PACE - Process & Control Engineering - February 2013

PACE.FEB13.PG001.pdf

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FEBRUARY 2013 | VOL.66 NO.1

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

INSIDE PACE

Focus on security

Operators must recognise that are now A D _ P A C E F L U F E B _ 1 3 control . p d f systems Pa ge 1 2the 1 / 0 1 / 1 3 , target of sophisticated attacks.

Water management

Engines of efficiency

Councils create common 2 : 4 6design P Mfor wastewater management systems.

Cogeneration could be the answer to improved environmental outcomes.

Post Print Approved PP255003/00539

NEW Fluke VT02

www.uke.com.au

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PACE.FEB13.PG003.pdf

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CONTENTS

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 Associate Publisher: Martin Sinclair Email: martin.sinclair@reedbusiness.com.au Editor: Kevin Gomez Tel: (02) 9422 2976 Fax: (02) 9422 2722 Email: kevin.gomez@reedbusiness.com.au

IN THIS ISSUE

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

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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

09 News Update 6

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Copyright © Reed Business Information 2013 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.

OFFICIAL MAGAZINE OF:

Growth and emissions It is absolutely essential to implement energy-efficient technologies as well as reduce the emissions required to generate energy for use.

Viewpoint 9

Increased focus on security The air gap seems like a perfect solution but for most installations it simply does not work.

12

17

Research Update 12

Business Update 26

Case Study 17

IICA Corner 30

Solving the fracking problem The high cost of disposing of hydraulic fracturing produced water represents a considerable cost to the industry.

Water savings flow Six SA councils create a common design for their wastewater management systems and realise significant benefits.

Unlocking your power Solutions chosen to manage power across a business are flexible in order to adapt to the changing environments.

Benefit from quality training The IICA’s 2013 training programme covers several introductory subjects as well as advanced engineering topics.

ON THE COVER P ACE . F E B1 3 . P G0 0 1 . p d f

Pa ge

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2 3 / 0 1 / 1 3 ,

2 : 2 6

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FEBRUARY 2013 | VOL.66 NO.1

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

INSIDE PACE

Focus on security Operators must recognise that

are now A D _ P A C E F L U F E B _ 1 3 control . p d f systems Pa ge 1 2the 1 / 0 1 / 1 3 , target of sophisticated attacks.

Average Net Distribution 6,599

Post Print Approved PP255003/00539

A D _ P A C E R Period O C ending F E September B _ 1 ‘12 3 . pdf

Water management

Engines of efficiency

Councils create common

Cogeneration could be the answer to improved environmental outcomes.

2 : 4 6design P Mfor wastewater

management systems.

Pa ge

1

NEW Fluke VT02

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09-Mar-12 4:29:16 PM FEBRUARY 2013 www.pacetoday.com.au 3

PACE.FEB13.PG004.pdf

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COMMENT

EDITOR’S MESSAGE

WHAT’S ON

We’re sixty and still counting

International Conference on Remote Engineering and Virtual Instrumentation 6-8 February 2013, Sydney www.rev-conference.org Product Innovation (PI) 2013 19-20 February 2013, berlin www.picongress.com IICA Technology Expo 20 February 2013, Moorabbin events@iica.org.au

Kevin Gomez Editor

National Manufacturing Week (NMW) 2013 7-10 May 2013, Melbourne www.nationalmanufacturingweek. com.au

For daily updates visit www.pacetoday.com.au

Next Issue

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

INDUSTRY analyst Jim Pinto, whose columns regularly appear in PACE, expects 2013 to be a transformational year in our industry. And not just because of the acquisitions that the big five are expected to make.

Rather, he sees every technician becoming an expert, using wireless connected tablets to view operating information, displays, alarms and diagnostics.

Fewer operators will be confined to control rooms facing banks of panels. Wireless and portable devices are changing the way we work.

We would love to hear from our readers on specific trends they see emerging this year –

which will also be unique for another reason.

2013 will be a landmark for PACE as we celebrate 60 years of publishing, having begun life as a journal for process engineers in Australia’s chemical sector.

The magazine, first published in 1953 under the title Chemical Industry and Engineering, has evolved along with the industry over the past six decades.

Today, we engage with the country’s instrumentation, automation and process control professionals and do that in a variety of print and digital formats as well as through social media.

We have some special plans

this year and more of that on page 8 of this issue.

Do talk to us, we look forward to hearing from you. kevin.gomez@reedbusiness.com.au

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

MANAGEMENT

A life-changing lesson from the founder of Hewlett-Packard

BY JIm PINTo

areas where I needed help. develop long-term plans covering two, THERE are few things in the business I soon received a call from a retired three and five years. As the company world that are as effective and worthsenior vice president at a major bank, grew, this planning process became an while as a good personal mentoring relawho prepared me for my first banking invaluable tool and the regular planning tionship. mentors made a tremendous “relationship”. Through his mentoring, I discipline helped make us successful. difference for me, personally, during the signed up for a line of credit. Eventually How does one develop good startup phases of Action Instruments, we got major financing at terms that mentors? You’ve got to be bold and have the company I founded. saved my company big bucks over the a good personal approach. I remember When the company was just a few next several years. calling Bill Hewlett, the co-founder of months old, I went to the local Small The other mentor who made a big Hewlett-Packard.

Business Administration (SBA) office difference I also met through the SBA It wasn’t easy to get through, but for free advice through their Service program. He had retired as Director my persistence and sincerity paid off.

Corps of Retired Executives (SCoRE) of Planning at a billion-dollar research I told him that I was an engineer like A D _ IPknew ACE ME T Aabout P R finance _ 1 2 . p organization df P a gand e he4took2 me 0 /under 0 3 his / 1 2 , him, 5 :starting 1 1 my PM program. very little own company and and banking, and checked those off as wing. He kept insisting that we should asked if I could meet with him at his

convenience. He invited me to his office in Palo Alto, California. His friendliness and open responses to my rookie questions served as “guru” advice which served me well.

When we were done, I said, “Your help is worth a million dollars to me.

How can I ever repay you?” His candid response has remained with me for the rest of my life, “You can indeed pay, simply by giving advice to any engineer who asks for it sincerely, as you did.”

I have tried to live up to that promise ever since.

Jim@JimPinto.com

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

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PACE.FEB13.PG006.pdf

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nEWS

EnErgy

Decoupling growth from emissions

By Isaac Leung On HIs recent trip to australia, aBB’s head of Discrete automation and Motion, ulrich spiesshofer took time out of his schedule to talk to PACE about advances in energy efficiency.

The Discrete automation and Motion business is worth about us$10 billion, and employs 30,000 people around the world. according to spiesshofer, aBB has had energy efficiency as one of its core tenets for many years, and it will continue to be an issue of growing importance for years to come. With about a billion us dollars spent on R&D a year, aBB devotes a large portion of that investment into energy efficient solutions.

“We have a simple paradigm to resolve: to decouple the correlation between economic growth and energy usage,” speisshoffer said. “We want to enable the industry to grow economically while still reducing energy use.”

There are two main ways to resolve the problem: by implementing energyefficient technologies, and by reducing the emissions required to generate energy for use. Industrial players who manage to achieve both will do better, while doing good.

“Doing better means having better economic results because energy costs

today in some industries take a very high share of the total energy bill from total revenue,” spiesshofer said. “For example, aluminium companies have energy costs making up about five percent of revenue. so this is a very important, big cost for the players in the process industry.” aBB provides both energy-efficient solutions (including drives, motors and robots) and renewable sources of energy generation, such as solar and wind.

“Industrial motors consume 25 percent of the electricity generated globally, this is one of the biggest energy users in the world,” spiesshofer told PACE. “Having energy-efficient industrial motors helps to reduce the consumption.”

High-efficiency standalone motors allow up to 10 percent savings in energy consumption, while variable speed drives, in which aBB is also a leader, allows energy savings of up to 40 percent.

“If all existing installed motor drive systems in industry were optimised using technology available today, the world could save the equivalent of the output of 250 nuclear power reactors,” spiesshofer said. aBB also plays within the industrial robotics and automation space, which not only enable safer operations, less energy required for operations, but also

ULRICH SPIESSHOFER: We need to break the trend of energy consumption. offer machine precision which can enable industrial players to reduce material waste, and thus indirect energy usage.

While savings can be made within industry, spiesshofer says a quarter of all primary energy is lost between generation and transmission and usage of electricity. aBB’s solutions cover not just the industrial usage end of the energy supply chain, rather the entirety of the value chain, from primary energy down.

aBB’s process automation solutions, for example, help improve well efficiency in the oil fields. Its efficient propulsion solutions and pumps are also used in oil transporters and pipes to improve the efficiency of moving crude oil products.

The firm provides automation, control and auxiliary systems to power plants to improve energy yield from fuel combustion, while its technology reduces power line losses and contribute to higher substation efficiency.

“Basically, aBB is a partner for players in industry along the entire energy chain, from primary energy to transport, generation, electrical transmission, industrial processes, and discreet automation and discreet industries, we cover the whole range,” spiesshofer said.

While many companies within the process industry hesitate to make the initial investment in such equipment, spiesshofer says most industrial players realise an ROI of two years or less, be it for more efficient motors, test rigs, auxiliary systems, or robots.

“We need to break the trend of energy consumption,” spiesshofer said. “Only with a smart combination between energy efficient solutions and renewable, cO2 friendly power generation will we get close to the required global emission reductions.” www.abbaustralia.com.au

Education

Dassault systèmes signs Mou with RMIT DassauLT systèmes and its australian partner, MeMKO, have signed a Memorandum of understanding (Mou) with Royal Melbourne Institute of Technology (RMIT university). under the terms of the Mou, Dassault systèmes and MeMKO will collaborate with RMIT to develop a new Master of engineering degree program in computer aided engineering and PLM. The new course will be made available to students in January 2014.

The new degree course will incorporate use of advanced applications of Dassault systèmes’ 3Dexperience 6 www.pacetoday.com.au February 2013

platform and include all aspects of PLM. students of both electrical and mechanical engineering will be able to gain V6 certifications in catia, enovia, Delmia, 3D Via and simulia software reinforcing their overall skill set for entry into the workforce. christian ebel, Director Value solutions, australia and new Zealand, Dassault systèmes, said, “although we have relationships with many australian universities, this is the first time that Dassault systèmes and an australian university are entering into a long-term collaborative agreement to develop and

deliver a complete and holistic PLM education at the post-graduate level based on our 3Dexperience platform.

“We are very pleased to be the first university to enter into this kind of long term collaborative agreement with Dassault systèmes,” said Professor aleksandar subic, Dean of engineering, RMIT. “It recognises the depth of RMIT’s long-standing expertise and industry engagement in engineering and associated disciplines.”

Dassault systèmes has a long-term strategy in place to work with educational institutions around the world in

developing the skills for future generations of engineers. Dassault systèmes’ australian partner, MeMKO, will work closely with RMIT to deliver the support required to ensure successful transfer of skills and learning.

Miro Miletic, MD of MeMKO, said, “Building on our longstanding relationship with RMIT I look forward to working with RMIT university to implement leading technologies that will combine with academic excellence to produce an industry-recognised professional certification.” www.memko.com.au

PACE.FEB13.PG007.pdf

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Pepperl+Fuchs acquire Govan Industries PEPPERL+FUCHS recently acquired protection products and customised all the assets of Melbourne based solutions are manufactured in this Govan Industries. facility to support customers throughout This acquisition will allow the Australia and the South East Pepperl+Fuchs to increase expertise Asian markets. and capacity in the manufacture of Pepperl+Fuchs electromechanical electromechanical explosion protection explosion protection products are based products for use in hazardous areas and around enclosures in the increased harsh environments. safety, intrinsic safety and flameproof Pepperl+Fuchs is a manufacturer of protection classes. intrinsically safe explosion protection The range provides several options of and electronic sensors. enclosures dependent upon the project Since 1949, Govan has been application and specification required, a supplier of electromechanical with a variety of sizes and materials explosion protection. available including stainless and mild Leveraging this expertise, steel, as well as glass reinforced polyester Pepperl+Fuchs Australia will continue (GRP) and cast aluminium. to supply “GOVAN – A Pepperl+Fuchs Leveraging Govan’s experience, Brand” products from the dedicated Pepperl+Fuchs will manufacture 4000 sq m facility in Campbellfield customised enclosures, a range of Industrial Park, AD_ P A CMelbourne.

E A M S F E B _ 1 3 . p multifunction df P a g local e 1control 9 / stations 0 1 / and 1 3 , A range of mechanical explosion control panels.

Standard and customised local control stations in glass reinforced polyester and stainless steel enclosures are complemented by Exd IIC Local Control Stations utilising cast aluminium and stainless steel enclosures.

Pepperl+Fuchs and Govan will draw on their expertise to create customised Exd enclosure solutions to meet the specific project requirements of customers. These bespoke solutions allow the hazardous area mounting of a wide range of industrial products which do not have “Ex” approval.

Components such as PLCs, intrinsic safety barriers, starters, and transformers can be mounted in an Exd enclosure which then allows them to be located in a Zone 1 certified area.

The enclosures are typically manufactured 1 0 :in0cast 0 iron, A Mcast aluminium and stainless steel materials with a wide range

of sizes and orientations available.

Solutions can also be engineered to customer specific requirements using combinations of the product range.

A typical example would be an Exd enclosure containing industrial equipment close coupled to an Exe enclosure via inline approved bushings.

The Exe enclosure is used to house control functions and terminals therefore allowing for easier installation and maintenance. All Pepperl+Fuchs products are certified to a variety of international standards including the latest ATEX and IEC Ex guidelines.

Their products are used in a variety of applications from oil platforms to pharmaceutical plants and their certification allows usage in gas and dust environments as well as a wide range of temperature extremes. www.pepperl-fuchs.com.au

February 2013 www.pacetoday.com.au 7

PACE.FEB13.PG008.pdf

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nEWs

EvEnts

PACE: six decades and going strong THIS will be a special year for a variety of reasons. For one, our industry is expected to post strong results as organisations seek to increase productivity, reduce energy consumption, and boost efficiencies.

Most of our industry sectors are under pressure and the best way forward for organisations is to invest in smart technologies which will deliver benefits.

2013 is also a special year for PACE as we mark 60 years as a member of Australia’s process control and automation community.

The November 2013 issue of PACE will be a special commemorative edition where we look at the evolution of various key technologies, assess their current status and try to ascertain what

the future holds.

We welcome our readers to get in touch with us. PACE would love to hear, and publish, some of the key milestones and developments in Australia.

Tell us your story. We’re just a phone call or email away.

Kevin Gomez, Editor 02 9422 2976 editor@pacetoday.com.au

Entering the PACE Zenith Awards?

NOW is your opportunity to be recogwww.pacetoday.com.au/awards or email nised for your contribution to process us at editor@pacetoday.com.au. The entry control industry. deadline is 5 April 2013, so hurry!

This is the tenth PACE Zenith If you’re a supplier, nominating Awards event and we are expecting your customer is a great way to say record numbers at the gala dinner in ‘thank you’ for their business to showSydney on 13 June 2013. case the unique application of your The entry process is simple, and free; A D _ M A N M A E C F E B _ 1 3 . p product df Pora technology. ge 1 1 4 / 0 1 / 1 3 , download an entry form from If you’re a team leader or business

210x122.indd 1 8 www.pacetoday.com.au February 2013

owner, entering is a fantastic way to boost staff morale and show off your company’s level of competence.

All finalists automatically receive two free tickets to the gala dinner and extra tickets are available to purchase.

Finalists will be contacted by early May. 9 :Good 5 6 luck!

AM

www.pacetoday.com.au/awards

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PACE.FEB13.PG009.pdf

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OPINION

CONtrOl SyStemS

Increased focus on security Control systems are now the target of sophisticated attacks, writes Rick Kaun.

A

BOUT 10 years ago, you wouldn’t have found many industrial control engineers asking questions about cyber security.

In fact, the Corporate IT gurus seemed to have responsibility for that area, and Industrial Control Systems (ICS) experts seemed to think the control system was almost immune to cyber attacks.

That all began to change when commodity operating systems and hardware became more prevalent in control system configurations.

But, even with those changes, it took several years to gain broad attention within the ranks of industrial control systems.

Then Stuxnet appeared in June of 2010, and now it seems everyone in the industrial control systems community is talking about security breaches, how to stop them, and how to plan for a more secure digital environment.

Threats and vulnerabilities are often discussed together, and the list shown here is no exception.

Consider that threats come from internal and external sources – they are any event that disrupts normal operation.

A vulnerability is a weakness in the control system’s network, policies, practices, or security culture.

The list of potential causes of digital breaches of an industrial control system parallels the list confronted by the business IT organizations around the world.

There are differences in mindset of the business IT professional and that of the Industrial IT professional – primarily focusing on the importance placed on system availability.

This difference in mindset results in the application of different techniques or approaches in resolving similar issues.

The key takeaway here is that Industrial IT requires the sensitivity of industrial control systems knowhow.

For today’s industrial control systems management, that might mean inducting business IT profes-

The air gap seems like a perfect solution but for most installations it simply doesn’t work. sionals into the control systems staff or training control systems staff to become Industrial IT experts.

Recently, you might have heard more comments about control systems environments being less vulnerable to cyber attacks.

This is because of an air gap – a method intended to secure a network by isolating it from potentially insecure networks.

Denial of Service Attacks • Backdoors Holes in the network perimeter • Worms Unsecured Devices Protocol Vulnerabilities Field Device Attacks • Database Attacks Man-in-the-middle Attacks • Improper Patching Techniques • Insecure Coding Techniques Improper cyber security procedures for internal and external personnel And on and on...

BREACHES: Threats and vulnerabilities are often discussed together and the list shown here is no exception.

The air gap seems like a perfect solution – but, for most installations, it simply doesn’t work. What happens

when you need updates to the airgapped system?

The first solution that comes to

>

February 2013 www.pacetoday.com.au 9

PACE.FEB13.PG010.pdf

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OPINION

MAPPED: This chart illustrates the expectation of control engineers for increased connectivity between control endpoints and corporate IT infrastructure. (Source: Managing Automation Systems - Critical Infrastructure Operators’ Challenges & Opportunities, Industrial Defender, 2011.)

DANGER: A vulnerability is a weakness in the control system’s network or security culture.

mind might be “put the changes on a expect to see either significant or corporate networks is unrealistic, as USB stick.” moderate increases in connectivity information exchanges are essential This sneakernet method is how between industrial endpoints and for process and business operations to Stuxnet was transmitted! corporate IT infrastructure over the function effectively.

As much as we would like to pretend next three to five years.

Therefore, all mechanisms for otherwise, modern control systems need So, what does this mean for industransfer of electronic information to or a steady diet of electronic information trial control system security? from an Industrial Control System must from the outside world.

We must recognise that a modern be evaluated for security risk.

Severing the network connection Industrial Control System or Focusing on only a few obvious with an air gap simply spawns new pathSCADA system is highly complex pathways, such as USB storage drives ways – like the mobile laptop and USB and interconnected. or the Enterprise/Industrial Control key, which are more difficult to manage This results in multiple potential System firewall, is a flawed defence. and just as easy to infect. pathways from the outside world to the All control industries should begin to Survey findings, depicted in process controllers. include security assessments and testing theApie D chart _ P Aabove, C E Iindicate N S F E B _ 1 3 . p d fAssume P a that g e an air 1 gap 1 0between / 0 1 / 1 3 , as part 2 : of 0 the 9 system P M development and 71 percent of control engineers Industrial Control Systems and periodic maintenance processes on all

Industrial Control Systems.

This is just one step in implementing defence in depth.

If the critical infrastructures of the world are to be safe and secure, then the owners and operators need to recognise that their control systems are now the target of sophisticated attacks.

Improved defence in depth postures for industrial control systems are needed urgently. Waiting for the next worm may be too late.

[Rick Kaun is Global Business Manager, Industrial IT Solutions, Honeywell Process Solutions.] www.honeywellprocess.com

Training courses from IChemE Human Factors in Health and Safety 6-7 February www.icheme.org/humanfactors

Particle Technology – The Science of Powder Handling and Processing 19-21 February www.icheme.org/pt

HAZOP Study for Team Leaders and Team Members 26-28 February www.icheme.org/hazopbris To view the full list of 2013 courses taking place in Australia visit www.icheme.org/ausevents C0053_13

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Make the unpredictable totally predictable.

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PACE.FEB13.PG012.pdf

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OPINION

OIL & GAS

Resolve the fracking problem The future of hydraulic fracturing depends on effective water treatment, writes Paul Miller.

T

HE benefits of employing hydraulic fracturing (HF) to stimulate the flow of gas and oil from both new and existing wells are obvious.

However, the downside is that the technique consumes huge quantities (along the lines of millions of litres per well) of often regionally scarce water, and — according to opponents — can contaminate drinking water supplies.

The US Environmental Protection Agency recently initiated a new, sciencebased study to determine if the practice does indeed pose a risk to human health or the environment.

To help address some of the waterrelated issues, several leading water technologies companies have introduced mobile water treatment solutions.

These are designed to make it possible to treat and recycle both HF flowback and the brine water produced during drilling, HF, and other industrial operations and, in this manner, reduce the strain on freshwater supplies.

On-site water treatment also reduces the need to transport HF flowback and produced water offsite for safe disposal.

Water technology companies are also building permanent treatment facilities designed to reduce the percentage of total dissolved solids from the HF flowback produced water prior to processing at municipal wastewater treatment facilities, which often are not equipped to handle this type of effluent.

In addition, several US universities have initiated research projects intended to develop new, more effective technologies for treating the effluent from oil & gas drilling and HF operations.

With hydraulic fracturing, water under high pressure forms fractures in the rock, which are propped open by sand or other materials to provide pathways for gas to move to the well.

Petroleum engineers refer to this fracturing process as “stimulation.”

A variety of different chemicals, typically representing less than 0.5 percent of the total volume, are also used to facilitate the process.

12 www.pacetoday.com.au February 2013

The tremendous volumes of water required must be recovered and disposed of responsibly or recycled for further industrial use before gas production can commence.

For example, for coal seam gas HF operations in Australia, the relatively benign chemicals used include sodium hypochlorite and hydrochloric acid, cellulose, acetic acid and small amounts of disinfectants. (Queensland has banned the use of other chemicals, such as benzene and toluene, in these operations.)

The tremendous volumes of water required (typically seven to 18 million litres per well), of which 25 to 100 percent may be returned to the surface as flowback water, must be recovered and disposed of responsibly (or recycled for further industrial use) before gas production can commence.

In countries such as Australia, where freshwater supplies are extremely scarce and have been for some time, hydraulic fracturing can further strain existing water resources.

In the Western US, for example, water used for drilling and fracking active wells in the Barnett Shale area can equal the typical water usage for 185,000 households (or more).

According to a US Geological Survey (USGS) fact sheet, Texas state and county agencies now closely monitor volumes of water used during drilling, and a consortium of Barnett Shale drilling companies have developed best management practices for water conservation, with the goal of keeping the pace of drilling and production activities within the bounds of sustainable water use. Producers in Marcellus Shale gas production areas have had similar discussions.

Produced water from HF operations is typically disposed of in three ways: o Transported off-site for disposal in permitted underground wells o Transported off-site for treatment prior to disposal to surface waters, or o Treated on-site for re-use in HF or drilling operations The unique nature of the flowback water produced from HF operations located in different geographic regions (and the different chemicals used) requires different water treatment solutions.

For example, water treatment operations in the Marcellus Shale region in the eastern US must be able to deal with

the extremely high brine content of the HF flowback water.

Several companies, including both Siemens Water Technologies and GE Power & Water, have introduced mobile treatment units that can treat produced water on-site for reuse using a variety of different technologies.

The on-site approach both reduces the strain on local water resources and minimises the cost, wear and tear on roads, and greenhouse gas emissions associated with hauling the large quantities of flowback and produced water to often-distant disposal wells or off-site treatment facilities in tank trucks.

The Siemens solution utilises flotation/filtration technology, while the GE solution utilises evaporation technology.

As with most technology approaches, each has its pros and cons.

Clearly, the limited availability of water appropriate for use in HF operations constrains the oil & gas industry’s ability to produce shale gas, coal seam gas, and other unconventional energy sources.

Furthermore, the current high cost of treating and/or transporting and disposing of both produced water and HF flowback water represents a considerable cost to the oil & gas industry.

The current concerted effort by leading water industry suppliers, government, and academia, to develop, commercialise, and deploy new mobile and fixed technologies for treating produced water and HF flowback water cost-effectively will provide significant benefit to the oil & gas industry and the general public alike.

ARC Advisory Group is preparing a series of reports on industrial water management for its Advisory Service clients.

These reports will include approaches and success stories across a variety of different industrial sectors, including both upstream oil & gas production and downstream refining and petrochemicals manufacturing.

[Paul Miller (PMiller@ARCweb.com) is an Analyst with ARC Advisory Group.] www.ARCweb.com

PACE.FEB13.PG013.pdf

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OPINION

SAFETY

Designing the future Adopting international safety standards can lead to expanded markets, writes Wayne Pearse.

S

AFETY systems have come a long way in recent times. They have evolved from simple mechanistic shut-down functions to technologies such as safety capable logic, which can react to machine conditions and improve productivity. To use modern safety systems effectively, designers need new tools.

Current international safety standards provide quantitative methods to calculate risk and reliability. This is a big shift from the simple qualitative approach of EN 954, which did not require designers to assess the reliability of safety components.

There are many compelling reasons to adopt international safety standards.

The most obvious include meeting the requirements of a global market and to lay the groundwork for future expansion.

For example, machines exported to Europe must comply with International Organisation for Standardization (ISO) 13849-1 or International Electrotechnical Commission (IEC) 62061 (also known as AS 62061-1:2005).

Manufacturers can also take advantage of the framework provided by international safety standards to homogenise the operation of their plants around the world.

This leads to cost savings in training and maintenance, as well as increased safety for workers and equipment.

The quantitative approaches of ISO 13849-1 and IEC/AS 62061:2005 are also useful for engineers seeking to explain the need for a particular safety system in an application, or to justify the cost of a safety upgrade in terms of actual risk reduction.

International standards allow companies to demonstrate compliance to customers, and give them confidence that their machines will operate safely, with reduced down-time resulting from component failures.

This can be augmented by employing engineers, such as myself, who have been certified as a Functional Safety Engineers by industry bodies. I obtained my training and certification

Modern quantitative standards may not be as simple to use as their qualitative predecessors but they give designers the tools to work with the current generation of complex machinery safety systems.

through TĂœV Rhineland.

Sometimes there are competing international standards governing an aspect of the design process. This is illustrated by the two competing safety standards in Europe.

Both of these standards contain a

framework and tools to analyse the functional safety of a system — the parts of the control system that ensure the safety of plant and personnel. For designers, the choice of which standard to apply can be confusing.

The ISO and IEC recognise the problem, and are participating in a joint working group to merge ISO 13849-1 and IEC 62061:2005. The process began in 2011 and it is likely that it will take several years to complete.

In the mean time, the main consideration for engineers is to choose a standard that they feel comfortable working with and select safety systems that meet the requirements of the operating environment and machine function.

The IEC standard already operates in Australia as AS 62061-1:2005. It applies to programmable devices, such as safety PLCs, and should be used for these applications. The standard describes

risk, and the ability of the system to reduce it, in terms of Safety Integrity Levels (SIL). SIL 1 is the lowest risk and SIL 3 the highest.

The IEC standard is useful for applications in the petrochemical or power generation industry, as these industries are familiar with the concept of SIL. In the process industry, risks can exceed SIL 3, so IEC 61508, and the process specific standard, IEC 61511, include SIL 4.

ISO 13849-1 is also applicable in Australia, and is referred to in AS4024:1504. It applies to electrical, mechanical, pneumatic and hydraulic systems. Under ISO 13849-1, mean time to dangerous failure (MTTFd) for the system is calculated in years.

Instead of SIL, risk and system performance are described using Performance Levels (PL). There are five levels, ranging from PL a to PL > e, where PL e is the highest. Table February 2013 www.pacetoday.com.au 13

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OPINION

1 shows an approximate relationship between PL and SIL. A key difference between these two international standards is the work involved in the calculations of system performance. Unlike ISO 13849-1, AS 62061-1:2005 does not consider mean time to failure in years, and uses considerably more complex methods to determine the probability of dangerous failure per hour (PFHD).

A free software tool, called SISTEMA (Safety Integrity Software Tool for the Evaluation of Machine Applications), has been produced by the Institute for Occupational Safety and Health of the German Social Accident Insurance (IFA) to perform automatic calculations of Performance Levels under ISO 13849-1. It can be downloaded from the IFA website (www.dguv.de/ifa/ en/pra/softwa/sistema/index.jsp)

DIAGRAM 2: Risk Graph from Annex A of EN ISO 1384-1.

DIAGRAM 1: Graphical determination of Performance Level.

Safety Lifecycle

Integrating safety and machine functionality during the concept and design phase can deliver a system that minimises risk, meets functional specifications and reduces training requirements.

Specific gains can be made though sharing components between the standard and safety parts of the application and using intelligent safety systems to enhance operations.

The safety lifecycle of a machine starts with a system risk assessment which then flows into the development of the functional requirements for the system. Once the risk assessment and functional specification are complete, it is time to put your chosen international standard to work in the design and verification process. For this article, I will use the design flow of ISO 13849-1 to describe what happens next.

Performance Level Structure (Categories) Performance levels are the basis for quantifying the ability of the safety related parts of a system to respond to risk. They are based on the system architecture (category); the reliability of the system, represented by the mean time to dangerous failure (MTTFd); and the effectiveness of the system in checking for faults using Diagnostic Coverage (DC) and Common Cause Failure (CCF).

Many engineers are familiar with

14 www.pacetoday.com.au February 2013

Performance Level (PL)

Probability of dangerous failure per hour (PFHD)

Safety Integrity Level (SIL)

a

≥10-5 to <10-4

None

b

≥3 x 10-6 to <10-5

1

c

≥10-6 to <3 x 10-6

1

d

≥10-7 to <10-6

2

e

≥10-8 to <10-7

3

TABLE 1: Approximate correspondence between PL and SIL.

Category

System Behaviour

B

When a fault occurs, it can lead to a loss of the safety function.

1

As described for Category B, but with higher reliability of the safety function (less likelihood of failure).

2

Control system checks safety functions at machine start-up and then periodically. Faults can lead to the loss of safety functions between checks.

3

A single fault in any part of the system does not lead to loss of safety function. When the single fault occurs, the safety function is always performed. Not all faults will be detected. An undetected fault can lead to safety function loss.

4

When faults occur, the safety function is always performed.

Faults will be detected in time to prevent safety system loss.

TABLE 2: System behaviour of safety related control systems. the use of categories to describe control system architecture. This terminology was used in the now obsolete EN954-1 but remains an integral part of ISO

13849-1. A graph relating Performance Levels to Categories and average mean time to failure is shown in Diagram 1.

In this diagram, DCavg is the average

DIAGRAM 3: Risk Graph from Annex B of EN 954-1. diagnostic coverage which is a measure of the test quality applied to components of the system.

The risk graphs from ISO 13849-1 and EN 954-1 are shown in Diagrams 1 and 2.

In these diagrams, S1 refers to the risk of an incident resulting in a minor injury, such as a cut finger, and S2 to incidents with more serious outcomes.

The main difference is that the S2 branch now subdivides, requiring more careful consideration of the safety measures for those systems have inherently lower risks.

Five categories

For a safety related control system, there are five categories: B, 1, 2, 3 and 4.

The system behaviour for each of these categories is described in Table 2.

Category B has no specific fault tolerance, but is the basis for the higher categories. In Category 1 systems, fault prevention is achieved through the use of simple design, and stable and predictable components and materials.

The three highest categories (2, 3

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Denotation of MTTFd of each channel

Range of MTTFd of each channel

Low

3 years ≤ MTTFd < 10 years

Medium

10 years ≤ MTTFd < 30 years

High

30 years ≤ MTTFd < 100 years

TABLE 3: Levels of MTTFd

Denotation of Diagnostic Coverage (DC)

Range of Diagnostic Coverage (%)

None

< 60

Low

≥ 60 to < 90

Medium

≥ 99 to < 99

High

≥ 99

2:46

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to determine whether the possibilities of faults in both channels of a dual channel system are separate and unrelated.

If failure of a component in one system causes faults in other systems or components, this is considered a single failure.

Events which cause more than one component of the system to fail are called common cause failures (CCF).

CCFs are many and varied, and it is necessary for engineers to employ a diverse arsenal of methods to combat them.

Technological diversity

TABLE 4: Levels of Diagnostic Coverage.

No.

Example of Measure Against Common Cause Failure (CCF)

Score

1

Separation/Segregation

15

2

Diversity

20

3

Design/Application/Experience

20

4

Assessment/Analysis

5

5

Competence/Training

5

6

Environmental

35

The approach outlined in the standard is qualitative, and summarised in Table 5. Simply put, designers need to analyse the possible CCF of their application and mitigate the risk of them occurring.

Annexe F of ISO 13849 lists various measures — including the technological diversity physical A D _of Pthe A design, CECO N J UseparaN_ 1 2 tion of signal paths and electromagnetic

compatibility — which can be taken to minimise CCF and assigns a score to each type. To demonstrate compliance with the standard, designers need to achieve a score of 65 or greater.

International standards not only support global markets and complex safety technologies.

They give designers tools to quantify risk and provide a structured framework to implement integrated safety lifecycle design.

There is no right or wrong when choosing between ISO 13849-1 and IEC/AS 62061:2005: engineers must do their research and decide which standard best suits their design parameters and provides the most workable tools for their application.

[The five tables that appear in this article have been taken from Safebook 4, Rockwell Automation, 2011.]

[Wayne Pearse is Safety Consultant, Rockwell . pdf PAutomation.] a ge 1 1 4 / 0 5 / 1 2 , www.rockwellautomation.com.au

TABLE 5: Scoring for Common Cause Failure. and 4) require that if faults cannot be prevented, they must be detected and the system must react appropriately.

Redundancy, diversity and monitoring are the key concepts employed in reaching this outcome.

System reliability

As mentioned earlier, ISO 13849-1 uses MTTFd (years) as a measure of system reliability. The MTTFd of a single channel system or subsystem is the average of the MTTFd of each of its elements.

This value can be calculated using the simplified formula provided in the standard. For a dual channel system or subsystem, the MTTFd of each channel needs to be calculated separately. Often, the PFHD of systems and subsystems are available from the manufacturer and can be entered directly into SISTEMA. The MTTFd is limited by the standard to 100 years, although in some cases it may be higher. The average MTTFd of each system or subsystem is

categorised as low, medium or high depending on its value, as shown in Table 3.

This reliability range can then be used to determine PL as shown in Diagram 1.

Diagnostic Coverage. As discussed earlier, the different categories of safety system have varying levels of diagnostic testing. Diagnostic Coverage (DC) is the term used to describe the system’s effectiveness in detecting faults. The failure rate within a system is expressed as Lambda (λ).

DC is defined as the ratio of dangerous failures which are detected (λdd) to total dangerous failures (λd) expressed as a percentage (DC = λdd / λd). The failures that pose the greatest threat are the dangerous undetected hazards (λdu).

DC is divided into four basic ranges, as shown in Table 4 and Diagram 1.

One of the important principles of ISO 13849-1 is the need for designers February 2013 www.pacetoday.com.au 15

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PACE.FEB13.PG016.pdf

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NEW PRODUCTS

High precision pressure sensors FLIR offers Wi-Fi App for Apple and Android FLIR Tools Mobile is free and now lets users stream live video to their mobile device from compatible FLIR E-Series and FLIR T-Series infrared cameras. This allows users to monitor from a distance and show others what the camera is seeing as it happens. Using the app, thermographers can incorporate images into professional reports, then send them from the field by email or up to the cloud for customers and co-workers. FLIR Tools+ create advanced analysis of infrared images and video files, and output results, anomalies and trends in PDF reports. In addition to the standard FLIR Tools, FLIR Tools+ features recording and play-back of radiometric video files, and time-temperature plotting. Compared to FLIR Tools, FLIR Tools+ has the following features: radiometric sequence recording and playback of recordings.

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Multi-touch panel series offers flexibility With the industrial implementation of consumer technologies such as multi-touch and widescreen displays, the CP2xxx and CP3xxx Control Panel and Panel PC series from Beckhoff open up opportunities for new operating concepts. Complemented by three further display sizes and a total of eight device options, they offer scope for a range of applications. The multi-touch panel series from Beckhoff offers greater flexibility: various display sizes, horizontal or vertical orientation, 4:3 or widescreen, built-in or IP 65 mounting arm panel. Up to now, the new Panel generation has been available in 20 device options. It is now extended with three display sizes and eight new device versions.

All devices can be ordered ex factory in landscape or portrait format.

Bestech Australia is introducing the high precision pressure sensors AHLBORN FDAD33 and FDAD 35M. Integrated with A/D converter and signal conditioner, this piezoresistive transducer features a high level of accuracy, a wide temperature range (-40 to +120°C) and digital outputs of measured values. It measures 1 to 1000 bar full scale and appears to maintain 0.05%FS error band between -10 and 40°C. Temperature-dependence and non-linearity are eliminated by means of mathematical compensation; thus ensuring a high level of accuracy. To acquire transitory pressure fluctuations and pressure peaks the maximum value, minimum value, and average value are calculated from the current values in the ALMEMO D6 plug and output in three function channels. All calculated values outputs can be transferred onto a PC via USB adapter cable or data can be logged in an ALMEMO data logger.

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Compact flow meter The new efector mid from ifm efector is an all-rounder. It monitors volumetric flow quantities, total quantities and temperatures. Additionally, the measuring and evaluation units of this sensor are combined in a compact housing. Versatile in use, this product is suited for different flow directions up to 600 l/min and liquids with conductivity from 20 µS/cm such as water, coolants, emulsions or waterbased cleaning agents. Analogue, binary, pulse and frequency outputs offer various options to process the measured data. In addition, the magnetic-inductive sensor offers an integrated empty pipe detection and simulation mode. It is also available with EPDM seal and therefore KTW approved. This makes it perfectly suited for drinking water applications. During set-up, efector mid enables intuitive handling via three buttons situated directly on the unit. This allows immediate use of the sensor in the field. ifm efector sales.au@ifm.com 1300 365 088

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Housing for use in harsh environments The HC-ALU aluminium housing from Phoenix Contact complements the existing range of rugged housing products for industrial use. This aluminium profile is horizontally split for easy assembly of components and fully fitted PCBs. The front surface has a 2 mm recess for flush-fit insertion of labels or membrane keyboards. The basic profile length is adjustable, allowing users to precisely adapt the housing size to the application at hand. The IP 65-compliant housing is built for an operating temperature range of -40°C to +85°C. EMC protection is attained due to a fully-closed profile design together with circumferential contacting of the side element. Due to its trapezoidal cross-section, the housing is suitable for use with hand-held devices for mobile data capture or wireless communication.

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PACE.FEB13.PG017.pdf

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BEHIND THE SCENES

Savings flow after collaboration Six councils in South Australia came together to create a common design for their wastewater management systems and realised significant benefits, writes Hartley Henderson.

A

UTOMATION of wastewater systems for a group of local councils in regional South Australia is set to deliver a range of substantial benefits.

Following identification of the need to improve maintenance standards and ensure regulatory compliance of community wastewater management systems by a group of six local councils in the South East of the State, it was agreed to conduct a pilot study to assess the benefit of an across-Council’s joint service arrangement.

Industry consultant, Michael Stephenson of Rashlee, has played a key role in coordinating a joint study involving the Councils of Wattle Range, Robe, Tatiara, Naracoorte-Lucindale, Grant and Kingston.

Simplified maintenance

Stephenson assisted in identifying commonalities between the wastewater pump stations of the councils and looking for potential efficiencies, with the aim of establishing a common control and monitoring system.

“Different switch gear and ways of doing things existed between the various Integration, was commissioned to create in bulk purchasing discounts, reduced council wastewater systems and there a common design and resulting standard spares, simplified maintenance and was an obvious need to improve complifor all community wastewater managereduced training for staff. ance and upgrade emergency communiment systems across the respective APC Integration business develcations heKsaid. regions.

A D systems,” _ PACE I N F E B _ 1 3 . p council df P a g e 1 2 2 / 0 1 / 1 3 , opment 5 : 2executive, 8 P MMichael LeVene, Adelaide-based company, APC Common hardware would result explains that a unique aspect of this

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MANAGED: The SCADA system provides a central point where all the data of the respective pump stations can be collected, stored, monitored and displayed. project was designing a system that could be used by six different councils with shared resources while controlling how much of the data can be shared between councils. > “This was a tricky political situa-

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PACE.FEB13.PG019.pdf

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INTEGRATED: The Siemens WinCC SCADA offered a seamless solution.

A unique aspect of this project was designing a system that could be used by six different councils with shared resources while controlling how much of the data can be shared between councils.

tion, and the solution was to avoid storing data at any of the council depots and instead use a ‘cloud’ based design,” he said.

Unique situation

APC Integration managing director, Anthony Dally, explains that the purpose of the SCADA system is to provide a central point where all the data of the respective pump stations can be collected, stored, monitored and displayed.

“A SCADA system is typically run locally within the organisation. It is a unique situation to run this system in an external data centre in a virtual environment combined with a virtual network, and it was critical that we chose a solution to ensure a robust reliable system for the councils,” he said.

“A SCADA software package was sought that was well established, reliable, used in the water industry, well supported in SA, compatible with the pump station controllers, and which could run on a virtual

machine in a data centre.”

It was found that the Siemens WinCC SCADA would offer a seamless solution, and as a single brand system, would provide the best integration and support.

Hygienic point level sensor with complementary output

Virtual server

Siemens product manager HMI & SCADA, Mark Karalapillai, says the Siemens SCADA is able to run on a virtual server and can provide a range of information and functionality including monitoring of pump station status, remote control of some pump station functions, collection, display, trending and recording of the data available from each pump station site.

“This SCADA can enable remote fault finding of problems at a pump station site, send alerts to appropriate service personnel, manage access to the system of relevant personnel from the various councils, and allow remote control and diagnostics of the pump station controller,” he said.

“Pump station hardware, also provided by Siemens, includes Simatic S7-1200 PLC, HMI with touch and alarm screen, and G120P VFD drives that offer energy saving due to innovative functionality and optimum integration into the process.

“Instrumentation from Siemens including Ultrasonic Level Sensors with Advanced Echo Processing, Mag Flow Sensors, and Pressure Sensors with high measuring accuracy, were all integrated through Simatic S7-1200 PLC.”

Communications framework

A suitable cost effective communication system was sought that could be expanded to connect upwards

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PACE.FEB13.PG020.pdf

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BEHIND THE SCENES

The SCADA system will enable the wastewater systems to be more effectively controlled and monitored in real time from a central point.

of 100 pump stations spread over an area of 23,000+ square kilometres, while allowing direct messaging between the pump station and remote access to the SCADA system via the internet.

The Telstra 3G network was selected on the basis that it could provide network coverage at all pump stations, it is an existing proven network with low cost to connect to new pump stations, and it allows remote internet monitoring. It also offers a high security private network with fixed IP addresses, and high speed data transfer.

Telstra’s local government specialist, James Hook, points out that each of the pump stations will have a connection on the Next G network that will have a fixed IP address so that the SCADA server can contact each of the pump stations at a known address.

“The server is also connected to the internet, providing web page access to the pump station status screens. Hosted within the Telstra data centre, the server provides a high uptime and de-centralised solution for the system,” Hook said.

“Regular UPS and generator backup power at the data centre is provided, as well as 24 hour maintenance support together with regular off-site backups and secure storage of server images.”

CONTROL: This graphic illustrates a typical pump station layout.

Big benefits

CEO of Wattle Range Council, Frank Brennan, believes substantial cost, environmental and operational benefits will flow from automation of the wastewater systems of participating councils.

“It will help us to avoid spillages and ensure that the community wastewater management schemes comply with the licensing requirements of the EPA and the Department of Health,” he said.

“A more interactive approach to managing the scheme will be provided because the SCADA system will enable the wastewater systems to be more effectively controlled and monitored in real 20 www.pacetoday.com.au February 2013

time from a central point. This should enable costs to be significantly reduced, particularly the cost of staff travel over substantial distances.

“Opportunities could now also open up to utilise similar SCADA systems to manage and monitor other council operations such as water quality in swimming pools, stockyard effluent systems, irrigation systems in parks, and stormwater pump systems.”

According to Rashlee’s Michael

Stephenson, set-up of Stage 1 of the project is progressing to plan and is expected to be commissioned early in 2013. “Once fully implemented, this pilot project is likely to provide a strong impetus for promotion of the model to other regions across the state, as well as potentially to other regions across Australia,” he said.

APC Integration 08 8366 2300

www.apci.com.au Rashlee 0417 876 846 Siemens 0409 957 921 www.siemens.com.au Telstra 08 8433 4477 www.telstra.com.au

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IN FOCUS

Engines of efficiency Conventional methods of electrical and heat generation effectively throw away most of the energy locked within fuels. Cogeneration could be the answer, writes Isaac Leung.

F

OR engineers, improving the efficiency of their processes is a major challenge, but also an opportunity to improve their outcomes while consuming the same or a lower amount of resources.

With the current focus on climate change and the high cost of electricity in Australia, maximising the efficiency of energy generation is a major opportunity, and for Dr Jacob Klimstra, Senior Energy and Engine Specialist for Jacob Klimstra Consultancy, a no-brainer.

Dr Klimstra was in Sydney to speak at the 2012 Australian Institute of Energy National Conference, and present a Cogeneration and Trigeneration Professional Development Course organised by the Chemical and Biomolecular Engineering Foundation of the University of Sydney.

Hailing from the Netherlands, Dr Klimstra has long been a proponent of cogeneration systems, which are typically engines that generate electricity, as well as heat and other by-products which may be captured and utilised, maximising the output from the fuel.

In traditional fossil-fuelled power generation, the efficiency is typically 35 to 37 percent, with about two-thirds of the primary energy converted to produce electricity being lost as heat. Transmission losses are responsible for nine percent of the losses from net generation.

Cogeneration systems, according to Dr Klimstra, aim to make use of the heat created as a by-product of burning fuels for electrical generation. This energy is harvested and utilised in processes, such that it is no longer wasted.

With plants in more remote areas, cogeneration systems can either be used as the primary source of electrical and heat energy, or as a backup in case the grid fails.

Useful by-products

Regions with a local distributed network of cogeneration plants, would also benefit from reduced reduce transmission losses, and boosted reliability.

Dr Klimstra utilises the exergy model

EXERGETIC: Dr Jacob Klimstra believes maximising the efficiency of energy generation is a major opportunity.

With plants in more remote areas cogeneration systems can either be used as the primary source of electrical and heat energy or as a backup in case the grid fails. to explain the relative value of different forms of energy, and why, even with processes that only require one form of energy, it is always a good idea to have cogeneration in place.

“You can always turn almost 100 percent of electricity into motive power for driving electric motors, for creating light, running electronics, and if you want to turn it into heat, you can have very high temperatures,” he explained.

“With electrical heating, you can create temperatures of maybe 3000 degrees Celsius even. You can’t do that with a gas burner. The exegetic value of electricity is very high, which is why the price of electricity is also higher than that of heat.”

Given the high exergetic and monetary value of electricity, it makes financial sense to create electricity, even if the application only calls for heat.

“If you just burn the gas, you create heat. If you use the gas in a cogeneration

plant, you get the high value energy, which is electricity, and a low value energy, which is the heat, available as a by-product,” Dr Klimstra said.

Of course, the reverse is also true: where only electricity is needed, harvesting the heat and using it in processes helps boost overall efficiency.

Ambient temperatures Heat has a variety of applications in industry, be it for drying foods or curing of materials. Where higher temperatures are needed, the relatively low level of heat from cogeneration plants can still be fed into the process to raise ambient temperatures, reducing the amount of electricity needed to achieve the target temperature, and achieving close to 100 percent utilisation of the energy locked in the fuel.

Heat can also be fed into absorption chillers to provide cooling, if that is what is required.

“This is a lot better than having a big coal-fired power plant and throwing all the heat away and running at an efficiency of 35 percent. That’s a waste of energy,” said Dr Klimstra.

Dr Klimstra also pointed out that cogeneration systems are flexible, and other by-products of the generation process, not just forms of energy, can be used as desired.

Carbon dioxide from the engine, for example, can be harvested and used to boost plant growth in agricultural applications.

“The principle behind this is that everywhere where you need heat, be it for a chiller or for somewhere else, you should try to put a cogeneration plant,” he concluded. “Even if you don’t need electricity, just put the electricity in the grid.”

Implementation

According to Dr Klimstra, the prime movers for cogeneration are things like reciprocating engines and combined cycle turbines.

Combined cycle turbines are an assembly of heat engines which work > off a single source of heat to reduce February 2013 www.pacetoday.com.au 21

PACE.FEB13.PG022.pdf

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IN FOCUS

Given the high exergetic and monetary value of electricity it makes financial sense to create electricity even if the application only calls for heat.

energy loss. In additional to a gas turbine and boiler, heat is turned into steam, and used to drive a steam turbine.

Gas-fired reciprocating engines can utilise exhaust heat, turning it into steam in order to produce electricity through a steam turbine.

When Dr Klimstra and his team started working on cogeneration, they used small gas engines from a Fiat.

Rated at 15 kW, they had an electrical efficiency of 25 percent.

Improvements in engine technology have seen efficiencies for single cycle engines boosted to 49 percent, and turbochargers further improve performance.

“Relatively, the engines have become cheaper,” Dr Klimstra told PACE. “For the last decade, the prices of these installations have not gone up. You don’t even have to correct for inflation. The price level has stayed about constant because of improved production processes and higher output from the same engine block.”

But while the equipment can be as simple and as complicated as the application demands, the specific expertise needed for the installation, commissioning and upkeep of cogeneration systems is something Australia lacks – and something Dr Klimstra hoped to address with the Cogeneration and Trigeneration Professional Development Course.

Energy engineering

According to him, dedicated knowhow is needed from the installation stages: cogeneration plants, while being based on engines, are still fairly high-tech.

With design, an energy engineering background is needed. Maintenance and operation requires the relevant mechanical qualifications, which already exist in Australia.

“With cogeneration, you have to know about lubrication, electrical system, safety systems, maintenance, and material properties,” he explained.

22 www.pacetoday.com.au February 2013

“It’s a multi-disciplinary object, and you have to train people. So you need a group of dedicated people who know what they’re talking about.”

“If you want to install it into a process plant for instance, then you have to look at the ins and outs, like what is the heat demand, the temperature level of the heat, what is your electricity mark, do they coincide, do you need a heat buffer for temporarily storing the heat produced, because heat and electricity coincide…these things have to be analysed.”

In the 1980s, as the Netherlands was starting to embrace cogeneration, Dr Klimstra and his team organised a small group of well-trained engineers who went to industries and explained the technology, and also helped with tuning of installations. This ultimately resulted in a mass take-up of cogeneration. Today, in the Netherlands, 35 percent of all electricity is produced with co-generation. In Denmark, this figure is over 40 percent.

According to Dr Klimstra, given the entire point of cogeneration is in efficiency and optimisation, the commissioning stage is the most important part of implementation, thus requiring the most specialist expertise.

“For commissioning, you need a multi-disciplinary engineer who knows about electricity, heat and emissions,” Dr Klimstra said.

He suggested having small groups of experts who can commission installations, utilising the right equipment for measuring emissions, stability of the installation, performance, and efficiency, in order to yield optimum performance from the investment.

Future technologies

Dr Klimstra has high hopes about the future role of cogeneration in an everevolving energy landscape. However, he is not so optimistic about the application of newer technologies.

While there is a lot of potential for fuel cells to be implemented in cogeneration plants, Dr Klimstra says they are too sensitive to environmental variables to be of very much use in cogeneration plants, which are often used in harsh environments.

As part of a supervisory committee of a research institute in the Netherlands, Dr Klimstra has been privy to research into fuel cells over the past 25 years, having seen test results for the use of various types, including phosphoric acid fuel cells, molten carbonate fuel cells,

and solid oxide fuel cells.

“Fuel cells are too complicated,” Dr Klimstra said. “They are sensitive to minor components in the gas like sulphur. When a truck passes with a little bit of sulphur in the diesel and it comes out of the exhaust, and the air is fed into fuel cell, the fuel cell deteriorates.”

However, the hardy nature of some cogeneration installations means many other technologies and fuel sources are compatible with such systems.

Application flexibility

Systems integrating a dual-fuel reciprocating engine, for example, can run on natural gas, bio-gas, diesel and bio-diesel, providing application flexibility.

For developing countries, for example, with areas which do not have access to power lines, such cogeneration systems provide a way forward. They can initially run off diesel in order to provide electricity and heating.

As the economy grows and infrastructure is introduced, the system can then be converted to use gas, allowing it to run cheaper and cleaner.

With the simple nature of engines making cogeneration systems effectively fuel-agnostic, cogeneration systems can exploit newer generations of energy

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sources, such as bio-gases, and fuels converted from waste.

The Netherlands, for example, is running a project to collect municipal waste, and convert it into synthetic gas.

The gas can then be made into a liquid fuel and used to run engines in cogeneration plants.

“Some of the heat will be used for treating the waste, but you also produce electricity for the grid,” explained Dr Klimstra. “So the amount of waste is substantially reduced, and you make sustainable energy from it.”

Photovoltaic systems

Cogeneration systems also have a role to play with other renewable energy sources. According to Dr Klimstra, a distributed network of cogeneration plants could be a solution to current limitations of photovoltaic systems, namely, that they do not generate electricity at night.

“With cogeneration systems locally, you have an excellent way to provide backup power,” he said.

“The systems are fast, and require relatively low investment. It can run on biogases, so if you have sewage treatment systems, you can use the biogases from there to run the cogeneration system.”

“The future will be a kind of integrated system, solar PV, wind power, available hydropower, geothermal power, and at the same time, cogeneration power as backup for these renewables.”

Cogeneration could also contribute to the current trends towards decentralised energy generation, which Dr Klimstra says would contribute to supply reliability.

For example, an industrial park could have a cogeneration installation in every facility, each of which feeds excess electricity into the grid.

Such a configuration means every factory has its own backup power even if the main grid fails, with the added advantage of having a stable source of power from the network of other plants if its local unit fails.

Government roles

Dr Klimstra hopes the government will help in laying down the regulatory foundations which will encourage the use of cogeneration plants.

“Compared to what you have in Europe, Australia has just a minimal amount of these cogeneration installations,” he said.

A D _ P A C E P L A MA R _ 1 2 . p d f

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BIOGAS: Sydney Water’s Malabar Cogen Plant turns waste methane gas into electricity to help power wastewater treatment plants. [Image courtesy of 1 Sydney 1 5 / Water.]

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“The government should acknowledge that cogeneration is one of the best ways of saving energy. If you want to reduce your ecological footprint to comply with the rules of the rest of the world, then cogeneration is the best solution.”

Having a robust feed-in tariff scheme, for example, would encourage plants to install their own cogeneration plant for faster return on investment.

Other possible moves would include the establishment of standards around the safety, emissions and performance of cogeneration plants, and establishing training and certification programs for professionals specialising in these systems.

For Dr Klimstra, the case for cogeneration is a simple one: continue throwing energy away in the form of inefficiency, or make full use of every drop of fuel. That, he says, is one of the biggest opportunities for Australia’s industries today.

[Dr Jacob Klimstra is Senior Energy and Engine Specialist, Jacob Klimstra Consultancy, The Netherlands.]

The University of Sydney 02 9351 5284 sydney.edu.au/engineering/chemical Jacob Klimstra Consultancy jacob@klimstra.nl www.klimstra.nl February 2013 www.pacetoday.com.au 23

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NEW PRODUCTS

Plastic valve with optimised body geometry The GEMÜ 647 2/2-way plastic valve has been revised and is now available as R647 with optimised body geometry.

The valve is suited - like its predecessor - to use in dyeing plants, in automatic animal feeding installations or for use in the paper industry. In addition, R647 will be used wherever there is no need for a closing spring, or where the installation conditions require small components. One benefit of the new type is the similarly high Kv value with a smaller actuator size. The R647 is thus more compact and reasonably priced than its predecessor. The valve can also be supplied in an intermediate size, the new diaphragm size 20.

This feature delivers additional space and cost savings in plastic piping systems.

GEMÜ info@gemue.de www.gemu-group.com

Angle encoder with digital incremental output The PRDS1 is a compact magnetic angle sensor that sets new standards for size and accuracy. Providing wear-free angle measurement over a range of up to 360 degrees, the PRDS1 sensor is suitable for machinery applications where accuracy and trouble-free maintenance are essential. Measuring 12mm in diameter and 50mm in depth, the PRDS1 is suited to applications where access is difficult.

By utilising an independent target magnet that provides an air gap between it and the sensor, the complete measuring range of up to 0° to 360° is obtained in a non-contact manner. This overcomes any connection or alignment problems often experienced if sensors with connecting shafts are used. The PRDS1 has a range of incremental digital outputs available and is manufactured from stainless steel. An integral M12 thread incorporated into the M12 body provides sealing options from IP67 to IP69K. The compact PRDS1 angle sensor can be used for all applications where angle detection and monitoring is required.

Automated Control 02 4964 4022 www.automatedcontrol.com.au 24 www.pacetoday.com.au FEBRUARY 2013

Midrange system builds on Integrated Architecture portfolio With features such as integrated motion, safety, EtherNet/IP connectivity and re-usable development tools, Rockwell Automation provides users the ability to standardise on a single control platform for small to large-scale applications. The CompactLogix 5370 series of controllers offer a wide variety of options to match specific application requirements. With up to 3MB user memory and supporting up to 16 axes of motion, these controllers are suitable for small, stand-alone equipment to general purpose machine control in applications such as indexing tables, process skids, case packers, erectors and packaging. The Kinetix 350 is a singleaxis EtherNet/IP servo drive designed for coordinated motion applications. When used together, they lower the cost to deploy integrated motion in a variety of machine applications. The expanded list of the Rockwell Automation Midrange portfolio features: CompactLogix 5370 Programmable Automation Controllers; Kinetix 350 Single-axis EtherNet/IP Servo Drive; PanelView Plus 6 and PanelView Plus Compact Human Machine Interface; RSLogix 5000 Design and Configuration Software.

Rockwell Automation 03 9757 1111 www.rockwellautomation.com.au

IVAC cylinder reduces energy and operating costs Norgren has launched a range of cylinders designed to reduce energy usage and operating costs for OEMs and end users in processing applications. Conventional pneumatic control involves an arrangement of valves or valve islands, actuators, flow controls and sensors, along with connectors and accessories. In typical applications, up to 13 different components can be required for each actuator function. This complexity presents some intrinsic disadvantages and performance constraints. Norgren has developed IVAC (integrated valve and actuator control) - an integrated unit which combines the valve, flow controls, cushioning and sensors in a single actuator package. IVAC is a weight and space optimised actuator, suitable for a range of bore sizes from 40mm to 80mm, featuring integrated valve and magnetically operated switches for complete actuator control. Able to be retrofitted or integrated within new systems, each unit requires only one pneumatic and one electrical connection, eliminating the need for multiple valve islands, components, tubing and accessories.

Norgren 03 9213 0800 www.norgren.com/ivac

Monitor wastewater discharge This “simpler sampler” automates the composite sampling required to monitor wastewater discharge for environmental regulatory compliance in the power generation industry. It uses compressed air to move samples more than 24m vertically and 30m horizontally. It is inherently explosion-proof (no pump, no vacuum system).

The rubber duckbill closes down and expels any large particles in a self-cleaning action. Lines are blown clear and dry after each sample is taken. The same controller can sample multiple sites simultaneously.

Markland Specialty Engineering markland@sludgecontrols.com www.sludgecontrols.com

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IN FOCUS

Helping to put you in Control

Control Equipment

Modular Storage Box

Unlocking your power The concept of energy management can be seen as a daunting task to many organisations especially when it means moving away from traditional well-known tools and systems that may already be in place, writes Samuel Coupel.

Great for storing small items these boxes snap together so you can keep all of your parts seperseper ated and together all at once.

SKU: SFB-005 Price: $5.00 + GST

Cerberus USB Cable 3 USB cables in one. A standard A-type connecconnec tor for your PC at one end and three common USB connectors: B, mini-B and micro-B. SKU: SFC-005 Price: $6.00 + GST

Programmable Universal Indicator Display readings from thermocouples/RTD, 4 to 20 mA and 0 to 10 V signals. 100 to 240 VAC and 24 to 240 VDC powered SKU: IPI-134 Price: $99.95 + GST

Unmanaged POE Ethernet Switch DIN rail mount, 10/100/1000 Mbps industrial unmanunman aged ethernet switch with 4 10/100/1000Base PoE ports and 4 10/100/1000Base T(X) ports.

SKU: ATO-020 Price: $599.00 + GST

PID Temp. Controller

With an auto-adaptive PID algorithm this controller features a universal input, pulse and relay outputs and RS-485 Modbus.

SKU: NOC-303 Price: $149.00 + GST

FieldLogger with HMI Screen

I

N TODAYâ&#x20AC;&#x2122;s environment, energy-intensive businesses are faced with a number of challenges to ensure they run effectively in a constrained operational environment.

Energy management is one of these concerns that has pushed itself up the business agenda.

Power is a critical element for any business no matter what industry, but it needs to be reliable and economically sustainable.

With organisations increasingly using more power, it has become a challenging task to manage it efficiently.

Traditional power management solutions such as switch gear, circuit breakers and metering devices are all key elements to managing energy usage.

However, relying on these solely to keep track of what is used could mean that businesses are missing the opportunity to run their operations even more efficiently.

Poor power management in a business presents a

number of risks. Without managing power effectively, it means there isnâ&#x20AC;&#x2122;t a clear understanding of what state the electrical infrastructure is in, meaning there is no visibility of what is happening inside a facility in terms of energy usage.

This could lead to overall reliability issues with power availability if problems are not tracked and monitored, which could have a huge impact to a business if power fails.

Additionally, without the visibility across the infrastructure, businesses are unable to identify where money is being spent on energy.

Wasted money

Organisations regularly face challenges in maintaining or even increasing profits.

Energy is a significant and often-overlooked expense that can represent a substantial area of opportunity.

Once energy usage and its related costs are exposed, the

FieldLogger Data Loggers have 8 universal analog inputs, 2 alarm outputs and 512k memory. Fitted with a HMI Screen, USB, RS-485 and Ethernet interfaces. These interinter faces allow USB memory sticks, SD cards and loglog ging of external modbus devices.

SKU: NOD-003 Price: $1,099.00 + GST

Modbus Temperature & Humidity Transmitter High precision and stability sensors for measuring temperature and relative humidity.

Can be configured via RS-485 with Modbus RTU commands. 12 to 30 VDC powered.

SKU: RHT-010 Price: $225.00 + GST

Contact Ocean Controls Ph: (03) 9782 5882 www.oceancontrols.com.au February 2013 www.pacetoday.com.au 25

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IN FOCUS

Network management

High availability and reliability

Asset management

High performing assets

Increased savings and sustainability

potential for releasing large amounts of more effectively. wasted money becomes more clear.

The concept of energy manageReducing these costs can help ment can be seen as a daunting task to firms survive tough times in the short many organisations, especially when it term while reducing financial risk and means moving away from traditional strengthening competitive positioning well-known tools and systems that may into the future. already be in place.

Energy management is one approach With multiple elements such as A D businesses _ F E N I can ND J Ukeep L _ track 1 0 . p maintaining df P a gpower e 1system 8 /reliability, 0 6 / 1 0 , in which easily of usage and monitor spend complying with evolving emissions

PC & PLC Programming Video Image Processing Cost Effective Solutions for your automation technology needs Australia wide.

We specialise in Systems Integration and Projects Big and Small.

Industrial Software & Electronics Tel: (07) 3856 2232 Fax: (07) 3355 1012 Email: info@industrialsoftware.com.au 26 www.pacetoday.com.au February 2013

Cost efficiency management

regulations, and reducing the risks posed by volatile energy prices, energy management can easily seem nearly impossible to achieve.

However, power management doesnâ&#x20AC;&#x2122;t need to be a difficult task. There are solutions available that allow businesses to improve operational, cost and 1 1 : efficiencies, 5 1 A M increase reliability energy and availability of power and overall, improve asset optimisation, through combined solutions.

Moving away from traditional power management tools and opting to use more complete solutions that offer an integrated, fully scalable and reliable power management system, allows businesses to improve the reliability of the electrical distribution system, from medium voltage to final distribution.

Improved continuity

This is done by using advanced software that provides central monitoring, control, and analytical functions, combined with customised applications, where needed. Opting for a complete mechanical, electrical and digital

MANAGEMENT: It is important that solutions chosen to manage power across a business are flexible in order to adapt to unique business requirements as well as the changing environments within organisations.

system that is modular and interoperable, allows improved continuity of supply and enhanced safety for people and equipment.

By using the information that these types of systems are able to provide, businesses have the opportunity to make decisions on how best to minimise costs and energy use without effecting overall business operations.

This increases the financial and operational efficiency of an enterprise, which is one of the key limitations of traditional power management solutions.

When choosing a power management system, businesses have a number of aspects to think about, but importantly a key consideration is compatibility with third party systems.

A number of businesses may have some traditional management solutions already in place, so third party integration is a priority in order to seamlessly integrate and leverage all systems.

However, not all businesses operate in the same way and infrastructure varies, meaning power management requirements will be different.

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Moving away from traditional power management tools and opting to use more complete solutions that offer an integrated power management system allows businesses to improve the reliability of the electrical distribution system.

It is important that solutions chosen to manage power across a business are flexible in order to adapt to unique business requirements as well as the changing environments within organisations.

Ensuring power management systems are fully integrated and complete solutions with the capability to offer organisations the required flexibility that can meet individual business requirements and help solve challenges is key, and assists in adapting to varying infrastructures.

Escalating usage

For example, if a data centre were concerned about escalating energy usage, by using a flexible solution it would be able to implement pre-designed power management solutions that include the ability to verify and track Power Usage Effectiveness (PUE), in addition to resolving issues such as battery maintenance, run time variations, and integration with fuel management systems.

Using an advanced power management system means the data centre would have the necessary information to be able to identify where and when energy is being used, and make informed decisions about the best solutions in which usage could be improved â&#x20AC;&#x201C; that is, to reduce power consumption and save money on operating costs.

Analyse and control

When considering the capabilities of a power management system, it is important that businesses are able to quickly and easily monitor, analyse and control the entire network to ensure that they have visibility.

Power Management Solutions that comprise of integrated hardware, communications and software components that unite disparate power infrastructure elements are a way in which a network can be closely tracked and monitored.

Personalised tools

By selecting seamless technology that underpins the solutions, both management and frontline personnel have the personalised tools needed to make timely, cost-trimming energy decisions without sacrificing reliability or operational efficiency.

In a world where businesses are constantly searching for a competitive advantage, complete power management solutions have the ability to support this by providing a more advanced system compared to traditional power management solutions.

When implementing an advanced system that offers more than traditional power management solutions, businesses have the potential to achieve energy savings of up to 30 per cent.

Power management is a concern across all industries, and an issue that is unlikely to disappear in the future.

It is important for all businesses

Improvements

Power management solution caPabilities o cost and operational efficiency management Integrated and complete power management solutions help organisations trim power-related costs and increase operational efficiency. This is done by benchmarking processes to identify new opportunities, tracking greenhouse gas emissions, identifying and categorising cost centres and confirming savings efforts, reducing or eliminating demand charges, identifying utility billing errors, limiting uncontrolled costs with sub-billing and negotiating lower utility tariffs by taking advantage of load curtailment opportunities. o asset management Advanced power management solutions assist organisations in extracting peak performance from assets by verifying proper equipment operation, supporting proactive maintenance, and providing information to ensure network capacity is optimised for present and planned loads. o network management Integrated and complete power management solutions improve power system reliability by identifying the sources of poor power quality, confirming the availability of backup power systems, and by removing the guesswork from issue diagnosis.

to be mindful of the power they use, and consider options that give them the complete visibility other than traditional solutions.

Not only will it improve on cost savings benefiting the business overall,

but it also means regulations are being adhered to in the future.

[Samuel Coupel is Product Manager, Energy Management & Power Quality, Schneider Electric Australia.] www.schneider-electric.com.au February 2013 www.pacetoday.com.au 27

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SPOTLIGHT

7best of the

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

Oval gear flowmeter Among the many PD flowmeter design principles available today, the oval gear meter still holds a unique place in terms of simplicity and field proven performance. Dimak provide a range of oval gear flowmeters which provide high levels of accuracy and repeatability for a wide range of most clean liquids irrespective of viscosity and conductivity, including fuel oils, additives, chemicals, food bases, paints, viscous emulsions, insecticides, alcohol and solvents, either pumped or gravity fed. The Dimak oval gear flowmeters come in size from 4mm to 100mm in aluminium, stainless steel and ductile iron for flow ranges from 0.04 l/h to 1500 l/m.

Their features include: Modular process connections; No requirement for flow conditioning; High accuracy, repeatability and reliability; Wide turndown (min. ~max. flow); Ultimate rotor stability (all metal rotors); Dual outputs (reed and hall effect) standard; Hyperpulse high resolution pulse output; Hazardous area versions; Bi-directional flow capability; Quadrature pulse output option.

Trimec Flow Products 03 9937 1811 www.trimec-fp.com.au

Overmolded Cordsets for harsh applications Turck’s overmolded Mil-Spec Cordsets for rugged applications offer a more robust connectivity solution than fieldassembled versions. These Mil-Spec Cordsets are 100 percent factory tested to ensure optimal performance for applications in harsh environments, including automotive, mobile equipment and oil and gas. Featuring a unique overmolded design, the Cordsets eliminate field assembly, soldering and wiring— allowing operators to reduce downtime and maintenance labour and costs.

Overmolded Cordsets also provide the

flexibly to seal to a wide variety of cable types. For easy application integration, these Mil-Spec Cordsets are compatible with other Turck products and standard Mil-Spec receptacles. The Cordsets are available in shell sizes 8-24, in addition to threaded, bayonet and reverse bayonet styles. They meet NEMA 1, 3, 4 and 6P and are rated IP67 and IP68. Cable options include NEK 606, ABS and IEEE 1580.

TURCK Australia 1300 132 566 www.turck.com.au

Digital pressure gauges compliant with ATEX Keller has introduced five intrinsically safe electronic pressure gauges for use in areas subject to gas explosion risks.

The type approvals are compliant with the ATEX Explosion Protection Directive regarding explosive gases. The electronic design of these devices is trimmed to minimise energy consumption, so it is also possible to replace the batteries inside areas with explosion risks. The simplest version, model ECO 1 Ei, offers high resolution and reproducibility for both measuring ranges (-1…30 bar and 0…300 bar), together with accuracy of 0.5% FS and an integrated min/ max memory. The application range as per the ATEX directive is defined by identification markings Ex ia IIC T5 or T6. Keller’s type LEO 1 Ei and LEO 2 Ei electronic pres28 www.pacetoday.com.au February 2013

sure gauges feature microprocessor-assisted compensation to ensure a narrow total error band of <0.2% FS over the entire range of operating temperatures from 0...50°C. The zero point can be selected freely within the four measuring ranges between -1…3 bar and 0…700 bar. An automatic switch-off function guarantees energy efficiency. Both models feature sampling rates of 2 Hz and integrated min/ max memories. Features shared by all Keller digital pressure gauges include simple parameterisation and operation with only two buttons. The pressure display can be shown in various physical units that can be selected freely.

Keller info@keller-druck.com www.keller-druck.com

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

Precision process calibrator delivers economy and accuracy Compact Ethernet radio modems Weidmuller’s long-haul WL Series of Ethernet radio modems are designed specifically for industrial use. The 40 mm wide units provide user convenience while saving on space to help users build networks quickly and efficiently. The Series incorporates a range of models including a 2.4 GHz, 5 GHz and 900 MHz option. The high throughput modems provide connectivity for line of sight distances from 5 km up to 20 km. All models have as standard an in-built routing function and black/white list for controlling traffic.

Plus, a built-in signal strength tester measures both bandwidth and the signal strength between two radios. In addition, all units include dual diversity antenna connections and a choice of different antenna accessories to provide reliable wireless connectivity. The 2.4 GHz model can be set up in a mesh network topology providing redundancy and greater reliability for industrial Ethernet devices. Each transceiver also has a built-in conversion for serial Modbus RTU to Modbus TCP. The WL Series is suitable for use in any industrial and water treatment plant, factory or mine site as well as in any remote monitoring application.

The 7526A Precision Process Calibrator simplifies calibration of temperature and pressure process instrumentation by incorporating an isolated measurement channel, letting users source and measure simultaneously. It is possible to calibrate RTD and thermocouple readouts, pressure gauges, temperature and pressure transmitters, digital process simulators, data loggers, multimeters and more. Precise pressure and temperature process control is required to maintain product quality, reduce waste, cut manufacturing costs and ensure compliance to regulatory standards. The calibrator simulates and measures nine RTD and thirteen thermocouple types, accurately measures pressure to within 0.008% of reading when combined with Fluke 525A-P Series Pressure Modules, sources and measures dc voltage from 0 to 100V to within 0.004% of reading.

Fluke Calibration 02 8850 3333 www.fluke.com.au

Coded magnetic safety sensor The Schmersal BNS 40S is a coded magnetic safety sensor made from precision cast high-grade stainless steel. Specifically designed for the food and beverage industry, it comprises a food-safe connecting cable, IP69K housing, LED indication, and a variety of contact configurations to allow integration to monitoring devices. Special care was taken with the hygienic design of the BNS 40S series. The laser-marked housing with rounded shape, complimented in a fine-polished surface, eliminates food-traps and ensures easy cleaning. The BNS 40S can be mounted using through holes, or concealed mounting is possible using threaded holes from the rear.

The BNS 40S was tested by ECOLAB to ensure long life in relation to the cleaning systems which are used in the food & beverage industry.

Weidmuller info@weidmuller.com.au www.weidmuller.com.au

Control Logic 07 3623 1212 www.control-logic.com.au

Distributed frequency inverters with Safe Stop Nord’s SK 200E distributed frequency inverters enable safe shutdown procedures in high risk applications that comply with Category 4 or Performance Level e according to EN 13849-1. Conventional frequency inverters in this performance class prevent motors from restarting by disconnecting the voltage supply or the 24 V control supply. By contrast, SK 21xE and SK 23xE models feature a certified safe pulse blocking device as well as digital inputs for the “Disable Voltage” and “Quick Stop” functions. These enable Stop Category 1 (controlled motor braking in line with SIL1), followed by Safe Torque Off (SIL3-compliant) or Stop

Category 0 (SIL3-compliant) according to EN 60204-1.

Since the voltage supply is blocked without switching off the control or power electronics, the units remain on standby and are ready to be switched on without re-initialisation after the safety circuit is closed. The inverters’ safety technology provides more economic benefits: contactor components are not required, and since the safety functions are activated electronically, there is no need for regular maintenance or exchange of electromechanical contacts.

NORD Drivesystems 03 9394 0500 www.nord.com.au February 2013 www.pacetoday.com.au 29

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CONNECTIONS

5

minutes with...

Paul Markwick, General Manager (Victoria), SAGE Automation How did you come to be in this industry?

I travelled the world and even lived in a kombi van for six months.

My parents owned a farm in the Mallee and encouraged me to explore other career options as opposed to staying on the land.

I started as an apprentice electrician in the city and found I enjoyed the challenge of working on control systems.

Sometime later while undertaking my associate diploma I met Justin Karl from SAGE. That was 15 years ago and the rest is history.

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

I’m lucky as our MD is very entrepreneurial and supports most of our ideas. At SAGE we sometimes feel that we have more ideas than time and money.

It’s a challenge as the business has grown and become more structured in its processes.

There is often a lot of debate about ‘which’ and ‘whose’ ideas gets implemented first; we always have a few on the go.

A couple of our better ideas have been a graduate program, 24/7 service and a didactic training facility.

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

Collaborating with industry partners and our customers that are prepared to take a longer view and treat their control system as a valued asset. When high levels of trust are evident, high performance teams can form, and on larger projects, senior engineers are able to train graduates in a safe environment.

What’s the greatest challenge in your job?

service technicians. There is almost always too much or not enough. We are focussing on being able to share our resources more efficiently between states so our engineers don’t have to get on a plane so often.

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

Easy, I would be a travel writer specialising in food and wine. About 20 years ago my wife and I travelled the world and even lived in a kombi van for six months.

It was a wonderful time that still grounds me to this day. These days my taste in food and wine is a little more refined, with the most travel I do being the commute between Melbourne and Sydney.

Balancing the workloads of our engineers and

paul.markwick@gotosage.com 03 8671 3006 www.gotosage.com

IICA CORNER

Benefit from quality training The IICA’s 2013 training covers introductory as well as advanced topics, writes Graham Moss.

THE IICA has now been offering training in control, instrumentation and automation for four years. In 2007, we partnered with ISA to present a range of their one-day courses. ISA is our equivalent organisation in America, and being the principal organisation representing the process control and automation industry in such a large market as America, ISA has substantial resources to develop and maintain high quality vendor-neutral training. Drawing on the expertise of a large number of industry experts, ISA training courses are internationally regarded as outstanding.

Our experience over the past four years has been somewhat mixed. The timing was unfortunate coinciding with the start of the GFC, followed by the engineering boom from mining and gas 30 www.pacetoday.com.au February 2013

investments. This has been a tumultuous period for Australia’s control and automation industry. Training budgets and the willingness to undertake long term professional development have been low priority as organisations try to balance their “boom and bust” demands.

The latent demand for training in this area has resulted in gradual growth of our training program.

Instrumentation, process control and automation have traditionally been technical disciplines gleaned from on-the-job experience rather than formal training.

However end user organisations are now relying more and more on outsourced technical skills, and these transient engineers or tradespeople are not obtaining consistent plant exposure to consolidate these skills. Simple skills such as how

to read a P&ID are being gradually lost. Formal training such as the IICA program is essential to fill these gaps.

All aspects of our industry have benefited from the ISA courses. Engineers, tradies, sales and even academics have registered for the courses and obtained the benefit of a formal explanation of technical fundamentals and pragmatic industry practice. Each course is run by a local instructor with extensive industry experience in the subject matter of the course – although courses inevitably become a group discussion as individuals bundle their experiences into a collective learning experience. Course feedback has been excellent, from the participants as well as their managers.

Our program continues in 2013, with training courses offered in all

states, including some country centres.

Programs focus on both introductory subjects such as sensors, P&IDs and basic process control, as well as advanced topics such as safety level systems and data networks.

If you are new to the industry and would like some formal explanation to help with on-the-job learning, please contact us.

For those who have been in the industry forever, our courses on newer technology topics may be relevant. For those who have already experienced our training courses, we hope that you have found the information helpful and thank you for an interesting four years.

[Graham Moss is IICA Training Manager.] training@iica.org.au www.iica.org.au

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The 10th annual PACE Zenith Awards will be held in Sydney on Thursday 13 June 2013. Nominations close 5 April 2013.

A total of 11 awards will be up for grabs on the night.

Each award will celebrate the achievements of the people behind some of the countryâ&#x20AC;&#x2122;s most innovative engineering projects.

Automotive & Manufacturing Food & Beverage Machine Builder Mining, Minerals & Exploration

Oil & Gas Power & Energy Management Lifetime Achievement Award Transport, Power & Infrastructure

Water & Wastewater Young Achiever Project of the Year

All finalists will be profiled in PACE magazine and on the website. They will also be given two free tickets to the gala dinner where the winners will be announced.

For more information please visit www.pacetoday.com.au/awards Proudly sponsored by

AD_PACEEMEFEB_13.pdf

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