PACE - Process & Control Engineering - February 2012

PACE.FEB12.PG001.pdf

FEBRUARY 2012

VOL.65 NO.1

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www.pacetoday.com.au

PACE

Post Print Approved PP255003/00539

PROCESS & CONTROL ENGINEERING

Remote control mining Productivity challenges are increasing investment in remote mining solutions.

Opinion 12

Sterile environments Intelligence in operator terminals allow cycles to be pre-programmed.

Special Report 20

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PACE.FEB12.PG003.pdf

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CONTENTS

PACE

IN THIS ISSUE

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 Publisher: Michelle Graves Email: michelle.graves@reedbusiness.com.au

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Editor: Kevin Gomez Tel: (02) 9422 2976 Fax: (02) 9422 2722 Email: kevin.gomez@reedbusiness.com.au Deputy Editor: Isaac Leung Tel: (02) 9422 2956 Email: isaac.leung@reedbusiness.com.au Group Sales Manager: Tim Richards Tel: (02) 9422 2818 Mobile: 0420 550 799 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 Graphic Designer: Justine Dunn Email: justine.dunn@reedbusiness.com.au Production Co-ordinator: Tracy Engle Tel: (02) 9422 2707 Fax: (02) 9422 2722 Email: tracy.engle@reedbusiness.com.au

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

25

8 News Analysis 8

Legal 14

Engineer's Update 16

Journey to excellence Invensys Operations Management's conference focused on applying technology to drive business optimisation.

Impact of OH&S changes The engineering industry must recognise the changes brought about by the new model Work Health and Safety Acts.

Select the right connector Tips and tricks to select the optimum plug connectors.

Opinion 10

Safety Controls 15

Energy consumption Tuneable diode laser spectroscopy can improve efficiency and reduce emissions in combustion analysis applications.

Hazard identification is key Safety products and controls when installed correctly will go a long way towards preventing injuries.

CUSTOMER SERVICE: 1300 360 126

29

Technology Report 25

Calibration with software How to use software-based calibration management systems.

IICA News & Views 30

Outlook for 2012 The IICA is enhancing its relevance in the wider community.

ON THE COVER

PACE FEBRUARY 2012

Copyright Š Reed Business Information 2012 All rights reserved. No part of this publication may be reproduced or copied in any form or by any means without the written permission of the publisher.

VOL.65 NO.1

www.pacetoday.com.au

PROCESS & CONTROL ENGINEERING

OFFICIAL MAGAZINE OF:

Post Print Approved PP255003/00539

Average Net Distribution Period ending September '11 7,034

Remote control mining Productivity challenges are increasing investment in remote mining solutions.

Opinion 12

Sterile environments Intelligence in operator terminals allow cycles to be pre-programmed.

Special Report 20

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FEBRUARY 2012 www.pacetoday.com.au 3

PACE.FEB12.PG004.pdf

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NEWS

EDITOR’S MESSAGE

Changing our attitude Kevin Gomez Editor

Next Issue • Instrumentation • PLCs & Soft Control • Energy Management • Process Control in Mining

A WARM welcome to our readers. We hope 2012 will be another year of solid growth for Australia's process control and automation industries despite dire predictions of GFC2.

The year did not get off to the best start, especially with adverse developments surrounding the automobile industry in particular and manufacturing in general. Sure mining continues to be a significant market for instruments, equipment and services but the fear is that Australia is becoming a two-speed economy with just one industry.

Manufacturing is a core competency for any country

and more so for one rich in raw materials and potential talent.

But poor planning and policy flaws are threatening to wipe out the limited manufacturing capabilities we still possess.

Andrew Liveris, chairman and chief executive of the Dow Chemical Company explains it well: "Australia needs to build and sustain a robust manufacturing base – one that's focused not on low-tech, low-value products that other countries can build cheaper than we can, but on high-tech, high-value products that require the kind of intellectual heft for which Australia is known."

Against this backdrop, it was

heartening to see Sydney engineer Michael Myers receive the Order of Australia Medal this year. Myers founded of the notfor-profit Re-Engineering Australia Foundation to inspire, equip and mentor young people to pursue an engineering, technical or manufacturing-related career path.

Australia needs many more people like Michael Myers to help drive transformation right across the country – else we risk falling too far behind.

But there are a few positive developments. Several manufacturers are finding success in designing and building machines for local and overseas

companies. This year, the PACE Zenith Awards have been expanded to include a Machine Builder category, sponsored

by B&R Automation, an Austrian automation products vendor distributed in Australia

by Daanet.

We are set for another fantastic Zenith Awards this year. If you have an interesting project, do send it in.

We must thank all our sponsors for supporting the Zenith Awards: AMS Instrumentation & Calibration, B&R Automation, Endress+Hauser Australia, ifm efector, Schneider Electric, SICK and Siemens.

Kevin.Gomez@reedbusiness.com.au

OUTLOOK

Automation and technology picks for 2012: Opportunities galore

BY JIM PINTO I HAVE a hunch that 2012 will not be another same-old, same-old year for industrial automation. Expect opportunity niches to arise around industrial wireless, Ethernet, mobile interface technologies. Here is a summary of my technology-picks for 2012: Industrial wireless: Standards are settling down into reality. Major suppliers are reporting revenues in the tens of millions of dollars. New markets and applications are generating revenues and market acceptance.

64 Tags 128 Tags 256 Tags 500 Tags 4 www.pacetoday.com.au FEBRUARY 2012

Industrial Ethernet: In the automation environment virtually everything is being connected to everything else via central networks and the Internet.

Automation systems based on standard network architectures are spreading everywhere. Enhanced industrial Ethernet protocols such as EtherCat, Modbus TCP and EtherNet/IP will continue to proliferate.

Pervasive Internet: Today's centralised controls and displays will give way to peer-to-peer input/output (I/O) and the other ingredients of decentralised

FROM

FROM

FROM

FROM

automation systems. Industrial I/O products will become increasingly more autonomous in functionality, with vastly more robust operation in systems that include literally millions of I/O points.

Portable operator interface: The oldstyle operator control console interface is giving way to access via ubiquitous, compact WiFi equipment. More diagnostics and service functions can now be viewed via mobile phones, with cheap but effective two-way audio and video visibility. Most automation companies are now offering advanced features and

functions using iPad, iPhone and Droid apps. This trend will expand quickly.

There are several growth opportunities hiding in plain sight and entrepreneurs – the risk takers – will see them first. Perhaps, some of the recently unemployed will be the ones to jump at the possibilities.

There are an incredible number of exceptionally talented individuals scurrying around the automation infrastructure, looking for an "opportunity" niche.

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PACE.FEB12.PG006.pdf

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NEWS

TOP TWEETS

INNOVATION

Here’s what you may have missed this January if you weren’t following @pacetoday on Twitter:

World-first SF6 recycling plant in NSW

❏ Laboratory automation market poised for tremendous growth. http://dlvr.it/16fSFB

ABB Australia has developed a worldfirst technology for recycling contaminated SF6 (sulphur hexafluoride) gas, which will be implemented at a new facility in Moorebank, NSW. The gas recycling technology is based on a new, energy-efficient cryogenic process developed by ABB’s Moorebank team.

The new SF6 gas recycling centre at Moorebank will be the first site to roll out the technology globally. According to ABB, purity of recycled SF6 gas using the new technology is ~99.99 percent, which exceeds the purity that can be achieved using traditional methods and removes the need for costly and energy intensive gas destruction.

Using recycled SF6 gas will help reduce carbon emissions and could result in a cost saving potential of up to 30 per cent, says the development team.

“This breakthrough actively supports a complete lifecycle management approach, improving asset optimisation

❏ ABB alliance plans to connect car batteries to the power grid. http://dlvr.it/166mnf ❏ Uson offers no-cost videoconferencing for leak detection. http://dlvr.it/15MF5Y ❏ Veolia to supply brine concentrator for uranium mine in NT. http://dlvr.it/11T3xs Follow @pacetoday on Twitter for the latest news, analysis, new product information and commentary. And never miss out again.

PIONEER: Purity of recycled SF6 gas using ABB's new technology is ~99.99%.

and performance while reducing environmental impact in a cost effective manner,” said Axel Kuhr, country manager for ABB in Australia. “It is a great example of Australia’s contribution to ABB’s global R&D program.”

SF6 gas is extensively used in the

electrical industry for dielectric insulation and current interruption in circuit breakers, switchgear, and other electrical equipment. Pressurised SF6 gas is used for the safe and reliable operation of gasinsulated switchgear.

It’s more than just a hunch,

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CONVERSATION

SKILLS SHORTAGE

Early training is the key Vivian Van Rensburg calls for an overhaul of the education system. By Kevin Gomez.

“ ” Vivian Van Rensburg, Managing Director for Western Process Controls talks to PACE about the skills shortage and outlines a possible solution.

What's the main reason behind Australia's lack of skilled resource?

The dual trade was the biggest and costliest mistake Australia ever made. An electrician with a couple of instrumentation modules is not effective. We need a three-tier system: process control engineers, process control technicians and process control artisans. The middle tier hardly exists in Australia, yet it is the most valuable one to have in an organiza-

tion as it's basically a hands-on engineer.

How can we interest enough young Australians to gain the right skills?

There should be an early assessment of school children, from around year six to determine their aptitude – whether it is academic or technical. We then encourage those with a technical aptitude to go to mainstream technical senior schools with a specific curriculum.

For example, compulsory subjects for technical school year 7 to 12 would be: language, mathematics, natural science, technical drawing, health & safety.

Years 7and 8 will see students exposed to the mechanical, electrical, civil and carpentry engineering trades.

Beamex® FB Field Temperature Block Beamex® MB Metrology Temperature Block

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Mechanical would cover fitting turning, boiler making and motor mechanics. Electrical would encompass electricity, instrumentation and electronics. Civil would cover masonry work, surveying and scaffolding. Carpentry would include cabinet making.

In the last three years of high school, students would specialise in one of the above engineering disciplines. After year 12, these skills would be formally recognised and credits granted for the trades.

How do firms retain skilled workers?

Currently not much as the big resources companies are driving up wages. It’s a case of supply and demand and we cannot train fast enough. As a medium-

sized independent company, we have been reasonably successful in our retention strategies, but we have to import skills to solve our shortage.

How should Australia upskill?

Continuous training is the only way.

Government support and tax incentives for companies that run training programs would help.

What's your recommendation to other process control equipment suppliers?

Get involved, stay involved, invest in the future of Australia. Too many multinationals are not investing in training but want the big project orders. www.wpc.com.au

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FEBRUARY 2012 www.pacetoday.com.au 7

PACE.FEB12.PG008.pdf

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NEWS ANALYSIS

CONFERENCE

OpsManage11: Journey to excellence

BY KEVIN GOMEZ

M

ID NOVEMBER 2011 was a busy time for Invensys Operations Management's team as the Gold Coast played host to OpsManage11, the company's Australia and New Zealand User Conference.

"Structured around the theme 'Journey to Excellence', OpsManage11 focused on applying technology to empower users and drive business optimisation across manufacturing and production enterprises," explains Ng Kim Meng, Vice-President & Managing Director, Invensys Operations Management, Australia & New Zealand.

The sessions were organised around four streams: Process Control, SCADA, Business Intelligence and Safety & Critical Control.

Demo Alley offered hands-on demonstrations of solutions from Invensys Operations Management and partners Avantis, Eurotherm, Foxboro, SimSci-Esscor, Triconex and Wonderware brands.

The speaker line-up included presentations from users BP Bulwer Island Refinery, Newcrest Mining, Saab Security and Woodside, among others.

Kim Meng is pleased with the attendance which saw around a hundred professionals from customer companies turn up for the event. "This is a 25 percent increase over last year," he told PACE. Invensys also used OpsManage11 to showcase some of the 70 new products

INVENSYS OPERATIONS MANAGEMENT: VP & MD Ng Kim Meng.

SMART: The I/A Series Intelligent Marshalling solution features the Universal Fieldbus Module.

the company will be launching through financial year 2011/12. "Skelta has been a fantastic acquisition for us," explains Kim Meng. "Skelta's suite of Business Process Management solutions have been integrated as 'Archestra Workflow' into our Wonderware System Platform. We're embedding business process management functionality into our applications allowing our customers to improve their procedures, consistency, meet regulatory

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compliances and safety standards."

One of the conference highlights was the site visit to the BP Bulwer Island Refinery. "The full suite of Invensys hardware and software is used at that site," explains Kim Meng. "This includes DCS, safety, simulation, advanced applications."

Soon after the event, Invensys Operations Management announced the next major evolution of its Foxboro I/A Series distributed control system. As the core DCS component of the company’s InFusion Enterprise Control System, the latest I/A Series system includes an Intelligent Marshalling solution and Foxboro Control Software and Simulation software, which reduce total cost of ownership and expand traditional DCS functionality for enhanced collaboration, execution and visibility across the enterprise.

With traditional control systems, field wiring must be sorted out in a marshalling cabinet before it is connected to the main I/O module terminal strips of the DCS panel. It’s an inflexible approach that often leads to expensive indirect costs. But because the

I/A Series Intelligent Marshalling solution features the Universal Fieldbus Module, a per-channel, configurable I/O module that supports a variety of analogue and digital signal types, it eliminates the need for marshalling entirely.

Designed to simplify engineering efforts and improve the user experience, Foxboro Control Software 3.0 embeds the company’s Wonderware System Platform and InTouch HMI within the Foxboro I/A Series system, applying common object technology from process control up to the business system level and out to any third-party system. This allows users to integrate all of their plant devices, systems, databases and software.

By enabling real-time access to critical plant and business data, users are better able to balance competing strategic objectives related to controls, assets, environment & safety and people to optimise their overall business. The new Foxboro Control Software Simulation 3.0 offering simulates Foxboro Control Software 3.0 applications for rapid, high-quality systems checkout without the need for control hardware. iom.invensys.com

AD_PACEROC2FEB_12.pdf

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Drive Sustainable Production Increase competitiveness and overcome the rising costs of energy, raw materials and lost worker productivity.

Safety Automation Forum This “event within an event” will showcase Rockwell Automation users as they share best practices and demonstrate how they deploy successful safety programmes. There will also be sessions on safety technologies and the latest standards. Melbourne and Sydney events only.

PACE.FEB12.PG010.pdf

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OPINION

EFFICIENCY

Energy consumption Improved combustion analysis techniques reduce energy consumption, writes Paula Hollywood.

W

HILE energy prices continue to fluctuate, energy remains the second leading cost pressure (behind only raw materials) currently affecting most manufacturers.

Some of the biggest culprits are incinerators, crackers, process heaters and other energy-intensive combustion-based equipment. The harsh operating conditions associated with combustion analysis applications can eat up a sensor in no time, resulting in inaccurate and unreliable sensor measurements. This can make it nearly impossible to control these processes adequately.

However, new analysis techniques, such as tuneable diode laser spectroscopy (TDLS), can improve efficiency, maximise throughput, reduce emissions and improve safety in combustion analysis applications. ABB, Siemens, Vaisala and Yokogawa all currently offer TDLS technology for process measurements. Most energy-intensive operations, such as those found in a refinery or chemical plant, experience considerable variability in energy consumption due to changing operating conditions, equipment degradation, fluctuating market conditions, and inefficient control strategies.

As a result, plants consume more energy than necessary, yet are unable to improve efficiency due to the inability to collect and analyse real-time performance data. Frequently, the goals of optimising efficiency and maximising throughput are at odds with the need to reduce emissions and ensure plant and personnel safety.

Effective energy management is essential for a “triple bottom line� business strategy that addresses social, economic, and environmental concerns.

TDLS contributes to a triple bottom line strategy by helping increase throughput and reduce energy costs, while supporting safe and environmentally responsible operations.

Advanced process control systems require sensitive and accurate process measurements in real time, or 10 www.pacetoday.com.au FEBRUARY 2012

Feature

Benefit

In-situ analysis Fast response Tuneable laser Non-contact sensor Optical sensor

Sample conditioning not required Real-time data for APC Interference-free analysis Suitable for operation in harsh environments Low maintenance

TUNEABLE: Features and benefits of TDLS technology.

near-real time. APC reduces process variability and inefficiency, improves product quality and provides for more stable operations.

With few exceptions, current process analytical techniques lack the speed, accuracy, and sensitivity to provide reliable measurements for APC. Online optimisation goes beyond advanced control to optimise a process based on an economic objective function.

This is becoming more important in applications where profitability depends upon improving quality, while maximising material utilisation and minimising energy usage.

Historically, obtaining reliable quality measurements in time to impact control

has been an issue in combustion control applications. The current best practice utilises a Zirconia sensor for point measurement of oxygen.

In applications requiring multiple measurements, point measurement cannot provide a representative sample, making it both error-prone and potentially dangerous. Process oxygen measurement requires samples to be extracted and then transported to an analyser for conditioning and analysis. This slows response time, adds cost, and degrades measurement accuracy.

Inefficient combustion can be attributed to the air/fuel ratio. Too much excess air (air rich) results in loss of efficiency and increased NOx emissions,

while too little excess air (fuel rich) is downright dangerous. Carbon monoxide measurement provides an indication of fuel-rich conditions, while oxygen measurement indicate air-rich conditions.

The optimum control point is the lowest possible excess air value that does not cause the system to enter into an unsafe condition or violate emissions limits. Tuneable diode laser technology is an innovative measurement technique that utilises semiconductor lasers to detect a variety of gases at trace levels in the part-per-million (ppm) or part-perbillion (ppb) range.

Tuneable lasers, which enable miniaturisation of transmission and receiving units, provide highly sensitive, quantitative measurements with fast response times without the need for recalibration.

The lasers can be tuned to detect specific constituents independent of process gas concentrations.

TDLS enables high-performance measurements in real time, even in challenging process environments. Exact performance specifications may vary somewhat according to supplier; however, the benefits are universal.

To date, the most widely reported application of TDLS has been for combustion control. However, the technology potentially offers much wider applicability. In refineries, it can monitor CO, CH4, and O2 in burner flameout applications, and identify process tube leaks.

Energy can be the largest component of a manufacturer's cost structure.

Despite the recent drop in energy prices, costs are expected to trend upward over the long term. A willingness to apply state-of-the-art technologies can have a significant impact on the success of energy management programs.

Technologies, such as TDLS, that can improve performance and provide quick ROI can have a significant impact on the bottom line.

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

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PACE.FEB12.PG012.pdf

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OPINION

MINING

Remote control your mine Productivity challenges are increasing investment in remote mining solutions, writes Paul Cooper.

I

NVESTMENT in remote mining technology has reached a tipping point. What was once talked about as a future trend is now a tangible reality with remote solutions used daily for many mines.

And whether it’s solutions for monitoring the safety of miners or energy management services that deliver realtime intelligence to managers anywhere in the world, investment isn’t about to slow down.

In the months ahead, expect investment in remote monitoring solutions to be higher than ever. At this year’s AIMEX conference, we surveyed the views of delegates and found almost a third of those we spoke to are planning on upping their investment in remote mining technology over the next twelve months.

So what’s driving this trend and is it something that’s unique to Australia?

On the latter point, to some extent the answer is yes.

The size and geography of Australia, combined with the number of remote mining locations, means solutions that enable the remote monitoring and running of plants are not just ‘nice to have’, but crucial to plant productivity.

It’s perhaps unsurprising then that investment in remote technology is particularly aggressive amongst Australia’s junior mines – something that’s being watched closely by mining markets overseas.

But it’s not just factors specific to Australia that’s driving remote mining investment. Other factors including labour shortages and productivity challenges are also fuelling investment.

On a global scale the mining industry is facing a severe labour squeeze. In fact, according to recent commentary from Deloitte, there is a 20-year gap in the mining industry as the sector was not attractive to graduates in the 80s and 90s.

The result, which is particularly acute in Australia, is that mining companies are lacking people with the right skills.

While this issue cannot be solved by 12 www.pacetoday.com.au FEBRUARY 2012

The ability to assess the efficient running of a plant from any location negates the need to have large numbers of plant experts on site all of the time.

technology alone, the benefits of implementing remote mining technology are far from insignificant.

Take the remote monitoring of operations. The ability to assess the efficient running of a plant from any location negates the need to have large numbers of plant experts on site all of the time. The savings that can be

achieved in terms of reduced labour costs can be huge.

These benefits are often magnified when monitoring systems are linked to a plant’s CCTV network. In this scenario, a maintenance expert will not only be able to be alerted to a fault remotely, but can actually assess the fault through a live video feed before making a decision on next steps.

According to recent analysis from CommSec, Australian mining has become less – not more – efficient over the past five years. While mining companies were receiving record prices and profits, there was little need to focus on productivity.

Now, however, the pressure to do more with less is constant, especially with increasing competition from overseas mining companies keen for their share of the mining boom. This means

that ensuring mines are running as efficiently as possible, making sure operating costs are kept down and throughput remains consistently high are top priorities for plant managers.

One way in which these challenges can be tackled successfully is through embracing a holistic approach to energy management. By monitoring energy use throughout a plant in real-time, mining companies can easily identify inefficiencies that not only waste energy, but affect outputs.

When this monitoring is done remotely, the benefits in terms of productivity can be even greater. That’s because no matter where a process expert is based they can easily log-on, at any time of day, to assess the efficiency of operations and take any necessary action.

In the months ahead we expect to see larger mining organisations making use of remote technologies that allow them to identify energy inefficiencies from plant to plant. Looking at energy efficiency remotely at an organisation-wide level will mean plant managers can compare the performance of their site versus other sites, and mining companies will be able to set benchmarks for efficiencies.

Never before has the mining sector seen so much change nor moved at such a rapid pace. Whether it’s overseas mining companies forming large-scale resource reserves through overseas investment or Australia’s continuing leadership in mining innovation there’s never been a more exciting time to work in the sector.

Increasing investment in remote mining technologies is not only a reflection of this change but a sign of what’s to come.

As issues surrounding labour and productivity become even greater within the mining sector expect to see not only junior mines but big players investing more heavily in remote operations.

[Paul Cooper is General Manager – Mining, Minerals and Metals, Schneider Electric.] www.schneider-electric.com.au

AD_PACEKELFEB_12.pdf

GSM-2

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D. ME D. OR F EE N NT SI A Y A R LW UA ,A .G TS ED L S L O TA RC INS OU Y 1x S CE DU RE

Picture: GSM-2 system for water level measurements

MEASURING DATA BY E-MAIL VIA GSM NETWORK The days when you had to run from measuring station to measuring station every day in all kinds of weather to read off the last water level or installed data logger are definitively a thing of the past.

GSM-2, which is quick and easy to install, now transmits the measuring data straight to your office by e-mail (via a GPRS Internet connection) or SMS. The heart of the measuring system is the GSM-2 DataManager software. The measuring data that is transmitted by the measuring stations is continuously read in, stored and displayed by the DataManager, so that you can permanently monitor your equipment.

Performance features of the GSM-2 measuring system:

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PACE.FEB12.PG014.pdf

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OPINION

LEGAL

Work health and safety Harmonisation ensures holistic safety regulation in the engineering industry, writes Patricia Ryan.

O

CCUPATIONAL Health and Safety laws are about to undergo their biggest overhaul in a generation with the introduction of a nationally harmonised legislation this year.

The new model Work Health and Safety Acts (WHS) came into effect 1 January 2012 (with the exception of Victoria and Western Australian who are likely to defer implementation until later in 2012). It is crucial that the engineering industry recognise the changes that will be made and start reviewing practices and documentation now.

Current state and territory OHS laws will be replaced by national laws based on a model Work Health and Safety Act. Currently, there are eight jurisdictions with different sets of laws, so the most obvious advantage is the consistency of laws and a more streamlined approach to the way OHS is regulated in Australia.

Codes of Practice will also be provided which are practical guides to achieving the standards of WHS. The code will provide detailed information on particular areas of the act or regulations, and may outline activities, actions, technical requirements, responsibilities and responses to events or conditions within a workplace.

Here are the basic facts about the new model WHS: • there are new roles and responsibilities for employers • new wording and definition changes will be implemented under the new WHS. Worker replaces the term employee and PCBU (person conducting a business or undertaking) replaces the term employer • there are critical changes under the new act with regards to consultation • changes to union rights of entry • there is protection from discrimination, coercion and misrepresentation under the new WHS • new penalties for breaches of the WHS new roles and responsibilities for HSRs under the new WHS. The duty of a PCBU is to take all

14 www.pacetoday.com.au FEBRUARY 2012

A person responsible only for implementing and not making decisions will not be considered an officer. reasonably practicable steps towards ensuring the health and safety of workers whose activities in carrying out work are influenced or directed by the PCBU. A PBCU must also: • manage or control a workplace • control the fixtures and fittings within a plant or a workplace • design, manufacture, import or supply plant substances or structures • construct or commission plant or structures for a workplace.

A worker has the duty to take care for his/her own safety, the safety of others and comply with any reasonable instruction from the PCBU, so far as they are reasonably able to, and cooperate with all reasonable policies and

procedures of the PCBU. By definition, an officer is a person who makes decisions or participates in making decisions that affect the whole or a substantial part of a business. A person responsible only for implementing, not making decisions will not be considered an officer.

For anyone that falls under this category, the key requirements include that they must: • acquire and keep up-to-date knowledge on OHS matters within the business undertaking • gain an understanding of the nature of the business and the risks and hazards that occur within that business unit • ensure appropriate resources and processes are available to people working in this business unit to eliminate or minimise risk • ensure the business unit has appropriate processes in place for receiving and reviewing information about incidents, hazards and risks that apply in a timely way To prepare for the new laws, business

owners should identify the changes between the existing OHS Act and the model WHS Act to understand what needs to change, and what can stay the same in order to achieve compliance.

I also suggest that businesses: • review organisational structure to determine where responsibility for WHS lies • review policies, procedures and consultation processes to ensure that not only are they compliant, but that terminology used is consistent with the new act • identify the stakeholders within your organisation. For example, workers (which again must go back to the expanded definition), officers and those responsible for the implementation of safety initiatives • review contracts with relevant third parties such as suppliers of plant equipment or labour to address and to clarify respective obligations • ensure your directors and senior managers (officers) have sufficient oversight over safety matters to meet their due diligence obligations • review your consultation arrangements to determine: o if you are consulting with all required parties, again coming back to the expanded definition of workers o establish whether you need to elect HSRs for identified workgroups, or if existing alternative arrangements are practicable • review your procedures to ensure that you protect against engaging in discriminatory conduct against a worker who raises an OHS issue • review the new regulations and codes of practice to determine what changes will need to be made to your safety systems • if you are unsure of anything I strongly recommend seeking legal advice to avoid non compliance.

[Patricia Ryan is the practice manager of EI Legal.] www.theeigroup.com.au 1300 731 931

PACE.FEB12.PG015.pdf

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OPINION

SAFETY CONTROLS

Minimise risk and save lives Adopt the right approach to understand risks to achieve workplace safety, writes Paul Morton.

A

USTRALIAN OHS Acts stipulate that both hazard identification and risk assessment must be carried out to identify and minimise risk; and yet, every year, people are injured and even killed by machinery while at work.

Safety controls play an integral part in preventing the risk of injury from various hazards that inevitably exist in the workplace. Hazards that are likely to cause injury or, in the worst-case scenario, death must be eliminated or dealt with by putting controls in place to reduce the risk.

One typical hazard in the workplace is poor machine-guarding practices.

Exposure to dangerous machine parts during operation, examination, adjustment and/or maintenance can pose many serious risks. However, there are various safety products and controls available that when installed correctly, and in conjunction with appropriate monitoring devices, will go a long way towards preventing injuries.

If the risk cannot be eliminated, it must be minimised which can be achieved through a three phased approach: • Understanding the risks • Evaluating the risks • Implementing the right solutions to reduce the risks The process to determine the needs of a complete safety system goes back to understanding the risks or hazards that could result in injury.

A common misunderstanding when it comes to the use of individual safety control components, such as safety switches, gate/guard interlocks and light curtains, is that they alone are capable of offering a complete, safe system of control. Safety systems comprise many components and no individual component, in isolation, will ensure the complete integrity of any safety control system.

It is often necessary to involve specialist safety consultants to perform a safety audit. These consultants will produce a report detailing any short-

comings and the recommended changes necessary to meet OH&S requirements.

Safety audits can also provide an understanding of the level of risk, as well as information on a suitable safety system, or improvements, for your workplace. Additionally, the auditors will often return after the installation is complete to verify that the site or machine now meets safety requirements.

In order to reduce the risk, all machinery must be securely guarded to prevent access to dangerous parts.

Machine guarding is vital to every workplace using machinery. It is also important to remember that machine guards do not have to be complicated nor interfere with productivity.

As mentioned, a safety interlock switch alone does not offer a complete safety control system. Safety control system installations require the evaluation of risk and hazards involved in line with the Australian standard AS4024.1 to establish the category of risk and the degree of protection that is required.

Figure 1 shows a risk graph that can be used to help determine the risk category.

Almost every safety control system has the inclusion of an emergency stop (e-stop) switch. The e-stops of today have come a long way from the earlier, more simple designs, and now include multiple contacts with a force-guided mechanism to prevent failure due to contacts sticking or welding.

For example, a new range of Electroslim safety interlock switches also incorporates a manual key for locking and unlocking – a quality not previously available in safety switches. The lock/unlock feature can add to the protection of workers by limiting the risk of accidental machine starts while personnel are carrying out maintenance and commissioning works on their plant machinery.

Safety trip wire switches offer similar features to an e-stop but use a fixed-wire rope which is connected from one end of the machine to the other. These safety trip wire switches can be triggered anywhere along the machine and allow

FIGURE 1: Approach according to EN/ISO 13849-1

access where an individual emergency safety switch may not be accessible.

Safety trip-wire switches also trigger in the event of the trip wire breaking.

It is important that all electrical equipment be installed, operated, serviced and maintained by qualified

personnel who are well trained and experienced in safety system requirements and standards implementation.

[Paul Morton is Product Manager – Sensors, Industry Business, Schneider Electric.] www.schneider-electric.com.au FEBRUARY 2012 www.pacetoday.com.au 15

PACE.FEB12.PG016.pdf

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IN FOCUS

How to select the right connector The optimum plug connectors for industrial use must always be selected depending on the particular application area, transmission medium and environmental requirements, writes Bernd Horrmeyer.

W

HETHER classic fieldbus, Industrial Ethernet or the new High-Speed Ethernet (which is now establishing itself), the cabling concept is decisive for the success of the system and its reliability.

Its topology, dimensioning rules and components must be precisely adapted to the production environment.

The optimum plug connectors (see Figure 1) must always be used depending on the particular application area, transmission medium and environmental requirements.

User organisations and standards specify the plug connector. In this case, important differentiating features include the transmission medium, either electrical or optical, as well as the protection against environmental stress, generally IP20 for protected and IP65/67 for unprotected environments.

They specify an appropriate connector profile for the particular use case (see Figure 2). Based on this, the user organizations have made a selection for their particular system.

For instance, it was ensured that the protective housings are suitable for electrical and optical inserts, and that all fibre types are supported.

Also the definition of the plug connectors from a standards perspective is an important aspect, in order to facilitate that they establish themselves over a broad basis and they are plug compatible with one another.

When selecting components, users must take into account that industrial communications often have to cope with tough conditions.

A systematic description of the environmental conditions is provided with the MICE concept according to IEC TR 29106 (see Figure 3).

Severity levels The typical stresses from the mechanical, ingress, climatic and EMC areas are defined with severity levels 1, 2 and 3 for office environments, and light and heavy for industrial areas.

16 www.pacetoday.com.au FEBRUARY 2012

FIGURE 1: Well-conceived plug connector solutions available in the market are suitable for all systems, transmission media and environmental conditions.

As a consequence, the design engineer can precisely define the environmental stresses for the planned area of application and in turn specify suitable components; this avoids unpleasant surprises as a result of unsuitable components. For instance, a component according to M3I3C3E3 can be used in an environment according to M3I2C3E2.

Frequently, fieldbus organizations have varying definitions, more precisely for inside and outside the control cabinet, so that this concept has not been established across the board as a standard concept.

For electrical data transmission,

fieldbus systems are configured as a linetype topology, and all of the signals are switched in parallel. The cable must be terminated at both ends with its impedance in order to avoid reflections. This is realised using terminating resistors.

Parallel signal These components must be taken into account when planning the system.

With a parallel signal configuration, connectors are required at the device for locally connecting the incoming and outgoing cables (see Figure 4).

In this case, plug connectors, which are optimally designed for the particular fieldbus as a result of how the cable and

conductors are connected as well as their colour coding, are advantageous. Quick connection technology also represents a further advantage.

The terminating resistors required are already integrated in the plug connector and can be switched in, which means that the outgoing cable is simultaneously disconnected. As a consequence, when a change is made to the plant or system, instead of requiring a new installation, just one switch has to be actuated.

The bus can be systematically switched in and out, step by step – also during commissioning and troubleshooting. Here, pre-fabricated cables that are especially easy to use can be

PACE.FEB12.PG017.pdf

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FIGURE 3: Systemology of the MICE coding according to IEC TR 29106 for load/stress from mechanical (M), ingress (I), climatic (C) and EMC (E) areas.

FIGURE 2: Typical plug connectors for field-buses and for Industrial Ethernet permit electrical or optical communication in IP20 and IP65/67.

utilised, assuming that the device has a T distributor in which the incoming and outgoing cable can be inserted.

Route the cables and then connect the plug connectors; this is also required for Industrial Ethernet. Many commercial RJ45 plug connectors can only be connected up using a special tool. They do not accept any AWG22 conductors,

which are generally used in the industrial environment. This is the reason that plug connectors that are equipped with fast connection technology are more suitable, and where all conductor types can be connected (see Figure 5).

360-degree shielding is also an important feature. This is required in order to minimise the EMC effects of >

FEBRUARY 2012 www.pacetoday.com.au 17

PACE.FEB12.PG018.pdf

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IN FOCUS

FIGURE 5: Introduce the conductor, cut and close the flap – it’s that simple to assemble an RJ45 plug connector in the field.

ered to be a one plug connection.

This gives the user a higher degree of freedom when designing a cable section.

Fibre-optic cable FIGURE 4: The incoming and the outgoing cables for DeviceNet plug connectors are easily connected using spring clamp technology.

adjacent devices, for example, a frequency converter. High-quality surfaces are required so that gases do not cause contact corrosion.

These prevent corrosion and therefore a creeping aging process, which can result in the connection failing due to higher transition resistances. Over the longterm, patch cables, which are generally used in the office environment, do not fulfil these reliability requirements.

RJ45 plug connectors with and without protective housing as well as

18 www.pacetoday.com.au FEBRUARY 2012

M12 plug connectors have established themselves in the market here.

With Cat6A they permit data transmission rates of up to 10 Gigabit/s.

A maximum of four plug connectors can be located in a cable section.

When a bulkhead is used, this is considered to be two plug connector socket transitions so that only two additional plug connections are possible.

However, when using high-quality versions, such a high signal quality is achieved that bulkheads are only consid-

Fibre-optic cables can also be used as a medium in all of the relevant systems.

Different fibre types are used depending on the length of the cable section in industrial environments; the most significant difference between the various types is the diameter of the fibre core that conducts the light.

As a consequence, plug connectors should be suitable for all fibre types. Not only this, the required data transmission link must be implemented with a technology that is as convenient as possible to install. The rugged SCRJ plug connectors have clearly established themselves in industrial applications. Their compact design allows them to be easily integrated into devices. The spring-loaded ferrules

with their 2.5 mm diameter can easily accommodate the fibre.

This results in a rugged, optical plug connector that can be used with all fibre types. In addition, this system also facilitates fast and easy assembly in the field, which often represents a significant advantage. Whether fieldbus or Industrial Ethernet, there exists an optimum installation concept for each and every system.

And more precisely, for copper and fibreoptic cables as the media as well as for all environmental conditions.

Industrial communication solutions in machinery and plant construction can be simply implemented using wellconceived components for fast installation in the field.

[Bernd Horrmeyer is Specialist for Industrial Network Cabling, Phoenix Contact.]

Phoenix Contact 1300 786 411 www.phoenixcontact.com.au

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23/01/12,

3:41

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PACE.FEB12.PG020.pdf

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BEHIND THE SCENES

Control in sterile environments Intelligence built into operator terminals allow different sterilizer cycles to be pre-programmed. By touching a screen the operator can select the appropriate function required, writes Hartley Henderson.

B

ASED in the Melbourne suburb of Thornbury, A.E. Atherton & Sons Pty Ltd manufactures a range of medium to large stainless steel infection control equipment including Tangent series sterilizers for use in hospitals and laboratories.

The company, which employs some 120 people and has branches in Brisbane, Sydney, Adelaide and Perth, is also developing export markets in a number of countries including New Zealand, Malaysia, Indonesia, Thailand, Brunei and the Philippines.

Atherton places a high priority on quality with both manufacturing and suppliers controlled by its quality management system which has been certified to both AS/NZS ISO 9001:2008 and AS ISO 13485:2003.

According to the company’s design engineer, Scott Lipman, the Tangent series, which includes the Gorilla, Tiger, Mongoose and Cobra, takes sterilizing technology to a new level. “A full colour touch screen operator interface guides you through selecting a cycle from a range of pre-vacuum and general purpose gravity cycles,” he told PACE. “The operator can just touch on an icon to select a cycle, and saved cycles are protected by a PIN to ensure process integrity. Specific levels of security can be set-up by the user to guard against access by people who do not have the necessary training or authority.

“PC and modem interface are standard, and Tangent series sterilizers can be supplied with their own built-in or freestanding generator.”

Atherton sterilizing machinery utilises EXTER T100, T70 and T40 units supplied by Global Automation to provide a state-of-the-art operator/ machine interface, together with PLC equipment from Omron.

Lipman says hospitals and laboratories have many strict and variable sterilization setting requirements which can involve pre-vacuum, vacuum, pulsing steam, holding time and drying time.

“PLC software to control the

20 www.pacetoday.com.au FEBRUARY 2012

ATHERTON: The operator can just touch on an icon to select a cycle and saved cycles are protected by a PIN to ensure process integrity.

Automatic leak tests can be carried out to ensure that there is a complete vacuum and no leaks under pressure. sterilizer is constantly being developed and refined at Atherton utilising an in-house test unit to test the effectiveness of communications between the user and the sterilizer, and to ensure user friendliness.

“We operate in a highly competitive market, so it is important to stay on the front foot through a strong focus on

R&D, especially in relation to the constant evolution of software.

Increased automation “Because sterilization is a critical function in hospital operations a central aim is to make the process as automatic as possible so that when a cycle starts it will automatically go through all stages.

Automation takes control of the system out of the user’s hands, which helps to ensure the integrity of the system and enhances the protection of both patients and staff from infection.

“Automatic leak tests can be carried out to ensure that there is a complete vacuum and no leaks under pressure. In addition, usage reports can be provided to show, for example, how many cycles have been completed over a specified

period of time. Various ways of record keeping are available including printouts, and email reports on operation of the system can be generated and sent back to our factory for system monitoring purposes.

“Cycle data can also be recorded on an SD card for future reference, and the control system is fully web enabled so that an iPhone can be used to remotely see how the system is operating.

“An automatic sterilizer warm-up function has also been developed through a PLC integration whereby the user can set the sterilizer to be ready for the start of work next day.

We are constantly looking to make systems easier and quicker because time is money.”

A power loading system is available

PACE.FEB12.PG021.pdf

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terminals in a network.

“Also, remote network access to EXTER operator terminals can be maximised by use of the free Remote Access Viewer software package. This is useful not only for remote control, but also for remote customer support and troubleshooting.”

Thomson points out that the remote user can access all of the operator terminal’s functions with Remote Access Viewer via a serial or network connection, so there is no need for Internet connectivity or software such as Windows Internet Explorer.

Laboratory applications

“These machines are utilised for a variety of laboratory requirements including sterilization of boxes for breeding animals, laboratory clothing, and laboratory hard goods,” he said.

“Different sterilizer cycles are computer programmed and by simply touching a screen the operator can select the appropriate function required.

All cycle parameters will come up on the screen and the sterilizer will automatically move through the specific cycle selected.

“This cuts the chance of human error, such as selecting the wrong cycle or the wrong temperature, for example.”

Atherton www.atherton.net 03 9497 2500

The Walter and Eliza Hall Institute of Medical Research in Melbourne operates laboratories where research is conducted in a range of areas including cancer, chronic inflammatory diseases and infectious diseases.

The Institute’s Graham Pratt says the organisation has a range of Atherton sterilizing machines including a large Tangent Gorilla unit.

Global Automation www.globalautomation.com.au 03 9338 5659 Walter and Eliza Hall Institute www.wehi.edu.au 03 9345 2555

Control Components COLOUR: The touch screen operator interface guides the user through selecting a cycle from a range of pre-vacuum and general purpose gravity cycles.

for ease of loading and unloading the sterilizers. Built-in push button controls combined with a belt drive system power the loading car movement.

Tangent models come with a fully automatic sliding door to the sterilizer chamber, which is operated by tapping the door icon on the touch screen. If anything gets in the way as the door slides across the chamber opening, the door immediately reverses and glides back. Lipman says that further developments in sterilizer technology include automated safety. “Currently there is a sensor plate with a micro-switch system on top of the doors to guard against any obstruction, but we are now investigating the use of light curtains as a potential safety measure.

“Sterilizer equipment must be compliant with the requirements of the Therapeutic Goods Association and safety considerations will be a major ongoing focus of technological development,” said Lipman.

Intelligent terminals Global Automation’s John Thomson explains that the intelligence behind the EXTER operator terminals is a high performance Intel XScale PXA270 RISC CPU processor with a Windows CE.NET operating system.

“Use of this operating platform provides the system with the flexibility for future development to keep pace with changing user demands,” he said.

“A unique communications feature of EXTER operator terminals is their use of dual drivers with data exchange. This means that an operator terminal can be connected to two completely different devices (such as PLCs or inverters from different manufacturers) at the same time without any special configuration.

“An EXTER terminal can serve as a gateway for passing data from one connected terminal to another, and it is possible to exchange data between controllers connected to different

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PACE.FEB12.PG022.pdf

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IN FOCUS

Costs of poor power quality The loss of power or poor power quality can significantly hurt a business in terms of lost production and disruption to operations, writes Chris Halliday.

T

HE loss of supply or a power problem can cause serious disruption to operations and may have a serious negative financial impact on a business.

The considerations with regard to electricity should start from the onset when deciding where to site the business. The location of connection to the electricity grid can have a dramatic impact on the reliability and quality of the supply to the new premise.

Those connected to a long rural or remote power line can expect more power problems than those connected in the CBD of a major city even though the cost of power may be higher in rural areas.

An application will need to be submitted to the power company to have the supply connected or if increasing electrical load. Conditions may be imposed on the business by the power company before approval is granted to upgrade or connect to the grid. A suitably qualified consultant is generally needed to assist with this process, particularly if in-house electrical engineering staff are not employed by the business.

Existing businesses will have a reasonable idea about how often power problems are causing disruptions to operations and how much this is costing but even so power problems should be factored into emergency planning.

Regardless of whether the business is new or there is additional equipment being installed as part of a retrofit or expansion, it will be necessary to purchase equipment that will operate satisfactorily and is compatible with the grid supply. There are many technical aspects to the power supply that may need to be considered when planning or purchasing equipment, such as: ❏ The loss of the electricity supply – it may pay to have automatic backup generators, or at least connection points for portable generators, uninterruptable power supplies for critical equipment or processes, and so on ❏ The nominal supply voltage – normally 230 volts in Australia,

though some states are still regulated at 240 volts (this is likely to change in the near future). It is not recommended to purchase 220 volt rated equipment as it will struggle with voltages on Australian networks. ❏ The range of supply voltage – 230 volt rated equipment should be able to cope with a range of 204 volts to 253 volts. Equipment rated above 1,000 volts must cope with range of plus 6% to minus 10% of the nominal voltage (neglecting any voltage drop within the premises). ❏ The level harmonic current drawn this will add to background levels of voltage harmonics and may cause unexplained disruptions, loss of

The AIE team has extensive control system experience including design, installation and commissioning of HV/LV equipment, PLC’s, HMI, Machine Vision, and PAC based systems across a diversified range of industries.

AIE offers the following services: • Control system design and implementation • HV and LV power distribution design • Functional Descriptions for software development • Electrical drawings using a specialist CAD package • Process instrumentation systems • Electrical installation and commissioning • Project risk based management • Machine vision • Inline spectroscopy for quality control systems • Industrial electronics • Service Phone (Mob): 0417 511 106 Phone (Office): 03 5368 7575 Web: www.aieglobal.com.au Email: garyb@aieglobal.com.au

22 www.pacetoday.com.au FEBRUARY 2012

EFFICIENT: Condition based maintenance programs allow critical maintenance to be carried out without disrupting operations or production.

PACE.FEB12.PG023.pdf

There are many technical aspects to the power supply that may need to be considered when planning or purchasing equipment. supply or cause severe damage to equipment. ❏ Voltage sags or swells occur when there are faults on other parts of the grid or when large loads are turned on or off, particularly within the premise or in neighbouring premises. ❏ The level of voltage unbalance can increase motor losses and cause current unbalance protection to operate, particularly if the motor is lightly loaded. ❏ Voltage fluctuations and flicker – these are often caused by heavy industrial equipment, particularly within the premise. Fluctuation in the light output from luminaries is generally the only effect. ❏ Transients occur when lightning occurs nearby or when it hits the power system or when large electrical equipment is switched on or off.

These very short events can damage almost any electrical equipment. ❏ Momentary loss of supply from the power company can occur for periods up to 10 seconds. Some equipment is especially designed to cope with minor events.

Most power companies or state based legislation have requirements for electricity users not to cause interference to the power system such that the power quality to other customers is not affected. One way to stop such problems is to specify equipment that meets all relevant Australian Standards. Imported products may not comply with the relevant Australian Standards.

Protecting equipment Specifying the requirements for equipment is one thing but protecting equipment from foreseeable conditions or events is another. Surge/transient protection is essential for sensitive and critical equipment, especially where the grid is an extensive overhead network.

Under and over voltage protection is always a good idea as things can go wrong with the grid supply or within

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the plant or business. AS/NZS3000 Wiring Rules require undervoltage protection unless the “potential damage to electrical equipment is considered an acceptable risk”. Phase fail/undervoltage protection is recognised as essential for large and expensive motors.

Motor protection relays now offer much better protection of motors than provided by more archaic/traditional methods of motor protection. Motor protection in rural areas offers some challenges with current unbalance if the grid supply has a high level of voltage unbalance and the motor is lightly loaded. Motor warranty can be voided if current unbalance protection is disabled.

Excessive levels of harmonics may require the use of passive or reactive filters. Tight specifications and compliance with Australian Standards for new equipment is likely to negate the need for retrofitting such equipment.

Maintenance Some businesses might take the approach of minimising maintenance and carrying out repairs once equipment has broken down. This is generally a much more expensive and stressful approach than implementing a condition based maintenance regime.

Condition based maintenance programs are now well established in many businesses and allows critical maintenance to be carried out without disrupting operations and/or production.

Condition based maintenance programs can include power quality monitoring, energy monitoring, thermography, vibration analysis and alignment of motors and gearboxes, and condition monitoring of motors, cables, high voltage equipment and transformers.Proper planning is of course the best solution to prevent problems but when things go wrong it pays to have a contingency plan in place. Being prepared for loss of supply is sensible, having spare parts for critical equipment is essential and replacing old equipment where spares are not available are just some planning options that will need to be considered. In some cases it will be obvious that a power problem has caused the business, plant or part of a plant to shut down. At other times, the cause will not be identified and it will be important to have technical electrical staff in-house or a power quality consultant available.

Sophisticated monitoring equip-

PM

ment is likely to assist in identifying the cause of problems.

Careful analysis of logged results will be especially important to ensure the necessary solutions are implemented. For events that might occur rarely, some assumptions may need to be made based on hearsay evidence of previous events and solutions implemented in an effort to minimise disruptions in the future.

Solutions to overcome electricity reliability or power quality problems will need to be cost justified. The cost of the solution will need to be offset against the cost of lost production, downtime to unclog production lines, damage to equipment, contract penalties for not meeting delivery deadlines.

Conclusions The electricity supply to an installation should be considered in the initial planning process. The siting of a business can be essential in ensuring a high quality and reliable electricity supply.

Specifications for new electrical

equipment should include requirements to ensure compatibility with the grid and trouble free operations. Specifying that equipment must meet relevant Australian Standard is one important way of achieving this.

Having a condition based maintenance program, including power quality monitoring, can also assist in this process by correcting power problems and ensuring that critical maintenance is carried out before equipment fails.

Contingency plans can assist when a power problem occurs to ensure production is resumed as soon as possible.

Sophisticated power quality monitoring equipment may need to be installed as part of the power quality investigation and analysis of the results. Solutions for power quality problems are always available and may be quite costly; a costbenefit-analysis is therefore important.

[Chris Halliday is Director of Technical Services and Training at Electrical Consulting and Training.]

Electrical Consulting and Training www.elect.com.au

How do you improve?

UE Solid state pressure switches ,PSURYH UHOLDELOLW\ ZLWK 8( HOHFWURQLF SUHVVXUH DQG WHPSHUDWXUH 6ZLWFKHV $YDLODEOH IRU KD]DUGRXV ORFDWLRQV WKH 2QH 6HULHV SURYLGHV SUHFLVH FRQWURO DQG IHDWXUHV 3OXJJHG 3RUW GHWHFWLRQ 6ROLG 6WDWH GHVLJQ ZLWK QR PRYLQJ SDUWV )LHOG SURJUDPPDEOH IRU VHW SRLQW DQG GHDGEDQG FRQWURO :LUH GHVLJQ LV D GURS LQ UHSODFHPHQW IRU PHFKDQLFDO VZLWFKHV ,$: , DP ZRUNLQJ

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Ph: 1800 688 211 Melbourne | Sydney | Brisbane | Perth

info@pryde.com.au

FEBRUARY 2012 www.pacetoday.com.au 23

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INDUSTrIAL DATA COMMS FOrUM Proudly presented by

eynote Featuring K

Speaker:

PPEN IAN VERHADA CANA

Technology Training that Works

dian IEC Chair Cana ittee and TC65 Comm 03 Chair ISA 1 mittee on FDT Com

21st & 22nd March 2012 Brisbane, Australia

The industrial data communications systems in your plant/project underpin your entire operation. It is critical that you apply best practice and have the skills to fix any problems that may occur.

IDC Technologies have selected an outstanding line-up of speakers for the Industrial Data Comms Forum. This forum promises to distil all the tips and tricks learnt in the field and will provide participants with hard-hitting useful data comms engineering know-how which you can apply directly in your workplace. The technical papers presented at this forum will showcase the best and most proven practices to follow and all presenters will be using practical case studies to illustrate their real life experiences.

Topics Include: A Practical Roadmap for Industrial Data Communications • Wireless LAN in Industrial Application – Planning, Installation and Commission • Industrial Ethernet with Video Streaming • Modbus Protocols • DNP3 Architecture • Remote Monitoring of Origin Power Station SCADA System's and Associated Security Threats • OPC Hub and Spoke Solution • Development of Web-Based HMI with IEC 61850 & 60870 Protocols for Substation Control System • Innovative Robotics in Terminal Stevedoring • Integrating the Physical Layer of Complex Communications Systems for the Australia Pacific LNG Project (APLNG) • Fibre Optics • Radio Telemetry

SPECIAL DISCOUNT - 20% OFF

We would like to offer readers of PACE magazine a 20% discount off the forum registration fee.

Contact Conference Manager Sarah Montgomery to receive your discount: sarah.montgomery@idc-online.com

For more information contact IDC Technologies: 1300 138 522 idc@idc-online.com www.idc-online.com

PACE.FEB12.PG025.pdf

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IN FOCUS

Why calibrate with software?

Using software-based calibration management systems with documenting calibrators allows calibration results to be stored in the calibrator’s memory and then automatically uploaded back to the software.

P

LANT instrumentation devices such as temperature sensors, pressure transducers and weighing instruments require regular calibration to ensure they are performing and measuring to specified tolerances. However, different companies use very different methods of managing these calibrations. These methods differ greatly in terms of cost, quality, efficiency, and accuracy of data and their level of automation.

Calibration software is one tool that can be used to support and guide calibration management activities, with documentation being a critical part of this.

But in order to understand how software can help process plants better manage their instrument calibrations, it is important to consider the typical calibration management tasks that companies have to undertake. There are five main areas are: planning and decisionmaking, organisation, execution, documentation, and analysis.

Documentation is a very important part of a calibration management process. ISO 9001:2000 and the FDA both state that calibration records must be maintained and that calibration must be carried out according to written, approved procedures.

This means an instrument engineer can spend as much as 50 per cent of his or her time on documentation and

ESSENTIAL: Companies require a software tool to manage their instrument calibration processes and associated documentation.

paperwork – time that could be better spent on other value-added activities.

This paperwork typically involves preparing calibration instructions to help field engineers; making notes of calibration results in the field; and docu-

menting and archiving calibration data.

Imagine how long and difficult a task this is if the plant has thousands of instruments that require calibrating on at least a six-monthly basis? The amount of manual documentation increases

almost exponentially!

When it comes to the volume of documentation required, different industry sectors have different requirements and regulations. In the power and energy sector, for example, just under a third of companies (with 500+ employees) typically have more than 5,000 instruments that require calibrating. Forty-two per cent of companies perform more than 2,000 calibrations each year.

In the highly regulated pharmaceuticals sector, a massive 75 per cent of companies carry out more than 2,000 calibrations per year. Oil, gas and petrochemicals sector is similarly high, with 55 per cent of companies performing more than 2,000 calibrations each year. The percentage is still quite high in the food and beverage sector, where 21 per cent of firms said they calibrated their instruments more than 2,000 times every year.

The figures outlined appear to suggest that companies really do require some sort of software tool to help them manage their instrument calibration processes and all associated documentation. However, the picture in reality can be very different.

In a Beamex Calibration Study carried out in 2007, a mere 25 per cent of companies with 500+ employees (across the industry sectors mentioned above) said that they did use specialist >

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PACE.FEB12.PG026.pdf

calibration management software.

Many other companies said that they relied on generic spreadsheets and/or databases for this, whilst others used a calibration module within an existing Computerised Maintenance Management System (CMMS). A significant proportion (almost 20 per cent) of those surveyed said they used a manual, paper-based system.

Any type of paper-based calibration system will be prone to human error.

Noting down calibration results by hand in the field and then transferring these results into a spreadsheet back at the office may seem archaic, but many firms still do this. Furthermore, analysis of paper-based systems and spreadsheets can be almost impossible, let alone time consuming. In a recent survey conducted

by Control Magazine, 40 per cent of companies surveyed said that they calculated calibration intervals by using historical trend analysis – which is encouraging.

However, many of these firms said they were doing it without any sort of calibration software to assist them.

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Calibration software can be used to support and guide calibration management activities.

The other 60 per cent of companies determined instrument calibration intervals based on either the manufacturer’s own recommendation, or they used a uniform interval across the plant for all instruments. Neither method is ideal in practice. Companies could save so much time and reduce costs by using calibration management software to analyse historical trends and calibration results.

Using software for calibration management enables faster, easier and more accurate analysis of calibration records and identifying historical trends.

Plants can therefore reduce costs and optimise calibration intervals by reducing calibration frequency when this is possible, or by increasing the

PM

frequency where necessary.

For example, for improved safety, a process plant may find it necessary to increase the frequency of some sensors that are located in a hazardous, potentially explosive area of the manufacturing plant.

Just as important, by analysing the calibration history of a flow meter that is located in a ‘non-critical’ area of the plant, the company may be able to decrease the frequency of calibration, saving time and resources. Rather than rely on the manufacturer’s recommendation for calibration intervals, the plant may be able to extend these intervals by looking closely at historical trends provided by calibration management software.

Instrument ‘drift’ can be monitored closely over a period of time and then decisions taken confidently with respect to amending the calibration interval.

Regardless of industry sector, there seems to be some general challenges that companies face when it comes to calibration management.

The number of instruments and the total number of periodic calibrations that these devices require can be several thousand per year. How to plan and keep track of each instrument’s calibration procedures means that planning and scheduling is important. Furthermore, every instrument calibration has to be documented and these documents need to be easily accessible for audit purposes.

Paper-based systems These systems typically involve handwritten documents. Typically, this might include engineers using pen and paper to record calibration results while out in the field. On returning to the office, these notes are then tidied up or transferred to another paper document, after which they are archived as paper documents.

While using a manual, paper-based system requires little or no investment, it is very labour-intensive and means that historical trend analysis becomes very difficult to carry out. In addition, the calibration data is not easily accessible.

The system is time consuming, soaks up a lot of resources and typing errors are commonplace. Dual effort and re-keying of calibration data are also significant costs here. Although certainly a step in the right direction, using an in-house legacy system to manage calibrations has its drawbacks. In these systems, calibration data is typically entered manually into a spreadsheet or database.

The data is stored in electronic 26 www.pacetoday.com.au FEBRUARY 2012

format, but the recording of calibration information is still time-consuming and typing errors are common. Also, the calibration process itself cannot be automated. For example, automatic alarms cannot be set up on instruments that are due for calibration.

CMMS calibration module Many plants have already invested in a Computerised Maintenance Management (CMM) system and so continue to use this for calibration management. Plant hierarchy and works orders can be stored in the CMM system, but the calibration cannot be automated because the system is not able to communicate with ‘smart’ calibrators.

Furthermore, CMM systems are not designed to manage calibrations and so often only provide the minimum calibration functionality, such as the scheduling of tasks and entry of calibration results.

Although instrument data can be stored and managed efficiently in the plant’s database, the level of automation is still low. In addition, the CMM system may not meet the regulatory requirements for managing calibration records.

With specialist calibration management software, users are provided with an easy-to-use Windows Explorer-like interface. The software manages and stores all instrument and calibration data.

This includes the planning and scheduling of calibration work; analysis and optimisation of calibration frequency; production of reports, certificates and labels; communication with smart calibrators; and easy integration with CMM systems such as SAP and Maximo.With software-based calibration management, planning and decision-making are improved. Procedures and calibration strategies can be planned and all calibration assets managed by the software.

Position, device and calibrator databases are maintained, while automatic alerts for scheduled calibrations can be set up.

Analysis becomes easier too, enabling engineers to optimise calibration intervals using the software’s History Trend function. Also, when a plant is being audited, calibration software can facilitate both the preparation and the audit itself.

Locating records and verifying that the system works is effortless when compared to traditional calibration record keeping.

AMS Instrumentation & Calibration 1800 804 516 www.ams-ic.com.au

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© 2012 Swagelok Company

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But beyond that, they can tap into the global knowledge accrued in more than 65 years of research, development and innovation.

Your authorized Swagelok representative is ready to work with you and provide you with the tools and problem-solving solutions that deliver a real business edge and so much more too – because in this business you need all the right connections.

Visit swagelok.com/connections.

1/12/12 2:40 PM

PACE.FEB12.PG028.pdf

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SPOTLIGHT

7best of the

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

Flow meter Wireless intrusion detection Fluke Networks has released the new threat signature updates for its AirMagnet Enterprise 9.0 wireless intrusion detection and prevention system. The updates offer protection against wireless threats and vulnerabilities, including Karmetasploit and Apple’s new AirDrop feature. By using its proprietary Dynamic Threat Update technology, AirMagnet Enterprise offers the only wireless LAN security system on the market today that can quickly generate signature updates for immediate protection and automatically push them to customers without requiring scheduled downtime or additional IT resources.

Fluke Networks 02 8850 3333 www.FlukeNetworks.com

The CentriFlow Meter is designed to replace weigh belts, impact meters, loss in weight meters, and static weigh scales, where accuracy, low maintenance and zero drift are important. The meter features two designs, for both horizontal and vertical feed devices, that are robust and can accurately measure a variety of products including powders and other traditionally difficult applications. The meter maintains a typical accuracy of Âą0.25% of full-scale and can be utilised in any industry where accurate mass flow measurement of free flowing solids is required.

Control Overload 03 9578-0144 www.easterninstruments.com

M12 receptacle connectors The M12 receptacle connectors from Belden's Lumberg Automation product range can be used to connect control units to ProfiNet/Profibus networks via bus modules as well as to transmit analogue data at field level. Integrated shielding between devices delivers a high level of functional reliability. The receptacle connectors are available with assembled control cables or with printed contacts for PCB mounting. In the printed contact versions, the integrated shielding ensures optimum flexibility for shield continuity.

With the assembled connectors, and depending on the port assignment of the control units, a diagnostics interface can be implemented outside the switch cabinet using an Ethernet connection. This practically eliminates the disruptions resulting from repair or maintenance work.

Belden 1800 500 775 www.beldensolutions.com 28 www.pacetoday.com.au FEBRUARY 2012

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

Camcorder format imager The testo 890, in the newly developed camcorder format with a rotatable handle, allows safe thermography, even for demanding applications. The thermal imager combines high grade optics with a wideangle and a telephoto lens, 640 x 480-pixel detector, and an NETD < 40 mK. SuperResolution technology delivers a fourfold increase in the thermal resolution allowing high-resolution images in megapixel quality to be recorded. Using the fully radiometric video measurement, thermal processes can be recorded in real time, and analyses for R&D carried out on a PC. The exact temperature values of all pixels are available at any time. Vice versa, reliable thermographic evaluations can be carried out even on far away measurement objects using to the telephoto lens and the high image quality. Measurements in temperature ranges up to 1,200°C may be recorded. testo 03 8761 6108 www.testo.com.au

Red Lion ProducTVity Station The ProducTVity Station is able to collect data from a wide range of automation components. Using a library of over 200 communications drivers, the ProducTVity Station can communicate to PLCs, VSDs, energy meters, bar code scanners and more. Additionally, the PTV can be expanded with I/O modules, allowing it to directly accept digital and analogue inputs from a range of sensors. A fully-programmable graphical interface allows users to create high-definition visual management displays. A built-in data-logger can record key performance indicators, as well as alarms and events for later review. It can synchronise the log files with any FTP server or Microsoft’s SQL Server for further analysis.

Control Logic 1800 557 705 sales@control-logic.com.au

Unmanaged industrial Ethernet switches Weidmuller's new industrial Ethernet product range includes a choice of fast Ethernet or Gigabit unmanaged switches, and 10/100 media converters. The range is designed to perform in harsh environments. All switches are housed in IP40 metal casings, which act as a heatsink, eliminating the need for fans and case venting. The switches have been created to withstand a wide operating temperature up to 85ºC as well as high vibration and good EMC protection.

Weidmuller 1800 739 988 info@weidmuller.com.au

Push-in connection technology Phoenix Contact’s installation terminals are available in various designs as three-level and N disconnect terminals with the matching feed-through, disconnect, and ground terminals. Conductors with cross sections ranging from 2.5 to 10 mm2 can be connected. They are compact with widths starting at 5.2 mm. As a result of 50% lower insertion forces, rigid and flexible conductors from 0.34 mm2 up to 4 mm2 can be inserted without requiring any tools. The high contact forces ensure that reliable conductor contacts are estab-

lished. The integrated button allows the connection to be released in an isolated fashion using any tool. The orange colour of the button identifies it as an actuating element, thus preventing mistakes from being made. A connection can be established to the PEN conductor busbar using the latching contact sliders with status display. Using the double function shafts, the L1-L2-L3 potentials can be multiplied as required.

Phoenix Contact 1300 786 411 www.phoenixcontact.com.au FEBRUARY 2012 www.pacetoday.com.au 29

PACE.FEB12.PG030.pdf

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COMMUNITY

WHAT’S ON

Flow Assurance and Integrated Production Technology 26-29 February 2012, Abu Dhabi www.flowassuranceme.com Introduction to Instrumentation and Process Control (HART) - Professional Development Course 27-29 February 2102, Sydney www.cce.usyd.edu.au/course/iipc

With reports of a hacker exploiting SCADA to attack a water system in the US, is it time to turn the spotlight on Australia and examine vulnerabilities in our critical services and industries?

PACE posed this question to industry members on LinkedIn, the professional networking site (www.LinkedIn.com). An enlightening discussion followed and extracts are provided below. The Institute of Instrumentation Control and Automation (IICA) has set up a discussion group in LinkedIn that is open to Australian residents and overseas IICA members. Contact Cathie Tynan (admin@iica.org.au) if you need assistance in joining this group. As of November 3, 2011, LinkedIn had over two million professional members in Australia.

Applied Process Control for Professionals - Professional Development Course 1-2 March 2012, Sydney www.cce.usyd.edu.au/course/apcp Rockwell Automation on the Move 6-7 March 2012, Melbourne au.rockwellautomation.com

Stephen Harrison • This is already an active subject within groups like the Forum of Australian SCADA Vendors (another LinkedIn group) and some areas of government. As it is a case of finding one or more weak points there is no simple low cost method of implementing significantly better security.

At this stage it is primarily about detection and recovery rather than prevention. Also turned out to not be an attempt to hack in at all, just legitimate activity from a remote user logged in from Russia.

Stephen Harrison

HAZOP Study for Team Leaders and Team Members 13-15 March 2012, Brisbane www.icheme.org/hazopbris Peter Imison

For daily updates visit www.pacetoday.com.au

Peter Imison • There is never a bad time to stop and (re)evaulate the vulnerabilities of essential services, but I would like to suggest that the rise of the technologies and processes that have laid the ground work for the decentralisation and remote operation of such essential services actually sow the ground for much greater risks... namely a lack of personnel.

If I truly had malicious, rather than opportunistic, intent then I could do more damage in five minutes by jumping a fence and probably have less chance of being caught. The vulnerabilities of our truly critical infrastructures cannot be understated and although our focus is justifiably IT/Technology focused, these prevention mechanisms are for naught if not part of a suite of holistic prevention measures.

IICA NEWS & VIEWS

Reflections for 2012 Recent IICA reforms will lead to greater practical relevance, writes Brett Simpson.

THE beginning of a New Year is often a time for reflecting about the past year as well as looking forward to the coming one. With this in mind, I too want to do exactly that, and offer these reflections on the Institute of Instrumentation, Control and Automation Australia (IICA) of which I am currently Federal President.

The Institute’s decisions over the last two years to embark on a number of significant reforms will enable the IICA to enhance its visibility, influence and most importantly, practical relevance within the wider community and to the instrumentation, control and automation (IC&A) sectors of industry and business. Let me explain what I mean.

The IICA’s Federal Council resolved that it had to reach out beyond its 30 www.pacetoday.com.au FEBRUARY 2012

immediate confines in order to influence appropriate decision makers to assist organizations like ours to help seek solutions to specifically identified problems that affect different areas within the IC&A fields from time to time.

For example, the IICA is currently working with a number of partner organisations and companies within the civil and defence aerospace maintenance areas to find appropriate solutions to certain matters of concern, which we hope will receive endorsement from both CASA and Defence regulators.

Likewise, we have become increasingly aware that an organisation like ours can play an increasingly greater role in advocating and working within the TAFE and University sectors. Of partic-

ular interest at the moment is the need to advocate and influence those persons and committees who devise tertiary curricula to include a more equitable focus on IC&A subjects and topics – which tend to be too often simply ‘addons’ to other subjects.

Of equal importance to our long term strategies has been the considerable expansion and reworking of the previous Corporate Associates Program (CAP). This Membership category had been particularly attractive and very relevant to largely the supplier and service provider companies in the IC&A sectors but has not sufficiently addressed the needs of companies on the reverse side of the coin.

The new Corporate Industry Program (CIP) seeks to do that. It

embraces and caters for the professional needs and interests of not only the supplier and service provider companies but also to those end user, consultant, contractor, maintenance, education departments and companies. They all will now find it in their interests to check out our website, and seriously think about joining as CIP Members.

In summary, the decisions taken in the past two years by the IICA have taken root and are each at different stages of development. Our expectation is that 2012 will be a busy and fruitful one and we extend an invitation to each and every one of the readers of PACE – those not already Members – to join us in our endeavours.

[Brett Simpson is President IICA.] www.iica.org.au

PA1909_Awards_Feb_R.pdf

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PACE ZENITH AWARDS

2012 NOMINATIONS

NOW OPEN The PACE Zenith Awards recognise companies and professionals who show innovation in engineering projects and technological excellence in one or more of ten industry categories.

Submit your entry and you may see your success and hard work rewarded at a glamorous gala event in Melbourne on 14 June 2012.

WHY NOMINATE? • Exposure and publicity • Recognition for your hard-working team members • Valuable networking opportunities with key industry leaders

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CATEGORIES: Automotive & Manufacturing Food & Beverage Machine Builder Mining, Minerals & Exploration Oil & Gas Power & Energy Management Lifetime Achievement Award Transport, Power & Infrastructure Water & Wastewater Young Achiever

Visit www.pacetoday.com.au/awards to download the entry kit.

Sponsorship opportunities are available:

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Contact Tim Richards on (02) 9422 2818 or tim.richards@reedbusiness.com.au

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