PACE - Process & Control Engineering - July 2013

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JULY 2013 | VOL.66 NO.6

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

Winners

Check out all the P A 0 7 1 3 _ 0 0 1 _ M A C . p winners df P aofg the e 2013 1 1 8 / 0 6 / 1 3 , PACE Zenith Awards

Security Systems Managing multiple 1 2 : 3 8 :complex 3 2 Psystems M A E from ST a simple single interface

Post Print Approved PP255003/00539

macnaught’s designed and manufactured in Australia macnaught.com.au

Profile Martyn Hilbers is Senior Electrical Engineer with Ausenco

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CONTENTS

Associate Publisher: Martin Sinclair Email: martin.sinclair@cirrusmedia.com.au Editor: Kevin Gomez Tel: (02) 8484 0976 Fax: (02) 8484 0722 Email: kevin.gomez@cirrusmedia.com.au Deputy Editor: Isaac Leung Tel: (02) 8484 0956 Email: isaac.leung@cirrusmedia.com.au

IN THIS ISSUE

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

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Graphic Designer: Nicolle Lawson Email: nicolle.lawson@cirrusmedia.com.au

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

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

Management 7

Energy 12

Winners 16

Case Study 9

Profile 14

IICA Corner 38

Manufacturing Embrace a strategy in which advanced technology is considered as soon as practicable Security Network The real key to vastly improved security response and productivity is deep integration

Operational efficiency How to get a single view of the truth with integration of systems A win for the locals Macnaught is set to release a range of locally-designed and manufactured flow meters

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Established in 1948, Macnaught has a 65 year tradition of excellence in manufacturing. Macnaught began marketing flowmeters in 1965 and has been manufacturing oval gear flowmeters since the early 1990s. Our decades of experience have resulted in a simple, robust, and highly accurate family of flowmeters that are optimised to suit a broad range of applications and markets.

Macnaught offers optimised solutions for Fuel and macnaught’s Oil measurement, Bulk Fuel Custody Transfer, Corrosive 1 2 0 1 3 - 0 5 - 2 3 T Chemicals, 1 0 : 4 9Solvents, : 2 2 and + 1a0wide : 0variety 0 of other industrial liquids.

JULY 2013 | VOL.66 NO.6

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

Winners

Check out all the

P A 0 7 1 3 _ 0 0 1 _ M A C . p winners df P aofg the e 2013 1 1 8 / 0 6 / 1 3 ,

Average Net Distribution 6,424

Post Print Approved PP255003/00539

PACE Zenith Awards

P A 0 6 1 3 _ 0 Period 0 0 ending _ R March O C‘13 -

Plan for the future Message from incoming IICA Federal President Jason Freyling

ON THE COVER PA0 7 1 3 _ 0 0 1

PACE marks 60 years

OFFICIAL MAGAZINE OF:

2013 PACE Awards Detailed winners profiles and photographs from this memorable awards event

Security Systems

Profile

Managing multiple

Martyn Hilbers is Senior Electrical Engineer with Ausenco

1 2 : 3 8 :complex 3 2 Psystems M A E from ST a

simple single interface

designed and manufactured in Australia macnaught.com.au

With full ISO 9001 and 14001 accreditation, you can be secure in the knowledge that quality and environmental responsibility are at the forefront of every decision at Macnaught. Trust Macnaught to deliver the performance, value, and reliability required in today’s most demanding environments. With distributors in over 60 countries and global sales support, Macnaught has become a global leader in fluid management solutions.

Our focus on oval gear flow measurement reflects our commitment to excellence in providing optimised solutions for fluid management applications. www.macnaught.com.au

PowerFlex 525 Drive, the complete motor control package no matter what you package.

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16-May-13 3:57:14 PM JULY 2013 www.pacetoday.com.au 3

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COMMENT

WHAT’S ON

EDITOR’S MESSAGE

Shifting the focus to innovation

The Science of Powder Handling and Processing 23-25 July 2013, Melbourne www.icheme.org/pt NIWeek 2013 5-8 August 2013, Texas www.ni.com/niweek 2013 Honeywell Users Group Asia-Pacific Symposium 25-29 August 2013, Perth apusersgroup@honeywell.com

Kevin Gomez Editor

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

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

• Motors, Drives & Motion Control • Wireless Technology • Process Control in Mining • PLCs & Soft Control

SHARING the room with 230 other industry professionals at the 2013 PACE Zenith Awards was indeed an exhilarating and humbling experience. If the projects are any indication, we are indeed blessed with talent and this bodes well for the industry.

Reading through mainstream media we see 3D printing featured a fair bit. While it is an impressive development, overzealous proponents been portrayed 3D printing as a saviour of manufacturing. Let’s face it – low-cost manufacturing has fled our shores forever.

What 3D printing does well is bring manufacturing

to the forefront and interest a whole new generation in creating solid objects and not just immersed in social media or working exclusively with bits, bytes and code.

Importantly, 3D printing enables the creation of non-identical customised products allowing this generation to satisfy its need for individualism.

But there are exciting industrial concepts being touted, for example the “Batman utility belt”. A mechanical engineer in Australia has suggested that mining companies could make their own parts on site in a fraction of the time it takes get one sent

in. This will benefit remote mining locations.

Similar opportunities exist in the process control industry and it will be good for companies to encourage this trend. GE does an excellent job with GE Garages – a high-tech, hands-on lab that celebrates inventors and entrepreneurs. Held in Texas, it provides “everyday people” the opportunity to get their hands dirty and discover modern manufacturing processes.

Perhaps we need to get a few of these set up locally and ride the wave before it’s too late. kevin.gomez@cirrusmedia.com.au

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

Science

Is this truly the twilight of the scientific age?

By Jim PiNto

The big bang theory, the structure of certainty and the potential to stamp out SCIENCE is in decline. After centuries DNA, evolution by natural selection, the the diversity of human thought. The of great achievements, fatigue has periodic table of elements are not going discussion left much room for optimism. developed in our culture and many to change. We are close to reality in so In every scientific arena there is others. Our society is saturated with many fields that the chances of seeing always the search for more and better. knowledge, with very little improvement revolutionary new thinking is much less.

What new principles, laws, processes in real happiness levels. Ideals are lost in John Horgan interviewed an or qualities need to be discovered? What the search. impressive array of scientists and new theory will supersede and subsume In 1996, Scientific American philosophers who were sharply divided general relativity? Which new complex columnist John Horgan published a over the prospects and possibilities of feature of DNA structure will produce book, The End of Science. The thesis: science. The pessimists suggest that as something really new?

The pursuit of science was ending science reaches the limits of knowledge, Spectacular new theories are rare A D _the P basic ACE M E T of 2 the M Anatural R _ 1 2 . itp isdreaching f P aa gpoint e of 1 diminishing 2 4 / 0 2 / 1 2 events; , 9 progress : 4 3 will A Mbe minimal. because theories world are now mostly understood. returns; they object to pretensions of Perhaps the problem is because of

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the way in which modern science is organized. It takes a lot of courage to challenge accepted views and needs a lot of stamina to battle the status quo.

Mavericks do not do well in large organizations, which is what most science has become. So, are we in the twilight of Science?

But technological progress will not stop. Technology developments are funded because the search for smaller, better, cheaper will continue.

Forever.

Jim@JimPinto.com

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NEWS

PACE Zenith Awards 2013

PACE celebrates engineering excellence FOR 230 industry professionals, Thursday June 13, 2013 is a day they will remember for a long time. The PACE Zenith Awards held that day in Sydney’s Darling Harbour was special as the community came together to celebrate ten years of the Awards programme and also mark the 60th anniversary of PACE. Kicking off proceedings was Jonathan Roberts who is currently Research Director of the Autonomous Systems Laboratory within the CSIRO ICT Centre. Roberts delivered a scintillating keynote address drawing on his research interests that cover field robotics, autonomous aerial vehicles, autonomous ground vehicles, underwater robots and mining robots.

He was followed by the men behind The Chaser and Hamster Wheel – Chris Taylor and Craig Reucassel – who were tasked with MC-ing the night.

Nothing was off limits and their unique take on technology, personalities, and events, had the guests in splits.

Sponsors and winners came in for some good natured commentary, but a great time was had by all.

And yes, in the midst of all the merriment we did find time to celebrate our winners.

A special shout out to all our sponsors for making this event such a success: Schneider Electric, B&R Automation (Daanet), SICK, Beckhoff,

AMS Instrumentation & Calibration, ifm efector, Burkert Fluid Systems, Emerson Process Management and Honeywell.

Check out the winners who are profiled in this issue starting on pages 16. The full list of Winners and Highly Commended are on page 37. You can also find detailed profiles on www. pacetoday.com.au/features www.pacetoday.com.au/awards

FUTURISTIC: Jonathan Roberts offered some fascinating insights into recent advances in automation and robotics.

ACHIEVEMENT: The Machinery Automation & Robotics team celebrate their Highly Commended Award given for their innovative MAR Robotic Idler Replacement System.

PRANKED: The men behind The Chaser and Hamster Wheel, Craig Reucassel (L) and Chris Taylor (R) may have had the audience enthralled, but keynote speaker CSIRO’s Jonathan Roberts (standing) is not one shy away from photobombing their moment in the flashlight. Martin Foetschi (center) of Brickwoods is just happy to be in the frame.

Achievement

Ian Gibson’s industry contribution recognised THE 2013 PACE Zenith Awards recognised a professional who has devoted his life to growing and strengthening the process control industry.

Ian Gibson has a long and distinguished career which includes leadership roles in the IICA and senior engineering positions in WorleyParsons and Fluor Australia.

He also plays an active role in several standards organizations and is a respected author. Ian turns 78 this month and although he “kinda” retired eight years ago, he continues to remain 6 www.pacetoday.com.au JULY 2013

in full time employment.

Ian was given a Special Industry Contribution Award on the night. He could not attend the dinner but sent in the following message: “I joined the Society of Instrument Technology Australia, the IICA’s parent back in 1960, and became Victoria Division Chairman and Hon. Fed Secretary early in the sixties.

“I have remained a committee member and occasional chairman ever since, was for many years a Federal Councillor and President, and have been minder of the corporate litter box for

DISTINGUISHED: Ian Gibson. the past 50 years. I wouldn’t have done it if it hadn’t proven to be interesting.

I represent IICA on several Australian Standards committees, and through them, provide Australian input to IEC, ISO and ISA standards groups on measurement and process safety.

“Every profession needs a memory and a mentor, to go with the enthusiasm and drive of the new members. This I continue to try to provide.

“I would urge those present to take a look at your professional society, and contemplate how much better it could be if it only had your personal input.

Give it a go. You may be surprised to find how much fun it can be.”

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OPINION

Manufacturing

MES comes to the forefront Embrace a strategy in which advanced technology is considered as soon as practicable, writes Greg Gorbach.

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N THE past, manufacturing operations management/ manufacturing execution system (MOM/ MES) software often took a back seat to automation systems.

That’s no longer the case. Today we’re beginning to see the automation companies’ sales teams using MOM/ MES software to help pull through the larger automation system sale.

So what is the reason for the newfound strength and attraction of these software offerings?

MOM/ MES solutions are commonly offered by industrial automation vendors, ERP vendors, and independent software vendors. In the case of industrial automation vendors, their MOM/ MES software offerings often came through the acquisition of one or more software companies. While this usually significantly expanded the potential scope of the solutions they could offer to their customers, the companies’ respective system sales forces didn’t always have a good understanding of how to sell the potentially differentiating software.

As a result, they often discounted it along with the rest of the system just to close the deal. Over time however, automation users gained a better appreciation for the business value that the software could bring to their operations and the automation vendors got much better at selling MOM/ MES systems at a price that more closely reflected their true value.

We have now reached an important milestone in the evolution of MOM/ MES systems with several industrial automation vendors admitting to

ARC that they now have some client engagements in which their MOM/ MES system “pulls through” the automation sale. ARC believes this represents a significant shift. Today’s manufacturers clearly have a better understanding of the business value that plant software system brings to the table; to the extent that – in these instances at least – the software selection decision took precedence over the hardware selection decision.

Manufacturers increasingly take a holistic view of their production plants’ position within an extended value network. With this perspective, they apply information technology broadly to improve or replace business processes.

Information technology – and MOM/ MES software - has matured to the point where a host of new possibilities can be considered. Information-driven manufacturers have come to realise that it can be riskier to let existing systems stagnate than to implement new systems and that, at the very least, they have to keep their existing software portfolio reasonably up to date.

New technologies such as cloud computing, mobility, social, analytics, intelligent assets, additive manufacturing, and 3D visualisation may disrupt not only what happens within the four walls of a plant, but entire business processes throughout the supply chain and across the value network. New business strategies are emerging, such as “Industry 4.0”, “Industrial Internet”, “Connected Manufacturing,” and “Collaborative Value Networks.”

In addition to a host of potentially > disruptive technologies entering the

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OPINION

marketplace, companies must also face rapid changes in government regulations, energy and raw materials availability, markets, and competition. By deploying leading edge information technologies, today’s companies can thrive.

Each manufacturing plant has some unique needs that must be accommodated. Tier one automotive suppliers need sequencing support.

Pharmaceutical manufacturers need 21CFR11 compliance.

Nanomanufacturers need complex routing. Aerospace and defence manufacturers need work instructions and non-conformance management.

Make-to-order manufacturers have different needs from make-to-stock or batch manufacturers.

Hence, the first cut should involve finding software designed for a particular industry segment and used in similar manufacturing situations. To ensure that a given MOM solution can do the job, engineering groups must also evaluate the ability to fully meet the unique needs (through configuration or add-on custom development, if needed) as well as from the perspectives of scalability, performance, and deployment model (on-premise, remote hosted, SaaS, etc.).

Manufacturers must also determine whether a MOM solution is based on an appropriate technology and is compatible with the company’s business strategy and processes. Beyond these functional requirements, manufacturers should also consider vendor qualifications PA0 5 1 3 _ 0 0 0 _ SEI . p d such as regional support, micro-vertical

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experience, implementation capability, and regulated production environments. and price.

Today’s information and analysis The newfound strength of MOM technologies can be transformative. software systems dovetails with recent Companies employ information-driven requests that ARC has heard from value networks, business processes, several large manufacturers for their and decision-making to support and automation suppliers to help provide transform corporate initiatives such as business justification for replacing their energy management and sustainability aging control systems, since much of the programs; global growth initiatives; and business value from automation is seen innovation in product, process, systems, to come from the software applications and business models. that sit above the basic control platform, ARC believes that manufacturers and rather than from the controls themselves. other industrial organizations should Clearly, manufacturers need modern embrace information technologies (IT) software systems to keep up with the throughout the enterprise. Almost every information needs of operating a plant in plant or facility should run the latest f Pa ge 1 1 8 / 0 4 / 1 3 , 1 0 : 2 4 : 1 7 AM AEST today’s increasingly connected, dynamic, version of the appropriate software

so that it can operate in a connected, information-driven mode consistent with the rest of the organization.

Organizations should also make decisions based on production process and business process information.

Employ software to collect, contextualise, visualise, and analyse the data.

With the advent of extremely fast in-memory computing platforms and Big Data analytical tools, informationdriven companies are beginning to use ever-more-massive datasets in a host of new applications.

Today’s industrial organizations must collaborate better, internally and externally. To this end, ensure that systems and business processes are well integrated within the enterprise, and connect and share appropriate information with partners in a real-time ecosystem. This collaboration should also extend to social technologies and communities, which can be a good source for marketplace inputs throughout the lifecycle of a product or service.

IT technologies will increasingly drive a manufacturer’s competitive advantage, and sooner than many realise.

Embrace a technology adoption strategy in which advanced technology is considered as soon as practicable, and where it’s seen as a virtue to be part of the “early majority,” or even the “early adopter” community, instead of a riskaverse technology laggard.

[Greg Gorbach (ggorbach@arcweb.com) is Vice President, ARC Advisory Group.] www.arcweb.com

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BEHIND THE SCENES

Benefits of integrated security The largest privately-funded museum in Australia has maximised its building automation capabilities and manages multiple complex systems from a simple single interface, writes Hartley Henderson.

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S THREATS to the security of business enterprises increase, there is a growing need to ensure that the latest cost effective protective technology is in place. The Museum of Old and New Art (MONA), located near Hobart, is the largest privately funded museum in Australia. The site, which covers around 9,000 square metres and has some 400 pieces on display at any one time, attracts about 370,000 visitors per year.

In order to safely house the owner’s personal collection as well as valuable pieces the I P Aon 0 7loan 1 3from _ 0 around 0 0 _ WE 1 2 0 1 3 - 0 6 - 1 8 T1 4 : 0 7 : 1 7 + 1 0 : 0 0 > CONTROL: Digital Video Manager’s Distributed Video Architecture. world, a customised integrated

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BEHIND THE SCENES

controls. “Open systems provide flexibility to integrate a wide range of sub-systems as well as expand cost effectively. For example, the Security Manager function of EBI allows you to integrate your building’s safety, access and security systems into a single operator interface with centralised alarming, CCTV and digital video controllers, and cardholder management.”

Open networking

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STRATEGIC: Enterprise Buildings Integrator building management system. building services system, incorporating the latest in security technology, has been designed and installed by Honeywell Building Solutions.

The installation includes the company’s recently launched Digital Video Manager (DVM) R500 closed circuit television surveillance sy stem which forms an integral component of Honeywell’s Enterprise Buildings Integrator (EBI) building management system.

Security response

According to the company’s regional leader of marketing and strategic development, Michael Brookes, the key to improved security response and productivity is integration. “This means managing the different functions as one integrated security solution and converging this with building management systems,” he said.

“EBI ties all aspects of a security solution together, including surveillance, access control, and intrusion detection. It also integrates building climate control, safety, energy management and other core facility 10 www.pacetoday.com.au JULY 2013

At MONA an integrated solution is provided that brings together CCTV, access control, security, BMS, electrical control and monitoring, fire detection, intercom, biometrics, and photo ID. DVM’s system architecture is built upon industry standard open networking, PC hardware, and software applications.

It supports a vast array of commercial off-the-shelf hardware providing freedom of choice when selecting cameras, PC, storage, and networking hardware.

The basic architecture consists of a Database Server and a Camera Server that can be installed on the same machine. Additional Camera Servers, backup Camera Servers and Analytical Servers can be added to the architecture to support larger numbers of cameras.

Operational efficiency

According to Brookes, the updated DVM R500 surveillance system sets new standards in operational efficiency, cost effectiveness and performance through a redesigned user interface, smart diagnostics and forensic search capabilities.

“The updated user interface provides improved productivity through ease of navigation, while smart diagnostic modules analyse system operations to help security operators to quickly process activity reports.

“Key features of the system include synchronised and instant playback of multiple cameras, motion searching that detects movement in a selected area and tags it for review, and time scrubbing to quickly locate critical incidents and footage.

“Importantly, DVM uses standard communications technology, off-theshelf hardware and existing network infrastructure and wiring for fast, easy installation.

“It also facilitates integration of existing analogue equipment to the LAN/ WAN, and supports

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integration with third party products and applications.

“Full integration with EBI is, however, achieved without the expense and future support inherent to custom software integration or complicated interconnection wiring.

The new DVM user interface allows the display of multiple cameras in the main workspace via a single drag and drop operation from a multilevel camera tree representing either physical locations or operator-defined logical groups.

“Live and recorded video from a maximum of 25 cameras can be viewed at any one time whereas previously forensic analysis required the time consuming investigation of individual cameras. Integration with EBI allows direct linkage of video recordings to alarms and events enhancing operator awareness of specific situations, and an enterprise-wide view is achieved from a single workstation screen, thus enhancing operational efficiency.

“At MONA, key facility management functions are controlled by one person from the one location, including HVAC, fire and security,

The real key to vastly improved security response and productivity is deep integration.

which provides significant cost benefits while delivering a reliable and effective building management system to protect a huge personal investment by the owner.”

Brookes points out that DVM’s flexible architecture makes it easy to add or relocate cameras along a buildings network, so there is no need to purchase and maintain racks of recording equipment, monitors and switches.

“New CCTV monitors require only a PC with suitable software and a network connection, and database and camera servers are available in

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a redundant configuration, so that if the master server fails, the system automatically reverts to the backup server,” he explained.

“A significant benefit of DVM is its scalability in that it is configurable from a small, one facility system, to a large corporatewide system. The distributed video architecture of DVM R500 is capable of seamlessly integrating the video operations of numerous systems into one virtual platform.”

Single interface

Site project manager at MONA, Steve Devereaux, believes that Honeywell has designed and installed a state-of-the-art integrated BMS/ access/ security/ CCTV system that is world class.

“Importantly, the integrated graphical user interface has enabled MONA to manage multiple complex systems from a simple single interface, and by maximising the building automation capability, security staff resources to run day-to-day operations can be minimised,” he said.

“Where the overall system stands out is in its use of EBI to provide a single integrated platform to deliver a safe and secure environment for the extensive art collection, staff and visitors.

“We are easily able to identify where there has been unauthorised motion or an incident in an area by dragging footage into a time-line view from multiple cameras, which can provide huge operational efficiencies.

Analysis and reporting that would normally take four to five hours is now measured in minutes.

“Another benefit of the integrated platform is that if a fire alarm goes off, cameras under the DVM R500 system automatically activate the EBI which integrates other parts of the security system. In addition, inclusion of HVAC control under EBI is an added bonus because of the importance of maintaining strict climatic conditions, including humidity levels, within the MONA facility.”

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Honeywell Building Solutions 02 9353 7000 www.honeywell.com MONA 03 6277 9900 www.mona.net.au

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IN FOCUS

Operational efficiency in mining Technologically advanced and efficient operations are no more an optional add-on to mining – they’re now a necessity, writes Vinod Kandoi.

VISIBILITY: Get a single view of the truth with integration of systems.

“ Installation in record time – for optimal performance in your plant.”

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New versions for food and pharmaceutical production and for high-pressure and high-temperature applications round out the series. www.vega.com/au/innovation.htm Phone: 1800 817 135

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M

ost mining companies have been facing the challenge of declining productivity for a while.

As mineral reserves closer to the surface are depleted, remaining deposits tend to be of a lower grade, in more remote locations and / or are deeper in the ground, making extraction more difficult and costly.

The leading mining companies have been taking advantage of technology to address this productivity challenge.

There are three components of operational efficiency: Visibility of operations; Correct presentation of information; and Improved decision making.

Visibility of operations. Adding visibility into your operations and business enables the management team to ensure that capital resources and processes are performing to plan.

Finding timely, accurate and relevant information to facilitate the effective management of capital equipment efficiency from the flood of operational data can be a challenging task and it is important that the correct software systems are in place to manage this.

Such systems provide a transparent route to production and business application

layers that enable management staff to make effective and timely decisions based on a single version of truth.

Correct presentation of information.

Information must be presented in the right place, at the right time and in the right context. At the production level, information must be integrated, collated and summarised from many sources.

Easy to read dashboards covering overall enterprise performance enable continuous monitoring and fast reaction to changing conditions, while ad hoc drill down reporting enables management to explore production dynamics and quickly identify root causes Improved decision making. Running a complex mining enterprise means making business decisions in a potentially volatile, uncertain, complex and ambiguous environment. Made in isolation from other process data or based on limited information, there can be unpredictable repercussions for the operations.

Today’s intelligent mining solutions gather data from the whole business in context, reducing volatility, uncertainty, complexity and ambiguity – therefore helping to make better decisions.

The three systems which improve

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RELEVANT: Comprehensive operational intelligence with an MES.

market potential product specifications over a longer time period.

To optimise and streamline aspects such as ore quality, throughout transport logistics, scheduling and delivery to contract, planning and logistics staff need to accurately model and manage the value chain and achieve a consolidated, enterprise view of operational performance.

Energy Management. Energy Management (EM) solutions are increasingly being installed in mining and minerals processing companies to provide information for tracking and forecasting operational consumption and providing information around energy quality. The information empowers people to make decisions to improve business outcomes related to the cost and availability of energy.

When combined with automation, energy management bridges the gap between process optimization and energy efficiency, enabling automation systems to make better decisions and set process variables based on information gathered from energy monitoring systems.

The integration of energy management with mine execution systems to form a Production Energy Optimization (PEO) system provides a solution with timely and automated information gathering at a granularity that facilitates the identification of energy efficiency opportunities.

[Vinod Kandoi is Segment Manager, Mining, Minerals & Metals, Schneider Electric.]

MM& P A C E 2

2 0 1 3 - 0 5 - 2 3 T1 0 : 3 4 : 0

THE SWITCHMODE POWER SUPPLIES YOU WANT NOW FOR LESS AT SOANAR 60W

45W

120W

operational efficiency are: • Operational intelligence to optimise your mine’s performance – Mine Execution System (MES) • Mine-to-Port Logistics – Integrated Planning and Optimization System • Energy Management – Energy visibility, prediction of use and minimising consumption Mine Execution System. Imperfect information, changing conditions, inconsistent mine geology and chaotic mining processes make delivering optimum performance a challenging task for mine managers. As such, accurate and timely operational intelligence is essential to addressing this challenge.

Mine managers need a system that can continuously monitor asset performance in real-time and can identify opportunities to optimise production, reduce operating costs, increase first-pass quality and decrease waste. Mining companies are moving towards a mine execution system (MES) to bridge the gap between their Enterprise Resource Planning (ERP) system and the plant floor.

Mining-to-Port Logistics. Mining companies often have many disparate systems and repositories of data in their organisation for planning and scheduling outbound mining supply chains. The mine logistics planning staff coordinate a complex series of activities to ensure production forecast accuracy.

Sales and marketing staff negotiate and execute complex contracts often with disconnected and limited visibility of production forecasts, quality, and variability with little ability to accurately

-

240W

IN STOCK NOW

NEW DIN RAIL SERIES

AC/DC DIN RAIL SWITCHMODE POWER SUPPLIES OUTPUT OUTPUT OUTPUT ORDER POWER VOLTAGE CURRENT NUMBER (W) (V) (A) 45W 60W 120W 240W

12V

3.75A

SD-45-12

24V

2A

SD-45-24

12V

5A

SD-60-12

24V

2.5A

SD-60-24

12V

10A

SD-120-12

24V

5A

SD-120-24

24V

10A

SD-240-24

48V

5A

SD-240-48

DIMENSIONS (W x H x D) (MM)

LIST PRICE

78 × 93 × 56

$32.55*

78 × 93 × 56

$38.70*

65.5 × 125.2 × 100

$64.65*

125.5 × 125.2 × 100 $109.60*

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

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

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

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

Bulk pricing available on request.

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

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

www.schneider-electric.com.au JULY 2013 www.pacetoday.com.au 13

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BEHIND THE SCENES

Local meters go against the flow A few years back NSW-based Macnaught brought its complete production inhouse. The company is now gearing up to release an innovative range of locally-designed and manufactured flow meters, writes Kevin Gomez.

I

N 1948, Colin Macnaught started manufacturing hand pumps for kerosene and oil in Turella, NSW. Today, sixty-five years on, the company bearing his name manufactures a range of equipment for the lubrication and fluid transfer industries including grease pumps and guns, oil pumps and guns, fuel pumps, hose reels and flow meters.

While many local manufacturers flee the country seeking low-cost bases overseas, Macnaught bucked the trend and focused on its in-house production. “Because of our heritage as a manufacturer in Australia, going offshore is always the last resort for us,” said Bob Hill, CEO, Macnaught.

Since the GFC in 2008, the company has invested heavily in equipment and skills, building strong local capabilities.

This month Macnaught will draw upon this investment and unveil a range of positive displacement flow meters that it believes, will set it far ahead of the competition.

Corrosion resistance

Macnaught’s new MX range replaces the older M series and comprises of nine base models. One of the major enhancements is in the area of instrument quality.

“We are now manufacturing from billet rather than castings, which gives us better dimensional stability, corrosion resistance, and improves the pressure rating,” explains Graham Wilson, Product Manager, Flow Meters.

“The ability to control the manufacture of the meters from the machining of the raw materials to the final assembly, enables us to apply strict Quality Assurance procedures throughout the entire process in order to produce a consistently high quality product.” [Editor: A billet is a length of metal that has a round or square crosssection. Billets are created via extrusion or rolling an ingot.]

The MX range will be available 14 www.pacetoday.com.au JULY 2013

CAPABILITY: Macnaught’s facility in NSW is able to make any component required to build its products. in nine models representing different sizing (1/4” to 4”) and flow rates (0.5 lph to 1200 lpm).

“We have designed this range with common components to make it easy for the end user to select a suitable meter for their particular application, with the mounting arrangement of the display or pulse module really setting it apart,” explains Wilson.

The mounting system, called M-lock, is a unique bayonet type quarter turn fitting that allows the output display module – which is common across the range – to be quickly changed or replaced if required.

“If you had a range of meters in your plant spanning various sizes, you only need to hold very limited stock of replacement displays, perhaps one or two to cover the range,” adds Wilson.

QUALITY: Macnaught set up for inhouse manufacturing and changed to in-process inspection.

With positive displacement flow meters, typically only a couple of things can go wrong: either the rotors are not turning which means that there is no mechanical movement, or the electronics has failed. Macnaught’s unique bayonet design allows the user to do a quick test to identify the source of the problem. “If we’re not getting a signal, I just need to quarter turn off the existing electronic module, quarter turn on another one, and check whether the system is working,” explains Wilson. There’s no need to stop the process or dismantle the meter.

The new MX range, available in two versions, is targeted at the fuel and oil, mining, and chemical processing and dispensing sectors locally and overseas.

The aluminium version is suitable

gearing

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for the general non-aggressive materials, like fuels and oils.

The stainless steel version has higher grade material and is suitable for the more aggressive industrial environments. “When we launch we will also seek to penetrate new markets,” adds Wilson.

to a great extent the first advantage offshore suppliers enjoy,” explains Hill.

The transformation to self sufficiency was a challenging one. Apart from raising funds for equipment purchase and extensive staff retraining the company had to move to a lean manufacturing culture.

For example, the earlier practice was to inspect components and assemblies as they come into the building.

“When set-up for in-house manufacturing we changed to in-process inspection which is at the beginning of a set-up and during the manufacturing process,” explains Gavin. “Consequently, there are not too many delays at the end of the production run when checking and passing the goods.”

Competitive position

The company is optimistic about its new product range and its competitive position in the market. Perhaps, much of this is belief is due to Macnaught’s local manufacturing culture, with all production carried out at its plant in Turrella, New South Wales.

“We can essentially make any component required to build our products – with the exception of general hardware such as nuts and bolts,” explains Steve Gavin, Operations Director. Agility is another key aspect.

“We have versatile CNC machinery that we can change over quickly, enabling us to switch from one of two or three products during the same day on any given machine.”

As demand changes, Macnaught has developed the flexibility to deploy machines on the required product lines and thus achieve very short lead times. “We can manufacture products within a few days rather than waiting on sub-contractors for weeks,” adds Gavin.

P A0 7 1 3 _ 0 0 0 _ CON “Also, our in-house engineering

Paying dividends LEADERSHIP: (l-r) Robert Hill, Steve Gavin and Graham Wilson. department is able to apply design changes or improvements to the components or the products in real time.”

The GFC of 2008 put a lot of stress on many companies but Macnaught used these challenging times to redefine its operations.

BAYONET: Macnaught’s new MX “By designing manufacturability range incorporates a unique mounting into our products, we can minimise the 1 2 0 1 3 - 0 6 - 2 5 T1 0 : 5 8 : 3 3 + 1 0 : 0 0 system allowing it to be quickly replaced. labour content and thereby neutralise

By building its operations around a local manufacturing strategy, Macnaught is definitely swimming against the tide, but this approach is paying dividends.

“Local design and manufacture ensure that we remain in touch with the needs of the market and are able to adapt,” explains Hill.

The company appears to be holding its own locally and overseas. As Gavin explains, “Being globally competitive is about working smarter with the right tools.”

Macnaught 02 9567 0401 www.macnaught.com.au

JULY 2013 www.pacetoday.com.au 15

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PACE ZENITH AWARDS 2013 WINNERS Helping to put you in Control

Modbus TCP Gateway

Interfaces a Davis Instruments weather station to a PLC or a SCADA system via Modbus TCP over ethernet or Modbus RTU via RS-485.

Provides a webpage for easy configuration and viewing of current data.

SKU: KTA-282 Price: $225.00 each + GST

3 mv/V Load cell to 0-5 V

52×22×18 mm tiny signal conditioner for 3 mV/V load cells. Provides a regulated 5 V excitation and 0 to 5 V output. 14-30 VDC powered. ±0.025% F.S accuracy. 100 ms response time.

SKU: AXS-509 Price: $99.00 each + GST

Transport, Power & Infrastructure WINNER

PSF50-G-Q15 Flow Switch

Based on a paddle operated magnet switch the flow switch features NO/NC output, operates in both flow directions, suitable for liquids up to 140 °C, IP65 housing.

SKU: CMS-402 Price: $174.32 each + GST

Potentiometer Iso. Transmitter DIN Rail or panel mount this isolated 100 Ω to 100 KΩ potentiometer transmitter features a selectable output range of 4-20 mA, 0-5 VDC & 0-10 VDC. 18-60 VAC/VDC powered.

SKU: AXB-010 Price: $129.00 each + GST

N1540-Universal Indicator

96x48x34 mm 5-digit universal process indicator accepts T/C, Pt100, 4-20 mA, 50 mV and 10 V signals. Features dual alarm relays & 24 VDC auxiliary voltage source. Mini USB interface for configuration & monitoring. IP65 front panel.

SKU: IPI-150 Price: $245.00 each+ GST

WINNER: Jason Watson of Braendler Engineering receives the Award from Ben Sole (R), Chief Revenue Officer, Cirrus Media.

Current Transmitter

DIN rail/panel mount this current transmitter presents a 4 to 20 mA DC signal representing the AC current flowing through the primary conductor. 0 to 30 A/50A/100A/200A AC available. 24 VDC powered.

SKU: WES-005 Price: $59.95 each+ GST

1-Port Iso. Modbus Gateway 1-Port Modbus TCP to Modbus ASCII/RTU converter gateway via isolated RS-422/RS-485 interfaces. TB5 screw terminal connection. 65×28×78 mm SKU: ATO-162 Price: $220.00 each+ GST

Current Monitoring Switch

Ideal for monitoring small AC fans & pumps. With 4 selectable current ranges it features a SPCO relay output, 2.5 Kv @50 Hz impulse isolation.

LED indication. Screw terminal connection.

SKU: NTR-060 Price: $59.95 each+ GST

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

16 www.pacetoday.com.au JULY 2013

Braendler Engineering Aether Asset Inspection Service Braendler Engineering developed the Aether Imaging Service for the capturing high quality visual records of the assets within the energy generation sector. In the energy industry, large scale assets such as cooling towers, chimneys and wind turbine blades must be routinely inspected to optimise their performance and reduce unscheduled maintenance.

Traditionally, the only way to get a visual record of these assets would be to employ rope, crane or scaffold based teams to scale the asset and photograph potential defects. The resulting pictures from these inspections are usually incomplete and reliant on the human eye and the conditions on the day. In addition, this practice is risky and (if operating outdoors) teams can only operate effectively in benign weather conditions.

Additionally, these manually captured images can be difficult to review and categorise for planning, reporting and ongoing comparison. Aether comprises an engineered Image Capture Platform and supporting software management tools (called Hermes) for image processing, annotation and analysis.

Both the Imaging Platform and the Hermes interface

have been developed in-house by Braendler’s team of electrical, mechanical and software engineers and drawing on years of experience in developing vision inspection and reporting systems for use in high speed manufacturing environments.

The Aether Imaging platform is an engineered control system customised to ensure precision automation of functions such as focus, pan, tilt and zoom. The system comprises “best of breed” optical, communications and computing componentry together with software to operate the Platform. Once the images have been captured, they are stitched or tiled using purpose built software to create a comprehensive visual image of a blade or concrete surface.

The Hermes software allows the user to zoom in to each image for highly detailed analysis. Pulldown menus allow for annotation and categorisation of defects. A range of reports can be generated for management and maintenance purposes.

Since the Aether Inspection Service uses high precision optics from Swarovski Optik, it allows high definition close-up images to be captured at a long distance. Thus, it can be operated safely and conveniently from the ground, eliminating the need for inspectors to be working at heights, reducing health and safety risks.

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PACE ZENITH AWARDS 2013 WINNERS

Food & Beverage

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MM& P A C E 2

2 0 1 3 - 0 5 - 2 3 T1 0 : 3 5 : 4

THE SWITCHMODE POWER SUPPLIES YOU WANT NOW FOR LESS AT SOANAR

WINNER

240W 100W 60W 25W

IN STOCK NOW WINNER: Martin Sinclair (L) Associate Publisher, PACE, congratulates winner Brian Jackson of Sunshine Sugar.

Sunshine Sugar Centrifugal drive system saves energy Sunshine Sugar needed to replace their ageing centrifugal drive system, and chose a Siemens AC drive-motor combination, which yielded 40 percent savings in energy consumption. The project was completed on time and within budget. The original centrifugal drive system was a 298 kW DC unit. When Siemens proposed replacing it with a 184 kW AC motor-drive combination, Siemens was challenged with proving the solution. Siemens drew on their 1200 reference sites worldwide of successful centrifugals operated by AC drives. They also provided detailed analysis on their success with reducing the size of motors and drives by controlling the switching rate of the Insulated Gate Bipolar Transistor (IGBT).

Siemens also sent in a global expert on drives from their Sugar Competence Centre in Germany to ensure Sunshine Sugar had all the technical information and insight into the solution to make its decision. Sunshine Sugar was won over to the solution by the support offered by Siemens.

In particular, the technicians at the company were drawn by the Active Front End technology, which is a standard feature in Siemens Sinamics drive systems. This feature of the 184 kW drive system allows a reduction of the size of the motor and drive without losing power, achieve harmonics of less than 1 percent and consequently significantly reducing energy costs. The Active Front End feature also provides a number of other benefits, such as an exceptional dynamic response and self-commutated converters with IGBTs and clean power filter in the input. It effectively combats main system resonance due to harmonics, neutralising the effect on mains voltage.

The system eliminates the need for compensation and filter circuits, with an overall power factor of cos phi = 1, due to sinusoidal currents and voltages with no mainstypical harmonics and so absolute minimum mains pollution on the line side. There is also no conduction-through with fuse tripping in response to mains under voltage or failure in generator mode thanks to active tripping, making the implementation especially suitable for weak or unstable systems.

Since commissioning, Sunshine Sugar has achieved a substantial (over 40 percent) saving in power consumption. Power recordings have confirmed a reduction from 1.7 down to 1.0 kWh/tonne of massecuite.

AC/DC ENCLOSED SWITCHMODE POWER SUPPLIES OUTPUT OUTPUT POWER VOLTAGE (W) (V) 25W 60W 100W 240W

OUTPUT ORDER CURRENT NUMBER (A)

12V

2.1A

SE-25-12

24V

1.1A

SE-25-24

12V

5A

SE-60-12

24V

2.5A

SE-60-24

12V

8.5A

SE-100-12

24V

4.5A

SE-100-24

12V

20A

SE-240-12

24V

10A

SE-240-24

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

DIMENSIONS (L x W x H) (MM)

LIST PRICE

98 x 97 x 35

$28.77*

159 x 97 x 38

$38.37*

199 x 98 x 38

$44.77*

215 x 115 x 50

$71.20*

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

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

Bulk pricing available on request.

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

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

JULY 2013 www.pacetoday.com.au 17

PA0713_000_SCH2

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Looking for plant-wide profitability?

PlantStruxure architecture delivers

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

Plant Manager I can optimise asset utilisation and reduce the plant’s environmental impact.

Engineering Manager I can reduce engineering time to accelerate project schedules.

Energy Manager I have visibility into the plant’s energy consumption and can finally control it.

Enhance your plant’s productivity with our collaborative process automation architecture.

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

PlantStruxure is a collaborative solution that allows companies to meet their automation needs whilst simultaneously addressing growing energy management requirements.

Produce effectively with PlantStruxure architecture

The integration of software, hardware, networking and communication forms the backbone of information transparency from field to enterprise.

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

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

PlantStruxure – the foundation you need to yield a holistically optimised plant.

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

Hardware From Modicon controllers to RTUs, drives and motor starters, our hardware is flexible, reliable, and highly efficient.

Networking and communication

Learn more about PlantStruxure architecture!

Download our PlantStruxure Solutions brochure today.

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

Visit www.SEreply.com Key Code 53192K

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

CLIPCOM 26523

Production Manager

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PACE ZENITH AWARDS 2013 WINNERS

Mining and Minerals Processing WINNER

FLSmidth Ludowici Ludowici Reflux Classifier FLSmidth Ludowici, working with research and development partner Professor Kevin Galvin of the University of Newcastle, has developed the Reflux Classifier (RC), a breakthrough in coal and minerals processing globally. The company and Professor Galvin sought a way to increase the recovery and concentration of fine particles in premium, high-grade metallurgical coal processes.

According to the Productivity Commission, there has been a 40 percent decrease in yield over the past 30 years in Australia. Inevitably, mining faces problems associated with falling grades and poorly liberated feeds, and hence a steep rise in energy intensity in mining. By enhancing the ability to recover and concentrate fine particles, the Reflux Classifier technology reduces the rate of increase in energy intensity in mining. The improved particle recovery and energy savings are expected to save the mining industry billions of dollars.

The Ludowici RC units are the latest fine particle technology (gravity based separation) and offer advantages in capacity, adaptability and efficiency.

Ludowici’s Reflux Classifier technology has already been proven with operating units applying the latest in gravity-based separation engineering in Africa, Asia, Australia and North America.

The RC is an industrial machine that separates fine particles on the basis of either density or size; it further improves the efficiency of the recovery process with its unique tilted design. The technology has succeeded in solving an existing processing problem by achieving the sharp separations essential in the recovery of premium, high grade metallurgical coal.

Already under patent, the Reflux Classifier is currently used in seven countries and Professor Galvin’s research team, which forms part of the University’s Newcastle Institute for Energy and Resources (NIER), continues to investigate the full potential of the concept in other areas.

The Reflux Classifier was developed by combing a conventional fluidised bed with a system of inclined channels to achieve enhanced rates of segregation of high density particles, and enhanced conveying of low density particles. The Reflux Classifier can be applied to a relatively broad range of particle sizes, and achieve higher recovery of valuable material than other water-based technologies.

The Reflux Classifier incorporates the new ‘laminar high shear rate’ mechanism: the latest in fine particle gravity based separation technology. This, along with advancements in channel spacing and width mean that Reflux Classifiers are more efficient and more compact than competing fine coal and

WINNER: Scott Wooldridge (R), Vice President, Industry Business, Schneider Electric Australia congratulates winners FLSmidth Ludowici’s Taavi Orupõld (L) and Professor Kevin Galvin from the University of Newcastle.

ADVANCED: The Reflux Classifier incorporates the laminar high shear rate mechanism. mineral processing equipment. Preliminary tests of the Ludowici laminar high shear rate enhanced reflux classifiers (undertaken at the University of Newcastle’s RC Laboratory) have increased coal yield by up to 80 percent when using a laminar high shear rate regime in the inclined channels.

In addition, remodelled RCs enable a set point operator to operate the machinery directly, reducing

operating time and making it more cost effective. The plant can choose the density at which the gate valve must open. A set point is entered, which causes the RC to dump coal as soon as it reaches its density.

The Ludowici RC also has a smaller footprint than any competing technology and offers a higher throughput for each square metre while displaying better separation efficiency than competing technology. Significantly, the Ludowici RC is designed in a way which allows ease of transport, site assembly and installation. Smaller units up to RC2000 size fit in a single standard 20’ open top shipping.

Larger units fit in 40’ open top shipping containers.

This compact design, coupled with high capacity, means the Ludowici RC is suited for any plant layout. It requires less than 2.4m x 2.1m of floor space, and the system is also easy to operate. Only one operational control is required, with the operator only needing to set the density set-point which controls the cut point. Pilot Scale testing is also available, with the smaller, pilot RC300 scaled units available for hire.

According to the judges, this entry was a winner because the improved particle recovery and energy savings enabled by the innovative Reflux Classifier could save the mining industry significant amount of money.

JULY 2013 www.pacetoday.com.au 19

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THERE IS NOTHING IN THE AIR TONIGHT.

From power generation and cement production to waste treatment and the distribution of natural gas – the more complex a plant, the greater the demands on systems engineering and services. When it comes to monitoring emissions, evaluating gases for optimal process control and ascertaining custody transfer measurements for pipelines, SICK is a step ahead in every segment of the industry. With complete solutions for gas analysis, dust measurement and flow measurement that are perfectly tailored for each process environment. With superior equipment availability, easy operation, certified explosion protection and robust measurement technology with long maintenance cycles. When it comes to finding a clean solution, the whole world takes measurements with SICK. We think that’s intelligent. For more information please visit www.sick.com.au or call 1300 405 807.

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PACE ZENITH AWARDS 2013 WINNERS

Young Achiever WINNER

Erin McMullen Unilever Following three years in the Unilever Future Leaders Programme (UFLP), Erin McMullen was promoted the role of Engineering Manager at North Rocks Unilever in January 2013. Erin became the first graduate of the Future Leaders Programme to be promoted directly into a management level role upon completion of the three-year program.

In this role, she has taken on responsibility for all aspects of Engineering activities of the North Rocks factory, including leading Focused Improvement, Planned Maintenance, and Early Equipment Management (Innovations and Capital Expenditure). Erin also has a team of seven Engineering and Maintenance staff reporting to her directly, as well as the responsibility of managing an additional team of nine mechanical fitters and five electricians to support the site.

As Engineering Manager of North Rocks, Erin has a great opportunity to help shape the high performance culture of the site. Through her leadership, and in driving the continuous improvement mindset, she is helping North Rocks deliver safety excellence (zero accident), quality excellence, improved productivity and cost reduction.

During the UFLP, Erin took on various, challenging roles across different functional and operational areas of the Unilever business including Materials Planner, Process Engineer, Production Leader for Deodorants in addition to a six-month rotation in the Sales and Marketing team.

As Materials Planner for key packaging materials for the production of Aerosols products at North Rocks, Erin played a significant role in helping the North Rocks team achieve 98 per cent customer service case fill for the Deodorants category in H2/2010.

As Process Engineer, Erin was assigned to lead the implementation of the significant process changes relating to the launch of a new angled-neck Domestos toilet cleaning product in Australia.

The North Rocks factory needed to install new packing and processing equipment to in order to be able to manufacture the new product. The project was delivered on time and in full, within budget.

In her role as Production Leader for Deodorants over a 15-month period, Erin helped the North Rocks factory maintain its zero lost time accident record (the site is now at zero LTA for the past seven years). She also helped the site deliver five percent increase in volume growth and a two percent reduction in production cost per tonne.

All this was achieved in a highly challenging environment as North Rocks was under pressure to

WINNER: David Duncan (L), Managing Director, SICK, congratulates Erin McMullen who took out the Young Achiever Award.

ACCOMPLISHED: Erin McMullen helped the plant maintain its zero lost time accident record. deliver a significant liquids transformation program (to include capital expenditure, innovation and cost savings – all in a 12-month period).

In her role as Production Leader for Deodorants, Erin gained leadership experience in a fast-paced and highly-changing manufacturing environment.

Erin was responsible for a team of 40 people running production 24 hours per day, six to seven days per week, for one year.

Being in an early stage of her career, this was a daunting and challenging, yet highly rewarding experience for Erin as it provided her with an excellent opportunity to develop her people and team leadership capabilities at the coal face of operations and to deal with tough day-to-day people issues, safety and quality problems.

In addition to achieving all relevant KPIs, Erin maintained a significant focus on costs to ensure the factory remained competitive.

Erin’s high level of maturity, intelligence, diligence, as well as her engaging personality, enabled her to flourish in her time as Production Leader.

In awarding the win to Erin, the PACE Zenith judges said, “As engineering manager, Erin is playing a key role in shaping the high performance culture of Unilever’s facility. Still in her twenties, Erin has demonstrated leadership in helping the plant deliver safety excellence, improved productivity and cost reduction.”

JULY 2013 www.pacetoday.com.au 21

AD_MANMIFMAPR_13

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Did you know...

We make more than you think!

Easy to use master with fast connection

Compact photo-electric sensor for the food industry

Hygienic point level sensor resistant to build-up

AS-i safety made easy

The new ifm gateways are the fast connection from AS-i to EtherNet /IP, Profibus or Profinet.

Thanks to a colour display and web interface, the status of all AS-i slaves is recognizable at a single glance. The quick set-up menu and intuitive handling facilitate installation and diagnosis. Further, the web interface allows full remote access.

The OG cube wetline photoelectric sensors combine high optical performance in a robust stainless steel housing. The industry standard M18 cube design has IP69K rating and a superior sealing concept to ensure it will survive in the harshest wash down conditions.

Default setting at the factory makes adjustment to the medium unnecessary. Hygienic design with maintenance-free sealing concept. Robust stainless steel housing. Resistant to foam and deposits. Orientationindependent installation.

Safety monitor monitors transmitted code sequences in an AS-i network. In the case of message deviations or timeouts it ensures the safe state of the system. The safety-related extension is fully downward compatible and can be retrofitted on existing installations.

Contact us today!

Have you tried our e-shop?

1300 365 088 sales.au@ifm.com www.ifm.com/au

Visit www.ifmefector.com.au/eshop

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PACE ZENITH AWARDS 2013 WINNERS

Automotive & Manufacturing WINNER

SAGE Automation Countermeasures Manufacturing Facility SAGE Automation successfully designed, developed and installed a new aircraft countermeasures production facility for Chemring Australia in the regional Victorian town of Lara near Geelong.

Chemring Australia has a 10 year, $160 million contract with the Australian Defence Force to supply aircraft mounted countermeasures designed to draw missile attacks away from the aircraft.

The $11 million new production facility was considered essential for the fulfilment of the contract.

Constructed in four stages, this is the first automated countermeasure manufacturing plant constructed in the southern hemisphere.

The project was a unique combination of manual and automated processes and required SAGE Automation to consider issues such as delicate product handling techniques, functional safety requirements, machine guarding, hazardous areas and high operating temperatures of up to 85°C. SAGE invested heavily in the first stage of the program to develop a solution which met the requirements of the project, especially a combination of hazardous areas and high temperatures. Both mechanical and electrical requirements within the manufacturing environment, products and control architecture were researched, locally and off-shore, to source and trial the appropriate equipment to develop a solution.

The aircraft countermeasures require highly energetic materials during construction. If these materials are not handled correctly, they will autoinitiate. As such, the safety critical manufacturing operation requires reliable and repeatable processes which work smoothly not only the first time, but every time.

Additionally, the facility was developed to keep people outside of the danger blast area – thus requiring full automation of systems. In addition, all the machinery and systems employed by SAGE had to meet exceptionally high standards of safety operation.

SAGE Automation was responsible for the development and integration of 13 different assembly stations. The first six stations were required to be unmanned due to the volatile nature of the product ingredients and therefore completely automated. The process undertaken within these stations is monitored from a central control room, with vision being provided via 100 CCTV cameras.

While featuring significant levels of mechanical assistance, the remaining seven stations included some elements of manual assembly or production. As

WINNER: David Delany (R), Managing Director, ifm efector congratulates winner Paul Johnson of SAGE Automation. part of the development process, the overall facility was integrated seamlessly under a common SCADA system. SAGE Automation rolled out Profibus at the device level and a combination of intrinsically safe Profibus in hazardous areas and standard Profibus in safe areas. Safety communications are managed with Profibus as well as Profinet Ethernet communications, while peer to peer communications between PLCs also have safety communications over Profinet.

Communication to VSDs are over Profibus.

Besides producing countermeasures for the Australian Defence Force, the Lara facility has the ability to produce countermeasures for the US and British defence forces. Since the facility would be required to undertake work within the international defence sector, it has to be compliant with strict compliance standards and ITAR (International Traffic in Arms Regulations) requirements.

Being able to demonstrate compliance with defence department standards and having the processes in place to protect defence intellectual property is essential in winning defence contracts.

Due to the complexity of the process and the need to import technology components from the UK, the project was delivered as a staged implementation, with

the back end of the facility put into operation prior to the front end.

To ensure smooth and timely delivery, SAGE Automation undertook and followed a detailed implementation schedule. The project was delivered over two years, with the majority of the work completed in the first 12 months. SAGE met all schedule requirements set by Chemring Australia.

According to Chemring Australia, working with SAGE Automation proved to be an effective partnership, especially given the complexities and difficulties of the project, with its many potential challenges. Being the first installation of its kind in the southern hemisphere, the facility’s outcomes are benchmarked against operations from around the globe. All production benchmarks are being met or exceeded. The product throughput is exceeding levels set and the reject rate is low.

SAGE Automation met the quality and safety requirements as well as the development of a Hazardous Areas dossier for the facility, consisting of over 750 hazardous rated devices within both Gas and Dust Hazardous Areas. The facility is now fully operational having produced in excess of 50,000 countermeasures for the RAAF. JULY 2013 www.pacetoday.com.au 23

PA0713_000_BUR

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Served up on a plate

AirLINE Quick: High quality, cost effective, fast delivery Meet AirLINE Quick. AirLINE Quick has internalised all pneumatic air channels, and integrated primary and secondary components to deliver one single complete pneumatic (or electro-pneumatic) valve bank on a stainless steel adapter plate. Unlimited modularity in valves, functions, feedbacks, I/O, and accessories, is offered, with local assembly from Bürkert’s ISO 9001 Sydney Systemhaus. The stainless steel plate mounts directly into a cabinet, effectively minimising labour for cost effectiveness and fast delivery.

Same day turn-around (on lower-quantity orders) is common.

Last year Bürkert shipped around 600 panels, and this year with AirLINE Quick it could easily be thousands. Call us, and get your valve banks served up on a plate, or mounted in a cabinet, ready to go.

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18/06/2013 11:59:58 AM

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PACE ZENITH AWARDS 2013 WINNERS

Water & Wastewater WINNER

Sinclair Knight Merz Critical Portfolio Work Program Goodna STP Upgrade Stage 4A In order to rehabilitate and protect the Brisbane River catchment, Queensland Urban Utilities (QUU) saw that the Goodna Sewage Treatment Plant (STP) required a significant upgrade to meet not only the identified future demand for wastewater services of the region, but also to meet stringent effluent release license limits which will come into effect in 2013.

The Goodna facility required leading edge automation to enable and monitor the required outcomes. Sinclair Knight Merz (SKM) was engaged to provide multidisciplinary engineering design services, including process, mechanical, civil, electrical, instrumentation and control for this upgrade of the Goodna STP. To achieve the outcomes of the Goodna STP upgrade project, SKM identified the need for an integrated solution which would both allow for increased treatment capacity and improved plant performance to meet the imminent implementation of stringent license conditions. The solution would be the implementation of a sophisticated monitoring and control system.

To ensure compliance, sewage treatment plants usually design in effluent criteria which is lower than the actual licence limit where adopted. In the case of Goodna STP, this criteria stipulated Total Nitrogen (TN) of 2.5 mg/L and Total Phosphorus (TP) 0.8 mg/L. To achieve such low TN and TP concentrations within the final effluent, the plant utilises a Membrane Bioreactor (MBR) configuration consisting of final stage membrane ultra-filtration within a 5 Stage Bardenpho process, with Enhanced Biological Phosphorus Removal (EBPR).

The incorporation of a bioreactor configuration with EBPR is not only beneficial to achieving the low TP concentrations required within the final effluent, but also reduces the amount of supplementary phosphorus removal chemicals required during the lifetime of the STP. Similarly the incorporation of membrane ultra-filtration improves the quality of the released permeate by limiting the carryover of phosphorus containing biomass into the permeate stream, assisting in achieving the low TP effluent concentrations required. This complex process required significant automation, including monitoring to ensure the treated effluent meets the requirements.

A key innovative feature of the STP is the increased water depth of the bioreactor. The increased bioreactor depth allows improved nutrient performance via the buffering of influent hydraulic and nutrient loads, which is performed by varying the effluent production rate of the MBR system, ultimately varying the height of liquid within the bioreactor. This allows for greater retention time within the bioreactor which enhances biological treatment

WINNER: Dean Bryant (R) NSW Sales Manager at Burkert Fluid Control Systems congratulates winners Damian Sharland of SKM and Peter Bailey (L) of Queensland Urban Utilities. performance. Although the main benefit of the increased bioreactor depth is improved biological nutrient removal performance, this functionality also provides potential power consumption efficiencies by allowing hydraulic loads to be buffered during peak power consumption periods, and allowing increased permeate production by the MBR system during off-peak periods.

Utilisation of the flow balancing available within the bioreactor of the STP minimises power consumption in addition to assisting with the plant meeting compliance during peak loading at final design loading conditions.

Another significant challenge for the design of the Goodna STP was the constrained land availability and the existing operating STP on the site, which contained a large amount of infrastructure. This resulted in the need for a very compact site layout for the upgraded plant, with existing structures used heavily during the upgrade.

The existing Stage 3 Modified Ludzak-Ettinger MLE configuration bioreactor was converted into a MLE configuration aerobic digester to provide stabilisation of the biosolids from the upgraded STP, which provides increased dewatering capability of the biosolids and reduces the overall biosolids production from the upgraded STP. The existing dewatering facility, incorporating Gravity Drainage Decks, Belt Filter Presses and polymer batching units was also retained to minimise the amount of redundant infrastructure onsite.

The existing final clarifier from the Stage 3 system was also retained and refurbished to provide emergency clarification during mixed liquor bypass from the MBR system. This continuation of operation requirement, whilst modifying the existing works, required extensive planning

regarding the automation cut-overs.

A number of energy efficiency measures were included in the design, including utilisation of load/unload control regimes for the bioreactor and MBR blowers systems, on/off control regimes for the digester blowers, digester mixers and bioreactor mixers, and high efficiency aeration diffusers within the bioreactor.

The Goodna STP incorporates real time monitoring and control of processes throughout the STP, specifically via the inclusion of analysers in all process streams to assess the real time performance of nutrients such as ammonia, nitrate and orthophosphate, with all monitoring conducted via a completely new SCADA system for the STP. This increased monitoring and process control, monitors nutrient reduction performance as expected, however in addition it also suggests automatic control actions to assist operators with maintaining nutrient performance within the desired range or alternately to reduce chemical consumption during periods of low influent load or excellent performance.

This is conducted through the implementation of optimised chemical dosing or aeration control, which is achieved through feedback from the associated analysers, such as alum trimming based on permeate orthophosphate concentrations, methanol trimming based on nitrate concentration and aeration trimming based on ammonia concentrations within the bioreactor.

Performance of the Goodna STP during the final commissioning and proving operations has been exceptional with median nutrient concentration in the effluent of 1.9 mg/L and 0.8 mg/L for TN and TP respectively.

JULY 2013 www.pacetoday.com.au 25

PA0513_000_DAA.pdf

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AEST

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PACE ZENITH AWARDS 2013 WINNERS

Machine Builder WINNER

Transmin Rocklogic Transmin developed the Rocklogic rock breaker control and automation system, eliminating safety risks associated with critical mining operations. It greatly increases the efficiency of rock breaking operations by minimising downtime, increasing throughput and annual revenue.

Transmin Rocklogic is an intelligent automation system for large hydraulic booms, targeted towards rock breakers. These machines have a typical reach of over 10 meters, and break oversize rocks with a large hydraulic hammer.

Rock breaking is an operation that resumes the flow of ore to the processing plant caused by oversize material that has formed a critical blockage that interrupts crushing operations. Often the rock breaker operates in a confined environment, often underground and near to blast-zones or hazardous dumping and crushing operations.

This means staff are required to operate the machines in dirty, dusty and dangerous conditions. Operating a rock breaker on site exposes staff and operators to a large number of risks including: machinery and vehicle risks (including on-site travel), working in confined spaces, working at heights, fly-rock, heat, hazardous atmosphere, ground disturbances, noisy areas, and many more. Many of these risks are highly likely to occur with major or catastrophic consequences.

The hazards associated with the mining operations, as well as the isolation of WA mine sites, have driven industry demand for increased safety, efficiency, and intelligent automation. The automated system is now being supplied to many of Australia’s major mining companies for both underground and open pit environments.

The system senses its position to avoid collisions, and communicates with nearby vehicles, providing information and control to a remote user. Rocklogic allows staff to operate the rock breaker from the comfort of an office environment, and removes the operator from the hazards associated with on-site rock breaking activities.

Rocklogic’s system includes cutting-edge collision avoidance and automated guidance technology to provide automatic parking and deploy operations.

A priority for Transmin was to eliminate inefficiencies and interruptions caused by complex processes, by comprehensively integrating the solution with existing automation control systems, simplifying interactions between its Rocklogic system and other mine-site capabilities.

Rocklogic has been in use 24/7 at a number of

WINNER: Armin Fahnle (L), Director - Operations, Daanet, congratulates the winner Adrian Boeing, Senior Engineer, Transmin. sites ranging from underground mining applications to applications in municipal waste handling. Rocklogic has a number of operational modes. A remote operator can initiate an automated movement with the press of a button to automatically park or deploy the rock breaker.

Alternatively, Rocklogic can operate in a “driveby-wire” mode where all inputs by the user are modified by the system into safe and smooth control commands to the machine. If there is a failure with the site communications network then the system can be operated from a local portable radio control console by selecting one of several fall-back operation modes.

Rocklogic consists of four major components. The remote operator workstation consists of a remote joystick control console and a PC equipped with the rock-breaker user interface, plant control software, and audio/ visual feedback (e.g. CCTV). This is typically located in a control room many kilometres away from the rock breaker.

The Rocklogic panel contains a high-performance ruggedized computer, a programmable safety system and plant control devices.

A rock breaker Input/Output (I/O) panel, located directly on the base of the rock breaker, houses a specialised I/O controller responsible for interfacing with all instruments, sensors and actuators on the rock

breaker. Rock breaker position sensors for accurately determining the extension of the hydraulic cylinders.

A remote operator can issue instructions to the Rocklogic system via the site’s communications backbone. These instructions can be high-level instructions, drive-by-wire instructions, or system functions, such as resetting alarms or turning on the hydraulic power unit. The Rocklogic computer then executes the higher-level control algorithms and issues lower-level motion commands and receives sensor signals from the I/O controller. The system also receives information from the plant control system and fleet management systems, and presents the information on the integrated systems state back to the operator.

The system is designed such that a novice can use it with only minimal training required. The skill set of the team that developed the technology included software, electrical, electronic, mechanical and mechatronic engineers, as well as draftspersons, project managers, sales, marketing and business development personnel.

This project had a large R&D component, as it required the development of a number of world-first technologies for large hydraulic manipulators including developing a robust and reliable sensing technology, and full 3D active-braking collision avoidance system.

JULY 2013 www.pacetoday.com.au 27

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PA0713_000_BEC

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Universal high-speed Ethernet.

PC- and EtherCAT-based control technology from Beckhoff.

PC-based Control Bus connected directly to Ethernet port software instead of hardware: PLC and Motion Control on one PC

EtherCAT I/Os real-time Ethernet down to every I/O module large selection for all signal types

www.beckhoff.com.au/EtherCAT-System Beckhoff EtherCAT components: fast, ďŹ&#x201A;exible and cost-optimised.

Industrial PC: PCs in various form factors EtherCAT Terminals: IP 20 I/Os for all signal types EtherCAT Box: IP 67 I/Os directly in the ďŹ eld TwinCAT: automation software for multi PLC, NC, CNC TwinSAFE: Safety PLC in a Bus Terminal IPC I/O Motion Automation

EtherCAT Drives highly dynamic Servo Drives integrated, fast control technology

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PACE ZENITH AWARDS 2013 WINNERS

Best Fieldbus Implementation WINNER

BlochTech, WorleyParsons and Profibus Association of Australia Southern Seawater Desalination Plant BlochTech, WorleyParsons and Profibus Association of Australia led the implementation of Fieldbus technology at the Southern Seawater Desalination Plant (SSDP).

The SSDP, located in Binningup is Western Australia’s second seawater desalination plant and is owned by the Water Corporation, the main provider of water, wastewater and drainage services in Western Australia.

Winner of the 2012 Global Water Award for ‘Desalination Plant of the Year’, the SSDP is a seawater reverse osmosis based plant, widely recognised around the world as the technology of choice for the desalination of sea and brackish water.

The second desalination plant built by the Water Corporation, SSDP was designed to be constructed in 2 phases, Stage 1 being commissioned in August 2011.

It delivers water to the Integrated Water Supply System that supplies over 1.7 million people in Perth. Stage 2 was ordered to commence before Stage 1 was even completed and is currently being commissioned.

From past experience, the Water Corporation was aware that a major greenfields water treatment plant would deliver significant benefits from the application of high speed networking technologies. Aside from the installation benefits of reducing the significant amount of point to point cabling employed by analogue technologies, fieldbus application and the deployment of smart devices would deliver enhanced data availability to the plant operator, information that is needed for advanced automation functions such as control, monitoring and supervision.

Water Corporation decided to adopt Fieldbus technology, specifically Profibus PA and Profibus DP for all water treatment and desalination plants.

High availability was a key requirement for the Water Corporation, so redundancy throughout the entire process and mechanical design a priority when evaluating and planning the SSDP’s network design.

Whilst WorleyParsons successfully won the tender to design the Control System, in practice the initial design is usually followed by consultation and design modifications with the System integrators – BlochTech – whose responsibility was to program the design and make it work. In consultation with BlochTech, the Siemens PCS7 control platform was selected. This includes the SIMATIC PDM (Process Device Manager), a cross-vendor tool based on EDD technology and used for configuring, managing and commissioning intelligent field devices.

The greater level of redundancy required by the client highlighted the need for greater segregation and therefore a greater number of controllers.

During the design stage typical questions to

WINNER: Steven Sischy (R), Managing Director, Beckhoff congratulates the winner Trevor Bloch of Blochtech. consider included the number of controllers required to manage individual process areas. Also considered were the location and size of the controllers, whether the controllers selected be big enough and have enough bandwidth to communicate with all the devices, and the number of smart devices which would be required to monitor each process area.

For most desalination plants the major processes required to deliver potable water are: Intake, Pretreatment, RO, Post-treatment and Waste Treatment.

The finalised design stipulated five controllers, located in the Seawater Intake, Microfiltration/Waste, RO Bank A & Auxiliaries, RO Bank B, and finally in Post Treatment.

WorleyParsons and BlochTech then set about addressing the electrical issues, specifically, how best to optimise the performance of each cable run so as to maintain connectivity while not compromising the accuracy of the data gathered.

From past experience with DCS application in the Perth Seawater desalination plant, it was decided that a DCS would be the preferred control system, rather than a PLC/HMI implementation. The large quantity of the I/O meant that the benefits of an integrated development environment would offer significant savings in time.

Performing remote set-up and maintenance of devices over fieldbus was a recognised benefit of Profibus application, perhaps more so on Profibus-PA through the use of either DDL or FDT/DTM interfaces.

Being able to centrally manage deployment of instrumentation saved significant time in the integration and commissioning.

In order to access the full information potential of smart devices, the PCS7 Maintenance Station add-on was used on the control system, which provided a portal from the HMI to access status and configuration data via the PDM application.

Unlike the Perth Desalination plant where one company was appointed ‘most preferred instrumentation supplier’, a decision was made to identify the major instrument categories and choose ‘best in class’, ensuring at the same time, their Profibus interfaces were certified.

Instruments selected included: flow meters from Krohne; pressure devices from Yokogawa; level devices from Vega; temperature from Moore Industries; and water analysis from Hachs, a German company.

Profibus PA segment couplers were also supplied by Moore Industries.

JULY 2013 www.pacetoday.com.au 29

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PACE ZENITH AWARDS 2013 WINNERS

Power and Energy Management WINNER

ICON Technologies Curtin University GEEP Laboratory Data Management System ICON Technologies developed the GEEP Laboratory Data Management System for the Curtin University GEEP (Green Electric Energy Park) Facility, as its core data acquisition and distribution system. The GEEP Facility was recognised as “…a new initiative in power engineering education…” by the IEEE Power and Energy Society at its annual general meeting in 2011. It was officially opened on 26 November 2012.

The energy sector is characterised by a growing number of different energy sources, each with different characteristics, linked together through common infrastructure elements such as inverters, energy storage systems, and grid management. The GEEP Laboratory provides a practical, real-world teaching and research environment that integrates multiple different renewable energy sources with a commercial scale power management and micro-grid infrastructure.

The facility is intended to provide meaningful graduate and postgraduate training covering renewable energy sources and infrastructure, such as to enable a new workforce capable of dealing with the continual evolution of the energy market. The GEEP Laboratory Data Management System is the critical system that integrates the diverse operational and technical functions of the Laboratory. The system needed to provide unrestricted 24/7 access to all real-time and historical data for researchers, and limited but flexible access to real-time and historical data for students. Any researcher or student, sitting at any workstation, needed to be able to access real-time and historical data from any combination of renewable energy sources.

In addition the system needed to provide multiple levels of remote access so that researchers or teaching staff could have full operational access to the system from a remote office or teaching space, while various subsets of data could be made available over the internet to various industry or public interest groups.

ICON Technologies was also faced with also significant technical challenges. The data acquisition system needed to integrate mixed signals from a variety of sources. Selected points within the system provided low-speed and high-speed current/ voltage data, while commercial smart devices within the power management infrastructure fed OPC and web-based data into the system. A commercial site weather station provided serial data, while each energy source present at the laboratory had its own ancillary devices, which output various data.

The data distribution system needed to distribute any user-definable mix of real-time data to any or all access points in the Laboratory or on the network as required,

WINNER: Stephen Coop (L), Managing Director Pacific at Schneider Electric congratulates winner Mark Trotman of ICON Technologies. and to maintain a 24/7 archive of a user definable subset of data. ICON Technologies worked closely with the Curtin University Department of Electrical and Computer Engineering, which was responsible for the power engineering design and physical layout of the Laboratory and the selection of system components. Together, they standardised on the “look and feel” of the application software interface.

The initial implementation of the Laboratory includes seven different energy sources, with three variants of a solar photovoltaic array (single crystal, polycrystalline, and amorphous), two wind turbines (horizontal and vertical), one micro-hydro system, and one fuel cell. All these energy sources are integrated with various battery storage banks, load banks, inverters, a micro-grid, and a site weather station.

ICON Technologies and Curtin University deployed full commercial scale devices wherever feasible to closely replicate real-world conditions. For example, the solar PV arrays, wind turbines and inverters were all standard commercial scale devices. Each energy source is physically connected to a Laboratory teaching station with associated switching to access different elements of the power management infrastructure.

ICON Technologies’ data acquisition and distribution system utilised one Win7 server PC, enough client PCs to provide a minimum of one per teaching station, three National Instruments CompactRIO PAC Controllers to acquire point and waveform current/voltage data at

selected system points, and to handle ancillary IO as required and a MOXA serial interface to integrate the site weather station.

The custom system application software was developed in National Instruments LabVIEW 2011, including LabVIEW for Windows Professional Development System, for PC Server and Client development; LabVIEW RT Module, for CompactRIO embedded software development; LabVIEW FPGA Module, for CompactRIO embedded software development; and LabVIEW DSC Module, for data management. The Curtin University GEEP Laboratory was officially opened in November 2012. It has to date been rigorously tested by a group of postgraduate students and researchers. The first undergraduate students undertaking a teaching laboratory program began in Semester 1, 2013.

The GEEP Laboratory Data Management System handles mixed static and waveform signals at acquisition rates from 1 sample/s to 5,000 samples/s, with serial and network data, in a single seamless system. It also allows all data, regardless of source, to be combined in user-definable groups, and made available to single or multiple client workstations as required. Independent users can simultaneously acquire, view and custom process the same logical data group. Client workstations automatically load the correct data group for the selected workstation interface, and auto-configure the display screens for the data group tags.

JULY 2013 www.pacetoday.com.au 31

PA0513_000_AMS.pdf

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PACE ZENITH AWARDS 2013 WINNERS

Oil & Gas WINNER

Qenos - Altona Olefins Torque monitoring system for steam-turbine powered cracked-gas compressor All turbomachinery is subject to degradation that, over time, will affect the system’s efficiency and operational performance. Precise monitoring of turbomachinery performance with continuous torque-monitoring systems can be used to identify gradual efficiency loss, allowing a more focused maintenance scope to be developed to return the system to its optimum operation and efficiency.

Australia’s sole manufacturer and supplier of polyethylene, Qenos, worked with Emerson Industrial Automation and supplier Rolling Bearings to deploy a torquemeter at its Alton Olefins site in order to diagnose the cause of a power loss in a steam-driven cracked-gas compressor train, and enable further tuning of the seal gas system on the compressor, to reduce turbine load.

The Qenos Altona Chemical Complex is the largest production centre for petrochemicals and plastics in Australia today. Within this complex, the Olefins plant produces ethylene for the company’s downstream plastic plants. It also supplies other manufacturers that use these basic raw materials. It has an ethylene capacity of more than 180,000 tonnes per year. At the Altona Olefins plant, the operating cycle of the steamdriven, cracked-gas compressor train is seven to eight years. However, during this cycle the plant reached its production limitations because the compressor train encountered a power limit.

This power limit was not easy to diagnose. The cause had long been the subject of an engineering debate between the Machinery group, Process Engineering group and Operations department. Some thought it was due to compressor fouling, while others held turbine inefficiency to be the problem. Existing installed instrumentation did not provide the answers needed.

One proposal was to upgrade the turbine from 7.5 MW to 9 MW at a cost of $2 million. However, during one of the system’s eight-year shutdowns, the company installed an Emerson Industrial Automation Powerlign torquemeter coupling. The Kop-Flex Powerlign torquemeter from Emerson Industrial Automation utilises phase displacement technology for long-term reliability, eliminating need for re-calibration.

Traditional torque monitoring based on heat balance, energy balance, and other methods utilises numerous parameters such as pressure, temperature, flow rate, gas composition, which require precise instrumentation to properly measure with low uncertainty.

In contrast, phase displacement technology, like that used in the Powerlign torquemeter, can be used to accurately measure torque directly at the

WINNER: Mike Elliott (R), NSW Sales Manager, AMS Instrumentation & Calibration congratulates winners Trevor Mayne (L) and Mark Ellul of Qenos. coupling to within one percent of full-scale torque, a combination of all electrical and mechanical sources of error. This accuracy provides the lowest amount of uncertainty when computing efficiency, compared to alternative methods.

The installation of the torquemeter involved replacing the existing coupling spacer and flexible halves with a “drop-in” torquemeter and its integral flexible elements.

Two rings with ferromagnetic pickup teeth are installed on a torsionally soft spacer, and intermeshed at a central location. Two monopole sensors 180 degrees apart are mounted on the coupling guard.

The torquemeter assembly was dynamically balanced to API standards so it was not necessary for the user to return any coupling components for the retrofit. The coupling guard was modified so that the two variable-reluctance sensors could be installed, completing the mechanical installation.

As the coupling rotates, the ferromagnetic teeth create an AC voltage waveform in the sensor coil, which is digitally processed using known calibration parameters. Because of the intermeshed pickup teeth, the system is referred to as a single channel phase displacement system, producing two independent torque measurements.

The Powerlign system outputs torque, power,

speed, and temperature, which can be easily integrated with any DCS system. On restarting the plant and having completed a number of compressor efficiency improvements, the torquemeter clearly showed the 7.5 MW turbine did not require an upgrade and that the major power losses were coming from the compressor.

This saved the hassle and cost of a turbine upgrade.

The torquemeter is now being used to monitor steamturbine fouling issues and process-related compressor fouling for timely activation of online washing. Ultimately, data collected on the baseline loading of the drivetrain will help determine if the maximum continuous speed rating of the system can be increased. Data from the torquemeter may allow the system to reach potentials previously unimagined.

The torquemeter also allowed online tuning of the seal gas system of the compressor to establish the lowest power draw from the recycles that the seal system introduces. An additional 200 kW of power was reduced from the turbine load with the manual adjustments made on the seal gas system.

In awarding the win, PACE Zenith Awards judges said that the retrofitting of a torquemeter in a cracked gas compressor train at Qenos Olefins allowed monitoring of compressor efficiency and early corrective action and avoided major capital expenditure.

JULY 2013 www.pacetoday.com.au 33

AD_PACEEMEFEB_13.pdf

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17/01/13,

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PACE ZENITH AWARDS 2013 WINNERS

Lifetime Achievement WINNER

Russell Hughes Integra Systems Russell Hughes is the Engineering Director and cofounder of Integra Systems. Having begun his career in 1957, he has over 35 years of engineering, innovative product development and senior management experience. Russell started as an apprentice at the

Maribyrnong Ordnance Factory. From there, he moved to Caterpillar’s Tractor Factory where engineering design became his specialty.

He later became an engineering and design contractor for companies such as Ericsson, International Harvester, Ford (Geelong and Broadmeadows), Zenford and General Motors Holden. Russell gained a vast range of skills and experience and became the Senior Engineer for Sidchrome. Russell then took on the General Manager role with Rymer Lighting, a Division of Howard Smith Industries, which then became Thorn EMI. During Russell’s 17 year tenure at Rymer Lighting, he was promoted to Managing Director, and Manufacturing & Engineering Director of Howard Smith Industries and led the growth of Rymer Lighting from a $1 million annual turnover to $33 million. In 1993, Russell joined Integra Systems as Joint Director with his son, Paul Hughes to develop his dream of harnessing innovation to develop engineering solutions for Australian industry.

Drawing on his engineering and manufacturing expertise, Russell identified a niche in the Australian market for a linear high speed coil processing line that would rival the steel punching competition by punching steel components at a rate that would ensure components less that 300mm wide were produced economically. As such, between 1993 and 1998, Russell, together with Paul Hughes, invented the world’s first high speed Coil Processing Line. Branded “Punch-IT Coil Processing”, this went on to become Integra’s first production machine.

The Punch-IT linear coil processing line is a five-axis system consisting of an electronic feed system and a series of 4 punching stations suitable for most linear punching applications. Punching at a rate of 120 strokes per minute, coil is consumed and converted to finished parts at a rate of 20 linear metres per minute – at least 6 times faster than a Turret Punch press.

The Punch-IT line was so technologically advanced that the University of Melbourne’s Engineering Professor, Colin Burvill presented a paper on the machine at the International Conference of Engineering Design (ICED). In 1999, a strategic decision was made by Integra Systems to build an in-house Punch-IT line for component manufacture, and became the first production machine and manufacturing foundation.

Integra Systems’ services now span beyond

WINNER: Karl Wigginton (L), General Manager/ Managing Director Australia & New Zealand, Emerson congratulates winner Russell Hughes. the Punch-IT Coil Processing Line, to a complete a manufacturing solution portfolio, but the Punch-IT line is a clear manufacturing differentiator for Integra. Today, Integra Systems is a 100 percent Australian family owned product development and manufacturing company specialising on engineering and designing products and components built from steel and aluminium to ensure maximum price/ cost competitiveness and quality.

Integra achieves this through up-front planning and design, followed by utilising its own manufacturing facility comprising sheet metal machinery and working with a trusted network of suppliers for outsourced services in Australia via its three divisions: Integra Development, Integra Manufacturing and Integra Products.

With 1250 square metres of factory and office space and 13 staff, Integra is based in Broadmeadows Victoria and services a broad range of markets with steel and aluminium product needs. Russell has been a mentor to his son Paul throughout his engineering and business ownership career and supported Paul’s passion for innovation to ensure this continues to be the key differentiator of Integra’s entire business.

Russell has also played a large mentoring role in the wider manufacturing community by supporting customers with their product development ideas, guiding them in manufacturing methodologies and engineering

solutions that are cost effective to produce, and assisting them with taking their products to market.

He has often done this free of charge. Customers have not been the only beneficiaries of Russell’s inventive nature; he has also worked with trusted suppliers over the years by offering new and better ways to produce certain items with their own manufacturing technology.

Russell has also put a lot of time into younger generations by providing business mentoring, engineering mentoring, personal development and support in the development of some important “life skills”. Those who have had Russell play a role in their lives are richer from their relationship with him, whether it be professional, personal or in a team environment.

Russell’s contribution to engineering design and development is highly regarded by the University of Melbourne and he is a member of the University of Melbourne Engineering Design Group. At 72 years of age, Russell continues to strive for excellence in innovation for Integra and its customers and is not showing any signs of slowing down.

In awarding the Lifetime Achievement Award, the PACE Zenith judges stated that “Russell is a wellrespected mentor to the engineering community.

Over the years, he embraced change and used it to drive innovation.”

JULY 2013 www.pacetoday.com.au 35

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PACE ZENITH AWARDS 2013 WINNERS

Overall Project Of The Year WINNER

SAGE Automation Countermeasures Manufacturing Facility Winner of the Automotive and Manufacturing category, SAGE Automation took out the Overall Project of the Year Award.

The judges said “SAGE Automation’s project was a clear winner. It is an excellent example of using control systems to meet the demands of quality-driven, safetycritical manufacturing processes.”

To fulfil a major Australian Defence contract, Chemring appointed SAGE Automation to handle the design, development and installation of a new production facility in the regional Victorian town of Lara.

Constructed in four stages, this is the first automated countermeasure manufacturing plant constructed in the southern hemisphere.

The project was a unique combination of manual and automated processes and required the team to consider issues such as delicate product handling techniques, functional safety requirements, machine guarding, hazardous areas and high operating temperatures of up to 85ºC. It was an especially tough field this year as can be seen from the following list of Winners and Highly Commended for 2013:

WINNER: Garry Mahoney (L), Pacific Director, Honeywell Process Solutions congratulates winner Adrian Fahey of SAGE Automation.

Oil & Gas Winner: Qenos - Altona Olefins for Torque monitoring system for steam-turbine powered cracked-gas compressor

Water & Wastewater Winner: Sinclair Knight Merz for Critical Portfolio Work Program Goodna STP Upgrade Stage 4A

Mining & Minerals Processing Winner: FLSmidth Ludowici for Ludowici Reflux Classifier Highly Commended: Adelaide Control Engineering for PhosEnergy Plant Food & Beverage Winner: Sunshine Sugar for Centrifugal drive system saves energy at Sunshine Sugar mill Best Fieldbus Implementation Winner: BlochTech, Profibus Association of Australia & WorleyParsons for Southern Seawater Desalination Plant Power & Energy Management Winner: ICON Technologies for Curtin University GEEP Laboratory Data Management System

Highly Commended: UGL Engineering for The Nepean Water Filtration Plant Electrical and SCADA Upgrade Automotive & Manufacturing Winner: SAGE Automation for Countermeasures Manufacturing Facility

Young Achiever Winner: Erin McMullen from Unilever Industry Contribution Award Awarded to: Ian Gibson from WorleyParsons, Fluor Australia, IICA Lifetime Achievement Winner: Russell Hughes from Integra Systems

Highly Commended: RPC Technologies for Light Weight (Carbon Fibre) Mine Vent Duct Machine Builder Winner: Transmin for Rocklogic Highly Commended: Machinery Automation & Robotics for MAR Robotic Idler Replacement System Transport, Power & Infrastructure Winner: Braendler Engineering for Aether Asset Inspection Service

WIRED: As part of the development process the overall facility was integrated seamlessly under a common SCADA system.

JULY 2013 www.pacetoday.com.au 37

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CONNECTIONS

5

minutes with...

Ultimately I would be a professional kite surfer.

Martyn Hilbers, Senior Electrical Engineer, Ausenco How did you come to be in this industry?

Before coming to Australia I lived in Holland, did a mid-level polytechnic degree in electrical engineering, followed by a degree in industrial engineering. I worked for a year in elevators as a technician and decided to continue my studies. After I finished my bachelors in computers and communication, I worked as an electrical and control system engineer.

Intermittently, I got on my bicycle and spent about 18 months cycling through Europe, North America, Asia, New Zealand and Australia. We liked Australia so much and decided to emigrate. Once settled in Perth, I got into mining and did several big projects as an electrical and control system engineer.

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

This would have to be the concept of putting carbon fibre sheets that act like sails on modern freight boats. The challenge would

be to operate this type of boat with the minimum number of sailors. Being a control systems engineer I can see this achieved by automation. There is no reason in this day and age why we don’t harness the wind on our freight boats.

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

The biggest opportunity is to incorporate more mainstream computer technology into control systems. A lot of clients still choose hardwired systems over fieldbus systems such as Profibus and DeviceNet. Fieldbus systems have been proven to reduce the capex, engineering efforts and most importantly, are more reliable and easier to maintain. With fieldbuses being replaced by Ethernet, there are opportunities for mainstream developers and entrepreneurs to create low-cost embedded devices for industry.

What’s the greatest challenge in your job?

The greatest challenge is to keep the boss

(my wife) happy by coming home around 5:30. Sometimes work is like reading a good book that you can’t put to the side – you just have to finish it. I find it very rewarding to empower an engineer to efficiently accomplish a task that is outside their comfort zone, by creating a suitable environment, procedure or tool.

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

I would be in R&D, getting together with like-minded engineers to come up with affordable clean energy solutions for transportation and generation.

But ultimately I would be a professional kite surfer. If you have ever strapped yourself to a kite, you’ll understand what I mean.

Besides having some very beautiful and unique beaches, the Safety Bay area in WA is the best kite playground in the world.

[Martyn Hilbers is Senior Electrical Engineer, Minerals & Metals, Ausenco.] martyn.hilbers@ausenco.com

IICA Corner

Planning for the future A message from Jason Freyling – the incoming IICA Federal President.

IT IS with great pleasure that I take up the role as IICA Federal President for the next term.

My thanks to Brett Simpson for his commitment and achievements during his two-year term.

I would also like to sincerely thank Phillip Ring, IICA Federal Treasurer, who for some years now, has undertaken this important duty with complete professionalism and expertise. Phillip has stood down for the next term and we wish him all the best. Frank Schrever, a long time member and supporter of the IICA Federal Council, will take up this role. Welcome Frank.

2013 has been a successful year so far. The IICA is looking positive for 38 www.pacetoday.com.au JULY 2013

the Technology Expo bookings and the events are regaining their popularity.

Overall membership is up from last year and a new CRM is almost ready to go live. It is all pointing towards to an exciting year ahead.

The rollout of the Corporate Industry Program (CIP) Membership has resulted in more corporate involvement with the IICA and an increase in CIP membership. The increase can also be attributed to our Executive Officer, Maruta Rodan’s new task of personally liaising with existing and potential companies at events and Technology Expos throughout Australia.

The support of the Universities and TAFEs for the Don Wilcox Memorial

Awards are also integral to the IICA and our profile at the student level. The IICA needs to explore this area with more vigour to ensure our visibility within these educational arenas.

We held our In-Person Meeting and Annual General Meeting in Melbourne on 24 and 25 May at The Rendezvous Hotel – a heritage jewel of a hotel on Flinders Street. The Minutes from this meeting will be made available to all members via admin@iica.org.au It is important to note from this meeting that the IICA Focus Group Meetings that were held recently in April and May. Twelve meetings were facilitated by John Immelman of BizBrand Solutions, in Sydney,

Adelaide, Melbourne, Brisbane, Gladstone and Perth.

The outcomes of these meetings will be thoroughly analysed by the committee and will then be used to create a Strategic Action Three-to-Five Year Business Plan. Ernst Krauss, Perth Branch Chairman, will chair a Strategic Action Plan Meeting to be held in July in Melbourne.

I look forward to the challenge of the IICA President’s role for this coming term and the exciting year ahead.

[Jason Freyling is President IICA.] Institute of Instrumentation, Control and Automation Australia admin@iica.org.au www.iica.org.au

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