PACE - Process & Control Engineering - July 2015

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JULY 2015 | VOL.68 NO.6

INSIDE PACE

Cyber Security

Building Automation

The age of networking control is here

Making buildings smater

Energy Management Its effect on productivity

2015 ZENITH AWARDS

Post Print Approved PP100008186

Full awards round up

EXCLUSIVE: Process control advances in the oil and gas industry

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CONTENTS

Publisher: Martin Sinclair Email: martin.sinclair@cirrusmedia.com.au Editor: Branko Miletic Tel: (02) 8484 0976 Fax: (02) 8484 0722 Email: branko.miletic@cirrusmedia.com.au

IN THIS ISSUE 30

36

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 Graphic Designer: Louis Santos Email: louis.santos@cirrusmedia.com.au Production Co-ordinator: Tracy Engle Tel: (02) 8484 0707 Fax: (02) 8484 0722 Email: tracy.engle@cirrusmedia.com.au

39 News 6

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The latest news from the world of process control Insight 8

Serial Systems Is serial redundancy important?

Opinion 10

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Security Systems Why it’s now all about network-wide security Awards review 12

Oil & Gas EXCLUSIVE: Process control advances in the oil and gas industry Behind The Scenes 33

Energy Management Best practices for operator effectiveness in energy management Innovation 38

The latest in building innovation Women in Industry Awards 39

The review of the 2015 Zenith PACE awards with interviews, pictures and a full list of winners

All the winners from the 2015 Women in Industry Awards New Products 40

The latest new product releases

ON THE COVER

Good ideas are contagious

JULY 2015 | VOL.68 NO.5

INSIDE PACE

Cyber Security

Building Automation

The age of networking control is here

Making buildings smater

Energy Management Its effect on productivity

2015 ZENITH AWARDS

OFFICIAL MAGAZINE OF:

Post Print Approved PP100008186

Full awards round up

EXCLUSIVE: Process control advances in the oil and gas industry

Average Net Distribution Period ending Sept ’14 5,725

Operations 30

Hosted by PACE magazine - Australia’s foremost process and control publication, the 2015 PACE Zenith Awards are now over and after a great night of talking, eating, sharing and laughing, its time to take stock of what these awards really mean to the industry.

It’s also timely to point out that these awards are the only ones supporting the process and control and automation industries across Australia and New Zealand.

This was evident by the 250-plus guests that came together to celebrate innovation and excellence in Australasia’s vibrant and growing process and control engineering industries.

One of the core objectives of the 2015 PACE Zenith Awards was to provide a platform for innovative teams across Australia to share their work with their peers, which was clearly evident by the companies that won on the night.

The awards ceremony concluded with many of the invited guests commenting to the Cirrus Media staff about how much they enjoyed both the venue and the format of the night.

This bodes well for the 2016 PACE Zenith Awards and lays a solid foundation of ideas for the format of next year’s awards.

(See Page 12) JULY 2015 www.pacetoday.com.au 3

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COMMENT

WHAT’S ON

EDITOR’S MESSAGE

Zenith Awards showcases the best in people skills

IICA Tech Night 22 July 2015 www.iica.org.au/info/events/ event_new.asp?bookingid=872 Practical Process Control Techniques Course 27-29 July, Perth www.apex-opt.com TRARALGON (Vic) Technology Expo Plus Key Note International Presentation - 29 July 2015 events@iica.org.au

Branko Miletic Editor

APCChE 2015 Congress Incorporating Chemeca 2015 27 September – 1 October 2015, Melbourne www.apcche2015.org Practical Process Control Techniques Course – Brisbane 27/8/2015 www.apex-opt.com/training/ courses

Next Issue

For daily updates visit www.pacetoday.com.au

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

SO the Zenith PACE Awards are done and dusted and the winners, I assume by now, have carefully ensconced their awards in secure nooks and crannies at their workplaces.

While those who were winners of their respective categories deserve full bragging rights, I have to say that overall, I was very impressed by all of the finalists - both in terms of quality and also quantity.

That said, while the likes of Sage Automation and HI Fraser should be congratulated on their multiple wins, the fact that so many Australian companies entered with technology and projects that are at the peak of their skills and capabilities is testament that manufacturing and its technological offspring is doing quite well in post-car making Australia.

Not that this loss of car making has been without pain,

but looking at what a number of companies are doing in the areas of advanced manufacturing, control, robotics, automation and process design, it does point to an industrial mini-renaissance of sorts.

What was equally of interest were some of the comments by those ‘in the know’ at the awards night. With the consensus being around food, additive manufacturing and defence as the next ‘go to’ sectors, it does look like the process and control engineering industry will be reaping rewards for some time to come.

Cisco has underlined this by saying that we are looking at 50 billion sensors on a global basis by 2020, with the Internet of Things as the biggest driver of this ‘sensor tsunami’.

However, we can gloat about this tech surge until we are blue in the face, but without those that create, perfect, install and

service all these controllers, sensors, cables, switches, pumps, hydraulics, test and measuring modules, all the world’s best ideas would come to a grinding, if not even screeching halt.

This was underscored by Ross Colvin from Hatch, who not only received the Lifetime Achievement Award for his amazing 38 years of service and his commitment to training, but also reiterated his understanding of what really makes this industry tick. “It’s about training our people,” noted Colvin.

Yes, as Ross said it’s all about people and how they are trained - the technology no matter how cutting edge it may be, will only be as good as the skills of those operating it. branko.miletic@ cirrusmedia.com.au Like us on Facebook and join the conversation facebook.com/PACEtoday

EXPORT

ABB wins $52 million robots order at Ford China ABB has won an order worth $US52 million to boost the flexibility and efficiency of Changan Ford Automobiles new production facility in Harbin, China. The robots will be used to make Ford’s new Focus and Mondeo models.

ABB said it will provide robots including the IRB 6700 and IRB 7600 for Changan Ford’s new highlyautomated “Body in White” welding production line. Included in the order is ABB’s GateFramer car body framing positioning system, capable of producing up to six vehicle models on the same line, with just 18 seconds needed to switch to a different model.

ABB robots at the new Changan Ford plant will bolster the carmaker’s flexible manufacturing allowing it to respond swiftly to changing consumer sentiment and demand while simultaneously reducing investment costs compared to traditional production lines.

ABB has worked with Changan Ford

since 2007, with ABB robots producing the joint venture’s Ford Mondeos at manufacturing plants in Chongqing.’

“Changan Ford and ABB have a longstanding relationship, and we are pleased to see ABB’s solid reputation for providing outstanding and reliable technology and excellent project management capabilities gain customer recognition once again,” said Pekka Tiitinen, president of ABB’s Discrete Automation and Motion division.

“Improving industrial productivity is one of the major drivers of ABB’s business growth under the ‘Next Level’ strategy. ABB’s flexible, intelligent manufacturing technologies help customers effectively reduce their investment costs and enhance their productivity and respond to the market needs in a timely fashion.”

The IRB 6700 robot family, a new generation of large industrial robots, was introduced to the market

in 2013. More robust and 15% more energy efficient than its predecessor, its maintenance has been simplified, making it the highest performing robot for the lowest total cost of ownership in the 150-300 kg class.

ABB said it also will also provide

Changan Ford with comprehensive and advanced Body-in-White solutions, including a flexible car body conveying system and laser welding system, as well as the robotic Roller Hemming system, which is used for the production of the vehicles’ four doors and roof.

JULY 2015 www.pacetoday.com.au 5

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NEWS ANALYSIS

NEWS

Siemens opens new South Australian facility SOUTH Australian Treasurer Tom Koutsantonis officially recently opened Siemens’ new $5 million facility at Tonsley in southern Adelaide.

The state-of-the-art maintenance and repair workshop at Australia’s newest technology precinct will initially house 25 employees; however Siemens Australia CEO Jeff Connolly is confident that number could double as the business grows.

“The things that matter to South Australia are the things that matter to Siemens and with the establishment of this facility in Tonsley we are in a unique position to partner with the state on a diverse range of critical industries and projects.”

Designed using a lean manufacturing methodology to make it flexible in terms of production set-up and delivery, Connolly said the new service centre would deliver a 22 per cent faster turnaround, with 65 per cent more throughput while using 14 per cent less floor space.

“The facility will be able to overhaul larger equipment for the oil and gas industries that previously would have been sent offshore. We will now be much closer to our customers and can provide greater responsiveness for critical local industries.”

“Much of the work that will be sent through the service centre will come from outside the state, making this a national centre for technology and engineering. It represents a benchmark facility in Australia, servicing rotating equipment for a variety of industries including oil and gas, wind power, mining and heavy industry.”

“The opening of the service centre coincides with the completion of the acquisition by Siemens of DresserRand. That will ensure a comprehensive

portfolio of equipment and capability for oil and gas, which will address the needs of the local market with world-class products, solutions and services.”

The Treasurer said the investment in Tonsley by the global technology giant demonstrated the growing confidence in the future for South Australia.

“To have this great company firstly invest and secondly be so vocal in its commitment to Tonsley speaks volumes for the vision the State Government has for this site as an incubator for innova-

tion, research and technology.”

“Tonsley offers great potential for innovation and industry collaboration, bringing together complementary businesses with leading academic institutions.”

“Tonsley represents the heart of a new industrial future for South Australia, with a net economic benefit to the state of $492 million.

“It will attract investment to build new capabilities into the South Australian economy, create an environment enabling businesses and educational institutions to collaborate and support innovation and future manufacturing,” Mr Koutsantonis said.

Covering an area of 2300sqm, the facility is fully serviced by overhead gantry cranes and includes an abrasive blasting facility and wash bay.

The main bay of the service centre has two 45 tonne overhead cranes that can be coupled for a maximum of 90 tonne capacity – capable of lifting a fullyladen space shuttle.

A second machining bay is serviced by two 10 tonne cranes. The machining bay includes CNC machining, gearbox overhauls, welding bay, and white metal bearing manufacture.

NEWS

Global RFID growth accelerates by over 21 per cent thanks to China CHINA has 85% of the world’s RFID manufacturing capacity and is a major exporter of tags, according to IDTechEx analyst Dr Xiaoxi He.

Overall, Dr. He’s report found that the total value of the RFID market in China was US$1.7 billion in 2014, covering chips, tags (including cards,

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fobs, labels and all other form factors), readers, software/services and system integration. The analysis was done based on application sectors, value chain position, frequency band (LF, HF, UHF and MWF) and different regions in China, noted Dr. He. This figure is expected to rise to US$4.3 billion by 2025. The current value of global RFID tags is US$430 million in 2014, taking about 25% of the total RFID market. IDTechEx expects that to reach US$952 million in 2025.

As RFID is increasingly being deployed around the world (Dr. He expected that over 8.5 billion tags will be sold globally in 2015 versus 7 billion in 2014), suppliers are in the process of shaving off fractions of a cent from each inlay, particularly for passive UHF, according to Dr. He.

This represents a growth of over 21.4 per cent which is in line with recent forecasts from RFID World Canada which has said that between 2013 and 2018, the global sourcing of RFID tags market will grow at a CAGR of approximately 22.4 per cent.

Furthermore noted the Canadian report, Honeywell International, NXP Semiconductors, Alien Technology and Impinj are listed in the report as key players in the global sourcing of RFID Tags market between the years 2014-2018.

According to IDTechEx’s Dr He, there have also been other new Chinese entrants who led by strong investment (including acquisition) have gained a relatively high market share from nothing in a few years such as Arizon RFID and Shangyang.

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NEWS ANALYSIS

NEWS

Investment in hydraulic components plagued by low oil prices ACCORDING to a recent report by IHS Technology, the global market for industrial hydraulic components, estimated to be worth just over $US7.5 billion in 2014, is undergoing a shakeup as investment in oil and gas exploration continues to fall.

Supply is dominated by a handful of large manufacturers, led by Bosch Rexroth from Germany and Parker Hannifin from the United States; which together accounted for slightly more than 45 per cent of global component revenues in 2013, according to the new report entitled “Industrial & Mobile Hydraulic Components” from information and analytics provider IHS. IHS reports oil and gas to be one of the largest stationary industrial markets for hydraulic equipment.

In 2013, investment levels in this sector were robust, particularly in offshore and sub-sea extraction applications in areas including Brazil, the Middle East, Singapore, and, to a lesser extent, the Gulf of Mexico.

In 2014, investment in the oil and gas sector was moderately high until the latter half of that year when oil prices took a dramatic plunge. The recent drop in oil price and the expectation by IHS for it to remain below $US70 a barrel until at least 2016 will

have a profound impact on investment for hydraulic components in this sector.

The reduction in oil price has forced many large oil companies to scrap or postpone large exploration projects.

For example, Anglo-Dutch scrapped plans for one of the world’s biggest petrochemical plants, a US$6.5 billion project with Qatar Petroleum. UK-based Premier Oil postponed an exploratory $US2 billion project around the Falkland Islands.

Overall, hydraulic components sold in the oil and gas sector ARE forecast to decline 15.5% in 2015 and not begin growing again until 2017.

Although oil exploration has taken a hit, it is not all doom and gloom for hydraulics serving the oil and gas sector. Mid-stream and downstream operations will continue to sustain sales of machinery in this sector.

The Middle East region, one of the largest producers of oil, will continue to invest in operations; and will require repair, maintenance and operations support from machinery manufacturers and component suppliers. Other oil producing regions including the United States and Northern Europe will look to streamline operations and focus on cutting costs in the long run.

In conclusion, investment in hydraulic machinery used in exploration has fallen as oil prices remain low. This is forecast to continue over the mediumterm future, as large oil and gas companies continue to cut costs.

The report went on to say that machinery used in operations in the oil and gas sector will sustain some demand for hydraulic machinery from large installed base, especially in the Middle East.

JULY 2015 www.pacetoday.com.au 7

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SERIAL DEVICES

Redundancy and serial device servers Today, serial devices still play a major role in many applications worldwide to collect or report process data says Brian Roth, Antaira’s Marketing Product Engineer.

N

o matter the industry, from Power/Utility, Water Wastewater Treatment, Oil/Gas or Mining, Transportation, Factory or Process Control Automation, Medical, to Security, many applications are still equipped with legacy serial equipment, such as PLCs, sensors, meters, barcode scanners, display signs, security access controllers, and CNC controllers for processes, that are not yet Ethernet ready for a TCP/IP network.

Today, in these industries, it can be challenging to connect serial devices to an Ethernet network. It benefits the limited transmission distance of serial-based connections and can be extended to essentially any distance with Ethernet. Serial-to-Ethernet can also benefit engineers in many applications to centralise remote management to easily and efficiently access, control, or monitor the status of field serial devices.

Data redundancy solutions

Within power substations, engineers cannot afford data loss from any piece of equipment. Building reliable systems and dual-network architectures for remote data acquisition and access control become mission-critical. There are so many serial-based devices, such as protection relays, controllers, switch gears, and RTUs that require integration with major redundancy systems and networks which can become a challenge

because traditional redundancy systems and networks require costly software development and specialized hardware.

Building a reliable redundancy system with a primary and secondary remote host PC or Server will allow field devices to exchange data simultaneously through a dual-network infrastructure. With this set-up, engineers will have no need to worry about any failures occurring because the primary and secondary hosts will continuously communicate with field devices.

Serial-to-ethernet redundancy Typical Ethernet networks consist of many links between hosts and Ethernet switches, and form a tree topology with hundreds of point-to-point wired connections. Any link failure in the network could bring the entire operation to a critical halt.

A redundant ring network allows a small portion of the network to be kept idle until another part of the network fails, at which point the “redundant” portion is activated to maintain the flow of data. However, building a reliable redundancy system can create other challenges to engineers, due to specific hardware and the costly software development.

Device server overview Device servers represent the segment of product also known as Serial-to-Ethernet

converters, which essentially allow any serial device with a serial port to communicate with an application across an Ethernet IP network.

Types of connections to device servers: • Raw TCP Socket • User Datagram Protocol (UDP) • Serial Tunnelling (a pair connection) • Virtual COM

LAN bridge mode solutions In many manufacturing automation applications, Ethernet-based devices are now being incorporated on the plant floor with a variety of legacy serial-based devices.

By enabling LAN bridge mode, the device server can also allow engineers to apply the second LAN port as a switching port to connect with the Ethernet-based device, instead of buying an additional Ethernet switch for the application.

LAN redundancy mode solutions LAN redundancy mode, allows users to setup a single-ring redundancy network with all device servers. This feature uses a physical link in the network as a backup path, and the built-in software allows devices within the ring network to transmit data to the next connection link in one direction. The data transmission will be routed to the backup path direction if the built-in software does not detect data transmission in an uplink port, eliminating any network downtime concerns.

Rapid spanning tree protocols IEEE 802.1D, Spanning Tree Protocol (STP) was introduced in 1990 to protect networks from broadcast storms caused by unintended loops, and to reduce network crashes caused by failure of a single link in the network. IEEE 802.1w, Rapid Spanning Tree Protocol (RSTP) is an enhanced version of STP released in 1998. Both STP and RSTP detect duplicate paths in the network and then block data from being transmitted across those duplicate paths.

The STP/RSTP protocol is a typical setup for a tree or star topology network and can be used with complicated meshtype networks. The advantage of setting up mesh-type networks is that there is no need to worry about loops.

The STP/RSTP algorithm analyses the network automatically to determine if any loops exist. If loops are discovered, the algorithm determines which links in the loops should be blocked, and the blocked loops are then reserved for use in the event that an active link is broken.

Meanwhile, the STP/RSTP algorithm springs into action by activating one of the redundant links in the network.

However, there is also a drawback to using STP/RSTP within an industrial network; slow recovery time. The STP protocol can take up to 30 seconds for network recovery, and RSTP can take up to 3~5 seconds. Since data transmission from device to device is in a matter of

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SERIAL DEVICES

milliseconds, the slow recovery time of STP or RSTP protocol can run a potential risk of losing data between 3~5 seconds.

ERPS (ethernet ring protection switching) ERPS (Ethernet Ring Protection Switching) was introduced in 2008 by the International Telecommunication Union (ITU). ERPS defines the automatic protection switching (APS) protocol and protection switching mechanisms for ETH layer Ethernet ring topologies. It was defined to protect the point-to-point, point-to-multi-point and multipoint-to multipoint connectivity within a ring network topology.

By enabling the ERPS function, users can connect all serial device servers to a ring topology network. In a ring topology, each ring node is connected to an adjacent ring node participating in the same ring using two independent links (i.e. two ways). Loops can be avoided by guaranteeing that traffic may flow on all but one of the ring links at any given time.

This particular link is called a Ring Protection Link (RPL). A control

message called an R-APS coordinates the activities of switching on/off the RPL. Under normal conditions, this link is blocked by the owner node, which is referred to as the blocking state. In case of a network failure, the RPL owner node will be responsible for unblocking the RPL to allow it to be used for forwarding, hence why it’s called the protection state.

Therefore, the RPL becomes the backup link when a link failure occurs.

Ethernet Ring Protection Switching (ERPS) provides a highly reliable and stable protection within the ring topology, and supports a network recovery time <50ms.

LAN dual subnet mode solutions LAN dual subnet mode can be used to set up a redundant LAN between serial devices connected to the device server and the host computer. The redundant structure involves using the device server’s two LAN ports to set up two independent LANs that connect the device server to the host computer. If any LAN port link

fails, the other LAN link will continue transmitting packets between the serial devices and the host, with the packets passing through the device server. As a result, LAN dual subnet mode performs a zero data loss mechanism to support data redundancy applications.

Multi-host redundancy In a multi-host setup, serial device servers can establish TCP connections to the serial port at the same time, duplicate the serial data, and transmit the data to all hosts at the same time.

Ethernet data is sent on a first-in, first-out basis to the serial port when data comes into the device server from the Ethernet interface.

Dual redundancy system Engineers can setup two remote host PCs or servers with two independent networks to connect to the redundancy serial device server. The remote redundancy system sets one host PC up as a primary host and another PC as a secondary host as a backup system.

When the primary IP fails, the backup

IP will take over by using a switching library. However, this type of setup will only allow the primary host IP to transmit data bi-directionally to the device server, and the secondary IP to receive data from the device server.

Conclusion Although there are a variety of Ethernetbased or USB-based devices in the market, they are more for consumer, commercial, or enterprise type equipment that thrive only in indoor or air conditioned environments.

Most industrial application measurement devices are still being developed by device manufacturers which means serial is still prevalent in today’s automation world and applications require real-time and accurate data exchange between field serial devices and remote control management maintenance system.

[Brian Roth is Antaira’s Marketing Product Engineer] Antaira Technologies www.antaira.com

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OPINION

NETWORK SECURITY

Protecting against cyber-attacks for Industry 4.0 According to IT security provider Damballa, cyber security systems will be rendered obsolete, with the concept of service provider level security set to become the norm.

G

artner estimates that by 2020 the Internet of Things (IoT) will grow to 26 billion units installed, and IoT product and service suppliers will generate incremental revenue exceeding $USD300 billion, mostly in services. In the meantime, the cost of adding IoT capability to consumer products will gradually decrease, and connectivity will become ubiquitous.

The IoT will also have a significant impact on how we, as an industry, approach security. Security approached as an afterthought, or layered preventive controls, will not suffice in the IoT. In order to fully benefit from all the IoT has to offer, companies must consider its security implications and address them early on.

10 www.pacetoday.com.au JULY 2015

What is the IoT and Why Does it Matter?

The business implications of the IoT cannot be overstated. When deployed internally, smart, connected devices will help companies improve operations, build better products and improve service delivery.

Externally, the IoT will be the impetus for innovative products and services. Sensors on consumer products will collect usage data, thereby enabling manufacturers to improve after-sale service as well as future products and services. This same data may be useful for the consumer and therefore increase buyer loyalty and switching costs, further providing a competitive advantage.

Connected products will reshape competition within industries, and also redefine the industries themselves as companies discover that integration with related products improves the functionality of previously standalone products.

Linking up all your cows

The farming industry is a prime example of the IoT’s impact on business.

Manufacturers are equipping farming equipment such as tractors, tillers and combines with sensors that track GPS location, and measure the number of seeds planted, the volume of fertiliser sprayed and the amount of crops harvested.

The data from any one piece of equipment is used to optimise the others within the product system.

Going a step further, this product

system is being integrated with other product systems to create a system of systems of which the farming equipment is just one component.

It might also include a weather data system, a seed optimisation system and an irrigation system, all of which feed into a farm management system.

Thus, the competition within the farming industry is shifting from discrete products to product systems, while the farmers themselves gain a competitive advantage through increasing yield.

A new technology paradigm

A new technology infrastructure is required to participate in the IoT. Companies must build, support and secure a new technology stack that begins with the endpoint – the ‘thing’

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OPINION

The data collected by the endpoint’s sensors are transmitted over a communications network (often the Internet) to the cloud, where the data is managed in a big-data database system, and analysed to optimise product operation and uncover new product insights.

Additional applications that manage the monitoring, control, optimisation and autonomous operation of product functions may also run in the cloud.

External information sources, such as weather, traffic and prices, as well as business systems (ERP, CRM, etc.) may also be integrated at both the endpoint and cloud layers.

Security risks inherent to the IoT

in the Internet of Things.

This hardware may have embedded sensors and processors, as well as embedded software including an operating system, on-board software applications, a user interface and product controls.

As with any technology stack, there are a number of risks inherent to the IoT. Perhaps the most obvious relates to data privacy. The collection of vast amounts of customer and product data sparks concerns regarding its ownership, how the data is used, who has access to it, who is responsible for securing it, what constitutes sensitive data, what constitutes competitive intelligence and more.

Algorithms are used to control endpoints in the IoT. Algorithms are rules that dictate the endpoint’s behaviour based on environmental changes or changes in the product’s condition. For example, an algorithm might dictate that when the temperature reaches 25 degrees Celsius, the air conditioner turns on. Algorithms can be built into the endpoint itself or reside in the product cloud.

Embedded software on endpoint devices also poses a risk. Vulnerabilities can be exploited using malware and

the devices used as bots to execute denial-of-service attacks. Attackers can potentially take over device functionality to, for example, intercept sensitive communications or even cause bodily harm in the case of health devices like pace makers and insulin pumps, or automobiles.

Security measures and challenges

The traditional development approach of quickly releasing a product then adding security after the fact in the form of patches, updates and preventive software, falls apart in the new world of the IoT. Users cannot be expected to download antivirus software for every

across the entire IoT technology stack.

This becomes a significant challenge in light of multiple stakeholders sharing interest in the assets and increasingly interconnected systems.

Service providers play a key role

ISPs and carriers play a key role in the IoT. IoT devices connect to the cloud over the ISP’s network. ISPs must undergo big changes to accommodate for this, beginning with flattening their networks. Today, ISPs have limited visibility to the devices that sit behind Network Address Translation (NAT) home cable modems.

ISPs are removing the NAT and

As with any technology stack, there are a number of risks inherent to the IoT. Perhaps the most obvious relates to data privacy. smart connected device they own. Nor does it make sound business sense to deploy patches and other updates to disposable, lightweight devices.

IoT devices must be built with security and privacy controls baked in. Security efforts don’t get any easier as you move up the technology stack.

The network must be protected against unauthorised access, and the data traversing the network must be properly encrypted to prevent sniffing. The cloud infrastructure and the third-party software running on it must be secured to prevent attackers from gaining access to endpoints through software vulnerabilities or weak configurations.

Finally, user authentication and system access must be properly managed

adopting IPV6 in order to address all these devices and offer services on top. One of the key services that ISP will offer is security. ISPs will want to differentiate by offering a safer, more secure way for the IoT world to operate.

The reality is the IoT will never be 100 per cent secure; the interconnected nature of the IoT makes complete security impossible. Therefore, like security by design, a detect-and-respond mindset must be adopted from the start.

Manufacturers and businesses must assume that the IoT technology stack will be attacked and prepare accordingly.

Damballa apj@damballa.com www.damballa.com

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JULY 2015 www.pacetoday.com.au 11

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2015-07-17T11:02:21+10:00

PACE ZENITH AWARDS 2015 FINALISTS Proudly sponsored by

HI Fraser wins Project of the Year

The winners of the 2015 PACE Zenith Awards: Peter Andrews (left) of H.I. Fraser accepts the Project of the Year Award from Neil Wold of Honeywell.

HI Fraser took out the coveted Project of the Year Award at the 12th annual PACE Zenith Awards at the Four Seasons Hotel in Sydney last month.

It was a great night for the Sydneybased company whose ‘Submarine Escape & Rescue System Support Systems’ also won in two other categories – Machine Builder and Oil & Gas. (See p.18 for a profile of the winning entry).

The Zeniths are the only awards supporting the process control and automation industries in Australia and New Zealand. The awards ceremony saw over 250 guests come together to celebrate innovation and excellence in Australasia’s vibrant and growing process and control engineering industries.

Hosted by Australia’s foremost process control publication PACE magazine, the MCs on the night were The Chaser Boys.

Apart from Project of the Year, there were winners in 11 other categories. All are profiled in this issue.

One of the core objectives of the PACE Zenith Awards is to provide a platform for innovative teams across Australia to share their work with their peers. Good ideas are contagious – our industry and the country can benefit if these are widely disseminated.

12 www.pacetoday.com.au JULY 2015

JUDGES’ COMMENTS

H.I. Fraser has shown its leadership skills in its design, manufacture and delivery of its Submarine Escape Rescue System (SERS) Hyperbaric Suite that provides submariners in all seven integrated diving locks of the hyperbaric chamber with heating and cooling control as well as breathable air.

The solution contains two air transportable containers and is a world-first as it meets and exceeds offshore diving environmental control standards despite the sheer volume of gas, number of people being decompressed and also because the compressor used exceeded a number of safety requirements.

Overall, the companies that won on the night represented the best in Australian manufacturing, as well as exhibiting a strong aptitude for adapting to the current economic climate.

The awards ceremony concluded with many of the guests commenting on how much they enjoyed both the venue and the format of the night, which has provided a good platform of ideas for when next year’s awards are planned.

YOUNG ACHIEVER Aaron Deal, Honeywell Process Solutions TRANSPORT, POWER AND INFRASTRUCTURE SAGE Automation for Roads and Maritime Services - Sydney Harbour Bridge Electronic Lane Change System Upgrade MACHINE BUILDER H.I.Fraser for Submarine Escape & Rescue System Support Systems OIL & GAS H.I.Fraser for Submarine Escape & Rescue System Support Systems MANUFACTURING ANCA for FX Linear Tool Grinder Range FOOD AND BEVERAGE B.-d. Farm Paris Creek for B.-d. Farm Paris Creek Extension & Upgrade BEST FIELDBUS IMPLEMENTATION Sigma NSW for BHP Billiton Mitsubishi Alliance Peak Downs Mine CHPP PLC Upgrade Project MINING AND MINERALS PROCESSING Sigma NSW for BHP Billiton Mitsubishi Alliance Peak Downs Mine CHPP PLC Upgrade POWER AND ENERGY MANAGEMENT Mescada for TIET Project (TPSC Integrated Engineering Tool) PROJECT OF The YEAR H.I.Fraser for Submarine Escape & Rescue System Support SystemsWATER AND WASTEWATER SAGE Automation for City West Water Enterprise SCADA Replacement LIFETIME ACHIEVEMENT Ross Colvin, Hatch

PA0715_000_HON

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2015-07-03T10:12:59+10:00 2562-SmartLine Ad – 235mm x 297mm + 10mm Bleed, 4c Process, 300ppi

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2015-07-17T11:03:26+10:00

PACE ZENITH AWARDS 2015 FINALISTS Proudly sponsored by

Young Achiever WINNER

AARON DEAL Honeywell Process Solutions Aaron Deal graduated from the University of Newcastle with a Bachelor of Engineering (Electrical) in 2012 and joined Honeywell Process Solutions shortly thereafter.

Since Aaron joined Honeywell Process Solutions, he has excelled among his peers and has been instrumental in making BeltAIS a commercially implemented online conveyor belt monitoring system in the Hunter Valley area of NSW. Aaron became responsible for BeltAIS technology in 2013 and developed it from a proof of concept to a viable industrial product with its first commercial installation in 2014 – within one year. As a result of his efforts, the solution is now also being evaluated for use in South Africa, North America and Japan.

Aaron’s first milestone achievement with the BeltAIS system was the enhancement of the user interface.

Thanks to Aaron’s diligent work, the data analysis and reporting functionality of the system has been streamlined which has enabled the addition of a plant operator interface, automated alarming and developed an automated email report system.

Thanks to his amendments, the BeltAIS system is now significantly easier to use so it can now be implemented into the plant with less training and technical operational skill, reducing costs and time whilst still providing immediate notification of operational personnel of a conveyer belt issue.

Aaron recognised that the existing system was not robust enough for heavy industrial installation and operation, so he then sought about developing a solution for this problem. After implementing an RFID tag reader

Aaron Deal (right) of Honeywell accepts the Young Achiever Award from SICK’s David Duncan. system to give position information, Aaron also further enhanced its functionality by integrating a position encoder into BeltAIS that allows the system to provide accurate location information of a defect long the length of the conveyor belt. This opened up a new market for the BeltAIS system with its new ability to be used in heavy industrial settings.

Delving into the source code of BeltAIS Aaron was next able to alter the existing code so that it could be executed faster and installed on less expensive server hardware. This has meant that the system operates more efficiently, but the cost of the hardware can be reduced, bringing down the overall cost of purchase and making it a more attractive proposition for potential purchasers.

Aaron has been heavily involved in BeltAIS installations and demonstrations and is actively pursuing the future development pathways of the technology. In summary, it has been with his unbridled passion for excellence that this product is now available for use in the process and manufacturing industry.

Honeywell Process Solutions www.honeywell.com

14 www.pacetoday.com.au JULY 2015

PA0715_000_SICK

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2015-06-22T15:35:19+10:00

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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2015-07-17T11:00:53+10:00

PACE ZENITH AWARDS 2015 FINALISTS Proudly sponsored by

Transport, Power and Infrastructure WINNER

SAGE AUTOMATION Roads and Maritime Services - Sydney Harbour Bridge electronic lane change system upgrade The iconic Sydney Harbour Bridge, one of the world’s most recognisable pieces of road infrastructure, carries eight traffic lanes and sees more than 160,000 vehicle movements per day.

The bridge is managed by NSW Government agency Roads and Maritime Services (RMS) who identified the existing control system for the lane usage signs and traffic diversion devices required a critical upgrade to meet future needs and serviceability. SAGE Automation was engaged to assist.

The bridge consists of eight lanes of traffic. Of the eight, six are reversible and controlled by an electronic lane change system (ELCS). The ELCS forms an important safety aspect to reduce the risk of head on crashes on the bridge as the road way does not allow for barrier installation.

The system control centre, 8km away, is where operators use a network of CCTV cameras to make over 100 traffic movements every morning and afternoon and optimise the traffic tidal flow through switching Lane Usage Signs and Movable Mediums.

The original ELCS, installed in the 1980s, was nearing the end of support and showing signs of diminishing reliability along with limited serviceability due to lack of spares, knowledge and documentation. A new ELCS was required to meet a User Requirements Specification developed by RMS. SAGE was engaged to deliver a turnkey solution, including: • Manufacture 27 marine grade control cabinets with redundant processors and IO cards • SCADA system design integration, with 10 user licences, and redundant servers • Oracle server historian • PLC programming/networking • Integration of existing and new CCTV platforms • Factory/Site Acceptance Testing • Documentation/user manuals • Training R MS operators with certified SCADA and PLC courses • A training simulator • Ongoing support Fastidious project management resulted in a technically complex project being delivered over 15 months with a very successful outcome. Project controls included a quality management system for audit trails, a 16 www.pacetoday.com.au JULY 2015

Adam Kiryk (left) of SAGE, Rohan Hungerford, Director of Sales & Marketing, Phoenix Contact (centre) and Bruce Humble of SAGE. JUDGES’ COMMENTS

Any Sydneysider who regularly uses the Harbour Bridge would appreciate the result of this successful project. Driven by the need for reliability and safety, the nominee deserves congratulations for delivering a well-tested system that will serve the city’s traffic needs well into the future. team collaboration and document repository site, weekly project schedule meetings, reviews of existing legacy drawings and detailed commissioning plans.

A collaborative project model, saw SAGE engineering embedded with the RMS project team and enabled a cross pollination of knowledge best-of-breed solution.

The ELCS design was driven by reliability and safety.

To implement the WinCC OA system without disruption to the public, SAGE designed a ‘rollback’ quick change system that interfaced to the various lane usage signs and movable median strips that controlled the SHB traffic flow.

This required developing special interface boards that were both safe (IP20) and practical, allowing both the old ELCS (240VAC) IO system and new ELCS (24VDC) ELV IO system to co-exist without posing any operational issues. Development of these boards required a research and development phase and sourcing of a supplier who could produce these to meet the required criteria and timeframes.

RMS have complete confidence in the robust WinCC OA system which has dual redundancy of devices to

Of the eight lanes on the Sydney Harbour Bridge, six are reversible and controlled by an electronic lane change system. ensure reliability of the system is maintained.

Since operation of the new system started, Roads and Maritime Services and the Transport Management Centre have been able to carry out essential lane control work faster and more effectively. RMS Project Manager John Bell described the benefits of the new system.

“The new Australian-designed electronic lane control system replaces software first installed in the 1980s and has reduced the time it takes to change north and south bound lane configurations and allowed incidents to be reported faster to the Transport Management Centre.” he explained.

“To meet traffic demand and accommodate future traffic patterns we needed to ensure we were operating with the best technology available. This system was developed specifically for the Sydney Harbour Bridge and is expected to serve road users well into the future.”

SAGE Automation 1300 00 7243 www.sageautomation.com

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2015-06-16T15:02:02+10:00

Nobody manufactures 6 mm safety relays.

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market the most narrow safety relays in the world. At widths of just 6 mm and 12 mm, they provide maximum functional safety through force-guided contacts according to the standard EN 50205. The highly-compact design means space savings of up to 70 %.

This is possible thanks to the newly developed relay technology from Phoenix Contact with switching loads up to 6 A. For additional information call 1300 786 411 or visit phoenixcontact.com.au/mini

PA0715_018

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2015-07-17T12:24:52+10:00

PACE ZENITH AWARDS 2015 FINALISTS Proudly sponsored by

Machine Builder Oil and Gas WINNER

H.I. FRASER H.I. Fraser is a wholly owned Australian engineering and manufacturing SME that focuses on critical gases and fluid systems.

The winning entry in the Zenith Awards’ ‘Machine Builder’ and ‘Oil and Gas’ categories was a solution for the support of the Australian Navy’s Submarine Escape Rescue System (SERS) Hyperbaric Suite.

It contains two air transportable containers that provide the submariners in all seven integrated diving locks of the hyperbaric chambers with environmental control (heating/cooling/humidity control) as well as diving quality breathing air.

According to the company, this is a world first and is novel for two reasons.

Firstly, it meets and exceeds the IMCA offshore diving environmental control standards despite the sheer volume of gas, number of people being decompressed and number of integrated diving locks.

Secondly, it addresses the issue of significantly reducing the footprint for traditional SERS by using a low pressure air compressor solution. The compressor solution exceeds the safety requirements for breathing quality diving air.

The project became an R&D project when two offshore diving manufacturers failed to deliver working systems and/or refused to quote to supply because the Defence contract functional performance specification was deemed to be unachievable.

H.I. Fraser achieved the complete spectrum from design to delivery in 12 months.

The company started off at first principles and designed and manufactured the ECS and LPAC/DB containers that meet the contract requirements. To do this they had to engineer world class solutions. The process of designing the ECS and LPAC/DB utilised state of the art 3D CAD manufacturing techniques.

The best example of the benefits from this was when the custom containers were held up in China due JUDGES’ COMMENTS

H.I. Fraser has demonstrated global leadership in designing ECS and LPAC/DB containers that meet the stringent requirement of defence contracts.

This is a very well designed and implemented project which has been achieved through significant effort and thought. Congratulations to the company for delivering complex certified equipment in such a demanding environment.

18 www.pacetoday.com.au JULY 2015

Peter Andrews (right) of H.I. Fraser receives the Machine Builder Award from B&R Automation’s Naomi Khoo. to two typhoons. Despite the aggressive timeframe, the company did not break schedule as they used the 3D CAD drawings to prefabricate the LP Air, sea water and fire system pipe work. This meant they were able to commence fitting the pipe work very efficiently and without delay once the container shell arrived in Australia.

The culmination of the project was three days of manned dives across all seven chambers. The risks associated with the manned dives cannot be understated. They pressurised the divers on six occasions to 50m (mean seawater) and kept them there for 25 minutes at a time. For each dive the recompression time was 1.5 hours in addition to the bottom time.

Prior to the SERS upgrade project, the SERS hyperbaric chambers did not have any environmental control. In the worst case scenario there would be 72 submariners in lots of 12 persons in each of the seven diving locks.

Considering that each person produces roughly the equivalent heat to a single bar heater, the absence of an environmental control system would certainly have resulted in heat stress fatalities, especially when operating in tropical waters where the external ambient temperature can exceed 35°C. Prior to the SERS upgrade project, the SERS did not have a diving breathing air pressurisation and breathing supply system that demonstrably met

SERS System showing existing dive chambers and the HIF support containers. offshore commercial or naval requirements. The H.I. Fraser solution provides redundancy and exceeds both the Naval and Australian Standard breathing air requirements.

In addition, the LPAC/DB containerised solution reduces the deck footprint required from over 40 offshore bottle packs to 13.

Prior to the SERS upgrade, power was daisychained to the systems with a single point of failure. The LPAC/DB containerised solution now accommodates normal and emergency supply as well as distributing power in a hub and spoke configuration. This removes the single point of failure.

H.I. Fraser 02 9970 7322 www.hifraser.com.au

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2015-07-01T13:55:04+10:00

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PA0715_020

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2015-07-17T10:37:14+10:00

PACE ZENITH AWARDS 2015 FINALISTS Proudly sponsored by

Manufacturing WINNER

ANCA FX Linear tool grinder range The FX range consists of three new machines - the FX3 Linear, FX5 Linear and FX7 Linear.

The entry level range is ideal for tasks from light manufacturing, to regrinding and full production.

Its many new features include a new touchscreen customisable with Windows, handheld pendant for easier set-up, and an easy to access front loader door for slide out pallets.

“The real measure of success I have with ANCA is whether or not we’re selling our products in the field,” co-founder Pat Boland told PACE after winning the award.

“We’re exporting precision grinding machines from Melbourne to Switzerland, to Germany, to Japan, to US, China, Holland, Sweden, Russia – that’s the measure of success, really.”

The company has seen great acceptance in the field of FX at this early stage after releasing the new range late last year. It adds to ANCA’s export success, with 99 per cent of what it makes exported.

ANCA developed its own LinX cylindrical linear motor technology for X and Y-axis movement on the new machines. These provide superior surface tool finish, reduced cycle times and increased productivity.

The company’s strength is producing machines that are versatile, precise and user-friendly.

The easy-to-use software is also a key feature of their machines. Key industries such as aerospace, medical, automotive, tool manufacturers and electronics are supported through a global network of offices and agents.

The FX Linear tool grinder is compact but also has a large working envelope. Every part on the machine, from the two choices of automation – both contained within the canopy, to the new AM5000 control system, has been designed to enhance accuracy and increase productivity.

The range consists of three machines (FX3 Linear, FX5 Linear, FX7 Linear) that grind a variety of tools from blanks (or regrind used tools) such as endmills, ballnose, etc for tool manufacturing companies, or specific industries (such as automotive, or electronic).

The machines take up less factory space than JUDGES’ COMMENTS

This appears to be an excellent and innovative machine. Its design is impressive and the company deserves recognition for its ability to market it internationally in a very competitive environment. It represents a significant step forward in the manufacture of CNC tool grinders.

20 www.pacetoday.com.au JULY 2015

Duncan Thompson (left) of ANCA accepts the award from Chris Vains from Siemens. competitor units, but still have a large working envelope allowing a wide range of tools to be made.

Also saving space is the fact the two choices of automation (including a robot) can be inside the machine Every element of the machine is new - hardware, software and the electrical system. The machine includes new, faster electronic drives and CNC, a new customisable user panel and Graphic User Interface.

Pat McCluskey, the co-founder (with Boland) and team leader, threw out the corporate rule book and developed a more lean and agile way to develop this project to maintain innovation and design speed for the radically new ideas in this project.

McCluskey pulled together a core group to work on the FX Linear machine, while another group developed the LinX cylindrical linear motors required for the machine.

This technology was new to the company. For the first time the company used an agile methodology called ‘Fast Track’, a sub-branch of concurrent engineering which aims to get things happening in parallel. Management reviews were replaced with peer reviews, rapid hypothesis testing was included

and enough time was built into the schedule to experiment with new ideas.

They had working FX Linear prototypes on the floor in 10 months - a process which would normally take over 18 months.

ANCA 03 9751 8200 www.anca.com

PA0715_000_SIE1

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2015-07-06T14:02:01+10:00

TIA Portal – take a look

Don’t you love it when everything just works?

Efficient automation starts with efficient engineering www.siemens.com.au/futureofmanufacturing

Siemens technology can be found at the heart of manufacturing and industrial plants throughout Australia and around the world – including our own factories. At our Amberg factory in Germany where we produce advanced electronics including SIMATIC automation, we have achieved a sevenfold increase in production volume since 1989, in the same-sized production area and with only a small increase in personnel. The defect rate is – believe it or not – at 12 defects per million process steps.

We understand there’s a difference between making things and making things right. That’s why Siemens is redefining manufacturing with new advanced automation technologies such as SIMATIC S7 1500 plus the Totally Integrated Automation (TIA) Portal.

The Totally Integrated Automation Portal S7 1500 is a new generation of controllers in the TIA Portal and marks a milestone in automation. It ensures highest efficiency and maximum usability for medium and high-end applications in machine and system automation.

With the TIA Portal, Siemens provides an engineering framework that makes it possible to implement automation solutions anywhere in the world in all industries. From planning to commissioning, operation, and maintenance all the way to upgrade of existing automation systems, the TIA Portal saves engineering time, costs, and effort. That’s engineering efficiency.

To find out how SIMATIC S7 1500 plus the TIA Portal can help your business, call 137 222 or email us at manufacturing.au@siemens.com

siemens.com.au/futureofmanufacturing

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2015-07-17T10:39:49+10:00

PACE ZENITH AWARDS 2015 FINALISTS Proudly sponsored by

Food and Beverage WINNER

B.-D. FARM PARIS CREEK ENERGY EFFICIENCY PROJECT B.-d. Farm Paris Creek is one of Australia’s finest producers of award winning, certified organic dairy products, including milks, yogurts, Quarks, butter, soft cheeses and hard cheeses.

For years, the company has constantly been increasing production, processes, productivity, and environmental sustainability and at the same time has been decreasing its environmental carbon footprint, the impact on waterways and air-pollution.

On the farms it maintains a sustainable environment, with biodynamic farming methods as the basis for this: no artificial fertilisers are used and no chemical treatment is used on soil, animals or crops.

Not just an advanced manufacturer, B.-d. Farm Paris Creek also employs advanced agricultural techniques in its business.

“I would say in our farming system, biodynamic farming is one of the most advanced farming methods,” Ulli Spranz, the company’s managing director, told PACE after receiving the award. “[And] I would call us an advanced manufacturer because we are using the most modern technology in what we are doing, in producing our dairy products: cheese and milk and yoghurt and butter.

“And we are always looking for the most modern technology to keep the healthiness in the products, to keep them as natural as possible.”

B.-d. Farm Paris Creek is located in Meadows, South Australia, between Adelaide Hills and Fleurieu Peninsula.

The original farm was purchased by Ulli and Helmut Spranz who immigrated from Germany, in 1988. It took in 165 acres and 40 milkers.

Ulli and Helmut have worked for more than 27 years educating consumers, farmers and processors to understand the impact of chemical farming on the land, extensive water usage on farms and the impact of chemically induced waste water from processing to the environment.

They have made improvement after improvement to the site since 1988. The farm was immediately JUDGES’ COMMENTS

This project is a prime example of translating energy efficiency into production gains. The implementation of energy monitoring and production management should be applauded and has resulted in a more environmentally friendly approach and an energy efficient manufacturing plant. This type of leadership in biodynamic sustainable farming should be applied across the dairy industry.

22 www.pacetoday.com.au JULY 2015

Ulli Spranz with Matt Hopkinson from ifm efector. conversed to biodynamic-organic farming principles and set up of liquid composting plant utilising dairy waste/ water.

To them, it was clear that biodynamic farming was the only sustainable way of farming to support preservation of the environment for future generations, they said in their entry. “[Eliminating] fresh/ground water pollution, nurturing the soil with ‘biodynamic preparations’, free of chemical input such as artificial fertilisers, fungicides, pesticides, no drenching, no GMs, no antibiotics, no hormones,” said Spranz.

The business was incorporated in 1995, and a stateof-the-art processing facility built to further increase production for steadily, Coles, Woolworths, interstate and exporting.

A cheese factory was added in 2007 to produce European soft and hard cheeses to balance milk overproduction.

The energy efficiency project started in 2012, with an energy monitoring system installed and energy audit conducted. In the next year a new dairy farm was purchased to further increase milk production The following year a Clean Technology Investment Program Grant was received and a photovoltaic solar system was installed (100kw electricity production).

A 250kw hot water solar system was installed in March 2014, and an energy saving flexi line pasteuriser installed (with optional ESL/homogenizing/pasteurising) in April.

What was involved in successfully making so many significant upgrades?

“Doing research, research, research,” explained Spranz, who said Australian businesses needed to look far and wide when considering the most effective way to invest.

“We travelled overseas. We looked at what other companies are doing. And we then picked the methods that fit us most.

“We have achieved over 30 per cent of energy savings. It was only possible because we looked worldwide for the best systems available for what we are doing. Because in manufacturing you can’t have downtime, so it needs to work every day – that’s very important. And we have done a very, very long research [program] over two years to then decide what we set up.”

At B.-d. Farm, work on a multi-million dollar, fully integrated ESL (extended shelf-life) project has begun.

A filling line for fresh milk production and bottling and new aseptic yogurt filling line will be integrated and connected to the solar system, with plans to double milk production by 2016 with minimal increased impact on fossil fuelled energy usage.

B.-d. Farm Paris Creek 08 8388 3339 www.bdfarmpariscreek.com.au

PA0515_000_IFM

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2015-04-27T11:12:27+10:00

Welcome to the world of

PA0715_024

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2015-07-17T13:08:26+10:00

PACE ZENITH AWARDS 2015 FINALISTS Proudly sponsored by

Best Fieldbus Implementation Mining and Minerals Processing WINNERS

SIGMA NSW BHP Billiton Mitsubishi Alliance PEAK DOWNS MINE CHPP PLC Upgrade Project The project encompassed the entire replacement of the coal handling and preparation plants PLC and SCADA Software and Hardware system from the ROM, processing plant, train loadout facility as well as four additional smaller PLC systems.

The project battery limit was typically the field terminals of the existing automation systems. The project execution was over a three year period. Annual maintenance shutdowns were utilised during this period to progressively cutover individual systems.

The previous system was limited by the following which provided the driver for change: • Diminishing technical expertise and support • Number of PLC systems in place reflected limitation of automation hardware capabilities which in turn increased inter PLC communication and complexity • Inconsistencies existed with respect to the software development across the site • Increased Spare parts costs and availability • Increased Support costs over time • Inefficient control strategies • No sequence control – manually operated Sigma engineered the system to provide the platform to alleviate the limitations of the former systems. It also provided the following: • A system with the capacity to absorb and change as business needs demand • Standardised software across the plant and inline with four other sister plants in the BMA Group • A software standardisation which provides a framework for cost effective future change • Control system installation and commissioning conducted during plants annual shutdown period whilst other mechanical and electrical maintenance work was in progress.

JUDGES’ COMMENTS

Sigma has demonstrated high level project management skills that have exceeded the high expectations of the customer. This has been a well-executed project in difficult conditions. The implementation should result in longer term benefits not only for the operation of the plant but for ongoing maintenance of the deployed systems.

24 www.pacetoday.com.au JULY 2015

Steven Sischy (left) from Beckhoff Automation presents David Martin from Sigma NSW with the Best Fieldbus Implementation Award.

• Use of Good Automated Manufacturing Practice (GAMP4) as a software quality framework • A system design that reduced the Coal Preparation Plant PLC systems from two to down to one system and promoted the distribution of field I/O through the use of two Profibus DP networks over a combination of fibre and copper • Reduced plant startup times as a result of sequencing The project cycle was highlighted by a Zero Harm safety record with no incidents recorded.

This was as a result of working closely with BHP Billiton Mitsubishi Alliance. Sigma developed Site Specific Safety Management Plans and focussed on adherence to Contractor Management procedures of BHP Billiton Mitsubishi Alliance. This included Fatigue Management Plans throughout the installation and commissioning periods to ensure that the installation and commissioning teams were safe at all times.

The project was commissioned with an extensive Installation Scopes of Work and Commissioning Plans where all testing activities were documented and signed off in accordance with the Coal Mines Legislation. The risk assessment prior to each commissioning activity was assessed and reduced by conducting substantial simulated software Factory Acceptance Tests in Sigma’s Sydney office and also on site.

The Peak Downs Mine CHPP PLC Upgrade Project was the fifth BHP Billiton Mitsubishi Alliance plant

completed by Sigma. The business skills fostered in the development of this partnering relationship have been to the benefit of both companies. Sigma is continuing plant related process group upgrades for BHP Billiton Mitsubishi Alliance.

Over the past 14 years Sigma as a small business has developed a culture of acting as a corporate but at the same time being a responsive as small business.

The focus on the use of international standards and Best Practice has led to high customer satisfaction and a relationship which relies on Sigma as a trusted partner.

Sigma NSW 02 8879 2500 sigmansw.com.au

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PACE ZENITH AWARDS 2015 FINALISTS Proudly sponsored by

Power management WINNER

MECSADA TIET Project (TPSC Integrated Engineering Tool) Toshiba Plant Systems & Services Corporation, Japan (TPSC) provides engineering, procurement, construction and commissioning services for thermal and hydro power plants. It operates actively in South East Asia.

With the proposed and executed Phase1 COMOS Project at TPSC, Mescada managed to consolidate, integrate and streamline TPSC’s Engineering Landscape.

With this solution, Siemens is the only company in the world to offer a software solution for the integrated management of plant projects – from engineering and operations to modernisation and dismantling. It ensures that engineers and operators can access all projectrelevant data at all times, across all company levels and in all project phases.

With the so called TIET Project (TPSC Integrated Engineering Tool) TPSC decided to introduce a new engineering solution to replace various tools and integrate other tools, e.g. 3D Authoring SW and Calculation SW, into COMOS. The objective was to establish the software as the basis for worldwide collaboration across the entire lifecycle of the plant.

It offers a seamless flow of information by providing a common database. Because all data is always available and up-to-date, it depicts the actual as-built status of a plant at all times. In this way, it lays the foundation for greater reliability in decision-making and more efficient processes throughout the entire plant.

The portfolio is built as a modular structure. That means all software solutions are integrated with each other and cover all lifecycle phases. They can be individually implemented as required or employed as stand-alone solutions.

The software is based on a uniform database which provides all information in an object-oriented manner. The open software architecture facilitates optimum integration of third-party systems and allows for seamless integration into existing Electronic Data Processing (EDP) landscapes.

JUDGES’ COMMENTS

This project is an elegant solution to the problem that confronts an organisation with distributed engineering facilities and a desire to take advantage of time zone and geographic differences to improve design time and to allow specialist groups to interact. It was a very challenging project which has application across all sectors of the manufacturing industry.

26 www.pacetoday.com.au JULY 2015

Andrew Hawkins (right) of Mescada accepts the Power and Energy Management Award from David Bolt of Delta.

With its unified data platform, the software provides plant design engineers, plant operating personnel, company management, and solution partners a continuous flow of data that meets specific needs across all project phases.

One requirement for effective plant management is optimum networking and coordination of all disciplines and departments involved in the engineering and operation of a plant. The software solution is the basis for the cooperation of worldwide collaboration across the entire lifecycle of a plant.

The concept is based on object orientation.

Components are described holistically and displayed graphically. The graphical and data-related description, which includes all data associated with the component, forms a single unit within the database – the object.

Related data sheets, lists, and other documents are linked to the corresponding objects.

The complete plant information is stored in a central database. As a result, the software allows all disciplines and departments involved in the engineering and operating phases to always access the same data for a given object. Objects can be processed on data sheets as well as in technical drawings.

This means that changes to objects or documents

Mescada managed to successfully consolidate, integrate and streamline TPSC’s engineering landscape. are always available to every user worldwide, whatever the time zone, and that they are up-to-date and consistent. The entire plant, right down to the individual components, can be examined and further developed from a functional and interdisciplinary perspective.

The open system architecture of COMOS can be adapted to exactly meet company-specific requirements. It allows links to third-party systems and can be integrated into existing EDP landscapes.

Mescada 1300 885 064 www.mescada.com.au

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PACE ZENITH AWARDS 2015 FINALISTS

Water and wastewater WINNER

SAGE AUTOMATION City West Water Enterprise SCADA replacement project City West Water (CWW) is responsible for the annual supply of 93 billion litres of drinking water, recycled water and the transfer and treatment of 94 per cent of the sewerage and trade waste throughout Melbourne’s CBD and growing western suburbs.

With major hospitals, sporting precincts and businesses, as well as residents amongst its clients, City West Water has an uncompromising focus on reliability and forward thinking approach to an efficient, sustainable and safe water supply.

Taking the opportunity to innovate through technology, City West Water appointed SAGE Automation to undertake the SCADA Replacement Project with the goals of improving security, reducing ongoing engineering effort and providing the wider business with access to data.

The project encompassed the replacement of a wide-area telemetry-based system as well as a plant control system with a single integrated ClearSCADA system with OSI PI historian. The system was designed in a modular way to allow for new plants to be easily integrated.

The new system took a vendor-neutral approach to field hardware, opening opportunities for City West Water to make use of a variety of PLCs and RTUs. It also enhanced security through support for the SecureDNP protocol for control sites.

The SCADA Enterprise Replacement Project was created with these key objectives: • Addressing security shortcomings in telemetry encryption and authentication • Achieving greater vendor independence and lower total cost of ownership using commercial off the shelf products and open protocols • Providing enhanced control capability • OSI PI historian as a single source of truth for time series data SCOPE SAGE Automation was engaged to integrate a new standardised ClearSCADA platform replacing their legacy SCADA systems. The project included the JUDGES’ COMMENTS

This project is an excellent example of implementing industrial security by implementing telemetry encryption and authentication. The nominee should also be applauded for being tolerant of vendor independence to deliver a lower total cost of ownership using commercial off the shelf products and open protocols. It was a wellplanned project, successfully completed.

28 www.pacetoday.com.au JULY 2015

data and trending information Users can mine and present data by creating their own customised visualisation dashboards and tools, this can be achieved without technical training, using plain English tools - The required process of data sharing with other water authorities is now simpler and more accurate Secure, fault tolerant and highly available platform - The system architecture contains multiple fail-over capabilities with both data source and interface redundancy - PI is able to aggregate data from multiple SCADA system locations Superior controls - CWW are now operating one SCADA system rather than multiple systems - The new systems enables faster trouble shooting and reduces the engineering effort for new site deployment - A set of web-service interfaces have been created to retrieve asset data from City West Water’s asset management system and allow operators to issue service requests directly from ClearSCADA -

PACE Editor Branko Miletic (centre) presents the award to Steve Coward (left) and Paul Marwick of SAGE Automation. design and construction of a secure, highly available and distributed virtualised IT infrastructure platform to host the SCADA system.

A high availability OSI PI historian system was provided to aggregate data from each of the ClearSCADA systems and make it available to the wider business. The scope of work included turnkey solution within tight project time lines; Stakeholder and subcontractor management; IT and SCADA System integration; Telemetry and PLC integration; Factory and Site Acceptance Testing.

The project was undertaken with a strong focus on quality, and made use of the HPQC software package for requirements traceability and test management.

CWW’s SCADA system is mission critical, so the cutover strategy was the key to the project’s success.

SAGE’s strategy was first conceived by the bid team and then challenged throughout the design, build and testing phases. The cutover of the two systems and the sites was seamless with no rollbacks.

The benefits to CWW being realised as a result of the new system are: Liberation of data throughout business - Formerly difficult to access, users now have valuable

Enabler for future development - The new PI system was developed with a scalable architecture, allowing for future growth to several hundred-thousand points - A template-based site generator was created in ClearSCADA to allow for the easy creation of new telemetry sites and platform expansion, enabling fast deployment and lower commissioning costs - The system is easily extendable to include new field instruments and devices, sites, plants, etc.

- CWW now has tools and data which can be analysed to identify opportunities for predictive maintenance, and to help avoid failure.

SAGE Automation 1300 00 7243 www.sageautomation.com

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PACE ZENITH AWARDS 2015 FINALISTS

OPINION

Lifetime Achievement WINNER

ROSS COLVIN FROM HATCH Ross Colvin is Systems and Process Control (S&PC) Office Lead at Hatch, a supplier of engineering, project and construction management services, process and business consulting and operational services to the mining, metallurgical, energy and infrastructure industries.

Ross’ role entails supervising the activities of some 25 engineers and designers in the S&PC Group, located in Brisbane. This includes recruiting, training, career development and assigning resources to local and international projects, site operations support and commissioning roles.

The role requires interaction with other engineering discipline leads under the office engineering manager.

Ross is an electrical engineer with around 38 years’ experience, including 25 years with BHPE/Hatch.

His career started in 1977, when he worked as an engineer for CRA Bougainville Copper in PNG. In 1981 he moved to Brisbane, where worked for CSR’s Coal Division; then from 1983 – 1987 he worked for CSR Delhi Petroleum in Adelaide.

Since then he has clocked up 25 years’ service with BHPE/Hatch.

He has extensive consulting experience in estimating, design, construction and commissioning of electrical, instrument and control systems for projects in the oil and gas, minerals processing, and materials handling industries.

He has held roles including instrument and electrical design team leader on a number of Greenfield and Brownfield projects. He also has diverse experience in the oil, copper, coal, silver/ lead/zinc, nickel, aluminium, sand mining industries and is familiar with both instrument and electrical design.

Ross was the office lead engineer for the S&PC team in Brisbane for around seven years to 2014 where he was responsible for S&PC recruitment, training and staffing of projects and operations support executed from the

Ross Colvin with PACE Editor Branko Miletic.

Brisbane office. Previously he was the lead Electrical and S&PC engineer on the ERA R3D Underground Mine Surface Infrastructure feasibility study.

He completed the Tati Activox Project feasibility for LionOre where his responsibilities included leading the Brisbane control and instrument team work sharing an area of a hydrometallurgical nickel project in Botswana with the South African office.

Previously he was the lead S&PC engineer on the Queensland Nickel

expansion Project in Townsville for BHP/ QNI. In that role he was responsible for the control and instrument design team.

In addition, Ross is currently the IICA Brisbane committee chairman and as such participates on the IICA Federal Council.

He has always held the philosophy that the people on his team can never receive enough industry related training, and has encouraged his people to attend as many IICA and other institutional training courses as possible.

This is a refreshing approach when most of industry is cutting back on training, and it has earned him the respect of his teams.

At the same time, he brings this strong culture of training to the Federal Council, and he is actively involved in implementing a member certification program in the IICA. A quiet achiever, Ross Colvin is an asset to the ACI industry and a worthy winner of the Zenith Lifetime Achievement Award for 2015.

JULY 2015 www.pacetoday.com.au 29

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OPERATIONS

ENERGY MANAGEMENT

Advanced burner management system delivers productivity and safety benefits Design and installation of an effective state-of-the-art burner management system can be critical in ensuring the safety and efficient performance of industrial heating systems writes Hartley Henderson.

T

he recently constructed Northern Oil Refinery (NOR) at Yarwun, near Gladstone, is the only facility in Queensland capable of recycling waste lube oil back into base lube oil, and is the most advanced re-refining plant of its kind in the world.

This joint venture brings together the re-refining expertise of Southern Oil Refining (SOR), based at Wagga Wagga in NSW, with the established waste collection knowledge of JJ Richards & Sons to provide an environmentally sustainable waste oil recycling option for truck fleets, heavy vehicle operators, mines and local governments.

According to SOR’s Refinery & Plans Manager, David Onions, the new NOR facility can re-refine up to 100 million litres of waste lube oil a year, meaning 100 per cent of Queensland’s annual waste lube production can be processed through Gladstone, underwriting a new industry and local jobs.

“This re-refining process is a ‘cradleto-grave’ treatment of oil and the highest form of recycling – keeping lube oil in productive use, lowering carbon emissions and delivering improved oil 30 www.pacetoday.com.au JULY 2015

security through avoided imports,” he told PACE. Apart from ensuring that the new plant operated in an efficient and effective manner, a high design priority was also to ensure safe operation of the facility.

Onions explained that the heat required by the various process stages is provided indirectly to the process via heat transfer utilising a closed loop recirculating hot oil system.

“This thermal oil is itself heated up to 340˚C via heat recovery in a Waste Heat Recovery Unit (WHRU) which recovers up to 3MW of heat to the hot oil from the exhaust of a Thermal Oxidiser (TOX) and a dedicated natural gas fired Thermal Oil Heater (TOH) adding up to an additional 7MW to provide up to 10MW of usable heat energy,” he said.

“The TOX is primarily fired with natural gas but this is supplemented by the supply of flammable process off-gases which are thermally destroyed/oxidised prior to discharge through the WHRU and an exhaust stack.

“Sour process water is also thermally destroyed in this unit and provides a heat sink to the TOX system. The operation of these hot utilities is critical to the

operation of the plant – they need to be running for the process to operate.

“Due to the complex, customised, specialist nature of this installation, Gasco was selected to design, supply and commission the TOH and TOX/ WHRU, as well as the associated infrastructure concurrently within the surrounding and interconnecting plant equipment.”

Principal Combustion Engineer at Gasco, Howard Crawford, pointed out that these gas fired Type B appliances must meet the requirements of AS3814 including that the air/fuel ratio must be controlled within acceptable limits.

“If the air/fuel ratio is lean then the system will be inefficient and use additional gas. On the other hand, if the air/fuel ratio is rich then the combustion will be incomplete resulting in the discharge of unburnt hydrocarbons to the atmosphere,” he said.

“For the TOH the control of the air/fuel ratio is simple and is done with conventional methods but for the TOX it is more complex. This is due to the TOX having multiple fuel sources: fuel gas for the burner, and hydrocarbon content of the waste gases.”

Integrated SIS

In order to ensure the safe operation of the natural gas fired Burner Management System (BMS) of each unit, and to maximise system uptime and efficiency, a decision was made to use Emerson Process Management for both the instrumentation supply as well as the provision of its DeltaV Process Control System (PCS) for the main plant.

In addition, it was decided to implement Emerson’s Safety Instrumented System (SIS) for the safety critical BMS requirements to complement the PCS operational control functions on the DeltaV Distributed Control System (DCS).

Process Safety Specialist at Emerson, Martin Kolos, pointed out that as per the manufacturing standard for Safety Instrumented Systems, DeltaV SIS uses a unique and separate hardware platform which is different to the DeltaV Basic Process Control System in order to reduce the chance of common mode failures.

“However, the software platform is unified or integrated, and therefore the software used for engineering and operations is common, which means that a separate platform doesn’t need to be

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OPERATIONS

learnt and maintained,” he said.

“The DeltaV SIS system helps to further improve process safety by continuously monitoring and diagnosing the ability of the sensors, logic solvers, and final elements to perform on demand as required.”

Gasco’s Howard Crawford explained that the use of the DeltaV system allows for the flow of individual fuel sources to be measured and summed in order to give the overall fuel input.

& Palmer, completed the electrical and instrumentation installation in compliance with statutory requirements.

“In addition, a HAZAOP (Hazard and Operability) study, as well as a separate Safety Integrity Level verification study was conducted under Gasco’s direction in accordance with the requirements of the certifier with specific detailed input from Emerson,” he said.

David advised that since installation of the new system the plant has been

“The combustion air is then set to match the incoming fuel to give an optimum air/fuel ratio. As the composition of the waste streams can change over time, the use of the DeltaV system allows the parameter to be adjusted to maintain the operation of TOX at the most efficient point,” he said.

“In addition to the requirement in AS3814 to control the air/fuel ratio there is a requirement to check it to ensure that it does not fall below a limit where it becomes rich, resulting in incomplete combustion.

“This is achieved with the DeltaV SIS which uses flow rates of the fuel sources and combustion air measured by independent flow transmitters to calculate the actual air/fuel ratio.

If the air/fuel ratio calculated in the DeltaV SIS falls below the set limit it will trip the TOX to a safe state. The DeltaV SIS is also used for the burner ignition sequence and ongoing flame supervision.”

Onions said a Hazardous Area Classification report prepared by Sherpa Consulting was provided in order to ensure that the principal electrical design and installation contractor, Gordyn

operating effectively although minor changes have been required to both the PCS and SIS logic.

“The use of a common, well known and familiar DCS platform allows NOR personnel to easily monitor system performance and troubleshoot any issues. Effective communication with both Gasco and Emerson has enabled changes to be made quickly and in compliance with regulations, and ensure continued safe operation,” he added.

[Hartley Henderson has been a regular contributing writer to PACE for the past eight years, covering industry developments in Victoria and South Australia.

Emerson Process Management 02 9919 1116 www.emersonprocess.com.au Gasco 03 9237 7111 www.gasco.net.au Southern Oil Refining 02 6931 9022 www.sor.com.au

Tiny wires set to provide big energy Wearable electronic devices are a rapidly growing area of consumer electronics; however one of their biggest limitations is the capacity of their tiny batteries to deliver enough power to transmit data.

Now, researchers say they have found a promising new approach to delivering the short but intense bursts of power needed by such small devices.

The key is a new approach to making supercapacitors — devices that can store and release electrical power in such bursts, which are needed for brief transmissions of data from wearable devices such as heart-rate monitors, computers, or smartphones, the researchers say.

They may also be useful for other applications where high power is needed in small volumes, such as autonomous microrobots. The new approach uses yarns, made from nanowires of the element niobium, as the electrodes in tiny supercapacitors (which are essentially pairs of electrically conducting fibers with an insulator between).

The concept is described in a paper in the journal ACS Applied Materials and Interfaces by MIT professor of mechanical engineering Ian W. Hunter, doctoral student Seyed M. Mirvakili, and three others at the University of British Columbia.

Nanotechnology researchers have been working to increase the performance of supercapacitors for the past decade.

Among nanomaterials, carbonbased nanoparticles — such as carbon nanotubes and graphene — have shown promising results, but they suffer from relatively low electrical conductivity, Mirvakili said.

“Imagine you’ve got some kind of wearable health-monitoring system,” Hunter said, “and it needs to broadcast data, for example using Wi-Fi, over a long distance.”

At the moment, the coin-sized batteries used in many small electronic devices have very limited ability to deliver a lot of power at once, which is what such data transmissions need.

“Long-distance Wi-Fi requires

a fair amount of power,” said Hunter, the George N. Hatsopoulos Professor in Thermodynamics in MIT’s Department of Mechanical Engineering, “but it may not be needed for very long.”

Small batteries are generally poorly suited for such power needs, he adds. “We know it’s a problem experienced by a number of companies in the health-monitoring or exercisemonitoring space. So an alternative is to go to a combination of a battery and a capacitor,” Ideally, Hunter said, it would be desirable to have a high volumetric power density (the amount of power stored in a given volume) and high volumetric energy density (the amount of energy in a given volume).

“Nobody’s figured out how to do that,” he said.

However, with the new device, “We have fairly high volumetric power density, medium energy density, and a low cost,” a combination that could be well suited for many applications.

Niobium is a fairly abundant and widely used material, Mirvakili says, so the whole system should be inexpensive and easy to produce.

“The fabrication cost is cheap,” he says. Other groups have made similar supercapacitors using carbon nanotubes or other materials, but the niobium yarns are stronger and 100 times more conductive. Overall, niobium-based supercapacitors can store up to five times as much power in a given volume as carbon nanotube versions.

Niobium also has a very high melting point — nearly 2,500 degrees Celsius — so devices made from these nanowires could potentially be suitable for use in high-temperature applications.

So far, the material has been produced only in lab-scale devices.

The next step, already under way, is to figure out how to design a practical, easily manufactured version, the researchers said.

[This is an abbreviated version of an original article reprinted with permission from IDTechEx.] JULY 2015 www.pacetoday.com.au 31

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Powerful CPU The 50MB of memory and fast scan time is just for starters - this CPU does the work of at least four or five pieces of hardware compared to other controllers.

With its five built-in communications ports, it does the usual CPU stuff like storing and running the program, plus • Plug-and-play USB programming (uses standard A-micro B cable) • Tag database and program documentation storage in CPU (Program pre-loaded on PC not necessary) • Supports five built-in communications ports simultaneously • High-speed Ethernet port for HMI and peer-to-peer or business system networking (no Ethernet communications module needed) • Support for EtherNet/IP devices • Two serial ports for peripheral device interface or controller networking • micro SD data logging right from the CPU

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5 built-in Communications Ports and 3 Protocols including Ethernet/IP! We offer the lowest cost of ownership when it comes to communication.

The Productivity 2000 P2-550 CPU comes standard with 5 built-in communications ports including Ethernet, USB and Serial and support for 3 communications protocols including Ethernet/IP, Modbus TCP and ModbusRTU, Are you getting what you paid for?

The Productivity2000 is a tag name based controller which allows for more freedom and flexibility than fixed-memory controllers.

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BEHIND THE SCENES

Energy management and productivity Improving energy productivity, including energy efficiency, is an increasingly significant factor in boosting the overall productivity of the economy.

I

ntroducing robust energy management systems and ways to identify performance improvements can drive significant cost savings, competitive advantages and mitigate energy price volatility.

According to the ClimateWorks Australia report Australia’s Energy Productivity Potential (2015), energy costs increased by 67 per cent in the decade to 2012, reaching $120 billion in 2011–12.

Companies with an in-depth understanding of their energy use and systems to manage it have demonstrated a range of benefits, such as reduced energy expenditure and maintenance costs, good reputation, and less employee turnover.

A report by the International Energy Agency (IEA), Capturing the Multiple Benefits of Energy Efficiency (2014), includes a chapter on industrial sector impacts. The IEA notes that, while industrial energy efficiency is improving at the global level, large potential remains untapped. By understanding and quantifying these benefits, the business case for energy efficiency is strengthened.

Best practice An integrated approach across systems and processes will improve outcomes.

Best practice includes: • commitment from executives • energy efficiency assessments • integration into existing business systems • company-wide involvement • measurable goals • monitoring and reporting performance Research by ClimateWorks Australia (special report on industry for the Tracking Progress Towards a Low Carbon Economy (2013) series indicates three practices as being most influential on energy savings: • regular analysis of energy data • inclusion of energy efficiency in corporate policies and operational guides • senior management oversight of energy

Companies that implemented these practices achieved 300 per cent more energy savings than those that didn’t.

It’s also important to understand the way the energy market operates and the components of your business’s energy bill, including the tariff you are being charged, your demand profile and the total cost of energy you are using.

See the Energy Efficiency Exchange website for more information on energy management, including news, resources and case studies.

Opportunities Once you understand how you use and pay for energy, you can focus on investigating the best available opportunities for savings. These range from low-cost to major investments.

Consider opportunities across the processes, systems and technologies in your business. Optimise or upgrade equipment and processes, improve waste-heat recovery or collaborate with supply chains. Innovations such as LED lighting, electric vehicles, building design and 3D printing are dramatically reducing energy requirements across sectors.

Look at your approach to energy procurement. With detailed data from your retailer and analysis from your own energy audits on how and when you use energy, you can negotiate the best deal from providers.

Use demand side management strategies to reduce energy costs. Adjust activities to lower peak demand or flatten your load profile to reduce your network costs.

Collect and analyse energy data.

Metering and control technology systems help reduce consumption and identify efficiency opportunities.

Systems optimisation takes management of energy data further by making changes to processes in real-time.

It automatically takes into account a range of complex parameters, such as variable material feed rates, temperature, commodity prices and customer demand.

It’s important to understand how the energy market operates.

Resources and initiatives

There is a range of resources and initiatives that can support your business in looking at its energy use, management strategies and actions.

Energy Efficiency Exchange website – This features detailed information on energy efficiency best-practice across industrial sectors for large energy-using Australian businesses.

EEX includes key resources and case studies from Australia and overseas. It highlights a range of manufacturing sectors, including food and beverage, chemicals and plastics, pulp and paper.

Also covered are technologies relevant to the manufacturing sector, including motors, compressed air, boilers, pumps and fans.

Energy Efficiency Information Grants programme – Administered by the Department of Industry and Science, the Energy Efficiency Information Grants programme assisted industry associations, including in the manufacturing sector, to develop practical energy-efficiency information for small to medium-sized enterprises (SMEs). Organisations which have taken

part include include Australian Food and Grocery Council, Australian Foundry Institute, Plastics and Chemicals Industry Association, and the South Australian Wine Industry Association.

Entrepreneurs’ Infrastructure Programme – The $484.2 million Entrepreneurs’ Infrastructure Programme is the Australian Government’s flagship initiative for business competitiveness and productivity at the firm level.

The programme delivers services to small and medium business through three elements: Business Management, Research Connections and Accelerating Commercialisation.

More in-depth face-to-face assistance is also available from AusIndustry’s national network.

Industry Skills Fund The Industry Skills Fund is a key element in the Australian Government’s Industry Innovation and Competitiveness Agenda. The fund will provide up to 200,000 training places and support services over four years.

EEX eex.gov.au JULY 2015 www.pacetoday.com.au 33

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BEHIND THE SCENES

Helping to put you in Control Smartphone Data Logger TagTemp NFC temperature data logger with 1 year (typical) life. Using the LogChart-NFC an android DSS \RX FDQ FRQ¿JXUH download temp. data to your phone. Measure range between -40 °C to +70 °C. SKU: NOD-060 Price:$85 ea + GST

Digital Pressure Transmitter IP65, digital pressure switch & transmitter. 0 to 10 Bar measurement range. Bright LED display, NPN open collector outputs & 4 to 20 mA output. Accuracy of Âą0.3% F.S. Âźâ&#x20AC;? NPT thread. 12 to 30 VDC powered.

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Pressure Transmitter IP67, 2-wire, pressure transmitter with 4 to 20 mA output. 0 to 10 Bar measurement range.

Accuracy of Âą0.3% F.S. Âźâ&#x20AC;? NPT thread. 9 to 30 VDC powered.

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Programmable Step Pulser The KTD-301 provide signals to control speed, acceleration/decleration rate & direction to a stepper. Simple adjustment of speed & acceleration is via 2 pots & a DIP switch. DIN rail mounted. 8 to 30 VDC powered.

SKU: KTD-301 Price: $99 ea + GST

Current Transducer 35 mm window, current transducer that converts 0 to 100 A AC to loop powered 4 to 20 mA DC output. 24 VDC loop voltage.

SKU: WES-030 Price:$79 ea + GST

Differential Pressure Transmitter IP54, DPS series differential pressure transmitter has a 0 to 1 mBar or 100 Pa input pressure range and loop powered 4 to 20 mA signal output.

10 to 30 VDC loop voltage.

Ideal for air conditioning applications.

SKU: DBS-5501 Price: $199.95 ea + GST

PSU With Battery Charger DIN rail, power supply with battery charger (UPS function). Provides AC fail and low battery alarms. 90 to 264 VAC input, produces 27.6VDC @ 3.5 A output.

SKU: PSM-1172 Price:$99 ea + GST

For OEM/Wholesale prices Contact Ocean Controls Ph: (03) 9782 5882 oceancontrols.com.au Prices are subjected to change without notice

34 www.pacetoday.com.au JULY 2015

Could Australiaâ&#x20AC;&#x2122;s mining slump be bolstered by energy storage?

Is reconfiguring their energy sources the new profit generating option for Australiaâ&#x20AC;&#x2122;s beleaguered mining sector asks Sciobhan Leahy, Marketing Manager, Redflow.

C

urrently, the price of iron ore and coal has plummeted by almost 50% in Australia, due to a shift in demand from China and a global trend of decarbonisation, coupled with accelerated supply. Amid a slump in Chinese share prices last week, metals such as copper and aluminium fell to near six-year lows. Iron ore at one point hit its weakest level for a decade.

To add to the downturn, seven of the most powerful nations have pledged to decarbonise the globe, end fossil fuels and aim to be 70% renewable in the next thirty-five years. Among these nations, China who has signed a landmark agreement to cut its emissions and has sighted a breakdown in energy intensity growth and has shown fast diversification of energy supply away from coal, to renewable sources.

With the heart of the mining industry being ripped out according to Fortescueâ&#x20AC;&#x2122;s CEO Nev Power, cost saving measures alongside reductions in fixed costs such as energy management should be investigated by mining companies to begin future proofing the way in which they operate.

Mines such as DeGrussa Sandfire mine, located 900km north east of Perth have turned solar power into a $AUD40 million project. Solar arrays alongside energy storage can provide a significant cost saving benefit when compared with the infrastructural costs of setting up gas pipping or the use diesel generators including the cost of fuel, especially when mine sites are not grid connected.

Large-scale energy storage can offer a cost effective on-grid, or off-grid solution when coupled with renewable energy. This scenario would see a large scale battery be dropped to a remote mine site and with a plug and play solution be utilised where required. Energy storage enables renewable energy or grid-energy shifting for time-of-day use, for example,

from day to night and combats the intermittency of renewable energy. Energy storage also safeguard from grid blackouts. This can have signification cost saving benefits when looking at operating expense and financial losses from power outages.

The LSB (Large Scale Battery) designed by Brisbane-based Redflow, is a 10 or 20 foot shipping container containing a nominal number of flow batteries, which are manufactured by Flextronics â&#x20AC;&#x201C; the worldâ&#x20AC;&#x2122;s largest end-to-end supply chain solution. The LSB can store up to 660kWh of energy and can be paralleled to form multiple container configurations, when larger energy storage is required. This makes the product very flexible when it comes to specific energy storage requirements.

The flow batteries housed in the container are made for unstable grids or intermittent energy sources, with 100 per cent depth of discharge characteristics, the batteries do not damage from regular power outages unlike traditional battery technology. The other advantage is a LSB has an indefinite shelf life fully discharged and does not need to be trickle charged when stored or deployed.

Making the investment dollars stack up with it comes to energy density, shelf life and battery life.

So while mining is currently in a state of structural decline, Australia will still be a major supplier of coal, iron ore and metals well into the future. The coal market in Australia is not dead yet, with two-thirds of the energy supply coming from our coal market and a political climate showing no sign of a significant change when it comes to renewable energy, Australia will continue to be a major supplier and consumer of coal.

Redflow Australia 07 3376 0008 www.redflow.com

PA0716_000_CON

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1

2015-06-16T15:07:26+10:00

worth a

song & dance!

record-breaking 24V/10A power supply Boasting impressive efficiency and size, the new CPS10 24V/10A Din-Rail power supply by PULS is setting records.

65mm

90mm

60mm

60mm

only 39mm wide

60mm

24V 10A 35% smaller 95% efficiency active PFC IECEx certified

Never seen before, the CPS10 manages a width of just 39mm utilising a sophisticated thermal design but retaining 95% efficiency. High quality construction achieves perfomance from -25째C to +60째C without derating plus 20% extra peak power when required through its power management system.

At just 600g, its weight makes them suitable for any application, handling shock and vibration with ease.

FULL PERFORMANCE, WITHOUT THE BULK.

for more information call 1800 557 705 or email sales@control-logic.com.au

www.control-logic.com.au

industrial. electrical. automation.

PA0715_036

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2015-07-16T14:02:37+10:00

BEHIND THE SCENES

EFFECTIVE ENERGY MANAGEMENT

Ease the profitability squeeze with effective energy management

Reducing energy usage and associated greenhouse gas emission is a widely recognised business requirement for many process manufacturers and delivers tangible business benefits says Peter Caro, Director, Area Sales, Aspen Technology Australia.

L

ess energy consumption is a key factor for commercial profitability and environmental compliance. However, if energy management is a significant objective with clear benefits, why are some manufacturers much better at it than others?

For example, the least efficient refinery may consume as much as twice the energy required by the most efficient refinery to produce the same products (e.g. gasoline, diesel, etc.) from the same feedstock (crude oil).

This discrepancy raises natural questions – ‘why does this happen, what factors differentiate the best from the worst and how can refiners close the gap?’

The answer is that effective energy 36 www.pacetoday.com.au JULY 2015

management is not a one-off project or one area of the business. Energy management needs to be an integral part of managing and operating the plant to achieve optimum levels of energy whilst meeting production goals.

However, many refineries and chemicals companies fail to recognise that energy management needs to be an on-going commercial priority.

The ability to visualise and analyse actual plant performance in real-time is essential to understand energy usage and emissions and take necessary actions. The notion that energy costs are fixed is a myth. They are a variable entity that can eat away profit margins and even affect plant performance.

By adopting a sustained approach to energy efficiency supported by integrated processes and managed by leadingedge process optimisation software, companies have the ability to control and significantly reduce energy expenditures.

Efficient savings made across the enterprise will positively impact plant profitability and, when margins are squeezed, this capability could mean the difference between commercial success and commercial failure.

Understanding where you are today In the process industries, energy is typically the highest operating cost, second only to raw materials.

Most chemical or refining processes experience significant variability in energy efficiency as a result of changes in process conditions, different operating strategies and poor control or visibility over wasteful practices.

When pursuing a comprehensive energy management programme, a basic starting point is to ask – ‘are you doing all you can to drive down energy costs?’

Many companies suffer from a lack of focus with regards to controlling energy usage because other priorities often take precedence.

As a parallel example to illustrate this point, we observe what the process industries have accomplished in Health

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BEHIND THE SCENES

management, companies also need to use every available means to improve energy efficiency and reduce costs. Software technology can make a big contribution in helping companies to design, plan and operate their production facilities in the most energy-efficient way.

At the first step in the life cycle of any production facility, software systems can help the designer to optimise the plant’s design from an energy efficiency perspective.

Many case studies have demonstrated that energy-efficient processes cost no more to build than inefficient ones because an energy-efficient process will require less hot utility (steam, fuel, etc.) and also less cold utility (cooling water, refrigerants or air cooling).

As a result, the utility equipment designed to service the production units, such as process heaters, heat exchangers and steam boilers will be smaller and, therefore, cost less to build and operate.

In this respect, the on going reduced operating cost is just a bonus. Energyefficient companies recognise this and now build energy reviews into each step of their design process.

and Safety over many years. Health and Safety has become the most important discipline in the process industries to safeguard both personnel and the plant.

Standards have risen dramatically over the past few decades and this is now seen as a vital practice that is embedded within the overall running of the operation. Therefore, what actions can process manufacturers take to elevate energy management to the same priority level and bring an energy management focus to everything that is done?

Plant energy management itself can be divided into two key areas: first, the reduction of energy demand and consumption in production processes;

second, the reduction of the supply costs of the energy used to meet the energy demand.

An effective energy management plan must address both sides of this energy equation simultaneously and from the initial planning of the operations to the minute by minute safe operation of the plant.

Energy management must be performed by all key stakeholders and these should, in turn, be given the right tools and procedures for the job in hand.

Software supports effective energy management In much the same way that all personnel need to be involved in energy

Once the plant has been built, planning systems can help define both the optimal energy use and also schedule the utility system’s operation to closely match the requirements of the production units, thereby reducing costly and unnecessary standby operations and ensuring the lowest cost purchase of external utilities.

During plant operations, real-time software systems can both monitor the current plant operation against target, highlighting any deviation and provide timely actionable advice on the optimal changes that could be made and the value of making these changes on userfriendly interfaces, such as DCS screens or web browser.

For energy-intensive process manufacturing sites, such as an oil refinery, petrochemical or chemical plant, investment in software should not be seen as a cost barrier. In fact, companies of all sizes have experienced enormous energy cost reductions by using energy optimisation software solutions.

According to a recent Gartner energy management report, one chemical company stated, “five years ago, it was difficult to make the case with senior executives, even when improvements with good internal rates of return were identified. Today, senior leadership is on board and clearly understands that it needs to fund good energy-efficiency initiatives when they come along.”

Prioritising energy management Energy efficiency is fundamental to achieving a sustainable business and reducing energy cost should be a key performance indicator for all process manufacturers. As global energy demand continues to increase and environmental regulation is tightening, initiatives to optimise energy efficiency are essential.

The difference between those companies who are energy efficient and those who are less so is the commitment to incorporate energy efficiency into everything they do. Consequently, this approach will help differentiate the organisation with best practice and close the gap on the competition.

An effective energy management plan must be tackled holistically and integrated across all aspects of the business. To be truly energy efficient, a clear action plan elevates the importance of energy management, defines the targets and timelines, tasks the workforce to execute the plan efficiently and maintains controls for the operation.

Equipping key stakeholders with leading-edge software delivers long-term benefits to help reduce costs and improve the overall performance of the plant. In today’s dynamic and competitive market, energy management is a key way to ease the squeeze on profit margins. The consequence of ignoring energy costs could be the difference between being commercially robust and profitable and not being in business at all.

Aspen Technology (03) 9869 7149 www.aspentech.com JULY 2015 www.pacetoday.com.au 37

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2015-07-16T14:42:56+10:00

INNOVATION

BUILDING AUTOMATION

Making buildings smarter Honeywell has released new smart building technology that uses visualisation and simple, intuitive interfaces to improve operations and business outcomes. Matt McDonald reports.

A

t first sight, the Command Wall is impressive.

Something like Tom Cruise’s control room setup in Minority Report, but toned down and located in the real world.

A key part of the Honeywell Command and Control Suite, the Command Wall is a 60-plus inch touch screen with interactive maps that can zoom across a whole building or multiple buildings in a large site or even around a country.

What is its purpose?

“To gather all of a facility’s important building management data - video feeds, access control, fire alarms, and so on - in one place,” Graham Graeme Laycock, User Experience Studio Manager for Honeywell told PACE. “This is really quite a change in the way that people are able to see what’s going on across their buildings. It’s really a new way of thinking about smart buildings.”

And it not only provides extra visibility but allows people from higher up in the organisation to see all of their services in one place.

Laycock explained that, whereas businesses have previously fallen into the trap of having all of their systems siloed into different departments, the suite provides them with situational awareness across the whole building.

He said that it allows for teams of people to solve incidents together and to work in a collaborative way.

How does it work?

There are three key components that make up the Command and Control Suite. The first is the abovementioned Command Wall.

The second is Incident Workflow, an electronic incident management solution which is built into the Command and Control Suite. It guides users step by step through scripted responses to security incidents and other emergencies, helping further reduce risk and improving accuracy in mitigating issues.

And the third key features of the suite are the Enterprise Dashboards which extend real-time visualisation by presenting detailed energy data and actionable guidance to help control consumption and boost efficiency.

Overall, the suite is intended to turn complex facility data into recommendations and easy-to-implement changes that help boost business outcomes - lowering costs, minimising risk and reducing downtime.

Asked about what quantifiable benefits the suite can offer, Paul Miekle, Marketing Manager for Honeywell told PACE that it needs to be worked on a case by case basis.

“For some deployments it’s about cost savings, for some deployments it’s about driving increased rent from your tenants. Other examples are purely around risk management,” he explained.

For example, the fast detection and assessment of fire at hospitals can avoid patient evacuations and save lives.

Or the avoidance of something similar at an

airport can result in significant cost savings. It can mean that airline schedules are maintained, retailers are not forced to stop operations and personal and business plans are not affected.

In such cases, Miekle explained, the presence of the Command and Control Suite becomes a marketing tool for property managers. It allows them to show potential tenants “what a great job they’re doing managing their building and their space.”

According to Miekle, in ROI terms the suite is generally suited to larger buildings or complexes. But in cases where the buying decision is more around mitigating risk rather than efficiency, it can be suitable for smaller spaces.

For example, it could be suitable for a diamond merchant, a small process control business manufacturing very important pieces of equipment, or a pharmaceutical site making very high end products with a high level of quality control.

“Not the traditional building management jobs, but those projects that have added risk” or a specific need to demonstrate extra security.

Training Available globally, the suite was primarily developed at Honeywell’s Sydney office.

The company pioneered the use of large scale format screens in its Experion Orion Console which is used for plant control in the industrial sector. From there, said Miekle, the idea to use the large screen format in the smart building space developed.

He added that the Honeywell user experience is about “putting people at the centre”. Therefore, the suite is easy to use.

“It’s very visual, very interactive…The type of experience that a lot of consumers might have come to expect from their smartphones and tablets,” said Laycock.

“Training time is dramatically reduced so [operators] can be using it almost as quickly as they can start using a smartphone and understanding their way around the building and really seeing what they need to attend to straight away.”

Such simplicity suits emergency situations well. It means that first respondents (police, fire fighters, etc.) can call up contacts and see what’s happening straight away. They don’t need to be experts or have prior experience to use the system.

Just like our Tom in Minority Report.

Honeywell Building Solutions www.Honeywell.com

38 www.pacetoday.com.au JULY 2015

PA0715_039

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2015-07-16T14:39:51+10:00

THE WINNERS

AWARDS

Marketing/Communications award Rosalinda Willcox – Marketing Communications Specialist, BOC Limited,

Advocacy of the Year

Suzanne Daubney – Managing Director, Bannister Downs Diary

BDM of the Year

Women making a difference

Social Leader

We wrap-up the second Women in Industry Awards which took place in Sydney.

Nicolette Hinson – General Manager Business Development and Strategy, Elgas Samantha Kerr – SCADA, COMMS & Protection Implementation Engineer, Energex

Employer of the Year Cablex

Mentor of the Year

Christine Cotton – Regional General Manager, Tyco Fire & Security

Rising Star

Kate Francis – Civil Engineer, Hyder Consulting

Excellence in Engineering

Christine Charles – Head of Space Plasma, Power and Propulsion Division, The Australian National University

Excellence in Mining

Maria Joyce – General Manager, MEC Mining

Excellence in Manufacturing Colly Galbiati – Managing Director, Soma Organics

T

he winners of the 2015 Women in Industry Awards were revealed at a gala dinner at the Ivy Ballroom late last month.

More than 200 people gathered in Sydney for the event, in which ladies from the mining, manufacturing, and engineering sectors were recognised for their achievements.

In its second year, the Women in Industry Awards recognises women who are leading change in their chosen field and breaking down barriers in what can often be maledominated industries.

A total of nine awards were up for grabs, and each celebrated the achievements of individuals and companies who are committed to raising the profile of women.

From space engineering experts, to invaluable mentors, and women in charge of multi-billion dollar mines, the awards night singled out women who have created innovations, driven productivity, spearheaded change, and provided social and economic benefits through their fields.

Highlighting the way in which companies are more eager than ever to celebrate their female talent, both nominations and attendees at the awards dinner were double that of last year.

Cirrus Media Industrials editor, Cole Latimer, said the

awards program was important in recognising the contributions being made to the changing face of industry.

“Though female participation has risen across all industrial sectors in Australia, companies are still focusing on more innovative attraction and retention strategies to foster this growing talent and support young women working in the sector,” he said.

“Women already working in the sector make up a big part of these support programs.

“They are paving the way for others and achieving great success, and we think this needs to be recognised in its own right.”

PACE would like to thanks the sponsors of the 2015 Women in Industry Awards – Pacific Merchandising (Platinum Sponsor), MMD Australia, BOC, ABB Group, and TMS Consulting. Without their help, the event would not have been possible.

Congratulations to the winners and thanks to all those who took part.

See you again next year!

JULY 2015 www.pacetoday.com.au 39

PA0715_040

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2015-07-16T14:34:50+10:00

NEW PRODUCTS

Wireless machinery health analyser EMERSON Process Management has enhanced its portable CSI 2140 Machinery Health Analyser with a wireless interface to laser shaft alignment tools. This advance reduces two burdens -- equipment and time -- for operators performing vibration analysis and corrective tasks in the field.

The CSI 2140 offers four-channel plus phase data collection to save time and effort, advanced vibration analysis that embeds expertise in the tool, and multi-plane balancing to correct imbalance in industrial fans. By adding a wireless link to laser fixtures, Emerson further streamlines the work process. Using the CSI 2140, personnel can

perform route-based vibration data collection; analyse the root cause; and align the machine -- all in one trip. At the same time, they can identify and solve machinery faults to prevent any unplanned downtime.

The shaft alignment option for the CSI 2140 uses the familiar, intuitive Emerson interface to guide technicians through a three-step process that quickly achieves precision alignment.

Emerson Process Management 03 9721 0309 www.emersonprocess.com.au

PLC-IO module for industrial use EVT has released the EyeMIO-v2 - a PLC-IO-Module for industrial use that takes on the control of the peripheral devices and therefore is an interface between the image processing system and the production plant.

The EyeMIO-v2 offers four digital in- and outputs, which can be

operated DC-isolated to the electronic.

It has an RS232 and USB interface.

Via the USB Block-Device Interface extremely fast IO requests are possible and this also directly on USB level.

This allows it to operate or read inputs and outputs much faster.

Additionally, the RS232 parameter, such as baud rate, parity and stop bits can be configured individual via USB. Each of the four digital I/Os are also PWM compatible.

In addition, the EyeMIO-v2 can also be configured with the EyeMIO Manager on customer request.

A once configured EyeMIO keeps its data and can be integrated into a production plant, while the revised arrangement of LEDs makes it easier to check errors or the communication.

ITâ&#x20AC;&#x2DC;S A GOOD FEELING TO ALWAYS KNOW WHAT YOU CAN RELY ON.

Sensors. Systems. Network technology.

www.balluff.com 40 www.pacetoday.com.au JULY 2015

Eye Vision Technology (EVT) www.evt-web.com

PA0716_000_PHO2

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2015-06-16T15:03:16+10:00

CLIPSAFE â&#x20AC;&#x201C; Innovative housing concept

Stainless steel junction boxes and empty housings for ex areas Phoenix Contact has many years of experience in developing reliable products for hazardous areas.

The close contact with our customers, knowledge of your requirements and design capabilities and expertise during production are important features of the new CLIPSAFE stainless steel housing series.

A housing concept â&#x20AC;&#x201C; made for realword applications.

For additional information call 1300 786 411 or visit

phoenixcontact.com.au

PA0715_042

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2015-07-17T10:32:19+10:00

NEW PRODUCTS

Harsh environment HMIs THE UniOP eTOP Series 500G HMIs are a suitable choice for all demanding HMI applications including factory, energy and marine applications.

The eTOP510G features a high-brightness, contrast-enhanced ruggedised 10.1” TFT widescreen display with LED backlight. The product has been designed for use in harsh environments and outdoor applications.

Glass bonding assembly and glass surface treatment provide for superior optical performance resulting in a sunlight-readable product.

The durable glass touchscreen requires the human touch, eliminating false activations, and offers high reliability and durability; it will continue to work even when surface is scratched or contaminated.

10.1” TFT colour display, resolution 1280x800 pixel, 64K colours Features include: • LED backlight dimmable to 0% • Projected capacitive touchscreen with true glass design • 2 Ethernet ports with switch function • 2 USB Host ports • SD Card slot • Plug-in modules for system expansion • IO69K Rating

• • • •

IECEX approval (as of Dec.2015) Extended Temperatures -20 to +60 High Brightness Sun-readable screen @ 600 Cd/m2 The eTOP Series 500G HMI panels have been designed to run the JMobile software.

Tecno Platform 0401747403 www.tecnoplatform.com.au

Space-saving motor valves THE new compact valves from Bürkert use two different drive and valve concepts, depending on the orifice size: the first is based on linear drive seat valves for orifices DN2 to DN6 (Type 3270: shut-off valve, Type 3280: proportional valve).

The valves are designed for space-saving and energy-saving operation and offer an alternative to the known solenoid valves in less dynamic applications which do not require response times in the millisecond range.

Di h Diaphragm valves l with integrated pneumatic actuators

The compact valves can be used with combustible gases at pressures from 0 to 3 bar, with neutral gases and liquids up to 6 bar.

Seals of FKM or NBR and a body of Polyphenylene Sulfide and Polycarbonate make them very robust and are designed for an ambient temperature from -10 to 60 °C and fluid temperatures from 0 to 70 °C.

GF Piping Systems has added the diaphragm valve type 604/605 with integrated pneumatic actuator to its product range.

The valve’s compact design fits standard installation lengths. Its integrated pneumatic actuator with quick opening and closing times enables more than one million closing cycles over its service life.

The actuator housing can be opened quickly for service due to the central housing nut. The connection with the valve body is plastic without any metal parts.

Therefore all materials have the same temperature expansion coefficients, which prevents leakages and avoids re-torqueing of screws.

The valves also feature unique QR code on the product leads to installation manuals, online training videos and certifications.

Burkert Flow Control Systems Phone 1300 888 868 www.burkert.com.au/en/

George Fischer Pty Ltd Ph: 02 9502 8000 www.gfps.com

Power supply boxes for mobile and off grid water disinfection OFF-grid and mobile water disinfection is now possible thanks to a unique product recently released

by Australian water disinfection specialists, UV-Guard.

A PLC operated controller packed with integrated features, including the ability to operate on 12V and 24V DC power supplies, now gives UV-Guard’s off-grid and mobile customers the ability to disinfect water via UV treatment.

42 www.pacetoday.com.au JULY 2015

The 12V and 24V DC PLC controller can control UV-Guard’s UV systems up to a power of 40W. This means that recommended UV dose rates can be provided at flows of up to 60lpmby using the SLF, SLT and S-Series of systems. .

UV-Guard 02 9631 4900 www.uvguard.com.au/

PA0715_043

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2015-07-17T13:11:37+10:00

NEW PRODUCTS

Reflecting surface inspection ON reflecting surfaces, restrictions are placed on conventional image processing systems. reflectCONTROL Compact supplied by Bestech Australia is specially developed and tested for these types of surfaces.

Applications such as Smartphone touchscreens, instrumentation and controls in cars are built to the expectation of free from damage. However, the inspection of these parts is often carried out only via visual inspection, which means in many cases the results are unclear and lack of accuracy.

Human disturbance due to tiredness or even the mood of the inspector on a day can lead to fluctuating results.

Reflecting surfaces, in particular, pose challenges to manual and automated surface inspection.

The reflectCONTROL Compact offered from Bestech Australia is specially designed for these types of surfaces inspection that will even automatically log and store results to enable objective comparisons. Important conclusions can then be made for process improvement based on the findings.

The fully integrated system made in

Germany is available in two versions that each provides different measuring fields. The 2D version recognises defects on reflecting surfaces.

Additionally, the 3D version allows the measurement of reflecting surfaces at sub-micrometre accuracies. This device can be used in individual operations (e.g. laboratories) as well as directly in production lines.

The reflectCONTROL Compact reflecting surface inspector can be integrated into production line via the Ethernet interface. A digital I/O interface enables triggering. An external operating monitor can be connected via VGA. Bestech Australia 03 9540 5100 www.bestech.com.au/

Ball valves with tight shutoff FISHER Z500 metal-seated valves from Emerson Process Management are engineered to withstand higher temperatures, pressures, and more erosive e, providing conditions than a standard on/off ball valve, cal assets in increased reliability and protection of critical demanding applications.

A bi-directional sealing design offers a unique off solution to process back pressure and shutoff uarding control requirements in both flow directions safeguarding valves and other equipment in the line. n integral metal seat and selfFisher Z500 valves are designed with an ate leak paths and withstand extreme energized metal body gasket to help eliminate temperature changes.

Live-loaded packing, side-mounted brackets, and fixed centerlines help reduce side loads on the packing and decrease overall wear for a longer service life. This addition of on/off valves to the Fisher portfolio complements the existing control valve offering and helps ensure seamless integration between products.

Emerson Process Management 03 9721 0309 www.emersonprocess.com.au

JULY 2015 www.pacetoday.com.au 43

PA0715_000_GLO

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1

2015-07-03T10:10:01+10:00

NEW

e

NEW

W

NE

NE

0 795.0 $ S U A T. x-GS W

0

W

NE

NE

W ge ss Brid Wirele -Bluetooth net ble kit Ether ing ca d lu c in ge A pair s Brid s e l e ir us W Anyb 0 4 1 23 *

Anybus Wireless Bridge enables you to create a robust, industrialized wireless connection to hard-to-reach locations where cables are not desirable.

Wireless transmission is made via bluetooth or WLAN technology and there are several versions available for both serial and industrial Ethernet communication.

Network cable

*Subject to change without notice

Network cable

www.anybus.com.au