PACE - Process & Control Engineering - June 2014

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JUNE 2014 | VOL.67 NO.5

INSIDE PACE

Cyber Security

Pervasive Sensing

3D Printing

First understand what company information is desirable to attackers

Gather additional data without impacting the operational system

Additive manufacturing can help Australia go from ore to more

Batch manufacturing

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Why good is no longer good enough

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CONTENTS

Publisher: Martin Sinclair Email: martin.sinclair@cirrusmedia.com.au Editor: Kevin Gomez Tel: (02) 8484 0976 Fax: (02) 8484 0722 Email: kevin.gomez@cirrusmedia.com.au 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: Dave Ashley Email: david.ashley@cirrusmedia.com.au Production Co-ordinator: Tracy Engle Tel: (02) 8484 0707 Fax: (02) 8484 0722 Email: tracy.engle@cirrusmedia.com.au

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IN THIS ISSUE Insight 6

Batch manufacturing Upcoming changes as a result of Internet of Things drive change that is transforming business processes Security 8

Deal with cyber attacks Energy & Utility organisations must react to the emergence of cyber criminals who are shifting their focus towards operational technologies Pervasive Sensing 11

A risk managed approach This technology enabler facilitates unconstrained access to process and asset data that was originally dictated by the plant’s physical layout Engineers Corner 14

Reduce TCO of pumping systems The electrical energy bill for the site can be reduced

Average Net Distribution Period ending Mar ’14 5,709

by implementing a series of simple actions

and high precision in less than ideal environments

Awards 18

Spotlight 24

Women in Industry These Awards recognise the achievements of women working within the mining, engineering, manufacturing and process control industries Technology 19

Eddy current sensors This is a robust technology that offers high resolution

7 of the Best A round-up of this month’s new product releases from elbow flow conditioners to compact laser micrometers 3D Printing 26

Additive manufacturing The only thing keeping Australia from being a powerhouse is people

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Challenges of batch manufacturing

MANUFACTURING operations are becoming increasingly complex, even as the need for flexibility, rapid response, and improved time to market continue to grow.

Batch manufacturing Why good is no longer good enough Leading manufacturers and their suppliers are using standards, IT technology, cloud-based solutions, and advanced analytics to improve operations and reduce overall support costs.

Improvements in information technology and the Internet of Things are driving change. This includes increased deployment of production management functions such as recipe management Pa ge 1 5 / 0 2 / 2 0 1 4 , plant 1 0performance : 4 9 : 3 5monitoring A M and evaluation in off-site data centres. and (See page 6) INSIDE PACE

Cyber Security

Pervasive Sensing

3D Printing

First understand what company information is desirable to attackers

Gather additional data without impacting the operational system

Additive manufacturing can help Australia go from ore to more

Post Print Approved PP100008186

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ON THE COVER PA0 6 1 4 _ 0 0 1

JUNE 2014 | VOL.67 NO.5

OFFICIAL MAGAZINE OF:

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The Future of Manufacturing

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JUNE 2014 www.pacetoday.com.au 3

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COMMENT

EDITOR’S MESSAGE

WHAT’S ON

IoT will drive SCADA upgrades

HAZOP Study for Team Leaders and Team Members 17-19 June 2014, Melbourne www.icheme.org/hazopmel Fundamentals of Process Safety 23-27 June 2014, Brisbane www.icheme.org/fpsbris Women in Industry Awards 25 June 2014, Sydney www.womeninindustry.com.au

Kevin Gomez Editor

LOPA training 14-15 July 2014, Sydney www.icheme.org/lopasyd Chemeca 2014 28 Sep-1 Oct 2014, Perth austcourses@icheme.org

Next Issue

• Energy Management • Oil & Gas • Security Systems • PACE Zenith Awards: Winners

For daily updates visit www.pacetoday.com.au

THE rapid growth of IoT (Internet of Things) promises to change the way our industry functions. Machines and processes will become more autonomous delivering greater productivity and efficiency.

There is however a ’but’.

Most operations depend on SCADA systems that are spread throughout plants. But older systems lack scalability and are often not quite ready to handle the large volumes of data now required to be processed.

An upgrade sounds like an obvious solution but plant managers are advised to first go back to the drawing board and start afresh.

We are seeing the need for larger systems, wider use of

automation and higher volumes of data.

Then there is the growth of wireless and the need to manage remote operations.

The advice from industry experts is - don’t just upgrade your SCADA system, rethink it.

This includes staff training and HMI enhancements.

And HMI is becoming key in ensuring successful SCADA implementations. The HMI graphics must be easy to learn and allow users to become productive quickly.

The ability to interface with software and hardware from multiple vendors is key as is the facility to easily expand the system for plant changes and growing data needs.

A well-implemented SCADA system can help analyse the large amounts of data and allow users to determine where the bottlenecks are in their production systems.

An experienced system integrator can play a critical role in the success or failure of a SCADA upgrade project as they need to manage hardware, software, networks, services, storage and the flow of information to various parts of the business.

We are interested to hear your opinion. Email us or sound off on Facebook. kevin.gomez@cirrusmedia.com.au

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

MANAGEMENT

Analyzing Big Data is becoming a key competitive advantage JIM PINTO

with the implications. The increasing amount and detail of information THE term “Big Data” was coined in captured by enterprises, the rise of 2008 and caught on quickly as a blanket multimedia and social media and the term for any collection of data sets Internet of Things will fuel exponential so large and complex that it becomes growth. difficult to process using traditional data There are five broad ways in which processing applications. using big data can create value: Analysing “big data” is becoming a 1. Unlock significant value by making key competitive advantage, generating information transparent and usable at waves of productivity growth, much higher speed.

P 1 _ _ 1 0 - 0 7 1 AA D0 _ 4 Pand A4 Cconsumer E0 M0 E0 T surplus.

AM PE RT _ 2 1 2 -. p 2. d As f 2organizations P1 a 4 g -e 0 4create 2 and 0 T / store 0 0 3 :/ 4 1 2 :, innovation Every business will have to grapple more transactional data in digital

form, they can collect more accurate and detailed performance information on everything, to expose variability and boost performance.

3. Big data allows narrower customer segmentation and more precisely tailored products and services.

4. Big data analytics can substantially improve decision-making.

5. Big data can be used to improve the development of the next generation of 3 products 7 : 0 0 5 + : 1 0 1 and P services.

M The use of big data will become a

key basis of competition and growth.

Every company needs to take big data seriously. In most industries, established competitors and new entrants alike will leverage data-driven strategies to innovate, compete, and capture value from wide ranging, deep and real-time information.

Policies related to privacy, security, intellectual property, and liability will need to be addressed in a big data world.

[Jim Pinto (Jim@JimPinto.com) is an industry analyst and commentator.]

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OPINION

INTERNET OF THINGS

Challenges of batch manufacturing Upcoming changes as a result of IoT drive change that is transforming business processes, writes John Blanchard.

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ANUFACTURING operations are becoming increasingly complex, even as the need for flexibility, rapid response, and improved time to market continue to grow.

A session at the recent ARC Advisory Group Industry Forum in Orlando highlighted the challenges facing batch manufacturing in today’s business environment and what leading manufacturers and their suppliers are doing to address these challenges.

Among other issues, the session addressed how leading manufacturers and their suppliers are using standards, IT technology, cloud-based solutions, and advanced analytics to improve operations and reduce overall support costs. Stefan Malmsten of AkzoNobel and Jeff Moore of Gallus Biopharmaceuticals presented compelling case studies. Matt Holland of GE Intelligent Platforms and Steve Schneebeli of Malisko Engineering joined them for the panel discussion that followed that focused on how to best leverage industry standards, such as ISA 88 and ISA 95, as well as cloud and Internet of Things (IoT) technologies to create business value. The panelists also discussed related cyber-security issues.

IT and IoT transforming business operations

ARC vice president, Craig Resnick, lead off the session by discussing the opportunities and challenges facing batch manufacturing enterprises, as well as how automation suppliers are helping address their business needs.

He explained that while the pharmaceutical, food & beverage, and specialty & fine chemical industries make up the majority of major batch manufacturing applications; batch manufacturing operations can also be found in many other industries including glass & ceramics, mining & metals, pulp & paper, textiles, and building materials.

Craig discussed the importance of standards, such as the ISA88 Batch 6 www.pacetoday.com.au JUNE 2014

Control standard, and the ISA95 Manufacturing Operations Management standard. Malmsten and Moore both further emphasized this point in their presentations.

Craig went on to explain how improvements in information technology and the Internet of things (IoT) drive change. This includes increased deployment of production management functions such as recipe management and plant performance monitoring and evaluation in off-site data centres. He cited pharmaceuticals as an example of an industry that is experiencing dramatic business transformation as a result of these technology advances.

Good is not good enough

Malmsten discussed how AkzoNobel is transforming its manufacturing operations to provide added value to its manufacturing plants and customers.

There is increased deployment of production management functions such as recipe management and plant performance monitoring and evaluation in off-site data centres The heart of this effort is to provide all the company’s plants with a single production management platform located in a remote data centre to reduce both implementation and support costs, while providing a single source for analysing production data.

This eliminates the multiple, disparate and often inaccurate systems previously used to make business

decisions. It also allows operators and plant engineers to benchmark their performance against colleagues within the company to make it easier to collectively identify global best practices.

Malmsten further emphasized that another important aspect of the success of this project was the prescriptive use of the ISA95 standard to define the overall system architecture and the touch points with related information systems.

Driving this effort forward is the company’s belief that “being good is not good enough.” Today’s competitive environment requires continual focus on AkzoNobel’s core strengths.

Engineering design critical to successful ISA88 implementations

Moore presented how Gallus Biopharmaceuticals, a leading biologics contract manufacturer, used an ISA88based recipe control and management

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OPINION

The pharmaceuticals industry is experiencing dramatic business transformation as a result of technology advances system to achieve competitive advantage.

The company changed its manufacturing site from a fixed large pharmaceutical facility to a contract manufacturing operation, creating the need to be more nimble and flexible to meet the needs of current and new clients. Its solution was to design product recipes, control modules, reusable and modifiable recipes without • Shortened recipe development times equipment, and phases based on the changing code.

• Shortened validation times for new ISA88 batch control standard.

Some benefits achieved through a product recipes ISA88 emphasizes a modular well thought out application engineering • Eased the process of modifying and approach to batch control and the design process included: creating new recipes separation recipe P A 0 2of1the 4 _ 0 0 procedure 0 _ A M Sfrom1 • Quickened 2 0 1 4 - changeover 0 1 - 1 4between T 1 1 : 4 9 : 0 •8Reduced + 1 1 : risk 0 0of loss of product and the equipment procedure, allowing multiple products and batch sizes production time

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• Lowered manufacturing costs • Reduced validation costs for additional reactors by 75 percent Moore emphasized that the extra time up front on the area model and getting the operators involved as soon as possible paid big dividends for the company.

Manufacturers should recognise that advances in information technology and upcoming changes as a result of IoT drive change that is transform-ing business processes. They should also recognise that standards play an important role in the design of process controls, and automation systems, as well as in defining the overall system architecture and the touch points with related information systems.

[John Blanchard (jblanchard@arcweb) is a principal analyst at ARC Advisory Group. He concentrates on the advanced control and enterprise integration needs of the batch processing industries including packaging line integration and regulatory compliance.] www.arcweb.com

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OPINION

SECURITY

Dealing with cyber attacks in E&U It’s imperative to implement adequate security measures, writes Craig Searle.

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HERE was an enormous increase in the number of attempted cyber attacks on the energy sector in 2013, according to a report from the US Department of Homeland Security. 53 per cent of cyber incidents handled by this department in the first half of the 2013 fiscal year were in the Energy & Utility (E&U) sector.

For most E&U organisations, such an attack is only a matter of time and will affect a critical operational infrastructure such as the electricity grid, water or gas supply systems. These organisations must therefore react to the development of cyber criminals who are shifting their focus towards operational technologies and, in many cases, are supported by a nation state.

To date, security across the E&U sector generally has been sufficient to deal with known threats, particularly since these environments have been either separated from general ICT systems through the implementation of air-gapped environments or through the implementation of traditional security endpoint enforcement technologies such as firewalls. Additionally, there have only been a very limited number of malicious cyber incidents to date in operational environments. However, the threats facing the sector are constantly evolving.

Alternate ways

When coupled with volatile external pressures such as connectivity, information sharing and access to these systems, these threats are forcing organisations to explore alternate ways of operating these environments, meaning current security measures may not always be sufficient.

As a result, there is an increase in the use of more efficient, intelligent and automated systems with the goal of realising cost efficiencies and providing more information to key stakeholders in the business. This trend will continue over the coming decade.

Therefore the prevalence, role and function of traditional Information 8 www.pacetoday.com.au JUNE 2014

Prepare

Energy & Utility organisations must react to the development of cyber criminals who are shifting their focus towards operational technologies.

Technology (IT) systems and Operational Technology (OT) systems will increasingly converge in order to provide this intelligence and system automation for all aspects of the business, without having to implement separate systems to get this connectivity and information to the key users.

While the E&U sector may be adequately protecting its operational systems today, the changing external environment, continued use of legacy systems, and the convergence of traditional IT and OT systems mean that cyber security efforts must be enhanced; otherwise organisations risk being exposed.

Those threats historically faced by corporate systems will inevitably transition into operational environments. However, in the future, the impact will not be limited to breach of privacy, fraud or loss of competitive advantage.

With the convergence of systems in mind, a breach of E&U systems could lead to: • downtime of critical services being provided to the public; • potential health and safety issues to

workers in the industrial environment and the general public, including loss of life; • financial impact to the organisation and shareholders due to large downtimes; and • brand and reputation damage.

Cyber attacks are no longer focused solely on IT environments. Cyber terrorists have turned their attention to operational technologies supporting the critical infrastructure they manage and support. E&U organisations now need to become more proactive to ensure they have adequate visibility and protective mechanisms.

Now more than ever, E&U organisations must continue to improve the maturity of their cyber security practices and both technical and governance in the operational technology areas, to ensure that they are in line with corporate practices and are equipped to deal with ever-evolving cyber security threats.

So how can E&U organisations protect their systems without losing the business efficiency that can be gained by connecting their operational technology with their corporate systems?

It is important to understand what information the organisation holds that is highly desirable to sophisticated attackers, as well as the risk, compliance environment and internal cyber capability.

Based on this knowledge, the company can develop strategies and tactics that will help address cyber risks based on priorities. It will also identify whether the organisation needs to train its workforce to become more cyber aware and what additional skillsets might be required.

Companies should ask these questions: • What is the current awareness and understanding of the potential impact on the business from cyber risk? Key to managing risk from cyber attack is understanding and managing risk and preparing for those risks that the organisation wishes to mitigate • Identify the key information and systems needed to protect from attack, and reduce the impact of attacks.

What information is most important to the business? What types of cyber risk does the organisation care about?

How exposed is it to those risks?

• How does the organisation monitor both IT and OT environments to detect attackers? It is important to understand and manage the consequences of an attack to minimise its impact.

Monitor

Do the engineers in the OT environments know if cyber attacks are occurring? Do they search for the cause of a malfunction, or just focus on getting the affected technology back up and running?

Businesses should continually monitor systems and networks for signs of malicious activity, but also keep track of changing business requirements, emerging trends and the external environment in which they operate.

Make sure to measure the effectiveness of cyber security (technical and

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OPINION

non-technical capabilities), as this will help the organisation stay on track.

Protect

It’s imperative to design and deploy cyber security solutions that will address risks and enable the business to operate with confidentiality and integrity.

However, these solutions need to be carefully developed so they don’t cripple systems by being too secure.

Apply sound engineering processes to the selection, development and deployment of cyber capabilities so that they integrate well with the overall business operations.

Respond

Having response plans in place sounds like a given, but this is often overlooked by businesses. Understand the organisation’s capability to contain and recover from cyber incidents and make sure to learn from previous ones and that the appropriate feedback is given to improve processes.

The human factor

Companies place a lot of importance on technology when it comes to cyber security. It is important not to overlook the human factor.

Do employees understand the sensitivity of the data they have access to and the implications if there is a security breach? Getting employees to care about security and understand that they have an important role to play in keeping the organisation’s cyber security risk to a minimum is key.

BAE Systems Applied Intelligence has a four-step process to test and assess A 0 6 of 1 industrial 4 _ 0 0 0control _ I Csystems HEM thePsecurity for the E&U sector:

Cyber attacks are no longer focused solely on IT environments. Cyber terrorists have turned their attention to operational technologies supporting the critical infrastructure they manage and support.

1. Key stakeholder engagement: understand the systems and determine working with key engineers and IT which ones are good for testing and staff helps organisations understand which systems entail a high risk the criticality of the systems in the of compromising the operational environment and their function availability. This system knowledge and platform upon which they are can then be used as a working tool hosted. In this first phase, it is also for all future implementations in the important to identify if there are any environment. test environments which could be 3. Vulnerability assessment: once used for the assessment. To provide a systems are cleared for testing, they strong assessment of the production need to be subjected to penetration environment, organisations need testing. This process is similar to to determine how close these test conventional penetration testing, but environments are configured with the with these industrial control systems production system. organisations need to make sure 2. System sensitivity mapping: the that they are not saturated and not information obtained in the key denying service to legitimate users. stakeholder engagement can be used 4. Threat modelling: with the to develop system mappings and information obtained from testing 1 2 the 0 1systems 4 - 0 based 5 - 2on8 sensitivity T 0 9 : 5 1 : performed 0 7 + 1 0 on : 0 group the0 ICS environment, and criticality. This lets organisations a threat model can be developed

and risks can be determined. This process is generally performed when a conventional penetration test is impossible. Threat modelling allows the organisation to understand how the systems in the environment will be attacked, the types of compromises that will occur and the likelihood of attacks.

There are a number of possibilities to conduct testing on an organisation’s environment. Testing can be done through onsite visits, a non-intrusive investigation or characterisation of systems in the environment.

This will provide a view of the critical systems in comparison to systems of lower criticality and this information can then be used to make decisions on penetration testing in the ICS environment or other technical testing options.

Conclusion

The chances of a cyber attack on critical infrastructure in E&U may be small but the impact could be huge. Downtime of critical public services, risks to health and safety, financial impact and reputational damage are all key issues for E&U organisations.

With industrial cyber sabotage on the rise, it’s imperative to implement security measures to counter this increased threat.

Organisations should ensure they have a structured capability and approach to prepare, monitor, protect and respond to cyber incidents, draw lessons from each incident and improve over time.

[Craig Searle is Head of Cyber – APAC, BAE Systems Applied Intelligence.] www.baesystems.com

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ADVANCING CHEMICAL ENGINEERING WORLDWIDE

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BEHIND THE SCENES

Pervasive sensing is a technology enabler

Unbeatable Control, Precision, and Flexibility

With pervasive technology, a better understanding is provided of the condition of assets and the process performance so that a more predictive, risk managed approach can be implemented, writes Hartley Henderson.

A

NEW frontier is opening up through the application of wireless technology and measurement instrumentation to provide data that was previously not available to enable enterprises in a wide range of industries to operate more safely, reliably and profitably.

Pervasive Sensing is designed to extend a company’s vision beyond traditional process control and safety systems to provide real time information on businesscritical areas such as site safety, reliability, energy efficiency and environmental protection.

Emerson Process Management estimates that over the next 10 years, the Pervasive Sensing market will more than double the existing US$16 billion traditional measurement market.

The company’s Vice President Wireless, Bob Karschnia, explains that Pervasive Sensing is built on three pillars: • Innovative sensors that are multi variable, non-intrusive and cover wide areas; • Easily commissioned components that are wireless, self powered and configuration –free; • No-maintenance devices that are accurate, calibrationfree and have lifetime reliability.

NI LabVIEW system design software and reconfigurable I/O (RIO) hardware lower cost and shorten design time by integrating

Automated algorithms

“Pervasive Sensing is not a product, but an outcome that leads to measurable and significant improvements with high reliability and high accuracy. A new level is coming to drive costs down through non-intrusive sensing utilising automated algorithms,” Karschnia said.

“The cost and difficulty of implementation has historically hindered the uptake of Pervasive Sensing, but now there are significant advances available in a whole range of areas. These include innovative sensors, wireless communications, non-intrusive installation, power technologies, advanced analytic capabilities, embedded expertise, and mobile and location technologies.

“The Emerson Pervasive Sensing focus is on providing the ability to modify and change systems through actionable information and solutions that are easy to use, with the aim of reducing issues such as plant slowdowns and shutdowns, helping to reduce risks to delivery on time, and avoiding environmental issues and fines.

motion, vision, and I/O within a single software development environment.

Using Pervasive Sensing, additional data can be gathered without impacting the current operational system and production.

“Safety and environmental compliance are key challenges to be addressed by Pervasive Sensing - from monitoring of pump failures in the field to steam loss in the food processing industry.”

According to Karschnia, advances in wireless and sensor technologies, as well as installation techniques, mean that companies can now install non-intrusive wireless technology together with a network of affordable easy-to-use sensors to continuously monitor all aspects of operations, which in turn enables improved decision-making and more rapid action.

“This approach to broader and deeper data collection is able to deliver a new class of business-critical

Accelerate your productivity at ni.com/ industrial-control-platform Australia: 1800 300 800 New Zealand: 0800 553 322

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BEHIND THE SCENES

operational measurements that can be managed separately from process automation functions,” he said.

Local scenario

Based in Perth, Emerson Automation Consultant, Jon Weidenbaum, says Pervasive Sensing is a technology enabler that facilitates unconstrained access to process and asset data that was originally dictated by the physical layout of a plant and the technology to support it.

“Now technology has moved on and there is an escalating need for increased data across all industries which is largely driven by a top down push for greater operational efficiency, asset optimisation, and improved OH&S,” he said.

“Industries such as oil and gas, power, water, mining and metals all have assets located in remote areas and they all experience associated concerns about people’s safety and environmental issues, which implies there is a unique need in Australia for Pervasive Sensing.

“By utilising wireless technology for Pervasive Sensing, additional data can be gathered without impacting the current operational system and production.

Monitoring and collection of data via Pervasive Sensing can enhance asset availability and personnel safety, saving thousands of site visits per year to these remote locations.

“One thing that is certain about today’s world is that there is no certainty on what data the customer may require tomorrow. Typical drivers for the growing need today are environmental and regulatory demands, asset optimisation, health and safety, process efficiency and cost sensitivities.

“Pervasive technology through wireless field implementation provides a flexible approach to react and expand these future needs whilst minimising the impact to current operations and production.

“Typically in remote facilities, monitoring of assets and consumables is often manual and can be as infrequent as every 2 to 3 months due to the remoteness of the sites. In this scenario, the question should be asked as to what the accumulative cost and damage could be to a company for not having the asset monitored and protected for this period of time.”

Corrective action

Weidenbaum points out that the consequences could be enormous, 12 www.pacetoday.com.au JUNE 2014

Pervasive Sensing is a technology enabler that facilitates unconstrained access to process and asset data that was originally dictated by the physical layout of a plant. including compromises to the integrity of the field asset, impact to the environment, and damage to the reputation of the operator. He says that with wireless Pervasive Sensing in place, companies are forewarned of potential operational and asset issues in real-time and can make quick decisions to take corrective action.

“With pervasive technology, a better understanding is provided of the condition of assets and the process performance so that a more predictive, risk managed approach can be implemented for timely intervention, and arrival on site with the correct equipment or replacement parts.

“A pervasive network will typically consist of wireless enabled instrumentation together with remote and distributed remote telemetry units to provide seamless connection for the assets in the site proximity.

“For example, in the oil and gas industry, this would include mobile assets such as chemical injection skids, gas jacks, mobile flare stacks, variable speed drives and generators, and mobile well testing equipment. In the latter case, wireless implementation means

that the mobile well testing activities can be monitored and validated in real time from the central control room or office, where an engineer can supervise remotely several remote well head tests concurrently.”

Weidenbaum says that the move to risk-based management together with

the emerging need to refocus the well head as a collection of mobile assets rather than a fixed site, will drive the future demand for Pervasive Sensing, especially in the unconventional oil and gas arena (coal bed methane and shale gas). www.emersonprocess.com.au

Companies can now install non-intrusive wireless technology together with a network of sensors to continuously monitor all aspects of operations.

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BEHIND THE SCENES

Reduce TCO of pumping systems By pursuing best practices in energy efficiency management, asset management, and energy cost management, total cost of ownership of pumping system networks can be reduced by up to 20 percent.

E

LECTRICITY usage costs on cost. Despite the fact that electrical • Lack of proper metrics – Energy have become an increasing energy cost represents 40 percent of efficiency has traditionally not been fraction of the total cost the total cost of ownership of pumping used in assessing performance. In of ownership (TCO) for systems, many organisations fail to most organisations, the responsibilities industrial pumping systems. In fact, introduce the proper steps to leverage of energy procurement and efficient energy cost represents 40 percent of the TCO of a typical pump.

With increasing pressures to reduce Operators need to have a clear view over their field energy costs and move towards a more of operations in order to pre-empt and mitigate any sustainable operating model it is possible to reduce the electrical consumption by issues that may arise at least 30 percent through appropriate energy management practices and maintenance. cost reduction through efficiency operations are separate and consistent Areas contributing to high energy use improvements. standardised metrics are not utilised Wherever pumping systems are present To solve this dilemma, the following • Knowledge gap – A lack of awareness in water/wastewater opportunities is P A 0 6 1 4 _ 0facilities, 0 0 _ Denergy EL 1 major 2 0barriers 1 4 - need 0 5 -to1be3 recognised T 1 4 : 0and 5 : 1 7in+ energy 1 0 : efficiency 0 0 consumption exerts a major influence addressed: prevalent and, as a result, potential

14 www.pacetoday.com.au JUNE 2014 Delta_poster_CP2000_20140505(122 x 210).indd 1

savings and other benefits are missed • Fear of investment – Operations personnel often struggle to present attractive large or even small investments to their finance organisations • Maintenance – Because of the number of moving parts and other variables it can be difficult to maintain a holistic view of the pump and facilities operations All these factors are major contributors to inefficiencies in pumping operations. Operators need to have a clear view over their field of operations in order to pre-empt and mitigate any of these issues that may arise and the most effective way to do this is through

2014/5/5 下午 02:39:02

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Making things right Industry 4.0

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Get on the journey to Industry 4.0 with the latest SIMATIC technology produced out of one of the most advanced factories in the world – Siemens’ electronics factory, Amberg www.siemens.com.au/futureofmanufacturing

It takes a world-class factory to produce world-class automation. At our electronics factory in Amberg where we produce advanced electronics including SIMATIC automation, we can demonstrate the integration between the virtual product generation and its actual production. And the productivity and efficiency results speak for themselves…

Since 1989 the factory has managed to achieve a sevenfold increase in production volume in the same-sized production area and with barely an increase in personnel, while allowing incredible quality. The defect rate is – believe it or not – at 12 defects per million process steps.

Siemens technology can be found at the heart of manufacturing and industrial plants throughout Australia and around the world – helping produce everything from the finest food and beverage, critical pharmaceutical supplies, clean water, oil and gas, mineral ores and metals, through to just about anything you can think of.

And we understand there’s a difference between making things and making things right. Our technology is helping many companies make things right. This means making the right kind of progress. It means understanding that decisions today will affect tomorrow. That’s why Siemens is redefining manufacturing with new advanced automation technologies such as SIMATIC S7 1500

plus TIA Portal. This is just one of the offerings designed to get you on the journey to Industry 4.0.

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.

Industry 4.0 Industry 4.0 is about helping your business become more nimble, adaptable and intelligent; from design to prototype to production and throughout the entire lifecycle– with rapid innovation cycles.

So industries can perform faster, better and produce more with fewer resources.

Scan QR Code for an exclusive free copy of the white paper ARC Insights: ‘Emerging technology & Industry 4.0’ or to find out how SIMATIC S7 1500 plus TIA Portal can help your business. Call 137 222 and ask about Industry 4.0. manufacturing.au@siemens.com

Answers for Industry.

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BEHIND THE SCENES

a comprehensive energy plan that takes into account the following steps: • Energy efficiency management • Asset management • Energy cost management

Energy efficiency management

Most inefficiencies in pumping systems comes from a mismatch between the pump deployed and the actual system requirement (i.e. undersized or oversized) or the improper use of throttling valves and damper technologies to control the flow of liquids.

It’s areas like these which are critical to maintain the energy efficiency of a pumping system and can be obtained by implementing the following simple actions: • Monitor production data and energy consumption data via software dashboards. The continuous tracking of the deviation between production output and energy consumed allows for rapid and cost effective decisionmaking.

Intelligent Electronic Devices (IEDs) such as variable speed drives that are tied into the monitoring system, play a major role in reporting data related to

The electrical energy bill for the site can be reduced by implementing a series of simple actions. operation, production, and energy in real time.

Monitoring points should be close to the load because that is where most of the power is consumed. The closer the monitoring is to the load, the more insights can be acquired relative to cost savings • Monitor the operating point of the pump and its efficiency on a continual basis in order to visualise trends.

Observance of the trends can then lead to sensible actions that improve efficiency, and verify the impact of improvements to the system • Use proper metrics to identify an

increase or decrease in efficiency on particular systems and to compare efficiency performances of different pumps in multiple sites.

A recommended key performance indicator (KPI) metric is the specific energy consumption metric (in kWh/m) • Replace fixed drives with variable speed drives to boost the efficiency.

Connected to a pump, a variable speed drive can control speed, pressure, and flow in conjunction with dynamic process and production requirements The variable speed drive is fully integrated in the numerous steps that can be taken in order to implement an effective energy management plan.

These include adopting energy efficient technologies, implementing conditionbased maintenance practices, and optimising cost control of the electrical bill.

The linking of pumping processes to energy systems helps to improve business performance through better energy management.

Asset management

Physical assets such as pumps and drives need to be maintained on an ongoing basis.

16 www.pacetoday.com.au JUNE 2014

Physical assets such as pumps and drives need to be maintained on an ongoing basis. Maintenance costs represent 25 percent of TCO and therefore maintenance practices warrant examination in terms of contribution to energy-influenced savings.

Maintenance costs are unavoidable due to the wear of components during system operation, and because the cost of downtime attributed to loss of production would threaten the solvency of the business.

In pumping installations, many moving parts mean that proper maintenance of motors, drives, pumps, and associated pipes is crucial.

Numerous steps can be taken to assure that maintenance costs are kept at a minimum while integrity of the systems is kept stable.

A number of approaches are available that can help to address the issue of asset maintenance in a cost effective manner: • Preventive maintenance implies the systematic inspection and detection of potential failures before they occur • Condition-based maintenance is a type of preventive maintenance, which estimates and projects equipment condition over time, utilising probability formulas to assess downtime risks • Corrective maintenance is a response to an unanticipated problem or emergency • Condition-based-maintenance monitors system data on an ongoing basis and provides an accurate assessment of the health, or status of components, devices, and/or the complete system There are other maintenance variables in pumps to take into account such as suction pressure, discharge pressure, pump speed, power, flow and temperatures. It is essential to track and monitor these in order detect a loss of efficiency.

The prior identification of potential problems caused by the variables is possible by combining the efficiency trends and process variables. If the pump/s are connected to an automation system, they can continuously monitor the health of the system and can indicate in a precise manner when proper maintenance is needed.

Energy cost management

The electrical energy bill for the site can be reduced by implementing the following series of simple actions:

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BEHIND THE SCENES

• Locate and review the utility contract itself to better understand the charges associated with the bill and how they can be controlled. Up to 10 percent savings without any capital investment could be achieved with the support of a company specialist in energy management • Adjust the timing of energy usage from the peak rate period to the off peak period as much as is possible (e.g. by controlling differently reservoir and pumping operations).

Reduce the monthly peak demand number in order to reduce the demand charge. In most cases, 75 percent of the applications are oversized.

Variable speed drives, which can reduce power demand by 50 percent, are a technology that helps organisations to size according to process requirements • Power factor penalties that are due to motor and that mitigate harmonics, can be cancelled out by deploying variable speed drives to pumps • Reduce the amount of energy that is consumed that is not linked with revenue generation. An active control of the leakage will significantly reduce the operational cost

Three steps for reducing TCO in pumping systems

By pursuing best practices in (1) energy efficiency management, (2) asset management, and (3) energy cost management, total cost of ownership of pumping system networks can be In pumping installations many moving parts mean that proper maintenance of motors, drives, pumps, and associated pipes reduced by up to 20 percent. is crucial.

Organisations that are ill equipped to jumpstart an energy efficiency program alternative invites unnecessary delay, organisations must act quickly to assess that emphasises improvement in energy should efficiency.

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www.symmetry.com.au JUNE 2014 www.pacetoday.com.au 17

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WOMEN IN INDUSTRY AWARDS

Introducing our 2014 sponsors THE 2014 Women in Industry Awards recognises and rewards the achievements of women working within the mining, engineering, manufacturing and process control industries. It aims to raise the profile of women within industry, as well as promote and encourage excellence. The accomplishments of these women will be recognised at an event to be held in Sydney on Wednesday, June 25.

Employer of the Year Award Since 1984, NLT’s mission has been to continually develop and deploy the most advanced technologies to make mines safer and more efficient.

Known globally for its award-winning cap lamp technology, the company has directed the same passion, commitment and understanding into the design of its underground communication solutions.

Northern Light Technologies (NLT) provides one of the most comprehensive offerings of network-based mining communication solutions available today.

Its open standards approach allows you to integrate existing and new communication technologies while removing the risk of becoming locked into a single platform.

Choose from a wide range of best-inclass monitoring applications including, Geotechnical, Proximity, Environmental and Airflow, with the ability to deploy solutions in any order and at a pace that matches your mines objectives.

In addition to being the first company to introduce Wi-Fi networks to underground coal mines, many of the largest and most reputable mining companies in the world rely on NLT Mining Networks communication solutions.

NLT is a turn-key partner in the design, manufacture, deployment, and support of scalable communication technologies that will change the way your mine communicates, collaborates and operates.

Northern Light Technologies 07 5495 2944 www.nltinc.com

18 www.pacetoday.com.au JUNE 2014

Excellence in Mining Award Mining Machinery Developments (MMD) designs and manufactures mineral sizing (crushing) equipment and services to the mining, metallurgical, industrial minerals, alumina and other industries.

The core products; mineral sizers (crushers) and feeders offer a solution to problems such as variable ore properties, product requirements, site conditions and environmental issues.

Founded in 1978, to design and manufacture equipment for the UK underground coal mining industry, today MMD size over 60 different minerals worldwide, in many varied process industries.

MMD Sizing equipment is available for surface or underground installations, stationary or mobile, and for climatic conditions ranging from arctic to tropical.

The MMD sizer range now includes, primary, secondary and tertiary sizers for wet and dry processing of metallic and nonmetallic minerals for mining, industrial minerals and quarrying industries.

The latest range of MMD mobile sizers have the ability to offer mine operators unprecedented levels of productivity, and therefore very low operating costs per tonne.

These energy efficient electrically driven “Green Mining Solutions” are all designed to assist mining companies to achieve the double bottom line of being both economic and environmentally friendly.

MMD Australia is an equal opportunity employer, encouraging women to join not only the mining industry but the varied industry sectors in Australia and abroad.

MMD Australia 07 3112 2640 www.mmdsizers.com

Excellence in Engineering Award Automation Direct is a direct seller of automation and industrial control products such as PLCs, sensors, AC drives/motors, operator interfaces, pneumatics and process control products. Through its free DVD catalogue and full-featured website, the company is able to offer the most practical industrial automation products.

Automation Direct follows that up with an efficient organisation that ships in-stock products the day you order them and then provides technical support that has been the leader in the industry. Customers have made the switch to Automation Direct because of their prices, products, service and helpful attitude.

The company’s history goes back over 48 years in the industrial controls market starting as B.I Systems Pty Ltd and now Automation Direct. It has quickly grown from a tiny PLC company to a well-recognised name in the industrial automation market.

As the first industrial controls company to successfully use a DVD catalogue for PLC products, Automation Direct is now using its e-commerce site, in addition to its 1-800 number, to reach the next plateau in industrial control sales.

Automation Direct 1800 633 040 www.automationdirect.com.au

Rising Star Award QMI Solutions has a strong history at the forefront of industry in Australia and has much to be proud of since its foundation in 1993.

QMI Solutions played an intrinsic part in the successful introduction of 3D Printing to Australia.

The company had the vision to ensure this ground breaking technology would not only be adopted but would dramatically change the capability of businesses in a number of industries.

QMI Solutions is the only company in Australia to have an Incremental Sheet Forming (ISF) machine. And stereolithography, water-jet cutting and laser sintering are just some of the many other techniques the firm has been involved in.

Thought leadership has won the company the respect of governments and academic institutions Australia-wide and the company continues to encourage industries to adopt new technologies. However, the company understands industries also need to improve productivity, reduce waste, identify new markets, innovate and, most importantly, engage and up-skill their staff.

As such, it provides a complete service to address these needs and support business at all levels and stages of their development.

As an equal opportunity employer, QMI Solutions looks to encourage everyone involved in industry to find ways of reaching their full potential and is a proud supporter of the Women in Industry Awards for 2014.

QMI Solutions 07 3364 0700 qmisolutions.com.au

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IN FOCUS

Inductive technology for noncontact displacement sensing Eddy current is a robust technology that offers high resolution and high precision in less than ideal environments, writes Daniel Spohn.

I

NDUCTIVE “eddy current” technology for position and displacement sensing has been around for well over 50 years.

When compared with laser and capacitance technologies for the same purpose, inductive technology offers advantages that make it ideal for a wide variety of industries and applications.

It is a robust technology that offers high resolution and high precision in less than ideal environments.

FIGURE 1: Basic inductive sensor system

consisting of a wire wound coil typically housed in threaded metal barrel, an Basics of inductive sensors electronics commonly referred to as a An inductive ‘eddy current’ sensor is driver, and an interconnecting flexible impedance A D _ P A C E D WY M A R _ 1 2 . p in d reality f P aavariable ge 1 1 0 / 0 1 / 1 2 , coaxial 9 : cable.

4 0 AM transducer and includes a sensor, The driver includes an RF oscillator,

balanced bridge circuit, synchronous demodulator, log amplifier and output amplifier.

As depicted in figure 1, the high frequency alternating current used to excite the sensor coil, typically 500kHz

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IN FOCUS

or 1MHz, produces an oscillating electro-magnetic field.

When electrically conductive material, referred to as the target, enters the field, eddy current is induced in the surface.

The eddy current produces an electro-magnetic field that interacts with the coil field changing the impedance of the coil.

The impedance change upsets the FIGURE 2: Basic inductive bridge circuit balanced bridge circuit.

The bridge imbalance is proportional to the distance between the sensor and sensors on the same side of the target target. The driver outputs a linearized, monitoring tilting motion.

Differential impedance variable DC voltage that is proportional What is unique about differential transducers offer common to the sensor-target gap. Figure 2 sensors is when the target is equidistant illustrates a typical inductive bridge between both sensors the system outputs mode rejection of circuit.

0 VDC. A variation of the basic bridge thermal sensitivity and As the target gets closer to one sensor circuit is the differential bridge circuit, the output will be +VDC and as it gets a bipolar output see figure 3. With differential sensors a closer to the other sensor the output will second sensor is added on the opposite be –VDC. The result is an indication side of the bridge. of both the direction and magnitude must be electrically conductive, but is The sensors are arranged so that as of the target motion relative to the null not required to be grounded. The more the target moves it will get closer to one position. electrically conductive the target is the sensor as it gets farther from the other Application concerns better the signal-to-noise ratio resulting sensor.

As with any technology for position/ in better performance.

This provides much higher resolution displacement sensing there are a number Highly conductive non-ferrous due to increased bridge imbalance for of things that can affect performance targets provide the best overall sensor the same target motion. Differential that should be reviewed to ensure the performance, but ferrous alloys are impedance transducers also offer sensor will function adequately, and as commonly used in applications such common mode rejection of thermal expected. condition monitoring of rotating sensitivity, and a bipolar output. equipment. In these applications it is Typical configuration is with the Targets typical to use an eddy current sensor to sensors mounted at 180 degrees with the As the sensing coil must induce eddy monitor the vibration of the rotating target in between.

PA0 6 1 4 _ 0 0 0 _ ADM 1 2 0 1 4 - 0 5 - 1 3 T1 4 : 0 2 : 1 1 + 1 0 : 0 0 current into the target surface, the target shaft.

An alternate configuration is with the

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With sophisticated data acquisition equipment the vibration spectrum can be analyzed to determine such things as bearing health.

Non-conductive material can be sensed by simply attaching a conductive target. An aluminium target as thin as couple of hundredths of an inch will provide performance that meets published specifications.

Environment One of the benefits of inductive technology is that unlike laser triangulation and capacitance technologies for displacement sensing, it is unaffected by environmental contaminants such as oil, dirt, grease, and water. The electro-magnetic field produced by the sensor coil will penetrate anything non-conductive that is between the sensor and the target surface.

No technology is without error sources. Inductive sensors are affected by changes in temperature of the coil and cable. Inductive bridge sensors are variable impedance transducers.

Impedance is a function of inductance, resistance, and capacitance.

As the coil increases and decreases in temperature, the resistance of the coil changes. This resistance change with temperature will affect the sensors output voltage. Whether this is a concern or not is dependent on the performance requirements of the application.

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20 www.pacetoday.com.au JUNE 2014

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all be modified to meet specific application requirements.

FIGURE 3: Basic differential bridge circuit Range The effective range of a given sensor is a percentage of the coil diameter. Typically the sensor’s calibrated range is kept between one forth and one third of a coil diameter. Extending the calibrated range is possible, but at the far end of extended ranges the sensor will become more sensitive to temperature fluctuations.

Mounting Inductive sensors output a DC voltage proportional to the distance between the sensor and the target, as a result they cannot discern between target motion and sensor motion. Hence it is important to mount the sensor in a manner that eliminates the potential for sensor motion. Avoiding long cantilevers, and using stiff material for the sensor mount is good practice.

The size of the effective electromagnetic field produced by a sensor can be radially as large as three times the sensor diameter. Any electrically conductive material that engages the field will have eddy current induced.

Any conductive material other than the target that can engage the field is referred to as side loading.

Figure 5 depicts the size and shape of the electro-magnetic field produced by both shielded and unshielded sensors.

Performance In any sensing application there is a desired accuracy. Stated very simplistically, accuracy is a summation of errors.

With inductive ‘eddy current’ sensors this typically includes resolution, repeatability, linearity,

An aluminium target as thin as couple of hundredths of an inch will provide performance that meets published specifications thermal stability, and frequency response.

Basic bridge circuits can easily achieve resolution of 0.01% of the calibrated range. Repeatability of these type of sensors is within the resolution specification, virtually no hysteresis. Linearity varies between 0.5% and 1% of the calibrated range.

Thermal sensitivity, with special calibration can be as little as 0.02% of the calibrated range per degree Fahrenheit.

Frequency response is typically 50kHz (-3dB point) but can be increased or decreased with custom filtering of the output.

Understanding the required accuracy to meet the intent of the measurement is important.

A desired accuracy that is more than what is needed to meet the intent of the measurement can increase the cost of the sensor, and in some cases beyond the value of the measurement.

Flexibility of the technology Inductive position/displacement sensors are versatile enough to meet the needs of a wide variety of applications. Cable lengths, custom sensor bodies, operating temperatures and calibrations can

Cables Standard sensor cable lengths are typically 1.8m to 4.5m (6 to 15 ft).

The standard length is determined with the intent of providing the longest length while still being able to meet performance specifications that will exceed the requirements of most applications.

Varying from the standard lengths comes with some decrease in performance. They specifications affected by increasing cable length include resolution and thermal stability.

Conversely, if the application will allow it, decreasing the cable length can improve resolution and thermal stability in certain instances.

Sensors The critical component in a sensor is the wire wound coil. Standard sensor body designs are typically threaded metal barrels for ease of installation and axial positioning relative to the target. Custom configurations include longer bodies, smooth OD vs. threaded, side view coil mounting, to name but a few.

Other application requirements that would indicate the need for a customized sensor would be harsh environments. Materials of construction can be changed if the sensor is being subjected to certain chemicals that may interact with the standard materials.

Sealing treatment of the sensors and the use of appropriate cable jackets for underwater sensor use is another example of customization to meet the application requirements.

Calibrations Published sensor performance specifications are based on a particular target material and calibrated range, as well as a specific operational environment, typically a normal manufacturing floor environment. The standard performance in many cases far exceeds the requirements of the application.

Inductive ‘eddy current’ sensors can typically be calibrated over a range 1.5x the published range.

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When required, the sensor system can be tuned to a specific target material other than the typical aluminium or steel used to derive the published specifications.

sense things such as thrust bearing wear, and differential expansion in steam turbines.

Example applications: Rotating targets

Total indicated run-out TIR, or total indicated run-out of a rotating shaft is a good indicator of bearing wear.

Measuring the TIR of a rotating shaft is easily accomplished with inductive sensors by simply mounting an appropriately sized sensor looking at an exposed portion of the shaft and data logging the output.

Inductive sensors are typically factory calibrated with a flat target at least 3x the diameter of the sensor. A rotating shaft presents a target surface that is not flat. This is only a concern if the sensor diameter is larger that 1/8th of the shaft diameter.

IfPthe A 0sensor 6 1 4diameter _ 0 0 0is _≤ 1/8th CON of the shaft diameter there will be no

FIGURE 4 AND 5: Electromagnetic field size and shape affect on the system output.

As an example, assume an inductive The more electrically sensor is monitoring a rotating shaft and conductive the target has been calibrated with a 0-10VDC output over a range of 0.100 inch. is, the better the signalReviewing the recorded data shows the to-noise ratio resulting in sensor output swings from a low of 2.687 VDC to a high of 3.012 VDC. better performance The sensitivity of the sensor is 0.1VDC/0.001 inch (10V/0.100 inch).

The difference between the maximum and minimum sensor output voltage If recorded at periodic intervals, is 0.325 VDC. By dividing the voltage bearing wear can be observed over time. delta of 0.325 VDC, by the sensitivity 1of 0.1 2 0VDC/0.001 1 4 - 0 5 inch, - 1 results 3 T 1 in 5 :a TIR 0 9 : 5Vibration 5 + 1 0 : 0 0 of 0.00325 inches, or 3.25 mils.

Knowing the frequency of vibration of a rotating shaft can provide insight into ball or roller type bearing health.

With sophisticated data acquisition and analysis tools, detecting a deteriorating ball or race is possible.

Example applications: Position

Axial position Axial motion of a rotating shaft can be measured by monitoring an exposed end of the shaft, or if that is unavailable, a collar added to the shaft with the sensor’s axial centerline parallel to the shaft axial centerline.

It is not necessary that a complete circular collar be used. Adding a simple flag type target to an exposed portion of the shaft and collecting data on minimum voltage each time the flag passes the sensor could be used to

Valve position Inductive proximity sensors are typically used for simple valve open/ shut indication. These types of sensors provide switch outputs when the monitored condition is met. These sensors are relatively inexpensive and easy to implement, but only indicate a full open or full shut condition typically.

There may be applications where component wear can negatively affect the ability of a valve to seal properly. In these cases knowing the exact position of the sensed component can indicate wear prompting maintenance to be scheduled.

Implementing analog position/ displacement sensors with a PLC will allow setting switches at specific voltage levels for open and closed conditions, and provide wear over time indication by regularly monitoring the actual voltage output.

Rotary position There are a number of technologies that can easily measure rotary motion.

Some are expensive and some are not well suited for the environment, and still some include mechanical motion and wear over time.

Eddy current sensors can provide rotary position indication with the use of a simple incline plane in the shape of an eccentric. As rotation occurs the OD of the eccentric will get closer to, or farther away from the sensor as shown in figure 6.

The changing gap causing a decrease, or increase in the voltage output. As an example, a sensor with 0-9VDC output over a 0.090” range provides a sensitivity of 100mV/mil (0.001”).

With an eccentric designed to provide a 0.090” gap change in 90 degrees of

FIGURE 6: Eccentric target for rotational position 22 www.pacetoday.com.au JUNE 2014

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Decreasing the cable length can improve resolution and thermal stability in certain instances Example applications: Alignment

FIGURE 7: Differential systems for alignment rotation, 0.1V of output change will equal 1 degree of rotation. 1mV of output change will equal 0.01 degrees of rotation.

Example applications: Thickness

Fluid film thickness Bearings that are fed with a lubricating fluid are designed to operate with a specific gap that can change with load.

By imbedding an eddy current sensor into the bearing material, looking at the other wear surface, the fluid film thickness can be monitored over time and in some cases can be used as a thickness feedback signal to vary the supplied lubricating fluid pressure.

Examples would include journal bearings, large telescope bearings that support heavy loads, and vertical support thrust bearings.

non-contact position/displacement sensors, inductive ‘eddy current’ sensing technology is ideally suited for applications in industries that offer less than optimum conditions.

The breadth of applications for non-contact inductive position/ displacement sensors is only limited by the imagination and ingenuity of the engineer implementing the technology.

[Since joining Kaman Precision Products in 1997, Daniel Spohon (dan. spohn@kaman.com) has focused specifically on the application of eddy current position/ displacement sensor technology for a wide variety of industries including semiconductor capital equipment, power generation, automotive test, and electro-optics.]

Conclusions Kaman Precision Products is Being unaffected AD _ P A Cby E environmental P L A A P R _ 1 2 . prepresented df P in a gAustralia e 1 by1TRE 4 / 0 3 / 1 2 , factors that negatively affect other Measurements 0427 275 327.

Gate tilt Opening and closing large hydro gates includes the risk of a gate getting jammed due to misalignment. Using a ‘differential’ eddy current sensor to monitor the gate motion relative to the track or guide is an easy way monitor gate orientation enabling the operator to stop raising or lowering a gate that is about to get jammed. Figure 7 depicts a differential sensor configured for gate alignment monitoring.

An inductive sensor is in reality a variable impedance transducer and includes a sensor, consisting of a wire wound coil typically housed in threaded metal barrel, an electronics commonly referred to as a driver, and an interconnecting flexible coaxial cable.

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SPOTLIGHT

7best of the

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

Elbow flow conditioner removes swirl Wastewater treatment engineers who can’t find room for the recommended straight pipe run needed by electromagnetic flow meters in sewage lift stations will find the Vortab Elbow Flow Conditioner from The Vortab Company eliminates the problem by removing swirl and asymmetric velocity profiles caused by pumps placed too close to the meter. To provide accurate and repeatable flow measurement, electromagnetic and other types of flow metering technologies require a specific amount of straight pipe run upstream and downstream from the installed location of the meter. The straight pipe runs create a swirl-free and symmetric velocity profile in the pipe that can be measured accurately over and over again. When electromagnetic flow meters are placed too close to pumps in sewage lift stations, there can be measurement problems. Sewage lift stations are required to pump wastewater from one elevation to a higher level when gravity flow isn’t feasible for any number of reasons. Often there isn’t enough available plant real estate to support the straight pipe run required by electromagnetic and other flow metering technologies. The elbow flow conditioner eliminates the flow meter upstream piping requirements by conditioning the flow stream into a flow regime, mimicking adequate straight run.

AMS Instrumentation & Calibration 03 9017 8225 www.ams-ic.com.au

Switches for high-availability EtherNet/IP networks The new advanced managed switches in the 7000 series from Phoenix Contact are suitable for use in Ethernet/IP networks because the industrial Ethernet switches are the first to be equipped with CIP. The switches can be configured and diagnosed from the EtherNet/IP control system. They are the first switches in the world to support the Device Level Ring (DLR) redundancy mechanism. With DLR switching times of less than three milliseconds can be achieved if failure occurs; this increases the availability of the network. Up to six non-DLR-enabled devices can be integrated into the ring with the FL SWITCH 7000 switch. In addition, functions such as IGMP snooping, multicast source detection, and auto-query port for intelligent multicast filtering are also available.

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

Compact laser micrometer for industrial applications The optoCONTROL 2520 laser micrometer with integrated controller supplied

by Bestech Australia features a compact design. Operators can choose a maximum distance of 2m between transmitter and receiver. The measurement object can be placed anywhere within the light curtain that is projected between transmitter and receiver. The convenient Ethernet-based web interface simplifies operation, integration and remote access during the manufacturing process. The micrometer is manufactured by Micro-Epsilon and offers variable mounting distances between 100mm and 2m. The distance between measurement object and receiver can be freely selected and the measurement object can be placed at any position within the light curtain. The measuring range is 46mm. An intuitive web interface is used to perform set up and configuration. A real time measurement chart provides a convenient method of display. A variety of measurement values, such as single edges, diameter and centre axis, can be displayed or hidden in the chart at the user’s discretion. In addition, the system provides various averaging and filter methods, as well as statistics features. Available interfaces are Ethernet/ EtherCAT and RS422. A video signal diagram is used for easy alignment and set up of measurements.

Bestech Australia 03 9540 5100 www.bestech.com.au 24 www.pacetoday.com.au JUNE 2014

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

TURCK introduces powerfast for process automation TURCK expands its powerfast line of connectivity products to include a full line of solutions for process automation applications. Designed to replace expensive, time-consuming hardwiring methods, powerfast for process automation provides a robust and reliable modular wiring solution. A full line of cordsets, receptacles, reducers, reducer tees, and power lokfast devices provides users with the ability to configure a complete power distribution system. TURCK’s powerfast for process automation connectivity products are UL approved and available in A-Size and D-Size connectors and are rated for up to 30A of power for a wide range of operation. Additionally, powerfast products carry FM approval for use in class I division 2 hazardous locations.

TURCK 1300 132 566 www.turck.com.au

Manufacturing Execution System Life sciences companies have the dual task of maintaining flexible production lines to respond to changing market demands and cost-effectively managing compliance requirements. Rockwell Automation continues to expand the flexibility of its Rockwell Software PharmaSuite v5.2 system (MES) to help manufacturers respond to these challenges and execute electronic batch records in new and more efficient ways. The PharmaSuite v5.2 system includes improved agility and production control, as well as native integration with FactoryTalk Historian software and the OSIsoft PI System to help pharmaceutical and biotech companies

optimise production, improve reporting and shorten development time. Improved Agility and Production Control – Recipe elements can be executed in parallel by multiple shop-floor operators with the PharmaSuite v5.2 system. On the production line, recipe tasks can be freely moved between electronic batch recording stations or can be fixed to a specific station by recipe design. This iteration allows operators to define and control the level of execution freedom on the shop floor and increases the efficiency of electronic batch recording.

Rockwell Automation 1800 762 593 au.rockwellautomation.com

Pilz PSS 4000 integrates Ladder Diagram programming Intelligent IP69K drives NORD Drivesystems supplies efficient drive units for dynamic speed control and automatic process control in applications that need to be regularly cleaned with high-pressure steam jets. Developed for strict hygiene requirements and featuring IP66/ IP69K ingress protection, smooth-surface motors with an integrated frequency inverter are available for the 0.37...1.1 kW performance range. Common applications include conveyors, pumps, mixers, and agitators. Sensor data such as pressure or flow rate values can be directly communicated to the drives, enabling them to automatically adapt to current demand.

If partial load operation is frequent, an automatic energysaving function decreases the running costs by a significant share. In conveyor applications, light barriers can be used for contact-free or gapless accumulation.

NORD Drivesystems 03 9394 0500 www.nord.com.au

The Pilz PSS 4000 now features integration of Ladder Diagram programming into the PAS4000 software tool. Users can select three of the five programming languages from IEC61131-3; Function block diagram, Instruction List and Ladder Diagram.

All the programming languages can be combined with the PASmulti editor to simplify the design of complex programs. The introduction of the Ladder Diagram programming follows from the release of Ethernet/IP connectivity in the previous release of PAS4000. The Pilz safety and standard control system can communicate with the common systems via ModbusTCP, Profibus-DP and Ethernet/ IP natively, and utilising the additional gateway modules, CANopen and Ethercat. Ladder Diagram is a common programming language in Australia, so it’s considered an important step in the evolution of the PSS 4000 as a complete safety and automation solution. Coupled with the PASmulti editor, the PAS4000 Ladder Diagram editor simplifies the setting up a safety PLC system. The PSS 4000 may be either used as a combined standard and safety

PLC or as a standalone Safety PLC. PSS 4000 has been implemented in solutions for mining, manufacturing, railway, bridge control, cable cars, oil platforms, hospitals, building fire protection and amusement rides.

Pilz Australia 1300 723 334 www.pilz.com.au JUNE 2014 www.pacetoday.com.au 25

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THE LAST WORD

ADDITIVE MANUFACTURING

3D printing is key for Australia The only thing keeping Australia from being a powerhouse is people, writes John Barnes.

T

HEY say that 3D printing is an overnight success 15 years in the making (P. Fu) and as a participant in its development going back to 1996 it has been fun and frustrating to be a part of.

The program that we run at CSIRO is very focussed owing to limited resources and a late start to the technology.

Our primary interest is in metallic additive manufacturing (or 3D printing in layman’s terminology, 3DP if you’re awesome) and within that space we developed a 2+1 strategy.

The 2 represents our need to be globally relevant in scientific research and the +1 recognises that Australian industry does not necessarily need cutting edge research to understand when and where to use 3DP. We have not emphasized plastics given that in general the plastics side of 3DP is years ahead of metals in maturity.

LAB22 is the name we gave to CSIRO’s facility for 3DP. We joke that it is like Area 51, just smaller. In LAB22 we primarily look at feedstocks for 3DP and simulation of the deposition.

My group’s external revenue mainly comes from overseas to the tune of about 90%. This helps me justify that we are globally relevant because we are a long way away.

As we have become more known and as the technology proliferates in Australia we have had some notable successes, specifically the therapy horse shoe, fish tags, Flying Machine bespoke push bikes and the Oventus sleep apnoea device.

We decided to work in feedstock, which means metallic powder in this context because we have a special strength in metallic powder processing at CSIRO. We have novel production methods which produce titanium more directly from the ore (which we lead the world in) and its output is powder like.

We also evaluated the cost of operation and the top 3 cost drivers are: (1) Labour, (2) Depreciation and (3) 26 www.pacetoday.com.au JUNE 2014

Feedstock – so we saw a natural opening where we could make a difference.

Today we are coming up with new sources of powder which cost dramatically less and have devised new techniques to qualify powders for use in 3DP equipment. In fact we are trying to completely alter the way industry looks at specifying metal powders for use in 3DP. We primarily are looking at titanium powders but recently have begun to look at new materials which stand to benefit

materials like titanium do not respond well to being at different temperatures and as a result can distort requiring stress relief during the build. This means added schedule, added cost and more room for mistakes to most people.

Our new tool, developed jointly with Boeing, allows us to very accurately predict distortion on large deposits so much so that we now use it to manage the deposition process based on the part geometry.

As best we can tell, we lead the world

The initiative that I am most proud of is the CSIRO Titanium Challenge which is now in its fourth year from the advantages of 3DP but don’t enjoy widespread success because they are expensive or heavy or difficult to machine.

Refractory metals have all of these attributes but have some pretty phenomenal properties. 3DP can enable these materials to affordable if you print less, requiring little to no machining which necessarily makes them much lighter.

The second area of research we have been active in is simulating the process such that we can predict things like distortion due to thermal gradients.

The 3DP process is very dynamic and

in this area and it mainly stems from the experience our researchers have in casting and welding.

Our industry engagement has been frustrating and rewarding at the same time. Australian manufacturing is quite diverse and made up of a lot of small businesses.

We run a lot of workshops, present at a lot of functions. We have also done some more light-hearted experiments like dragons for seven year olds and purple titanium horseshoes for Melbourne Cup - which have gained serious attention and provided insight into what is possible in 3DP.

We try to tell companies that 3DP can make a difference throughout the product development cycle, from prototypes to tools to shop aids and even final parts and sub components.

Since we opened our doors in 2012 we have an increasing flow of people through the lab – 120 in 2012, 230 in 2013 and thus far in 2014 we’re on a pace to have 400.

We’ve produced over 700 objects for 50+ entities, most of whom were industry. We are even making limited production components for people until a commercial enterprise can be self sustaining running the machine we have.

Recently, we have launched the Additive Manufacturing Network – the hub for all things additive and we are now in talks to hand that over to the manufacturing group AMTIL as a place for companies to learn what “it” is, who’s who and a bridge between the researchers and industry within Australia.

The initiative that I am most proud of is the CSIRO Titanium Challenge now in its fourth year. The Challenge is focussed at university students to help promote their knowledge of 3DP and also titanium.

If they can show a novel product that benefits from being printed in titanium that makes any kind of business case with a simple explanation of its innovativeness they will win a 3D Systems Cube personal printer.

The Challenge is now self sustaining due to generous companies like 3D Systems, Boeing, Coogee Chemicals and the International Titanium Association.

In short, the only thing keeping Australia from being a powerhouse in 3D Printing is people. We have the natural resources, the national wealth and the talent. It simply needs to be channelled and focused to go from ore to more.

[John E. Barnes is Leader, CSIRO Titanium Technologies and Adjunct Professor, Royal Melbourne Institute of Technology. Follow him on twitter: @JohnBarnesAM]

Australian Mining, Manufactures Monthly and PACE Magazine invites you to attend the 2014 Women in Industry Awards in Sydney. This exclusive event aims to raise the profile of women within industry, as well as promote and encourage excellence. The winners will represent high achievers from mining, engineering, manufacturing and process control industries, from the most senior to the stars of tomorrow.

VISIT WOMENININDUSTRY.COM.AU TO BOOK YOUR TICKETS

TICKETS Date: Time: Venue: Tickets: Dress:

Wednesday 25 June men in 6:30pm pre drinks, 7pm start Wo Industry Awards Presentation Street, Sydney Ivy Ballroom, 320 - 330 George table of 10 (+ $150 per person or $1,200 for a , pre drinks, GST). Tickets include, admission two course dinner and beverages Cocktail/lounge suit

To view finalists or for more information please visit womeninindustry.com.au or contact Nicole Pusic 02 8484 0944

www.womeninindustry.com.au Media sponsors www.miningaustralia.com.au

Sponsors

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