small development company associated with Modicon (now part of Schneider). This resulted in a market segment that has grown to several billions of dollars worldwide.

Rosemount, a start-up involved with temperature measurement, developed innovative capacitive differential-pressure sensors for flow measurement, offering major advantages over conventional products offered by Honeywell and Foxboro.

The late 70s and early 80s marked the arrival of personal computers in industrial automation. Several innovative start-ups, like Wonderware and Intellution, grew fairly rapidly with human-machine interface (HMI) PC software.

Conservative companies dominate the automation business where true creativity does not really seem to be possible.

An exception to the start-up-innovation rule was distributed control systems (DCS), developed in the early 1970s by a team of engineers at Honeywell. This product category has also grown to several billions of dollars worldwide.

These growth products all originated

decades ago. Where is the Creativity that will result in growth today?

Conservative, rule-bound companies dominate the automation business, where true creativity doesn't really seem to be possible. Smaller companies don't have the resources to create new, breakthrough categories.

In contrast with today's tech world, which seems bubbling incessantly with new ideas and creativity, industrial automation is a stagnant backwater where slow growth is simply a selffulfilling prophecy.

In today’s automation business, Creativity sleeps. jim@jimpinto.com www.jimpinto.com

Extra Functionality, Faster Testing and Rugged as Ever!

The future of Installation Testing is here, NOW

$11 0 F luk 165 e 1B

30 $1 uke

0

at prices that are The Fluke 1650B Series builds on the rugged reputation of the earlier 1650 series, only it is re-designed to meet your need for more productive test tools. These rugged testers offer there users: Dual display showing PEFC/PSC and loop impedance results in parallel Faster high current loop testing

0

Fl 2B 5 16

Variable RCD current modes for customised settings

PASS/FAIL indication for RCD tests

$22 Flu 0 0

k 165 e 3B

Promotion effective till February 28th 2011.

Prices are recommended trade price, excluding GST.

Fluke 1651B: The everyday tester, for every electrical installer Fluke 1652B: The ideal tester for professional trouble shooters Fluke 1653B: The complete tester for advanced users

02 8850 3333 sales@fluke.com.au www.fluke.com.au DECEMBER 2010 www.pacetoday.com.au 9

OPINION

VIEWPOINT

Why care about PAS 55?

An asset lifecycle management program offers benefits, writes Paula Hollywood.

T

HE ABSENCE of standards for managing physical assets leaves technology suppliers with little direction on how to design appropriate products, and industrial enterprises with no guidance for developing initiatives. This can be particularly problematic for multinational organizations.

Formal industry standards provide a framework for both economies of design and improved product and service quality. Standards facilitate interoperability, production improvements, and scalability of asset management programs among different industries and between plants. Standards can also help improve quality of life by contributing to safety, human health, and environmental protection. Unless mandated by regulatory bodies, standards compliance is voluntary; however, it demonstrates an organization’s commitment to quality, performance, or safety.

PAS 55 is a general standard for managing physical assets. Thus, it is particularly relevant for asset-intensive enterprises. Originally launched in 2004 under the leadership of the Institute of Asset Management (IAM), it was intended for regulated infrastructure and public utilities, but has since garnered interest in a variety of non-regulated industries. It was updated in 2008 with input from 50 organizations in 10 countries, representing 15 industry sectors.

Asset management The structure of the standard is analogous to Deming’s Plan-Do-Check-Act (PDCA) continuous improvement cycle utilised in quality management systems.

Any strategic asset management plan should reflect the overall objectives of the enterprise. Once the plan is implemented and key performance indicators established, they should be measured and actions taken to improve performance. Under the guidance of the IAM, organizations such as Lloyd’s Register offer PAS 55:2008-1 assessment, training, and certification services. Many enterprises will recall similar programs 10 www.pacetoday.com.au DECEMBER 2010

when obtaining ISO 9001 certification for quality management systems. PAS 55 certification requires an enterprise to optimally manage capital investments, daily operations, maintenance, resources, risks, performance, and sustainability for all its assets.

To date, PAS 55 adoption has been largely limited to electricity and gas distributors in the UK where compliance is mandatory, but has also expanded into the railway and water sectors in that country, as well as into other countries, including Australia, New Zealand, and China. In 2008, SP AusNet, a major electricity and gas distributor based in Melbourne, became the first company in Australia to be certified to the PAS 55 standard. MTR Corporation, a leader in mass transit rail services, attained PAS 55 certification for its Kowloon-Canton rail line in Hong Kong and is committed to adopting the PAS 55-1 specification for all future rail lines to demonstrate its commitment to achieving the highest standards in reliability, safety, and efficiency.

Many other organizations around the world already use PAS 55 as an assessment tool to help develop robust, sustainable asset performance management plans, but have elected not to pursue certification. These include WEL Networks, the fifth largest electricity

Finalising industrial approvals is typically a long and arduous process that can take many years. distribution company in New Zealand, which used PAS 55 guidelines to assess the effectiveness of the company’s overall asset management plan.

PAS 55: An ISO Standard?

PAS 55:2008 is a publicly available standard sponsored by the British Standards Institution. Although compliance with a BSI standard has credence in the UK, it does not necessarily translate internationally with equal significance. In August 2009, BSI filed a proposal with ISO to develop a global asset management standard for physical assets. With the support of 21 ISO country members, the proposal has been successful garnering comments.

BSI will host a preliminary meeting in April to discuss the comments and to plan future activity. ISO has assigned a formal project number to the work, PC 251, with a proposed timeline of yearend 2012 for approval. Finalising industrial approvals is typically a long and

arduous process that can take many years. However, PAS 55 appears to be on a fast track as a result of the consensus it has already attained and general interest in the subject.

In these trying economic times, the stakes are too high for enterprises to ignore the benefits that an organised asset lifecycle management program can provide. ARC’s Asset Lifecycle Management (ALM) is a multi-level model that takes a broad vision of asset management encompassing the Design & Build, Operate & Maintain, and the Evaluate & Select activities of ALM. Significantly, PAS 55 recommends what organizations should do, but not actually how to implement an ALM initiative. It does not provide detailed strategies, plans, processes, and technologies. Because every enterprise is unique, users will need support from third-party consultancies and software/hardware suppliers to accomplish corporate goals.

C-level executives interested in understanding ALM excellence from a broad perspective may consult with the ARC ALM team or make plans to attend ARC’s 2011 World Industry Forum in Florida, February 7-10, 2011 where ALM will be discussed in depth.

[Paula Hollywood (phollywood@arcweb.com) is Senior Analyst ARC Advisory Group.]

OPINION

IICA NEWS & VIEWS

Edric Ferdinands, BM Components Rockwell Automation

A good year Work bears fruit, writes Dirk Kuiper.

I

T SEEMS almost impossible to register that we are virtually at the end of the first decade of the 21st century. But there it is – 2011 is just around the corner! As I look back over the past year, I feel the need to highlight just a few of the many successful achievements.

The single biggest success story of 2010 has to be the review and overhaul of the IICA’s Rules and By-Laws.

This process took over 12 months from start to finish and resulted in bringing our Rules and By-Laws into currency and practical relevance to present day needs.

The unqualified approval from the Victorian Department of Consumer Affairs in September this year was the final stage in that process.

Another initiative was the formation of the Tasmanian Branch of the Institute. This came about as a result of efforts by a number of key Tasmanian members who felt that once there was a formal branch, it would act as an impetus for driving growth in Tasmanian members.

Although the new branch is only in its early phase, it is indicative of regional interest in the IICA. Well done Tasmania, I am confident 2011 will bring success! If you are a Tasmanian resident interested in being involved with the IICA please contact Cathie Tynan at admin@iica.org.au or the Tasmanian Committee at tas@iica.org.au We are extremely fortunate in having gained the services of Graham Moss, the IICA Training Manager. Graham has worked tirelessly in taking on responsibility for our educational courses and related matters, including working on converting the ISA training courses to Australian Standards.

The ISA Training Course calendar for 2011 is currently being reviewed and a wide range of courses are being scheduled around Australia. Keep an eye on your inbox or the IICA website at www.iica.org.au to see what is coming up in your area.

The ISA Training Course calendar for 2011 is currently being reviewed and a wide range of courses are being scheduled around Australia.

Members will recollect that Federal Council approved the renewal of an updated Fellow Membership category for the Institute late last year.

New criteria were drawn up and approved by Council and a Fellow Review Committee comprising existing Fellow Members Ian Gibson, John Dusting, John Bergin and Gavin Willox was set up. A trial application procedure was commenced with a number of potential candidates who looked as though they might meet the criteria.

After what turned out to be a rather lengthy process, including the need for some relatively minor, but necessary adjustments to the criteria, the Fellow Review Committee was satisfied that both the Application and the Selection processes are now working well.

I’m pleased to announce that four Fellows have been appointed under the new criteria. They are Kevin Barnes from Perth Branch and Phillip Ring, Geoff Rogers and Bob Weiss from Melbourne Branch. Congratulations to each of the inaugural new Fellow Members! There is no change to the Fellow Membership held by previous Fellows.

Finally, to every IICA Member and his or her family, I wish each of you a very happy and safe Christmas, and look forward to a successful and rewarding 2011.

[Dirk Kuiper is IICA Federal President.]

Optimising controlpanel design

S

WITCHBOARD and control-panel design and installation can have a significant impact on the performance of automation and control applications.

Flawed design and installation methodologies and incorrect hardware choice can cause operational inefficiency, overheating and present potential safety hazards. By optimising control panel design, installation and ongoing maintenance, end-users can minimise risk, while maximising application uptime and operator safety.

To assist industry in designing and implementing safe, high-performance control panels, Rockwell Automation offers a series of instructional software applications. Ideal for switchboard builders, system integrators, electrical contractors and design engineers, the intuitive step-by-step software tools simplify hardware selection, system layout and component interoperability.

Available now, are ‘Mounting System Solutions’ and ‘Temperature Rise Calculation’ software tools. These are to be complemented by soon-to-be released software tools dedicated to short circuit calculation, motor protection and energy management. All software tools incorporate current and relevant industry standards, simplifying mandatory compliance requirements.

The software tools feature innovative inter-module linking functionality. Here, data inputted into one software tool can be exported to other applications, removing the need for manual data re-entering and ensuring consistency in design and performance calculations. Furthermore, bills of materials, CAD drawings and wiring diagrams are automatically produced, simplifying component selection and compatibility, while minimising switchboard design and manufacturing lead-times—all contribute to safer more cost-effective control panels and switchboards.

For more information, visit: www.rockwellautomation.com

IICA 1300 781 715 www.iica.org.au DECEMBER 2010 www.pacetoday.com.au 11

BEHIND THE SCENES

Automated baking system gets boost A software solution has helped Auto-Bake improve its operational flexibility and product consistency, increase plant uptime, improve diagnostics, reduce costs and reduce workload, writes Paul Brennan.

A

UTO-BAKE, a producer of commercial machinery for the baking industry, has been in operation for thirty years. With headquarters in Sydney, Auto-Bake designs and produces automated continuous baking systems for its global commercial food customers.

As a registered member of the Wonderware SI Program, Auto-Bake first deployed an operator interface using Wonderware’s InTouch HMI software in 1999. At the start of 2003, Auto-Bake standardised on the Wonderware Supervisory HMI Software Solution with Touch Panel Computers from Wonderware’s line of Industrial Computers. To date, more than twenty Auto-Bake lines have been installed or upgraded to the Wonderware Supervisory HMI Solution featuring Industrial Computers bundled with InTouch software.

Wonderware Distributor Metquip Systems helped Auto-Bake upgrade its legacy touch-screen panels to Wonderware Touch Panel Computers.

“Auto-Bake engineers were looking for an independent supplier of touch panels to replace some [proprietary] technologies that had become outdated.

They also needed an interface that would work equally well with both Rockwell Automation and Siemens programmable logic controllers (PLCs).

They felt that Wonderware was the best partner for this,” said Kevin Adair, senior technical applications consultant with Metquip Systems.

While Auto-Bake personnel have enjoyed the attractive stainless steel appearance of their Wonderware Touch Panel Computers, what they especially appreciate is the time and effort they have saved from the pre-installed InTouch software. Pre-installation means that the operating system and Wonderware software have been installed and configured to work optimally together – reducing potential enduser issues with pre-requisite software, configuration and compatibility.

Auto-Bake’s Serpentine systems blend 12 www.pacetoday.com.au DECEMBER 2010

SNAPSHOT

BENEFITS DELIVERED

SAVINGS: Auto-Bake staff can monitor equipment and processes remotely.

traditional baking practices with modern technology to provide baked goods that look, feel and taste “homemade.” The baking system uses a vertical oven, through which chain-suspended pans and trays move along a vertical “S” serpentine path.

The advantages of this method over a conventional oven system include reduced footprint for the same baking capacity and increased flexibility. Simply changing the trays and pans in the oven enables the bakery to change products, for instance, from cakes to muffins or cookies. In addition, the compact vertical ovens facilitate more precise control of temperatures for each level or zone, resulting in more even baking and improved consistency.

“Wonderware Touch Panel Computers and InTouch software cut down development time, so that we can put more time into improving the functionality and aesthetics of the operator interface,” commented Peter Collett, electrical engineer of Auto-Bake.

Wonderware Touch Panel Computers provide both historical data logging and alarming. Once records are stored, the production-line operator simply selects a product or recipe name from the menu to load a parameter set to the control system.

This technique automatically populates individual control settings, which enables very quick changeovers between production runs without having to reprogram for each product. Moreover, the Touch Panel Computers provide simple access to stored baking schedules, so that operators can execute product changeovers with the touch of a finger.

Language support Additionally, as a result of the InTouch software’s integrated security functions, only operators with the appropriate security levels can modify, delete or save existing product recipes. Recipe profiles are saved to the internal hard disk, permitting very large numbers of files to be stored. The InTouch software’s

• Increased plant uptime through improved diagnostics and troubleshooting functionality. (These features are built in and thus do not require additional software or PLC programming.)

• Remote troubleshooting via an HMI that provides both visualisation and control • Reductions in the number of personnel required to operate the baking line • Data logging of process values, and a historical audit trail of alarms and events • Decreased maintenance costs and downtime • Fewer on-site visits, which reduces travel costs • Decreased overall testing and commissioning times • Global language support, in which a single button enables immediate switching between English and other local languages online • More attractive and intelligent graphics that leverage Wonderware’s SmartSymbol technology • Internet Protocol (IP) cameras that monitor and control the production line from a single location

connectivity options also permit straightforward back-up and synchronisation to external systems and devices.

The InTouch software’s multiplelanguage support was the deciding factor for Auto-Bake’s upgrade to Wonderware Touch Panel Computers. Auto-Bake markets its products worldwide and, thus, must support numerous local languages. The ability to develop a project in a single language and then export all text via industry-standard XML has reduced the time and cost to develop and support multiple language translations. Once exported, the XML

files can be sent to a translator and later re-imported to the application without requiring developer expertise. Minor additions or grammatical corrections can be easily implemented on site by the customer and updated into the application. During training sessions, product development stages and support situations, the local operators and Englishspeaking Auto-Bake staff can work alongside each other by quickly toggling between languages. Previously, either no English language existed after translation, or two separate developments of the same application were required. This was very difficult to manage, and inevitably, revisions were not kept up-todate in both applications.

Since the InTouch software has given Auto-Bake language-switching capability, Auto-Bake has shipped several baking machines that offer support with English and a second language – including Spanish, Norwegian and Japanese.

The earlier problem of developing HMI applications in multiple packages extended beyond issues of language trans-

The baking system uses a vertical oven through which chainsuspended pans and trays move along a vertical S serpentine path. lation because Auto-Bake’s previous system consisted of proprietary hardware and software on different isolated machines. Extraordinary effort was required to keep data consistent and upto-date because the engineers had to develop on separate, disconnected systems.

Prior to this implementation, AutoBake had to do some work on one computer and some on another, and the two systems were too hard to synchronise. Now, with Wonderware, they are able to do all of the work in a single HMI application, without wasting time catching up between the different

platforms. The Wonderware software works with all of the different brands of PLC hardware.

System monitoring The Auto-Bake Serpentine line is fitted with several IP cameras that are connected to the dedicated Ethernet LAN of the line. Through Wonderware’s InTouch HMI, personnel can select a camera and view the images captured by the camera as a video stream directly into the software. The IP cameras enable a single operator to monitor and control the complete production line from one location. What’s more, Auto-Bake employees can now monitor equipment and processes from a remote location, saving time and expense by reducing travel to each individual customer site. By enabling its staff to see what’s happing in the plant without actually being there, the support and response times that AutoBake can provide to its customers is greatly improved. Now Auto-Bake personnel can usually resolve equipment issues and provide advice on optimal

baking processes remotely from AutoBake’s offices in Sydney.

“The Wonderware software’s standardised development tools make it easier for us to handle a variety of modules and configurations,” added Peter Collett. “We can now manage a higher volume.”

In addition, Auto-Bake has noticed that the quality of their end-products has improved because the team can now spend more time on quality assurance and less time replicating the same data on multiple computers. The Wonderware Supervisory HMI Software Solution has helped Auto-Bake improve its operational flexibility and product consistency and improve diagnostics.

[Paul Brennan is Senior Electrical Engineer, Auto-Bake.]

Invensys Operations Management 02 8396 3500 iom.invensys.com Metquip Systems 02 9763 5422 www.metquipsystems.com.au

DECEMBER 2010 www.pacetoday.com.au 13

BEHIND THE SCENES

Compact robots pack a punch From quality enhancements to lowering scrap rates, small-footprint IRB robots have been able to deliver a raft of productivity gains, writes Hartley Henderson.

A

N INDUSTRIAL robot supplied by ABB Australia and recently installed by Applied Automation & Engineering is delivering significant benefits for a manufacturing company in the Melbourne suburb of Melton.

MHG Plastic Industries, with some 140 employees, is a leading manufacturer and innovator of protective, functional and decorative automotive parts and accessories including body side mouldings, wheel covers, grilles, mudflaps and fender vents.

The company’s plant at Melton is an 8,000m2 state-of-the-art facility equipped with computerised injection moulding machines and extruders.

ABB Australia’s Olivier Coquerel says the IRB 4600 robot supplied to MHG enables more compact manufacturing cells with increased production output and higher quality.

“Greater process speeds and lower scrap rates mean improved productivity, and the new compact and optimised design enables flexible floor, tilted, semi-shelf, or inverted mounting,” Coquerel said.

“The small footprint of this compact robot, with its slim swing base radius, fine elbow behind axis 3, small lower and upper arms, and compact wrist, means that your production cell can be created with reduced floor space by placing the robot closer to served machines.”

Steel tubes Applied Automation & Engineering managing director, Andrew Shaw, says that the IRB 4600 robot installed at MHG is utilised to handle blank hydroformed steel tubes into a JSW1300 injection moulding machine (IMM), and the over-moulded automotive frontend bolster assembly tubes (or RGOR’s) out of the IMM. “The steel tubes are conveyed into the cell where they are over-moulded, checked for absent runner, trimmed, and then conveyed out of the cell as an RGOR. This process commences with 14 www.pacetoday.com.au DECEMBER 2010

AUTOMATED: IRB4600 robot tending an injection moulding machine.

the tubes being loaded onto the infeed conveyor which transports them into the cell where they are singulated prior to being picked by the robot. The infeed conveyor can accommodate 35 minutes of production,” Shaw explained.

“The robot is fitted with an end-ofarm tool (EOAT) that can handle both a blank hydro-formed steel tube and an RGOR at the same time.

“During normal operation, the robot picks a tube from the infeed conveyor, moves to a holding position, and waits for the IMM tool to open. The robot then moves into the tool and collects the completed RGOR. “The EOAT then rolls over and places the blank tube into the mould before exiting the IMM with the RGOR. “The robot then positions the RGOR over the attribute station to ensure, via stationary photo electric sensors, that all of the runners are

A production cell can be created with reduced floor space by placing the robot closer to served machines. attached. On confirming this, the robot loads the RGOR into the trim station.

“A trimming tool on the EOAT proceeds to trim all runners from the RGOR and trimmed waste is collected in a waste bin beneath the trim fixture for recycling. With trimming completed, the robot picks and places the RGOR onto the outfeed conveyor, which delivers it back to the operator.”

According to Matthew Mannix, product engineer at MHG, the robot has provided significant productivity improvements, as well as other benefits.

“Some 15-20 seconds has been taken

out of the cycle time, with the machine only operating at 25 per cent capacity,” he said.

“There has also been perfect consistency of product and a significant increase in quality. In addition, there are substantial safety and ergonomic benefits. The structural members for the front end of cars that we produce have holes and sharp edges, but the robot takes away the need for manual handling.”

Carpet manufacturing Godfrey Hirst Australia (GHA) is a totally integrated manufacturer of both woollen and synthetic tufted carpet, and the largest supplier of carpet into the Australian market. With over 1,000 employees, GHA has manufacturing facilities in Geelong, Melbourne, regional Victoria and New Zealand.

The company recently expanded its modular carpet manufacturing facility to

improve manual handling and to increase capacity.

Group engineering manager, Brian Cassidy, says several bottlenecks were identified and solutions designed and implemented which resulted in a doubling of output.

“Technologies from several sources were utilised in the design of this modular carpet tile manufacturing process. Conceptual design was developed by GHA with individual design input from the various suppliers,” Cassidy said.

“Equipment was sourced out of Germany to assist us with the handling of the modular carpet tiles. This included single filing, bevelling, inline check weighing, flipping and stacking.

“A wrap around case packer was selected for the packaging solution and was designed and manufactured by HMPS of Adelaide.

“It was decided to use robotic palletising as this solution provided the versatility required for future development. The palletising cell was manu-

factured by Automation & Innovation of Melbourne.

“To maintain and enhance the high quality of the modular carpet tiles, an automated two-station inspection system has been developed in conjunction with Industrial Photonics of Sydney.

This involved the introduction of

cutting edge technology previously not seen in the carpet industry.”

Automation and Innovation’s Walter Meyler says that the palletising solution was designed utilising 3D CAD. “Equipment supplied included an ABB robot (IRB 660), a fully automated pallet dispenser with a 20 pallet capacity,

an infeed conveyor with accumulation capacity of 15 boxes, a slip sheet dispenser, and a vacuum head to pick up two boxes at a time,” Meyer said.

“Control equipment was sourced from Allen Bradley, Festo Pneumatics and Sick, and our electrical integration partner Sage Automation was key in bringing this control gear together.”

Cassidy advises that the overall project has proven to be very successful with a significant increase in production achieved, along with a reduction in manual handling and a further increase in the quality control associated with the entire integrated production process.

ABB Australia 03 8544 0000 www.abb.com Applied Automation & Engineering 03 9545 5011 www.appliedauto.com.au

IMPROVEMENTS: GHA’s Brian Cassidy (L) and Colin Fitton have been involved in all stages of the modular carpet tile automation project.

Automation & Innovation 03 9547 8178 www.ai-oz.com.au

DECEMBER 2010 www.pacetoday.com.au 15

IN FOCUS

How to use a regulator to reduce time Process measurements are typically instantaneous but analyser responses are subject to delay which can often be

P

ROCESS measurements are instantaneous but analyser responses never are. From the tap to the analyser, there is always a time delay. Unfortunately, this delay is often underestimated or misunderstood.

For now, we will focus on the field station and the important role of a regulator in reducing time delay there.

Minimising time delay begins with the location of the tap.

It is best to locate the tap as close to the analyser as possible, but it should be upstream of sources of delay, such as drums, tanks, dead legs, stagnant lines, or redundant or obsolete equipment.

Transport lines When sampling a liquid, pressure at the tap should be sufficient to deliver the sample through the transport lines or fast loop without a pump, an expensive component that introduces performance variables.

In many cases, you may not be able to dictate the location of the tap. You may have to make do with an existing tap location, and often, an existing analyser shed location as well.

If the tap is a long distance from the analyser, a fast loop is recommended as a means of quickly delivering fluid to the analyser and returning the unused portion to the process.

In most analytical instrumentation systems, another source of time delay is the probe. The larger the probe’s volume, the greater the delay.

Volume will be affected both by the length and width of the probe.

Therefore, when attempting to minimise time delay, choose a low-volume probe.

Field station In cases where the analyser requires a liquid sample, a regulator in the field station is not employed. It is better to keep liquids at high pressure to avoid the formation of bubbles.

In the case of a gas sample, a field station is employed as a means of reducing pressure in the transport lines.

16 www.pacetoday.com.au DECEMBER 2010

FIGURE 1: Basic sections of an AI sampling system.

Time delay decreases in direct proportion to absolute pressure. At half the pressure, you will get half the time delay. The field station is located as close to the tap as possible. The sooner the pressure is dropped, the better.

Different configurations Let’s look at three possible applications for a regulator. With each, the regulator is configured somewhat differently. In the first application, the objective is to reduce gas pressure.

The pressure drop is not expected to produce condensation. Therefore, a simple pressure-reducing regulator may be employed.

A pressure-reducing regulator maintains constant pressure at the outlet. A thin metal diaphragm within the regulator flexes in response to downstream pressure, allowing a cone-shaped poppet to regulate the size of the orifice through which the gas passes.

As the diaphragm flexes up in response to higher pressure, the opening is smaller. As the diaphragm relaxes with lower pressure, the opening is larger.

Outlet pressure A dial (handle) on the regulator allows the operator to set the outlet pressure.

A metal diaphragm is ideal in applications where the inlet pressure does not

In applications where the pressure may be inconsistent or spike a piston-style regulator may be more appropriate. vary sharply.

However, in applications where the pressure may be inconsistent or spike, a piston-style regulator may be more appropriate.

In our second regulator application, the objective is to reduce gas pressure.

delay in an analytical system underestimated or misunderstood, write Doug Nordstrom and Mike Adkins.

Lose heat with pressure drop However, in this case, the pressure drop is expected to cause condensation. With a drop in pressure, almost all gases lose heat, which is known as the JouleThomson effect.

If the gas is close to its dew point, the result from this cooling is condensation. In some cases, the loss of heat may be great enough to cause the regulator to freeze up.

Heated regulator When the Joule-Thomson effect is in play, a heated regulator may be required to keep the temperature of the gas above the dew point.

A heated regulator is a pressurereducing regulator in which the system fluid flows over a heated element. A heater cartridge is required.

You can calculate the number of watts required of the heater cartridge so you buy one in the right power range.

Every gas has a Joule-Thomson coefficient, which is plugged into a formula along with the pressure drop and flow rate to produce the number of watts required.

[The formula for calculating required wattage is Pw = Qn Cp DeltaT, where the wattage (Pw) is proportional to molar flow (Qn), heat capacity (Cp) and the amount of cooling from the JouleThomson effect (DeltaT).]

Gas chromatograph In our third regulator application, a liquid must become a gas before it can be analysed by a gas chromatograph or other analyser.

In this case, a vaporising regulator is employed. Vaporising regulators are tricky but if properly sized and installed, they can be a reliable means of preparing a liquid sample for analysis in a gas analyser.

The objective of a vaporising regulator is to instantly flash the entire sample into a gas, which requires a lot of heat in just the right location. The heat must be applied at the precise location of the pressure drop.

With vaporising regulators, one must pay close attention to flow. If the flow is too great, the sample will be only partially vaporised and liquids will flow through the regulator and toward the analyser. If the flow is too little, the liquid sample upstream will be vaporised.

Volume increase Finally, be sure to set up your vaporising regulator correctly or you will create considerable time delay. As the fluid changes from liquid to gas, volume will increase dramatically. The rate of increase will depend on the liquid’s molecular weight.

Typically, the measured vapour flow after the regulator will be > 300 times the liquid flow before the vaporising regulator.

For example, with a vapour flow of 600 cm3/min, liquid flow may be less than 2 cm3/min.

Therefore, the liquid will take 25 minutes to travel through 3m of 6 mm tubing. To reduce this time, we must reduce the volume of the tubing preceding the regulator.

Faster response For example, with only 0.3m of 3 mm tubing, it would take only 30 seconds for the liquid to reach the regulator. To this time, however, we must add time delay in the probe. The narrower the probe, the faster the response.

Another means of attaining a faster response is to move the regulator closer to the analyser with the aid of a second fast loop.

In Figure 2, the regulator is located after the fast loop filter with a second liquid fast loop ensuring that good liquid flow continues right up to the vaporising regulator.

The objective is to minimise slowmoving liquid volume going to a vaporising regulator.

Time delay A regulator is a critical tool in addressing time delay in an analytical system.

FIGURE 2: In this configuration, the vaporising regulator is located after the fast loop filter. A second bypass loop eliminates the long delay that normally occurs on the liquid side of the vaporising regulator.

By reducing pressure, you reduce time delay.

The lower the pressure in a gas system, the faster the response time. In general, the sooner the pressure can be dropped in a system, the better.

In cases where a liquid is being vaporised, remember to make intelligent use of fast loops. The objective is to keep the liquid moving right up to the vaporising regulator.

The field station is one place in a complex analytical system where time delay can be significantly reduced, but the approach to time delay must always be comprehensive.

To reduce time delay, all potential causes of delay in the system must be scrutinised.

[Doug Nordstrom is market manager, analytical instrumentation and Mike Adkins is general industrial valve product manager, both with Swagelok Company.]

Swagelok Company 03 9355 3500 www.swagelok.com.au

TECH TIPS

INSTRUMENTATION Time delay is defined as the amount of time it takes for a new sample to reach the analyser. One way to control time delay is with a regulator. Regulators control pressure, and pressure in an analytical system is closely related to time. In the case of gas systems with a controlled flow rate, the lower the pressure, the shorter the time delay.

Delay may occur in any of the major parts of an analytical instrumentation system (Figure 1), including the process line, tap and probe, field station, transport line, sample conditioning system, stream switching system and analyser.

Time delay is cumulative. It consists of the total amount of time it takes for fluid to travel from the latest step in the process line to the analyser, including time required for analysis in the analyser.

DECEMBER 2010 www.pacetoday.com.au 17

IN FOCUS

Simulation: promise vs. reality Engineering simulation can cut manufacturing costs and time but working out a favourable return on investment is one of the technology’s many challenges, writes Stephanie McDonald.

P

ARTLY art but largely science, simulation allows users to manipulate 2D and 3D CAD models to simulate the physics of how a structure or a process might form in a virtual/digital environment.

But like most technology, it is not without its challenges – working out a favourable return on investment, upskilling employees and deciding how much of the design process simulation can replace. There is currently a range of simulation software on the market, including some of the most popular – Femap and NX Nastran – for use in structural, mechanical, thermal and fluids finite element modelling and analysis. Other products cover FE modelling and simulation (NX Advanced Simulation) and injection moulding optimisation (Moldex3D and winLIFE).

The main benefit of simulation is it reduces costs and time as it lowers the number of physical prototypes required.

It also reduces errors in the design process. Vernon McKenzie, director at EnDuraSim, told PACE the cost benefit of simulation for high value products such as airplanes and spaceships are 18 www.pacetoday.com.au DECEMBER 2010

SIMULATION: Femap with NX Nastran with finite element analysis software is used in structural, mechanical, thermal and fluids finite element modelling and analysis.

obvious – situations where a prototype would be extremely costly or not possible. When working out the cost benefits of lower value products such as small mechanical products and structural products and process, the same ROI is yielded. The only difference is the model and equation are smaller.

The cost benefit equation has several inputs. For example, comparing the cost of a prototype (including material and labour costs) and the cost of revising the physical prototype if an error is found to the cost of running numerous iterations in simulation software.

“Even though the simulation might not get it exactly right because it’s fairly complex physics, it gives [users] more insight into what parts of the product is doing the work when the … test is performed,” McKenzie says.

He believes the cost of the software and computing power required is relatively low. The main financial expense is hiring either a consultant to carry out and analyse simulation results or

employing or training an engineer inhouse to carry out those tasks.

According to McKenzie, it can take from 12 to 18 months for a person to become completely competent in simulation capabilities. The skills shortage has exacerbated this time. “We know of customers who will spend 12 to 18 months trying to find people who are experienced in this area. They might find a graduate who has a little experience in this sort of technology at university. That means they then go through the process of training people to become experts in this area,” he says.

EnDuraSim can train engineers on specific jobs. This method of training can give users a quicker learning process, but McKenzie concedes it can still take a while for users to become fully competent.

“For us, that’s our biggest concern for customers getting value for money – whether they should be getting us to [consult] or whether they should be developing this expertise in-house and making the effort to do this sort of

work themselves,” McKenzie says.

He believes companies should be developing the expertise in-house, particularly if engineering design makes up a large part of their company and where intellectual property is at stake. “I don’t believe they should be outsourcing the simulation aspect of that,” McKenzie says. “I think they really should make the decision that this is technology that they should be developing expertise in and using the advantages of simulation within their own organisation.”

The cost benefits may not always be immediate or even quantifiable. GRG Consulting Engineering has been using simulation software for around 2.5 years for the analysis of steel structures, tank analysis, structural connections and mechanical components.

“At this point in time, I do not believe there has not been significant cost savings,” says Graeme Klee, senior design at GRG Consulting Engineers.

“However, GRG Consulting Engineers

do not use the software package on a day-to-day basis and as such, the biggest challenge due to the lack of regular use is [it is] difficult to be conversant with the diversities of the software and the various options available in its dialogue boxes. [However], the software has broadened GRG’s scope to a wider range of more complex design projects that can be undertaken, therefore exposing GRG to a broader engineering market.”

A big advantage of simulation is it provides insight into several aspects of product development – which parts didn’t work, but also aspects which did work. This allows engineers to not only assess errors, but also to look at whether areas have been over designed or where they could be better optimised. These insights may not be gleaned from physical tests. Although simulation may seem most suitable for large companies, EnDuraSim’s clients range from one person organisations to mid-level companies with 15 staff to much larger companies. The key for smaller companies making the most of simulation

TEAMWORK: EnDuraSim’s Vernon McKenzie (L) and Graeme Klee of GRG Consulting Engineers.

comes back to expertise and whether they choose to develop it in-house or use consulting companies.

“That decision is not a trivial decision because it involves either a high cost in terms of a person they’re going to employ and how much time that person will be used in that particular area of their expertise, or if they develop up a person, how long is that going to take?”

McKenzie says.

Simulation has theoretically meant

prototypes aren’t required, but McKenzie is adamant this process should not be entirely eliminated. He recommends a physical testing program to calibrate simulation processes to provide external validation of simulation results. Otherwise, the simulation will work on a user putting in all information correctly, which may not always occur. Without checking simulation results, the risk of errors at the end increases.

Despite McKenzie’s warnings, it seems the industry is heading in this direction. Several years ago, Toyota announced it would increase its reliance on designing cars in a digital environment and cut back on prototypes. The company was this year plagued by recalls, with an estimated eight million cars recalled globally.

“The connection between the practical, real world conditions and how the product operates needs to be preserved, otherwise there is that risk that the product is not going to be as good as it needs to be,” McKenzie says. “We hope that organisations that are sensible enough to invest in digital simulation technology take heed of our message, which is – don’t completely disconnect this from the physical world.”

EnDuraSim 1300 790 661 www.endurasim.com.au GRG Consulting Engineers 07 3849 5600 www.grgengineers.com.au

DECEMBER 2010 www.pacetoday.com.au 19

IN FOCUS

Putting wireless sensors into action Being able to transmit data directly from multiple wireless sensors using mesh network technology and central monitoring industrial systems is a relatively new approach, writes Motti Gill.

I

N THE last few years, wired industrial sensors have become smarter and smaller. At the same time another key development has taken place: A growing interest and utilisation of wireless sensor in industrial applications.

Scenario 1 – As an instrumentation maintenance supervisor in a mine, mineral processing or industrial plant you were asked by management to monitor a number of process temperature parameters for a period of two weeks and report the results to a metallurgical engineer. Following the completion of the first set of tests you were asked to repeat the tests in three other locations around the plant utilising the same hardware but add an alarm output Scenario 2 – While running the above tasks you receive an urgent new request from management to modify the current monitoring system and add flow and pressure parameters to your existing monitoring system. To monitor flow and pressure parameters you must add another monitoring node a short distance away from the current location.

The monitoring period for flow and pressure is scheduled for 72 hours only Scenario 3 – As a maintenance technician you were asked to monitor the plant’s production line electric motor’s ‘health’ by attaching temperature, ac current and vibration sensors to a number of motors scattered around the production area. You will be required to report of any imminent sign of motor breakdown by generating an alarm To meet such ever-changing monitoring requirements, you will need to install sensors, lay cables, install a data logger device in each location and appoint an employee to oversee these tests. You then need to ensure the downloading of data logger files on a daily basis, transfer the logged data to a PC, analyse the tests results and report to management

Points to consider • How much time will it take to install the various sensors?

20 www.pacetoday.com.au DECEMBER 2010

CONNECTED: Demonstrating the overall concept of a ZigSense wireless sensing network combined with Modbus RTU/TCP gateway interface to SCADA, HMI and PLC systems.

• Can sensors be installed ad-hoc?

• What is the cost of digging a cable trench?

• What is the cost of installing a cable tray?

• Should I install the required cable above or below ground?

• What is the cost in man-hours required to transfer data from the tests site?

• What is the cost of shifting to a new location in order to replicate

the original tests?

Many such scenarios are being addressed worldwide day in and day out by instrumentation technicians, maintenance supervisors, process engineers and plant managers.

Enter the world of wireless sensors.

Wireless data transmission between sites is nothing new in industrial applications.

Being able to transmit data directly from multiple wireless sensors using mesh network technology and central moni-

toring industrial systems is a relatively new approach. Successful integration between wireless sensors and Supervisory Control and Data Acquisition (SCADA) or PLC systems proved so far that using such technology can effectively meet the dynamic requirements of today’s industrial control systems.

What industries can make use of wireless sensors? The short answer is: almost all industries.

Wireless sensors can be easily incor-

Pulse counting applications such as water and energy metering are good candidates for battery operated wireless networked sensors.

BENEFIT: ZigSense mesh diagram. A ZigBee mesh network adds high reliability to network communications enabling it to potentially be used in numerous industrial control systems.

porated into numerous applications.

Many heating and cooling HVAC applications can wireless temperature and humidity sensors. Industrial furnaces may use RTD or thermocouple wireless temperature sensors.

Pulse counting applications such as water and energy metering are good candidates for battery operated wireless networked sensors. Monitoring of liquid level in tanks or grain level in silos is another group of applications that can benefit from this technology. Food processing and pharmaceutical plants belong to a growing group of wireless sensors users. Water quality and wastewater monitoring in remote locations are good candidates for wireless sensors One of the more important aspects of using wireless sensors is the ability to transfer data between a network of wireless nodes to SCADA stations, data loggers and PLC control systems.

Popular control systems are already installed on-site using their own serial or Ethernet cables communicating using various communications protocols.

Since these sensors use advanced communications technology known as wireless mesh networks, a gateway device will be needed in order to close the gap between the wireless network on one side and the existing wired network on the other. One of the more popular communications protocols to be used in the gateway is Modbus RTU. Modbus RTU is being used by literally hundreds of instrumentation and control systems suppliers. Other communications

protocols to be aware of are: Modbus TCP, OPC, Fieldbus, Profibus, DF1 and more.

It is important to understand that wireless sensors can be powered by both external power sources and by internal batteries. Battery power provides the user with the flexibility to relocate sensors from site to site generally simplifying the installation. When wireless sensor nodes are powered by their own internal batteries you will need to be aware of a potential slower rate of data update at the central monitoring station.

Mesh networks basics Wireless mesh networks are designed to provide high bandwidth communications channels between wireless sensor nodes over a specific coverage area.

Wireless nodes cooperatively and automatically make data forwarding decisions based on their “knowledge” of the existence of other network members.

A wireless node normally needs only

BRIDGING: A gateway device will close the gap between the wireless network on one side and the existing wired network on the other.

transmit to its closest neighbour. If a node drops out due to hardware failure or other reasons, its neighbour should automatically be able to find another route to transfer data to the next node.

ZigBee is one implementation of wireless networks. It is a low cost, low data rate and low power wireless mesh network proprietary standard. The advantage of low power consumption is translated into long operating life using smaller batteries. ZigBee mesh network adds high reliability to network communications enabling it to potentially be used in numerous industrial control systems.

conserve battery power through a SLEEP/ WAKE-UP cycle Wireless sensors can be deployed almost anywhere at a far lower overall cost than wired sensors. These devices running the latest in microprocessors and embedded wireless technology will become more acceptable and more widely used as users gain confidence in the technology.

Now that wireless sensors comply with industry standards for radio communications such as IEEE 802.15.4, ZigBee, and WirelessHART, wireless sensors are more acceptable and will become the future of communication and control networks in industrial environment. End-user adoption of this technology in manufacturing and process control plants, mines, power generation plants, maintenance instrumentation, and medical devices is already on the increase.

[Motti Gill is managing director of Conlab.]

Conlab 03 9842 7711 www.conlab.com.au www.zigsense.com.au

Issues for consideration

TECH TIPS

• Wireless sensors eliminate the need for cables, cable trenches or cable trays • Wireless sensors can be easily moved from point A to point B within minutes • A network of wireless sensors is quite flexible. New nodes can be added at any time without disturbing existing network installation or communications strategy • Standard communications interface between wireless sensors network and existing SCADA and PLC systems is essential • Always perform a wireless site survey to identify the optimum location for your wireless sensors • Wireless sensors may reach communications distance of 500m or better when installed in open space line of sight and about 30 to 100m or better inside buildings • Wireless sensors can operate for extended periods powered by very small batteries • When powered by batteries data is transferred only when required or based on a programmed sleep cycle • When powered by batteries, data transfer between wireless sensors and the central monitoring station may be delayed by a few seconds in order to

DATA TRANSFER There are three main reasons to affect data transfer rate: ❏ Wireless sensors in mesh networks are designed to ensure communications integrity in industrial environment. As such, messages between nodes and the central monitoring station are sometimes repeated. Repeating messages may introduce small delays (latency) to the overall communications response time. ❏ In mesh networks you will sometimes be required to install routers designed to extend the communications distance. Each additional ‘hop’ adds to the overall network latency. ❏ When powered only by batteries, wireless sensors are designed to conserve power in order to extend the effective life of the battery itself.

ZigBee based wireless sensors may operate for a relatively long time sometimes up-to two or even three years using Li-Ion battery cell as long as the wireless sensor node is programmed to take advantage of a pre-programmed SLEEP and WAKEUP cycle.

DECEMBER 2010 www.pacetoday.com.au 21

BEHIND THE SCENES

Control platform inks the deal The automatic filling, checking and sealing of ink cartridges with high speed and ink purity as well as precise dosage requires a powerful controller and a fast communication system, writes Jason Thelander.

T

HE INK cartridge filling machine developed by Precision Mechatronics, based in North Ryde, fills five 50 ml ink cartridges every 20 seconds. This is a complex and, from the point of view of control, very demanding task, which requires a large number of I/Os and servo axes as well as some interesting subprocesses.

When it came to choosing the control system, Precision Mechatronics decided on the PC- and EtherCATbased Beckhoff control platform with integrated Motion Control functionality: “This is not the first project in which we have cooperated with Beckhoff,” says Craig Strudwicke, engineering manager at Precision Mechatronics. “The experience gained in the past meant that we could expect the Beckhoff control solution with its high memory capacity and computing speed, integrated Motion Control and local I/Os to suit our machine design well.”

Four Beckhoff AX5203 EtherCAT Servo Drives and eight servomotors of the type AM3024 are installed in the ink cartridge filling machine. A rotary table design enables a large number of processes to be executed simultaneously in the machine. The prerequisites for this are the large storage capacity and the high processing speed of the EtherCATbased control components.

The filling plant is fed with the ink cartridges by a connected conveyor, whereby each cartridge is checked by a sight-assisted sensor for alignment and correct type of container. Subsequently, the containers are handed over to the back magazine and submitted to a sealing and pressure test.

Only then are the ink cartridges filled. The machine can fill five containers simultaneously with different colour inks. This purpose is served by a mechanism that rotates step-by-step, driven by a Beckhoff servomotor. The processes are executed in parallel, to maintain the required cycle time of approximately four seconds per container. The ink is provided by an

AUTOMATED: The filling of the containers is controlled by precision displacement pumps.

The processes are executed in parallel to maintain the required cycle time of four seconds per container. ultra-clean supply, which filters the ink, de-aerates it and doses it into the individual containers. The filling is controlled by precision displacement pumps with Beckhoff servomotors.

Seven fluid circuits allow an immediate change to a different colour.

After filling, the containers are sealed and their quality analysis data stored, before they are set down on the

discharge conveyor. The heart of the controller is formed by a compact Beckhoff C6920 control cabinet Industrial PC with TwinCAT PLC NC I automation software.

“We use TwinCAT PLC NC I, even if no interpolating movements are needed, since all movements take place independently of other axes,” explains Strudwicke.

[Jason Thelander is CEO, Precision Mechatronics.]

Precision Mechatronics 02 8875 1200 www.premecha.com Beckhoff Automation 03 9912 5430 www.beckhoff.com.au

SNAPSHOT

FULLY AUTOMATED Precision Mechatronics supplies application- and customer-specific machine solutions for various industries and several application areas.

With the development of an ink cartridge filling machine, the company is positioning itself in a niche market; but, the demands on the machine are anything but small.

The fully automatic filling, checking and sealing of the ink cartridges with high process speed and ink purity as well as precise dosage requires a powerful controller and a fast communication system.

DECEMBER 2010 www.pacetoday.com.au 23

BEHIND THE SCENES

Overcoming the solar challenge using To understand the challenges involved in clean energy production, storage and use, power companies need to

U

LTIMATELY, as consumers, we are responsible for how we use our energy resources. A forward thinking solar facility in China’s Yunnan province is taking clean power generation to a whole new level, not only providing power from the sun to nearby communities but also educating the users on how the energy is produced, the challenges involved and the role the consumer has in using energy responsibly.

The global energy crisis has been headline news for several years now and the race to find the alternative to fossil fuels still eludes us. China aims to increase the use of non fossil-energy to 15 per cent of its primary energy consumption by 2020. In fact alternative energy is big business in China expanding at an unprecedented rate.

On a personal level, I know I can help save energy by using less hot water at home, ride my bike to work instead of driving a car and take a shower rather than use the bath to save on water and heating. What I have little idea about is how alternative energy such as wind and solar is created, and how it compares to conventional energies such as oil, coal and gas in terms of efficiency, cost to produce, and integration into our community.

Hidden valley I arrive in Kunming, the laid back capital of China’s Yunnan province to begin an exciting project, to find a mythical hidden valley somewhere in the Himalayas, using pedal power. But, before I set off on my quest I have been invited to visit a new state of the art solar facility just two hours drive away in Yunnan’s Stone Forest National Park.

At 1.33 ha and boasting an output of 1.2 - 1.5 MkWh per month, it’s one of the largest of its kind in China but unlike other solar installations, the facility at Stone Forest is not only a large power producer in its own right; it is also a key research and education centre for the local community.

24 www.pacetoday.com.au DECEMBER 2010

As our car pulls off the highway and on to a muddy track which leads in to the plant, I can’t help but notice the overcast weather. It’s not exactly how I imagined this moment would be. I had visions of futuristic sunglasses being given out at reception, sunrays bouncing from the solar panels in all directions all but blinding me as I try to grab a photo.

Facing up to challenges I’m travelling as a guest of Schneider Electric, the provider of the plant’s Supervisory Control and Data Acquisition (SCADA) infrastructure which provides the monitoring, control and reporting software to Shanghai Electric Corporation. The facility manager, the aptly named [Mr] Sun, greets us and we sign in to the reception

area; a pre fabricated hut at the entrance to the plant.

“Any site graded over 1 MW is considered large. By 2012, this site will produce 66 MW of power. Presently we are a 10 MW site producing anywhere between 1.2 - 1.5 MkWh of power per month,” Sun explains as he hops over a muddy puddle pointing out the boundaries of the facility.

China’s power sector has posed one of the biggest challenges to the sustainability of China’s economic growth. The industry is also one of China’s largest polluters. In 2006, the power sector consumed more than half the coal supply and discharged nearly 59 per cent of all sulphur dioxide emissions.

Compared with conventional fossil fuels, alternative energy production is

Thin Film uses smaller, cheaper crystals than silicon and is able to use more of the available light spectrum than silicon to trap more energy. still inefficient; solar for example is 6-10 times less efficient than thermo electricity generation.

Alternative energy Consumers can help play a part in using alternative energy more responsibly but we need to understand how. Stone

thin film photovoltaic panels educate and involve the communities they serve, writes Dave Turner.

WIRED: Facility manager, Sun, demonstrates the equipment in the monitoring and control room.

Rotating axis structures produce on average 15 per cent more power than fixed axis but the structures are more expensive.

Forest hopes their on site education facility will go some way to showing end users how they can help conserve and use energy more effectively.

Using household appliances in off peak times will help reduce load from the grid, for instance. Consumers can charge their electric motorcycles at night and one day even feed surplus electricity back into the ‘smart’ grid.

Sunshine province Yunnan province has huge amounts of land ideally suited to solar power generation. Sun explains: “there are three main considerations when choosing a location for a solar facility”. Firstly, and not surprisingly, the area needs to receive a lot of sunshine, something the Yunnan province has in abundance. Second, it is forbidden to build on land that could be used for agriculture.

With a population of 1.4 billion people to feed, every patch of land which can be used grow crops is sacred.

Thirdly, “We must also consider the end user. The facility must be near to the load centre, the consumers of the electricity. It is not efficient to transport this

energy over long distances at the present time”.

The sun begins to break through the clouds and dozens of panels come to life, tilting and rotating in perfect choreography. Not all of the panels are turning though, hundreds more remain stationary. “The facility is trialling two types of panel structures, rotating axis and fixed axis,” Lv Feng, lead solar engineer from Schneider Electric explains as we walk towards the panels.

Why have single axis structures when you can have panels which rotate and are exposed to sunlight for longer? “It’s a cost problem,” Lv Feng continues, “the rotational axis structures are more expensive but they produce more power in the long term.”

Comparing technologies Rotating axis structures produce on average 15 per cent more power than fixed axis but the structures are more expensive to buy, install and maintain.

Stone Forest is testing both of these technologies and the results are being LOCATION: Yunnan province has huge amounts of land ideally suited to solar power generation.

logged in to the facility’s SCADA monitoring and control software for analysis.

Stone Forest predominantly uses silicon panels to convert the sun’s rays to electricity. On an overcast day like today, I ask if the panels can still produce power. The short answer is a disappointing ‘no’. It’s not all bad news though; Stone Forest is making considerable progress in the area of testing Thin Film Photovoltaic (PV) panels.

Light spectrum Thin Film uses smaller, cheaper crystals than silicon, such as copper-indiumgallium-selenide. Thin film is able to use more of the available light spectrum than silicon to trap more energy. This has obvious benefits over silicon panels on overcast days like today. At the time of writing however, Thin Film Photovoltaic technology is considerably less efficient when compared to silicon.

China has often been criticised for their aggressive river damming projects to make room for hydro electric power.

In the west, we’ve had our industrial revolution but in China it’s a brave new world. There is a buzz of excitement in the air, and with the help of growing wind and solar projects, hopefully a lot less pollution too.

[The author, Dave Turner, thanks Shanghai Electric Corporation, Schneider Electric China & Stone Forrest Provincial Power Investment New Energy Development Co. Ltd.] Schneider Electric 1300 369 233 www.schneider-electric.com.au

SUSTAINABILITY

DIFFERENT APPROACH Solar farms like the one at Stone Forest have been carefully designed to blend in with their surroundings with as little disruption to the local environment as possible, a totally different approach to that of hydro. Not only that, Stone Forest is a key research and education centre for the local community.

The responsibility for how we use, store and generate our electricity does not fall solely on the shoulders of government and power producers, but rather the responsibility is collective. If we, the end users, can learn about how we can effectively reduce energy consumption and how we can use energy smarter at an individual and local community level, then everyone will benefit. Stone Forest has a holistic vision of energy working alongside the community, for a solar ‘park’ where consumers can come and learn about the energy they use which will make them better informed about the decisions they make today.

CONTROL: Lv Feng, solar segment manager for Schneider Electric, inspects a solar panel at the Yunnan plant.

DECEMBER 2010 www.pacetoday.com.au 25

NOMINATE NOW

FOR 2011 8TH ANNUAL PACE

ZENITH AWARDS The Process, Automation, Control and Engineering night of nights!

The PACE Zenith Awards is the prestigious industry awards program that recognises and rewards companies that show leadership in engineering projects, and technological excellence and innovation.

CATEGORIES:

Automotive and Manufacturing Food and Beverage Metal Products Manufacturing Mining, Minerals and Exploration Oil, Gas and Hydrocarbons Power and Energy Management Transport, Power and Infrastructure Water and Wastewater Young Achiever Award (NEW!)

For a nomination kit or criteria, please go to www.pacetoday.com.au/Awards or contact Kevin Gomez at kevin.gomez@reedbusiness.com.au or by phone 02 9422 2976 For sponsorship opportunities please contact Tim Richards at tim.richards@reedbusiness.com.au or by phone 02 9422 2818

SPONSORED BY:

IN FOCUS

Intelligence for control loops Integrated valve systems link electrical with pneumatic actuation to eliminate the disadvantages of conventional automation concepts, writes Chris Hoey.

W

ITH conventional centralised automation of process valves it is often difficult to meet the necessary service delivery and life cycle standards. Intelligent process valves with integrated electronic and pneumatic automation functions offer an interesting alternative in this field and can help reduce planning, installation and maintenance costs. To meet facility and water authority compliance water treatment processes must be accurate, constantly monitored and incorporate reporting outputs.

Pneumatically operated valves are currently used at numerous points in industrial and civil water treatment processes. These valves are normally automated through conventional centralised control cabinet systems, including a valve terminal, an I/O system and interfaces for communication via fieldbus. Each individual pneumatically operated fitting in the process must be connected to the control cabinet through a control air line as well as a discrete feedback line. The costs for the planning and installation of such solutions are very high, especially on physically larger and more widespread sites.

Automation functions In many cases, long control air lines increase the air consumption and have a negative effect on the switching times of the valves. A viable alternative to the conventional use of central control cabinets is the integration of the required automation functions in the valves themselves. In this case, the process control system is only in charge of control and status monitoring. At field level, pneumatically operated process valves are used, which can be equipped with all required automation components such as a pilot valve with manual actuation, electrical feedback units and optical status indication, fieldbus interfaces and even positioners and process controllers. Plants based on such decentralised automation systems are therefore working with complete intelligent valve

Long control air lines increase air consumption and have a negative effect on valve switching times.

EVOLUTION: This schematic illustrates the difference between traditional and new control systems. systems. By integrating an AS interface (ASi) as a fieldbus interface, the entire range of advantages of this approach can be fully utilised. All that is required for power supply, feedback and communication is a two-wire line connecting the PLC with up to 62 valves. Each process valve is connected directly to the main compressed air supply line in the field, whereby these connections are kept as short as possible. This reduces the number and length of hose and wire connections as well as the number of required control cabinets to a minimum.

The valve systems themselves are designed for field deployment in demanding conditions for robust service and long life cycle. As a result, they feature the high IP protection required by the actual application and are made exclusively of weather/chemical resistant materials. The IP protection is therefore not affected by prolonged use in environments with exposure, high air humidity or by aggressive chemicals. In comparison to conventional automation solutions, this design marks a real

progress as regards ruggedness.

There are further advantages to reduced electrical wiring and fewer control air lines. A clearly visible status indicator integrated into the fitting allows the operator to monitor processes and the operating status of valves not only at a central point at control level but also directly at the fitting.

With conventional automation by means of control cabinet solutions, the drivers used in the plant must already be equipped with a device for electrical feedback. Innovative valve systems go a few steps further and cater for the integration of pilot valves with manual actuation, optical position indicators and other automation functions inside compact and rugged stainless steel housings.

Configuration options Depending on the application, users can choose between different equipment and configuration options. The wide range of available options includes mechanical limit switches, inductive proximity switches and NAMUR initiators as well

as mechanical position indicators and self-teaching limit position feedback modules with inductive linear displacement transducers.

At the lower end, decentralised automation based on intelligent valve systems start with a process valve with integrated electrical feedback, simple optical feedback and integrated pilot valve.

Such systems already do away with valve terminals in the control cabinets. Moving up one step in the modular valve program, users can achieve the previously described advantages of decentralised automation. In addition to the electrical feedback and the pilot valve, these solutions include large-size super-bright colour LEDs for improved optical feedback, facilitating process monitoring at field level, and an optional AS interface serving as a fieldbus interface, with all these features integrated into the valve system.

The actuator housing is flushed with control air at each switching process as some control air is fed through at the pilot valve. This means that, upon switching, a small volume of control air is fed into the housing. This process takes less than 10 milliseconds and ensures that a slight overpressure is built up in the housing, further improving its IP protection and preventing the penetration of humid air, for example in the event of changes in temperature or splash/submersion. The integrated pressure-relief valve ensures that the pressure in the housing is automatically reduced, if, after several switching processes, it reaches a value of approx. 0.5 bar. The control valves meet the same high level of ruggedness as the process valves.

B端rkert Australia 1300 888 868 www.burkert.com.au DECEMBER 2010 www.pacetoday.com.au 27

EDITOR’S CHOICE

7best of the

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

PS300 Pressure Sensors TURCK introduces PS300 series pressure sensors for hydraulic applications, featuring a rugged, IP69K rated design to withstand harsh environments. PS300 sensors provide a wide measuring range, from 3 to 400 bar. Signals are directly processed on the PS300’s newly developed pressure measuring cell, and then digitally transferred to the sensor’s fully potted, self-contained display. This design offers a high level of EMC resistance and switch point accuracy: 0.5 per cent of the full scale. PS300 sensors are available in male or female 1/4" NPT or G1/4" thread versions, with digital or analogue (voltage or current) outputs for all measuring ranges. Bonded seals ensure a reliable process connection. The new pressure sensors additionally support the I/O-Link communications standard, allows processing data to be transferred via a digital output.

TURCK Australia 1300 132566 www.turck.com.au

SolStation controller Yokogawa Australia has released the HXS10-SolStation controller. It controls the actuation systems that move heliostats, solar concentrating dishes, solar troughs and photovoltaic panels. It helps maximise power generating efficiency by controlling the angles of heliostats and solar panels so they stay pointed at the sun as it moves across the sky. The HXS10 combines Yokogawa's measurement and control technologies.

The measurement system is inherited from Yokogawa's recorders that are used in mission critical applications

throughout the world; while the control engine comes from Yokogawa's loop controllers. The HXS10 function block features precise time synchronising using an SNTP, which allows the HXS10 to be linked to a master PC clock, or an atomic clock for precise time tracking.

The system is designed for use on single tracking control for small photovoltaic systems on remote mine sites through to major large scale solar power plants.

Yokogawa Australia 02 8870 1100 www.yokogawa.com.au

Isolation procedure software focuses on accuracy Maintenance Engineers at some of Australia’s top mining and industrial sites were recently surveyed on the subject of lockout procedures. Many have experienced incidents involving the incorrect identification of isolation points. The risk is that the right equipment may, or has, unexpectedly activated.

IsolationPoint, released by Redbusbar, is a new lockout procedure, management programme. It allows the use of a PDA to execute energy isolation procedures. IsolationPoint comprises an isolation procedure library located on a PC and a handheld PDA as the means to execute isolation procedures. When 28 www.pacetoday.com.au DECEMBER 2010

required, an isolation procedure is scheduled for execution onto the PDA. The isolation officer then follows the isolation steps specified in the procedure and uses the PDA’s barcode or RFID scanner to verify isolation point identity. When the procedure is complete, time stamped progress information is archived to the PC. Using this approach, IsolationPoint enhances safety, uses less people and requires less administration.

Redbusbar 07 3630 2112 www.redbusbar.com

Email your product news to pace@reedbusiness.com.au

Automatic welding now made easier Automatic welding saves time and helps improve work throughput. However, weld quality can suffer if the arc is not kept in the optimal position. ESAB’s GMH joint tracking system removes the users’ need to focus on the weld head and its position during welding. It is supplied with a joint tracking controller, servo slides and sensor unit. Using GMH allows the operator to keep an eye on the entire welding process, without having to concentrate on the weld head. The welding process then becomes fully automatic, with the operator able to add flux and change wire spool well in advance of when needed. The system provides the user flexibility of doing many types of welds, such as, J-weld, V-weld, double J-weld, X-weld, fillet, double-flanged butt joint and others. The welding head is mounted on a motorised X and Y servo slide, where the head can be moved up-down and left-right.

ESAB Australasia 03 9383 7652 www.esabasia.com

Faster vibration analysis sensor SEW-Eurodrive has launched its updated vibration analysis sensor, the DUV30A. Replacing the company’s DUV10A sensor, the DUV30A features faster sampling time at a constant speed, allowing the monitoring of more dynamic gear-unit applications. The DUV30A vibration analysis sensor allows the early detection of roller bearing and gearing wear or damage, as well as gear-unit unbalance and resonance detection. Housed in a compact body and closely mounted onto a gear-unit, the DUV30A employs both fast Fourier transform (FFT) and high frequency FFT (HFFT) harmonic signal evaluation to monitor gear-unit and bearing condition and vibration.

SEW-Eurodrive 03 9933 1000 www.sew-eurodrive.com.au

Non-contact wave transmitter Hawk has developed a very low frequency acoustic wave transmitter that is non-intrusive and penetrates through the froth to measure pulp height. The Hawk sensor is mounted above the froth and pulp height. The transmitter can be supplied ready for connection to the 2 wire loop power supply used for the displacement float transmitter which it is replacing. Hawk also provides as an option, a non-intrusive transmitter to

measure froth height. Continuous measurement of froth height, provided as feedback to the control loop for the inlet Dart Valve, allows a floatation cell to maintain constant overflowing of froth to the launder, even when the ore body type may produce variations to frothing consistency.

Hawk Measurement Systems 03 9873 4750 www.hawk.com.au

FS10A analyser flow switch monitor with SP76 adapter Model FS10A Analyser Flow Switch/Monitor from Fluid Components International features an SP76 adapter that supports NeSSI compliant hardware. This adapter for NeSSI modular manifolds allows the FS10A to be installed into a standardised mechanical platform for analysers and sensors. The FS10A can be used with nearly all types of process and emissions sampling systems, including: gas chromatographs, mass spectrometers, optical spectrometers and photometers. It features a flow range in air from 50 cc/min to 20,000 cc/min and a flow range in water from 4 cc/min to 100 cc/min. The FS10A is designed with a

rugged, fully-sealed aluminium housing to protect electronics in harsh plant environments. The electronics can be mounted with the sensor element in a uni-body configuration or remotely mounted for front panel display viewing. The FS10A features a top-mounted, 10 LED array and two pressure-sensitive button touch controls. An optional 420 mA output is available for trending.

AMS Instrumentation & Calibration 03 9017 8225 www.ams-ic.com.au DECEMBER 2010 www.pacetoday.com.au 29

EVENTS & EDUCATION

WHAT’S ON

Inaco Automation Controls: Communications School 2 December, Newcastle newcastlesales@inaco.com.au Rotating Equipment Health and Reliability Excelleence Training 6-7 December, Perth 9-10 December, Melbourne capricornia@TonkinCorporation.com SCADA Asia 2011 25-26 January 2011, Hong Kong www.scadasummit.com Practical Power Distribution Workshop 10-11 February 2011, Perth 14-15 February 2011, Sydney 17-18 February 2011, Brisbane idc@idc-online.com ARC Orlando Forum 7-10 February 2011, Florida www.arcweb.com/res/forumorl

REVIEW

Developing an effective safety culture ‘Developing an Effective Safety Culture: A Leadership Approach’ James Roughton, James Mercurio Elsevier Academic Press $117.00 The book implements a simple philosophy, namely that working safely is a cultural issue. An effective safety culture will eventually lead to the desired goal of zero incidents in the work place, and this book will provide an understanding of what is needed to reach this goal. The authors present reference material for all phases of building a safety

GIVE

For daily updates visit www.pacetoday.com.au

30 www.pacetoday.com.au DECEMBER 2010

AWAY

management system and ultimately developing a safety program that fits the culture.

Information is easily accessible as the authors move first through, understanding the cost of incidents, then to perspectives.

‘Instrumentation and Control Systems’ W Bolton Elsevier Academic Press $77.00 In a clear and readable style, the author addresses the basic principles of modern instrumentation and control systems, including examples of the latest devices, techniques and applications.

Unlike the majority of books in this field, only a minimal prior knowledge of mathematical methods is assumed.

The book focuses on providing a comprehensive introduction to the subject, with Laplace presented in a

simple and easily accessible form, complemented by an outline of the mathematics that would be required to progress to more advanced levels of study. Taking a highly practical approach, the book combines underpinning theory with several case studies and applications.

You could win one of these engineering textbooks by answering the following simple question: Which book presents Laplace in an accessible form? Email your answer to kevin.gomez@reedbusiness.com.au

Both books are available direct from Elsevier Australia Customer Service, 1800 263 951 or customerserviceau@elsevier.com

A BIG thank you to all our 2010 supporters.

We hope you have a very merry Christmas and a happy and successful New Year!

From the team at PACE ABB Australia Absolute Filters Acrodyne Amalgamated Instrument Company AMS Instrumentation & Calibration ATA Scientific Australian Baldor Australian Exhibitions & Conferences Automation Direct Balmoral Technologies Beckhoff Automation Bintech Products Burkert Fluid Control Systems Conlab Control Components Control Microsystems (Asia Pacific) Dwyer Instruments Emerson Process Management Endress+Hauser Australia Fast Automation Fastron Technologies Flair Engineering Fluke Australia GLP Plant Hawk Measurement Systems HIMA Australia IDEC Australia ifm efector Inchcape Industrial Automation Group Invensys Process Systems Lear Siegler Australasia Maser Communications (Australia) Maxon Electronics Australia

Metromatics Moore Industries Pacific National Instruments Australia OEM Technology Solutions Omron Electronics Pentair Water Australia Pepperl+Fuchs Australia Phoenix Contact Pilz PLC Options Precision Light & Air Pricam Automation Product Lifecycle Management (Australasia) Reed Exhibitions Australia Rockwell Automation Rotork Australia Schneider Electric Shepelec Instrumentation Siemens SMC Manufacturing (Australia) SMC Pneumatics (Australia) SEW Eurodrive Swagelok Symmetry Innovations Ten Alps Communications Asia Testo Turck Australia Tonkin Corporation Vaisala W & B Instruments WEG Australia Weidmuller Wonderware Zedflo Australia

www.pacetoday.com.au

DON’T THROW ANOTHER

UNTARGETED

CAMPAIGN

THERE ARE

EASIER WAYS

TO TARGET YOUR AUDIENCE

With 30 years experience, Mardev can help target your direct marketing campaigns with access to 160,000 personalised Australian B2B records FOR A FREE QUOTE CONTACT Osman Muharrem on 02 9422 2644 or email osman.muharrem@reedbusiness.com.au