PACE - Process & Control Engineering - May 2014

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MAY 2014 | VOL.67 NO.4

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MAY 2014 | VOL.67 NO.4

INSIDE PACE

PACE Zenith Awards

Motors & Drives

Top 9 trends

A look at a selection of the many entries received this year

Take special care with valve selection and piping design

Hottest trends represent a convergence of enabling technologies

Settling scores Advanced thickener modeling is delivering huge value for Australia’s minerals industry

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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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Cirrus Media Tower 2, Level 3, 475 Victoria Ave, Chatswood, NSW 2067, Australia Locked Bag 4700 Chatswood Delivery Centre, NSW 2067, Australia Phone: 02 8484 0888 Fax: 02 8484 0633 ABN 80 132 719 861 ISSN 1329-6221 www.cirrusmedia.com.au © Copyright Cirrus Media, 2014

IN THIS ISSUE News 8

Showtime 16

Weidmuller takeover Weidmuller issues takeover offer for supplier of electrical and electronic products and systems for explosion protection

NMW Preview NMW 2014 in Sydney will showcase technologies that help businesses build market-driven manufacturing capabilities

Internet of Things 10

Technology 19

IoT vs. M2M The M2M market’s sustained inability to realise its forecast growth potential provide indicators of the true differences between IoT and M2M Minerals Processing 12

Advanced modeling A 25-year project on thickener modeling that has already delivered huge value for the mineral processing industry has now entered a new phase Masterclass 14

Control in the internet era Next gen PAC meets the future requirements of manufacturing and production companies

Flow control The valve selection and piping design of machinery packages are often different to valves and piping in an ordinary plant Application 22

Solids modeling Modeling is important for common processes Masterclass 24

Barcode vs. RFID RFID and barcode deliver information about products as they move from incoming materials to the production line Awards 26

PACE Zenith Awards 2014 Presenting a selection from the many entries received this year

24 Safety 43

Biometric access control Biometric switches eliminate security risks associated with lost, forgotten or stolen keys, cards and passwords Insight 46

Top 9 emerging technologies This special ARC report highlights selected technologies that will have significant impact over the next several years

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Settling the score with advanced modeling

MAY 2014 | VOL.67 NO.4

OFFICIAL MAGAZINE OF:

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WATER is used in processing most minerals to metals, ranging from simply washing away waste solids, to leaching of target metals with acidic or basic solutions. Having done this, how are the solid and liquid phases then separated quickly and efficiently?

Advanced thickener modeling is delivering huge value for Australia’s minerals industry Gravity thickeners (large tanks) are used widely to for this and flocculants and suspensions assist in producing a clear liquid stream from the top of the tank and a thick sludge of settled solids, which is discharged from the bottom.

Average Net Distribution However, despite their importance and widespread use, thickeners can be erratic and inefficient. Researchers Period ending Sep ’13 from CSIRO are advancing the science and modeling of thickeners using mathematical and computational fluid 6,400 s i e me n s _ q p . p d f P a g e 1 5 / 0 2 / 2 0 1 dynamics, 4 , 1 with 0 : great 4 9 results. : 3 5 According A M to an independent assessment, their work has already delivered well over US$500 million in value to end users.

(See page 12) INSIDE PACE

PACE Zenith Awards

Motors & Drives

Top 9 trends

A look at a selection of the many entries received this year

Take special care with valve selection and piping design

Hottest trends represent a convergence of enabling technologies

Settling scores

The Future of Manufacturing

Making things right Industry 4.0

Making things right with Totally Integrated Automation All automation components working together efficiently to lay the foundation for making things right: faster, smarter and more flexible.

Smart answers for every manufacturing industry requirement – with a full range of products, solutions, and services.

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www.siemens.com.au/futureofmanufacturing

MAY 2014 www.pacetoday.com.au 5

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COMMENT

WHAT’S ON

EDITOR’S MESSAGE

PACE Zenith Awards Gala Dinner 12 June 2014, Melbourne www.pacetoday.com.au/awards

Training and education is a partnership

HAZOP Study for Team Leaders and Team Members 17-19 June 2014, Melbourne www.icheme.org/hazopmel

THE May issue of PACE is always eagerly anticipated each year – both by our readers as well as by the team that puts it together. I continue to be amazed by the skill and engineering capability that exists in the country. This year is no exception with several innovative projects and high achievers.

Sixteen pages of this bumper issue are devoted to the entrants as well as the sponsors who have supported the PACE Zenith Awards 2014. A big thank you is in order to ifm efector, Siemens, B&R Automation/ Daanet, Burkert, Beckhoff, Honeywell Process Solutions, Emerson Process Management and SICK. We already accomplish

Fundamentals of Process Safety 23-27 June 2014, Brisbane www.icheme.org/fpsbris

Kevin Gomez Editor

Women in Industry Awards 25 June 2014, Sydney www.womeninindustry.com.au LOPA training 14-15 July 2014, Sydney www.icheme.org/lopasyd

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

• Test & Measurement • SCADSA & MES • Water & Wastewater • Instrumentation

plenty with limited access to trained engineering resource and the topic of skilled resource continues to consume plenty of web space and column centimeters. The related question is whether the graduates we produce are readily employable. The answer, many of the company heads I speak with, is no.

There is an expectation from industry that graduates should be trained to work with specific equipment and software. Educational institutions are more focused on providing their students with engineering principles which is key to continued learning and development.

It is time for industry to step

up and help address this issue.

A suitable solution is for more companies to offer internships, work placements and student sponsorships. Currently very few process control and automation companies offer such opportunities.

High school leavers need to see engineering as an area that is more likely to offer gainful employment and has strong support from industry, it’s time to stop moaning and start acting.

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

INDUSTRY

Automation acquisitions are hotting up an acquisition binge. Major companies Automation – are breaking down with will try to gobble up new technology acquisitions across the boundaries. For REVIEWING results during the leaders to gain new ground. example, Schneider, which was focussed 2011/2012 timeframe, it seems that In a recent review, Credit Suisse on discrete manufacturing, with the automation majors did not grow analysts point out that manufacturing programmable controllers and related very much. But, hidden behind the automation technology companies acquisitions, recently acquired Invensys a numbers are good financial results which are an attractive long-term investment leader in process automation systems. generated lots of cash. target. They claim that the US$152 Siemens and Rockwell Automation, The stock market measures success billion global industrial automation two other big players in automation for by both growth and profit. With not market has grown 6 percent per year discrete manufacturing, are also looking much real growth on their horizons, the on average, since 2003, which is nearly to expand into process arenas. majors will all start to acquire smaller twice as fast as overall industrial growth.

And ABB, the power and automation A 0 3 1sized 4 _ companies.

0 0 0 _ MAnd e t then, q u i p 2 The - traditionally 1 2 0 1 separate 4 - 0 3silos - 0– 7 T 0 9 company, : 3 1 : 1traditionally 9 + 1 1 : strong 0 0 in andPmedium when new growth occurs it will lead to Process Controls and Discrete Factory process, is moving to strengthen its JIM PINTO

discrete manufacturing capabilities.

There are a couple of other traditionally separate areas that are also starting to merge into the manufacturing automation arena. Assembly robots are moving into higher-level automation systems in factories and plants – creating machines and software for assembly lines and machinery.

Look for automation to become a hotbed of mergers and acquisitions over the next few years.

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

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NEWS

ENERGY

Cut brown coal emissions by 50 per cent CSIRO and its industry partners plan to trial the Direct Injection Carbon Engine (DICE) in Victoria’s Latrobe Valley, the second largest and lowest cost brown coal resource in the world, with the aim of reducing emissions from brown coal-generated electricity by 50 per cent compared to current technology.

Brown Coal Innovation Australia (BCIA) has allocated $1 million to the technology trial, which is designed to maximise the value of Australia’s unique resource by significantly reducing emissions associated with the use of brown coal.

CSIRO Energy Group Executive, Alex Wonhas, said DICE technology may allow Australia to economically develop coal reserves while reducing the environmental impacts of the sector.

“Australia has the second largest brown coal resource in the world but P current A 0 2utilisation 1 4 _ 0 technologies 0 0 _ I NV are carbon intensive so we need to

implement cleaner and more efficient ways to generate energy from coal,” Dr Wonhas said.

“CSIRO is excited about the potential for DICE to lower power costs, halve carbon dioxide intensity and create a new export market for both brown and black coal.”

The advanced coal technology involves converting coal or biomass into a water-based slurry that is directly injected into a large, specially adapted diesel engine. The fuel burns to produce intense temperature and pressure in the engine, which provides highly efficient power to turn electrical generators.

An existing laboratory scale prototype engine will trial fuel based on Victorian brown coal and this work will be followed by trials using the same fuel in a large scale test engine in Japan.

This research will help determine DICE 1whether 2 0 1 4 - can 0 2 enable - 0 3 brown T 1 0 coal : 4 1 : to produce Australia’s lowest cost,

reduced CO2 electricity for the staged replacement of existing coal plants.

The project is supported by industry partners including Exergen, Ignite Energy Resources, AGL, MAN Diesel & Turbo and EnergyAustralia.

“The energy sector has long been a lynchpin of our country’s economic prosperity and coal is expected to continue to make an important contribution in decades to come. I believe CSIRO has a critical role to play in supporting industry to minimise the environmental impacts from coal through the application of world leading science,” Dr Wonhas said.

“Thanks to the support of BCIA, we can partner with industry to deliver solutions like DICE that will ensure more efficient and sustainable use of our brown coal reserves and give Australians continued access to affordable and 3reliable 6 + 1 energy 1 : 0 supply.”

0

www.bcinnovation.com.au

The Direct Injection Carbon Engine trial is designed to maximise the value and reduce emissions associated with the use of Australia’s brown coal resource. (Image: Murray McKean)

COMPANIES

Protect Engineer

Evo Foxboro

Maintain

Operate Manage

8 www.pacetoday.com.au MAY 2014

Weidmüller submits public takeover offer to shareholders of R. STAHL WEIDMÜLLER has issued a public takeover offer for all shares of R. STAHL. The takeover offer will provide a price of EUR 47.50 per share of R. STAHL. R. STAHL is one of the world’s leading suppliers of electrical and electronic products and systems for explosion protection.

But it may not be all smooth sailing. R. Stahl’s executive board released the following statement: “Representatives of company Weidmüller already tried to talk to the family consortium as our principal shareholder.

“The family consortium refused entering into discussions. In the past, R. STAHL has been confronted with such inquiries from time to time. In all these cases, the family consortium always stood by the company in order to continue to maintain the company’s independence.

“We, the Executive Board, think that we will be able to continue the positive developments of the last decades and continue to lead the company in its present structure to a successful future. That is why we will go on concentrating on our core competences.”

With R. STAHL, Weidmüller is pushing ahead its objective of developing itself from a components manufacturer into a solutions provider in all of its business areas. This entails a focus on comprehensive connection systems and connectivity solutions.

Dr Peter Köhler, Chief Executive Officer of Weidmüller, said: “The combination with R. STAHL would be an important step to offer a broader product range to our respective customers, thereby allowing us to position ourselves even better in the face of international competition.

“Company size is of crucial importance in this environment. Together, we will be able to offer better solutions to our customers at competitive prices.”

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NEWS

SOFTWARE

End of XP support to affect industrial systems SUPPORT for Windows XP officially ceased on April 8, 2014. In effect, Windows will no longer provide users with security updates or technical support for the 12 year-old operating system.

Windows has stated that “PCs running Windows XP after April 8, 2014, should not be considered to be protected, and it is important that you migrate to a current supported operating system.”

This issue will impact industrial automation. The discontinued support impacts millions of both personal and professional users worldwide, including the many companies that have implemented Windows XP in industrial automation applications.

Windows XP is the most widely used in industrial automation.

As the longest-supported Windows operating system, XP is most widely used in industrial automation, which Cybersecurity is the largest concern to protect systems from attacks, users means that potential issues arising from related to the continued use of will be exposed to new threats that can thePdiscontinued affect of the operating A 0 2 1 4 _support 0 0 0 could _ AM S a1 Windows 2 0 1 4XP- in 0 industrial 1 - 1 4 Tautomation.

1 1 : 4 9 : 0 exploit 8 + 1 vulnerabilities 1 : 0 0 large number of end users.

Without the ongoing security updates system. Such threats exist to industrial

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Since the original announcement, many end users have upgraded to more modern operating systems that Microsoft says will continue to be supported. Larger companies – especially those driven by IT departments – were typically more proactive in making advance preparations to upgrade early where necessary. In contrast, smaller companies – those that may be less driven by IT – have delayed upgrades until absolutely necessary, with many yet to convert.

IHS believes that the overall impact on the industrial automation equipment market will be fairly modest. A large stock of older equipment with basic flaws in its security architecture remains and that could prove problematic. andrew.orbinson@ihs.com

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MAY 2014 www.pacetoday.com.au 9

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OPINION

INTERNET OF THINGS

What’s the difference between IoT and M2M? Suppliers of M2M and IoT applications have different competencies, writes Chantal Polsonetti.

I

NDUSTRY discussions on the these data are traditionally targeted at troubleshooting, remote updates, and industrial Internet of Things point solutions in service management other remote capabilities that reduce the (IoT) and its potential benefits applications. need to deploy field service personnel. have raised numerous questions Rarely, if ever, are the data integrated In industrial IoT solutions, the regarding distinctions between the IoT with enterprise applications to help “what, how, and why” of remote and its forerunner, machine-to-machine improve overall business performance. device access involves much broader (M2M) communications. Remote device Integration of device and sensor brushstrokes. The IoT accommodates access is a core common deliverable for data with Big Data, analytics, and not only the same devices/assets/ both solutions, so questions concerning other enterprise applications is a core machines as M2M applications, but also how to distinguish between the two are concept behind the emerging Internet low-power and passive sensors as well as understandable. of Things. This integration is key to inexpensive devices that may not be able Commonality between the two achieving numerous benefits throughout to justify a dedicated M2M hardware solution types largely ends there and the manufacturing enterprise and, module. IoT devices communicate via they differ in how they achieve remote ultimately, growth in the marketplace. standards-based IP networks and their device access. For example, traditional Access to remote devices, machines, data are incorporated into enterprise M2M solutions typically rely on assets, and other entities provides a applications to enable not only point-to-point communications using primary value proposition for both improved service, but also operational embedded hardware modules and either M2M and IoT solutions. M2M improvement and new business models cellular or wireline networks. In contrast, applications are typically composed such as product-as-a-service.

IoT solutions rely on IP-based networks of hardware modules embedded in The ability for applications to interface device data to a cloud or a machine at a customer site that throughout the enterprise to access middleware platform. communicate via proprietary cellular device data to enable performance The M2M market’s sustained or wireline networks to a dedicated improvements, business innovation, or inability to realise its forecast growth software application, often at the other possibilities, clearly distinguishes potential, and the reasons for that supplier’s service operation. the potential of IoT versus M2M. This failure, provide telling indicators of This capability allows the IoT-based data delivery is usually to a the true differences between the IoT device/ asset/ machine supplier to cloud, enabling access by any sanctioned vs. M2M. While M2M solutions reduce its service management costs enterprise application. In contrast, M2M PA0 5 1 3 _ 0 0 0 _ SEI . p d f Pa ge 1 1 8 / 0 4 / 1 3 , 1 0 : 2 4 : 1 7 AM AEST offer remote access to machine data, through remote diagnostics, remote typically employs direct point-to-point

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communication. The cloud-based architecture also makes IoT inherently more scalable, eliminating the need for incremental hard-wired connections and SIM card installations. This is one reason why M2M is often referred to as “plumbing,” while the IoT is seen as a universal enabler.

Enterprise integration, higher-order benefits potential, and the ability to accommodate more and a wider variety of devices underscore why the IoT market bears much greater potential than traditional M2M. Customers of M2M and IoT applications alike aim to reduce unplanned downtime, and both types of solutions offer the potential to improve service management, a higher order benefit. The IoT excels here as well, providing the ability to assess these issues from a system level as well as at the device or machine level and applying analytics and processing Big Data to tweak out incremental benefits.

[Chantal Polsonetti (cpolsonetti@ arcweb.com) is Vice President, ARC Advisory Group.] www.arcweb.com

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IN FOCUS

Settling the score with advanced modeling A 25-year project on thickener modeling that has already delivered huge value for the mineral processing industry has now entered a new phase. Jodie Parry investigates what the world’s first three-dimensional thickener model will deliver to industry.

W

ATER is used in processing most minerals to metals, ranging from simply washing away waste solids, to leaching of target metals with acidic or basic solutions. Having done this, how are the solid and liquid phases then separated quickly and efficiently?

Gravity thickeners (large tanks) are used widely to for this and flocculants and suspensions assist in producing a clear liquid stream from the top of the tank and a thick sludge of settled solids, which is discharged from the bottom.

However, despite their importance and widespread use, thickeners can be erratic and inefficient.

Fluid dynamics

Researchers from CSIRO are advancing the science and modeling of thickeners using mathematical and computational fluid dynamics, with great results.

According to an independent assessment, their work has already delivered well over US$500 million in value to end users.

“Thickeners suffer from limited throughput, poor solid-liquid separation, operational difficulties and high consumption of expensive flocculants,” Dr Phillip Fawell, CSIRO project leader, says.

“In tailings applications, they frequently fail to deliver the desired solids concentrations, leading to the waste of water and the need for excessively large tailings disposal dams that can cause environmental issues.

In response, Dr Fawell and his team are creating the world”s first threedimensional full thickener model as part of the existing multi-faceted AMIRA International project.

“We are applying the models to systematic studies of different designs 12 www.pacetoday.com.au MAY 2014

Researchers from CSIRO are advancing the science and modelling of thickeners using mathematical and computational fluid dynamics, with great results.

The project has been running for over 25 years has been strongly supported by the Australian and International minerals industry

test that will give the parameters needed to characterise the settling and consolidation of a flocculated feed for process or control modelling from a series of simple cylinder tests.”

Standard method and operating conditions (changing solids concentration, volumetric flows, dosages) to establish best performance guidelines,” he says.

“Our team expects to deliver control strategies for dealing with specific issues or performance targets.

“We”re also developing a new

Dr Fawell believes this could end up being a new standard method of all such testing.

The project, or series of projects, which has been running for over 25

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IN FOCUS

years has been strongly supported by the Australian and International minerals CSIRO has been able to industry with sponsorship funding of pass on to sponsors their over $20 million since inception.

Sponsors benefit from the sharing of broader understanding of key information and technology from each of the projects, including online how flocculation should be resources such as a knowledge base, a done in gravity thickeners thickener self-appraisal tool, and process models and training presentations.

They can also engage the research team to work on their site-specific [Dr Phillip Fawell (phillip.fawell@ problems. This has resulted in significant csiro.au) is Research Team Leader improvements to the performance of at CSIRO. His research focuses on more than 150 thickeners. flocculation under highly controlled “What has impressed me is how conditions that reflect industrial CSIRO has been able to pass on to parameters. CSIRO’s Minerals Down sponsors their broader understanding Under Flagship is one of the largest of how flocculation should be done minerals research groups in the world and in gravity thickeners,” Gray Bailey, has a proven track record of working with Program Manager from AMIRA industry to deliver innovative solutions.

International, says.

Through targeted research CSIRO “There”s no better feedback than addresses the industry’s challenges, driving hearing from sponsors who have gone sustainability, productivity and innovation back to their sites, looked at their for their collaborative partners and clients.] thickeners in 0 : 1 5 : 4 Thickeners P A 0 5and 1 4said, _ 0“Now 0 0 _that E Lmakes E 1 2[This 0 1 story 4 - 0first 4 appeared - 2 8 T1 9 + 1 0 : 0suffer 0 from limited throughput, poor solid-liquid separation, operational difficulties and high consumption of expensive flocculants. sense!”” resourceful: www.csiro.au/resourceful]

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MASTERCLASS

Process control in the internet era The next generation PAC meets the future requirements of manufacturing and production companies and will also protect their investments by delivering high levels of performance, flexibility and reliability across many different applications found in the production industry.

In today’s environment, many businesses are focussed on maximising output from existing installations. A way that manufacturers and producers are looking to improve performance and overcome their challenges is by making better use of the vast amounts of information which exists within their operations.

This information exists across the many devices, equipment, applications and systems that are required for manufacturing operations to function effectively. In the past, extracting valuable information required complex integration projects to be undertaken to tie together the various disparate and proprietary networks into some semblance of an integrated system.

Today, manufacturing companies are taking advantage of the information technology and operator technology

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The move to Ethernet enabled Programmable Automation Controllers (PACs)

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CHNEIDER Electric has launched the new Modicon M580, the world’s first ePAC, the next generation PAC (Programmable Automation Controller) with Ethernet built right into its core.

The M580 gives industrial plant teams the power to design, implement, and run a process that actively employs all the benefits of open networking, such as increased visibility to key process data and events, enhanced transparency and consistency of information, and large capacity for data traffic.

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Cyber-security threats from external or internal sources are issues confronting all manufacturing companies today 14 www.pacetoday.com.au MAY 2014

trend, where open IT standards have extended to the shop floor via the process control system (PCS).

This improves connectivity and interoperability and allows them to become a connected enterprise.

The move towards the connected enterprise requires a technology architecture that is capable of moving large volumes of data and information from the many connected devices found across the operation. This data is

moved to the higher level applications and systems used for visualisation and analysis. At the centre of this technology architecture is the Programmable Automation Controller (PAC).

The traditional role of the PAC

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PRESENTED BY

and its predecessor, the PLC, has been to monitor and control the devices, equipment, applications and processes found within the industrial operation.

Ethernet development to suit industrial processes

In the 1990s, vendors recognised that the inherent advantages of Ethernet would make it an attractive fieldbus network and began to build open application protocols based on Ethernet. The protocols used layers one and two of the Ethernet stack and a new application layer optimised for automation applications.

The resulting protocols needed to have the flexibility to meet a range of industrial requirements while being easy to use for non-IT personnel within the plant.

An additional requirement was for these open protocols to use standard Ethernet hardware technology so users could utilise common off-the-shelf network components. Now large device catalogues allow customers to pick best-in-class devices for their system, and be assured that these devices will work together.

Limitations to Ethernet

Concerns pertaining to the use of Ethernet technology on the ground level have chiefly focussed on a nervousness regarding the real-time capabilities and robustness of Ethernet to operate in the harsh environment of a plant floor.

While some of these concerns

The new generation PAC with Ethernet at its core ensures that performance exceeds the demands placed upon it both now and in the future may have been valid previously, developments in Ethernet technology mean they are no longer an issue.

Advantages of Ethernet in industry

Ethernet technology has evolved to meet the needs of the industrial automation market and its capabilities provide significant advantages compared to the older proprietary networks.

Some of these advantages include: • Reduced cost to install, start up and commission – Ethernet cabling accelerates the path towards distributed input/output replacing the traditional, more expensive I/O extension and field bus cables.

• Improved network transparency and data visibility – Ethernet transparently links all enterprise levels from control to the field. As a result, operators can harvest near real-time data from key process areas.

• Easy connectivity to remote applications – Ethernet enables easy access to either onsite or cloud-based enterprise applications such as manufacturing

execution systems (MES), enterprise resource planning (ERP), enterprise asset management (EAM) and supply chain management (SCM).

• Flexible reconfiguration capabilities – Ethernet provides high speed, open connectivity that gives operators the critical ability to change automation configurations and architectures on the go, without stopping the process.

• Open integration environment – Ethernet delivers single-seat instant access to applications without the limitations of proprietary software interfaces and protocols.

• High information bandwidth – Ethernet networks can process large quantities of data in a fast and constant flow end-to-end which allows users to build highly efficient, zero-bottleneck process architectures.

• Sustainable evolution path – Ethernet is the preferred industry standard for open networking, allowing easy integration of third-party devices and an easy evolution path for the future.

The new generation PAC with Ethernet at its core not only ensures

that performance exceeds the demands placed upon it, both now and in the future, but that it achieves this while maintaining high levels of security.

Cyber-security threats from external or internal sources are issues confronting all manufacturing companies today, and deliberate or accidental breaches to system integrity have the potential to impact not only profits but also people and the environment.

Not only will the next generation PAC meet the future requirements of manufacturing and production companies, it will also protect their investments by delivering high levels of performance, flexibility and reliability across many different applications found in the production industry.

For more information on Modicon M580 ePAC contact your local Schneider Electric representative. www.schneider-electric.com

More Information ARC whitepaper http://bit.ly/1lYrq2J M580 brochure http://bit.ly/1mQmLUn Cybersecurity whitepaper http://bit.ly/1hEIOdf

MAY 2014 www.pacetoday.com.au 15

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NMW PREVIEW

Sydney leads the way to manufacturing’s high tech future NEWS that Sydney has overtaken Melbourne as Australia’s largest manufacturing centre speaks to the success of its many niche manufacturers, says Anthony Reed, Exhibition Director of National Manufacturing Week 2014 (NMW), in Sydney from 13-16 May. It is also good news for visitors to NMW, which is constantly evolving to reflect the latest trends. Designed to showcase technologies that help businesses build innovative, market-driven manufacturing capabilities, NMW is a significant opportunity for local manufacturers to arm themselves with the tools to maximise productivity, evolve their product offering and grow their business.

NMW will also put visitors in direct contact with research providers at its R&D Hub.

R&D Hub highlights include: • Keynote Address: Professor Ian Chubb, Chief Scientist of Australia.

When: Tuesday 13th May, 10:30am-11:00am • The NSW Manufacturing Sector – Innovation and the Future: The Hon. Andrew Constance, MP. When: Wednesday 14th May, 11:00am 11:15am • The Imperative for Innovation: Marlene Kanga.

When: Wednesday 14th May, 10:20am-11:00am

16 www.pacetoday.com.au MAY 2014

Here is a selection of this year’s exhibitors: 1 TXM – Stand 2422

Learn how lean thinking can help your business survive and grow from Australian lean manufacturing consultants, TXM. TXM has enabled over 100 Australian manufacturers across a diverse range of industries to improve their competitiveness and productivity and to grow in today’s competitive environment.

The TXM team bring practical manufacturing experience to your business as well as a deep understanding of lean manufacturing principles. The team see themselves as manufacturing people first, consultants second.

This means they can get to grips with the issues in your business quickly and work with your team to deliver practical solution. Their experience extends over a broad range of manufacturing industries including engineering, metal manufacturing, food and beverage, construction materials, machinery manufacturing, boat building, transport components, electronics, high technology, plastics, packaging, pharmaceuticals etc.

2 CGB Precision Products – Stand 2518 CGB will be presenting its range of

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specialty bearings and engineered products, including major developments for plain bearings and the spindle bearing markets: • Bowman-Bowmet Bearings – Bowman International Ltd, of the UK have developed the new BowMet range of rolled plain bearings/ bushings manufactured in the material ToughMet Spinodal bronze from Materion. BowMet rolled plain bearings/bushings are said by the company to deliver increased load carrying capacities, heat resistance, speeds, corrosion capabilities and a long service life.

• CMC Grooved Roller Bearings – CMC have created a product for the spindle bearing market with their patented grooved roller bearing. The new bearings have radial, thrust and combination load option, with space saving opportunities for new and existing designs.

3 Colt Group – Stand 2923

Internal heat generating processes and the typical Australian climate turn many industrial production and warehouse facilities into uncomfortable, unproductive and unsafe hot boxes. In some applications, the hot temperatures affect the process and therefore quality of the end product.

Most businesses accept this as a fact of life, but Colt has an innovative, energy efficient and climate friendly system which aims to solve this problem.

Colt International’s Coolstream evaporative cooling and ventilation system is an innovative, energy efficient, green space cooling systems for industrial applications. It is intended to provide comfort for people and controlled environments for workflow processes.

Colt combines the Coolstream

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NMW PREVIEW

system with its range of natural roof ventilators to extract hot air at eaves or roof level whilst utilising the Coolstream unit to circulate cool air at lower levels.

6 Staetite Fasteners –

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Stand 2438

4 Precision One – Stand 1209

Precision One is a subsidiary company of Thermoway Industry of Taiwan. The company specialises in manufacturing thermocouple equipment and heaters.

They also distribute leading industry brands including Omega, Inor, TYCO, Johnson Metthey and more.

Their current customers are spread across various industries including steel, power plants and small and medium enterprises. They can develop and customise products to suit your needs.

Today the company’s product range new to the Australian market and are includes blowers, compressors and air currently available in the range from knives; pumps, mixers and meters; 7.5 to 55 kW. Main features of these heaters, air handlers, split systems and compressors are energy efficiency and cooling fans; gas, oil and process burners ease of maintenance. as well as boilers.

Roots blowers are presented both as 5 Hurl Nu-Way – Visitors will see their compression bare shaft models to retrofit on existing Stand 2622 product range, including Hitachi screw base and complete blower packages Hurll Nu-Way has been importing air compressors, GE Roots blower designed to suit any application. topPquality knives.

A 0 5 products 1 4 _ 0to0 Australian 0 _ E M E 2 - packages 1 2 0 and 1 4 Secomak - 0 4 - air 2 4 T 1 4 : 5 0 : Vacuum, 1 8 + 1 pressure 0 : 0 0 and high pressure manufacturers overfora ANZ-HR.pdf hundred years.

Hitachi blowers are available.

M&Mfor ads_hori 1 4/24/2014 11:17:24 AM screw compressors are

Staetite is Australia’s largest private Australian owned manufacturer of cold forged components, certified to ISO/ TS16949.

The company services a range of industries – from automotive, transport, mining, building, manufacturing, and agricultural through to general hardware and industrial supplies.

Staetite can custom make products to a variety of specifications, in a ange of materials and surface finishes.

In-house capabilities include tool manufacture and design, forging, rolling, sems assembly, vision sorting and heat treatment.

Value added services such as kit assemblies are also available.

Their capabilities are further complimented through licensed products such as MAThread and the agency line Pratley DIY and Industrial adhesives.

Rosemount® Reliable measurements for better operating results

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For over 50 years, Emerson has been the leader in providing reliable measurements in the mining & mineral processing industry. Providing only the best in class instrumentation, Emerson is poised to prepare you for any difficult application challenges and position you with perfect control.

Learn how Emerson can help you at www.rosemount.com/flow For enquiries, please email to emersonprocess.australia@emerson.com The Emerson logo is a trademark and a service mark of Emerson Electric Co. © 2014 Emerson Electric Co.

MAY 2014 www.pacetoday.com.au 17

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NMW PREVIEW

7 Xtralis – Stand 2822

Xtralis plans to introduce VESDA-E, a smoke detection solution for automated manufacturing plants at NMW. Described by the company as being part of the next generation of air-sampling smoke detection systems, it can discriminate between different smoke and particle types.

This is a major benefit for manufacturing operations characterised by background levels of manufacturing smoke, welding fumes, dust and soot that can trigger nuisance alarms, resulting in business disruption, and costly visits by emergency services.

The system’s intelligent flair detection technology and VESDA Analytics mean targeted detection of threats is possible without nuisance alarms.

VESDA WireTrace allows specific targeting of burning wire events P Aat0 level 3 1 close 4 _ 0to0the 0 ambient _ PLC environmental smoke level.

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18 www.pacetoday.com.au MAY 2014

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IN FOCUS

Flow control and piping in machinery The valve selection and piping design of machinery packages are often different to valves and piping in an ordinary plant, writes Amin Almasi.

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VALVE and piping system in a machinery package usually controls the flow of fluids through machinery and other items in the package.

Valves are essential parts of a machinery package and play important roles in operation, performance and reliability. The valve selection and piping design of machinery packages are often different to valves and piping in an ordinary plant.

Gate valves

The gate valve is a common type of block valve for on/ off service. Typical gate valves use a wedge type gate.

Gate valves are usually used in sizes from 1” up to 24”, in pressure classes from 150# to 2500# with flanged or, in rare cases, butt-welding ends. Smaller valves or other connection types such as threaded are not recommended in machinery packages.

Gate valves are usually used for wide ranges of services and temperatures up to, say, 530°C. They are usually one-piece and wedge-shaped: either “solid” or “flexible” wedge.

The “flexible” wedge design provides for a small amount of angular deflection of the disc faces to provide for a better engagement with the body seats.

This allows the wedge to accommodate some deviation from the ideal seat position caused by deflection of the valve body due to line stresses or thermal expansion, thereby resulting in improved seat tightness and reduced potential for gate binding in the closed position.

Gate valves with a special “pressure seal” bonnet closure design that avoids bonnet flanges are available for class 600# and higher. They might be used in machinery packages of light gas services such as gases containing hydrogen.

The pressure seal bonnet design uses a compact body-bonnet joint that is pressure-assisted, so that with increasing pressure the bonnet seals more tightly. The

Figure 1: An example of a ball valve.

Check valves with a bolted or welded cover in horizontal lines should always be oriented with the cover upwards use of this design should be restricted to services that are not highly corrosive to avoid damage to the pressure seal element.

Gate valves (particularly those larger than about 4”) oriented in any position other than with the stem vertical may result with the disc getting hung up against the inside body guides. As the result the valve may get stuck and it cannot operate. Even with the stem vertical, there may be an accumulation of dirt and other deposits between the seats such that the valve may not close fully.

For gate valves, trim is defined as the seating surfaces of the closure member and body seats as well as the material of the stem and backseat bushing.

A consideration to avoid galling of valve seats is to provide a difference in hardness between the mating seating surfaces except when both surfaces are hardfaced. Other gate valve designs used in plants include double-disc designs, “knife gate” designs and special “slide” valves which used in high temperatures, highly erosive fluid services and other difficult applications.

They are less common for machinery packages.

Ball valves

Ball valves are another valve type designed mainly for on-off block valve operation. Ball valves are often not recommended for throttling service. However, they have been used in special throttling services or flow control applications, such as some specific anti-surge systems in turbo-compressors.

Their throttling or flow control behaviors might be highly nonlinear. Some experts believe that ball valves’ applications other than on-off services should be limited to very special cases where other control valve types cannot be used.

Ball valves are known as “Quarter Turn” valves as a 90° turn (quarter turn) of the stem provides for MAY 2014 www.pacetoday.com.au 19

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IN FOCUS

full-open to full-closed position. This is one of the reasons for their nonlinear behaviors (movementopening curve) in control services. On the other hand such a small movement from fully-closed to fully-open might be useful in some special anti-surge applications.

Usually three port designs (sizes) can be used for a typical ball valve: “full bore”, “single reduced bore”, and “double reduced bore”. A “full bore” (full port) ball valve has an over-sized ball so that the hole in the ball is the same size as the connected piping resulting in lower friction loss. In a “reduced bore” ball valve, the flow through the valve (hole at the ball) is one pipe size smaller than the valve’s pipe size resulting in flow area being smaller than the pipe.

Ball valves are available in two design options: “floating ball” and “trunnion” mounted ball. In floating ball designs, the ball is held between fixed, resilient upstream and downstream seats. Trunnion designs are usually found in higher pressure and larger size applications where the top and bottom of the ball are held in position in the valve body by means of a short shaft or other means and the seat rings are spring loaded against the ball.

Ball valves are available with both metallic and nonmetallic seats.

Nonmetallic seats and seals can limit the pressure-temperature rating of the valve. Some ball valves are provided with soft seats, for instance, a type of “Poly-tetra-fluoro-ethylene” (PTFE) to provide for tight shutoff and reasonable turning torque requirements, but with a pressuretemperature limitation due to the soft seat material.

As an indication, seat material pressure-temperature limitations could be about 175°C for PTFE and around 200°C for reinforced PTFE. Metal seated ball valves, often with a hard-facing on the seating surfaces, have been widely used in high temperature and high pressure services as well as applications exhibiting erosive and abrasive characteristics.

Plug valves

Plug valves are designed for on-off services using a truncated cone-sealing element that is typically supported either by a thin grease film (lubricated plug) or by a polymer sleeve (sleeved plug). Plug valves are not recommended for throttling services.

Some plug valve designs are metal seated to provide for higher temperature services. Plug valves are useful

Double plate valves in horizontal flow should be installed with the pins vertical 20 www.pacetoday.com.au MAY 2014

They are also available in a wide range of construction materials such as gray iron, ductile iron, bronze, steel, nickel-base alloy, and special alloys.

Although butterfly valves might be operable in any orientation, the preferred orientation for butterfly valves is with the stem horizontal to avoid debris collection and bearing wear that may occur with the stem vertical.

Check valves

Figure 2: An example of a glove valve. for tight shutoff applications and for highly corrosive and erosive services because of its large sealing area.

Lubricated plug valves with nonmetallic components (such as seals, sleeves, liners, diaphragms, seats, and sealants) may limit the applications of valves to more restricted pressures and temperatures.

As a very rough indication, stem seals (or packing) might have a temperature range of –30°C to 120°C. Non-lubricated plug valves may use metal seats as sealing elements or hydrocarbon-resistant plastic of elastomer sleeve linings.

Butterfly valves

Butterfly valves are available in several configurations including double-flanged, and wafer (lug) types that provide more or less tight shutoff in the closed position; they are also suitable for flow regulation.

The wafer type butterfly valves, particularly for large sizes (say above 4”), can offer the most compact valve design for machinery packages. They can be used in some very compact skid designs.

Check valves prevent undesirable backflow without any outside intervention. A typical example is to prevent backflow into a pump or a compressor either when the pump (or the compressor) is shutdown or from the discharge side of a pump (a compressor) installed in parallel. Machinery damages could occur if such backflow was not prevented.

Check valves should usually be properly sized for the flow conditions to avoid mechanical damage resulting from the disc opening and closing against the seats if the flow is not sufficient to keep the disc fully open. In some conditions, check valves having the same size as the line size may be too large.

Since for typical designs the closing force on check valve seats results from a combination of pressure differential, gravity and closing spring force (where provided), typical metalseated check valves may not provide fully tight shutoff.

In other words, “a check valve usually leaks”. This should be respected for machinery package design. On the other hand, they may provide tight shutoff in some situations even if not intended.

Resilient seated check valves, which are specially designed ones, are available for improved tight shutoff performance.

A special design is the “stop-check” valve where the piston-type disc can be closed against the seat by mechanical means similar to a globe valve operation. These valves, often used in steam services, serve dual functionality; acting like a check valve in normal operation and providing block valve capability when needed.

Proper orientation of a check valve is essential for correct operation. Check valves with a bolted or welded cover in horizontal lines should always be oriented with the cover upwards, because the valve’s internal check element is designed to function in this orientation.

Check valves installed with the cover turned to the side will probably not operate properly unless spring loaded by the manufacturer for this purpose. Double plate valves in horizontal flow should be installed with the pins vertical.

Some types of check valves, notably the double plate, spring assisted and swing-type, may also work in vertical lines with the flow upward. Y-pattern check valves, which could be lift type or modified swing type (tilt disc) internals, can usually be used in either

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Unbeatable Control, Precision, and Flexibility

horizontal or vertical-up lines with flow upward Globe valves The globe valve design is intended to control flow equally well. and may also be used as an isolation valve. The globe To minimise wear or damage to internal parts, valve design minimises seat wear during valve opening check valves should not be located in areas of turbulent and closing as the disc moves toward and away from flow; such as adjacent to changes in direction or the body seat providing a uniform clearance and flow machinery discharges. around the disc edge.

When a check valve closes on flow reversal, it is Globe valves are suitable for throttling ideally when possible for a large surge force to develop due to the the disc is at least 20 percent open; otherwise flowmomentum of the stream acting against the closed induced vibration may valve. Typically check valve result in valve damages. designs that close quickly Valve sizing is important to can minimise the adverse The selection of check valves needs ensure that the valve is not effect of the flow reversal too large for the intended by preventing the build-up special consideration when used in flow condition. of a rapid reverse flow. pulsating or unstable flow such as in Where conditions Typical applications are require the valve to be less at pump discharges. Fast reciprocating compressor services than 20 percent open, the acting check valves are the use of a non-rotating disc ones with a small travel (for rather than the standard instance, the aerodynamic swivel disc should be considered as an option. This is to axial flow check valves also known as nozzle check reduce harmful disc and stem vibration, but may result valves), small mass of the closure member (for example, in accelerated seat wear and leakage. dual plate check valves), and short distance between For larger size and higher-pressure class valves, a the centre of rotation and centre of the closure member provision to guide the disc throughout its travel should (such as tilting disc types). be considered for better operation and reliability. A The selection of check valves needs special guided disc ensures that the disc will not deflect or consideration when used in pulsating or unstable flow cock during travel, resulting in uneven seat wear and such as in reciprocating compressor services as they may leakage. open and shut rapidly as the flow-rate changes.

[Amin Almasi (amin.almasi@ymail.com) is a rotating This may lead to hammering and valve damages. machine consultant in Australia. He specialises in rotating Some difference of opinion exists on this subject, but machines including centrifugal, screw and reciprocating generally dual plate, tilting disc, and axial flow (nozzle) compressors, gas turbines, steam turbines, engines, pumps, type check valves are the types suggested for pulsating condition monitoring and reliability.] and unstable flow.

NI LabVIEW system design software and reconfigurable I/O (RIO) hardware lower cost and shorten design time by integrating motion, vision, and I/O within a single software development environment.

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

Š2013 National Instruments. All rights reserved. LabVIEW, National Instruments, NI, and ni.com are trademarks of National Instruments. Other product and company names listed are trademarks or trade names of their respective companies. xxxxx

MAY 2014 www.pacetoday.com.au 21

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IN FOCUS

Benefits of solids modelling Modelling the solids section of a process is important for common processes including specialty chemicals, agrochemicals, metals and mining, pharmaceuticals and biofuels.

I

GNORING or underestimating the need for rigorous design and optimal operation of the solids section of processes in industries such as mines, food processing, chemical, agrichemical, and pharmaceutical industries, may reduce design efficiency, encourage over-design of equipment, add unnecessary operating energy costs, and result in reduced throughput and lower product quality.

In addition to fluids, many industrial processes PA0 5 1 4 _ 0involve 0 0 _solids DEL processing steps that often have a

22 www.pacetoday.com.au MAY 2014 Australia ad(122X210).indd 1

significant influence on the overall process performance, product quality, or energy demand.

In general, most industrial processing plants have liquids and solids sections. The solids section has to fulfil one or more of the following tasks: adjust the particle size distribution (crushing/grinding, classifying, compacting), formulate particles (granulation, crystallization), adjust the moisture content (drying), change the composition by chemical reactions 1 2 0 (fluidised 1 4 - 0 bed 4 - reactor), 1 7 T 1and 1 : 2 0 : 3 6 + 1 0 : 0 0 separating solids from liquid or gas Figure 1: Solids unit operations available in Aspen Plus V8.4

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Helping to put you in Control

Digit - TLH

streams (cyclone, centrifuge, filters).

The solids section is typically only a small part of an overall production process, but may have a significant influence on the overall process performance and the quality of the final product. The process engineers model the fluid part of a process in a simulator software tool, while particle scientists within the same company model the solids part of the process in a spreadsheet tool.

There is limited sharing of process data with these disparate software tools resulting in data redundancy, inconsistency, and inaccuracy.

Optimisation of the overall process design is more or less impossible using this historical workflow.

The second challenge is that to reduce the risk of bottlenecks, equipment is often over-designed or installed in excess leading to inflated capital costs. Rigorous solids’ modelling encourages the selection of appropriately sized solids processing equipment and reduced recycle streams to minimize the load of equipment. Examples of solids processing equipment that is often overdesigned include crushers, compactors, and dryers.

Thirdly, for many applications, intermediate or final products need to fulfil very tight moisture content specifications to be suitable for use in subsequent process steps, or to be sold as final products. Managing the moisture content requires energy, and without detailed modelling, energy costs can be high.

Most importantly the design of a profitable process hinges on the throughput and the quality of the final product. The formulation of particles is an example of where both quality and quantity can be improved. Starting from a solution or slurry, particles are formulated with the aim to produce a dust-free, free-flowing powder with welldefined properties. This is done in most cases by crystallization, granulation/agglomeration, or spray drying. The design and operating conditions of these units determine the particle size distribution (PSD) and moisture content of the product, and incorrect design and operation results in reduced throughput and inferior quality.

The solids section of a process

Battery powered temperature & humidity logger that can store up to 260k readings. Up to 4 year battery life. 7 log intervals, 2 programmable alarm thresholds.

Download to .csv files over USB to Windows based computer. IP58 enclosure included.

SKU: LAJ-061 Price: $86 each + GST

100 VA Control Transformer The T series control transformer is used to “step down” a 240 VAC power source to a 24 VAC output. The primary coil (240 VAC side) can be wired for 230 VAC, 240 VAC or 250 VAC. SKU: TRA-001 Price: $103.50 each + GST

4 Channel Thermometer

Figure 2: New workflow: Holistic process model of the urea synthesis and granulation in Aspen Plus V8. plant, in many instances, is considered a minor part of an overall production process, but may have a significant influence on the overall process performance and the quality of the final product.

In response to the lack of a commercially available industrial simulator to rigorously model the solids section of an industrial process, the standalone solids simulator SolidSim was developed by solids experts and industry participants.

SolidSim introduced a generally applicable flowsheet simulation system to rigorously describe granular solids and the machines and equipment of particle technology.

Subsequently Aspen Tech acquired SolidSim, and the Aspen Plus V8 model library was enhanced with the SolidSim technology, incorporating unit operations models, including models for crushing and grinding, classification, drying, crystallization, granulation and agglomeration, gas/ solid, and solid/liquid separation.

In addition, an easy-to-use workflow for the definition of particle size distributions was introduced with an enhanced results representation that allows visualising particle size distributions (cumulative, density, or RRSB), and apparatus-specific results with the click of a button. Also, characteristic diameters such as d25, d50, or the Sauter Mean Diameter (SMD) are shown as stream results.

The new solids modelling library

is a combination of the legacy solids modelling unit operations and the new models introduced from SolidSim. Currently 20 solids unit operations are available, representing over 70 different types of equipment.

Also included are the conveying and fluidised bed models and the spray dryer model, and the ability to model reactions in the fluidised bed model.

Since Aspen Plus has historically focussed on fluids modelling, this enhancement enables the user, without any additional software costs, to model processes that contain both fluids and solids in one simulation environment using consistent physical properties and industry leading optimisation techniques.

One example of this more holistic workflow is the process model of the entire urea production process, shown in figure 2. Urea is a fundamental ingredient of lawn fertiliser, is used to produce some plastics, and is a component of detergents, and some healthcare products. Since this model describes the upstream urea synthesis (fluid part) and the downstream urea granulation section (solids part), the influence of each part is considered in a rigorous way.

If, for example, the air flow rate to the fluidised bed coolers in the granulation section of the urea process needs to be increased, this will lead to a higher entrainment of fines from the coolers.

Lutron TM947SD is a pocket-size 4 channel logging thermometers which can accept 6 thermocouple types and Pt100. Real time SD memory card datalogger.

USB & RS-232 interface. Carry case included.

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PID Temp. Controller

N1020 micro-size autoadaptive PID temperature controller with universal input, mini USB interface and RS-485 interface with Modbus RTU protocol. 24 VDC right up to 240 VAC. SKU: NOC-305 Price: $ 159.00 each + GST

USB to RS-485/422 Converter Robust USB converter for fourwire (full duplex) RS-422 and RS-485 or two-wire (half duplex) industrial serial busses.

1.5 kVDC isolation between PC and serial bus. USB port powered.

SKU: COV-001 Price: $129.00 each + GST

Relay Card On DIN Rail

Eight 24 VDC relay card, each relay can be operated by TTL levels, NPN & PNP open collectors or 2 to 12 VDC. 24 VDC powered.

2/4/8 relay cards are also available in 12 VDC or 24 VDC. SKU: RLD-248 Price: $109.95 each + GST

Slim Multifunction Timer Slim Line, DIN Rail mount, multi-function timer. SPCO output, dual LEDs indication. Multiple time range 0.1 s to 100 hours. 12 to 240 VAC/ VDC powered.

SKU: NTR-101 Price: $59.95 each + GST

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

www.aspentech.com MAY 2014 www.pacetoday.com.au 23

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MASTERCLASS

Barcode versus RFID: What’s the difference?

RFID and barcode are engineered to deliver specific information about products as they move from incoming materials to the production line and finally through to distribution. But which one is right for your application?

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NDUSTRIES are facing fierce market competition, making product consistency and customer satisfaction cornerstones of today’s industrial automation. Companies are striving for any competitive edge.

To satisfy these initiatives, products must be verified to ensure the highest quality – from material verification and production to delivery. Consequently, today’s fast-paced manufacturing and processing environments rely on highly precise product identification, monitoring and tracking.

RFID vs. Barcode: A technology comparison

Currently, two solutions/ technologies rule the marketplace for industrial track and trace: barcode/2D matrix and radio frequency identification (RFID).

Both are engineered for the same purpose, to deliver specific information about products as they move from incoming materials to the production line and finally through to distribution.

Utilising separate operating principles and tracking methods, RFID and barcode technologies each have their own distinct advantages and purposes.

Barcode Barcode technology provides more of a legacy solution for product monitoring, 24 www.pacetoday.com.au MAY 2014

RFID offers a more sophisticated approach for track and trace applications. and is an optical machine readable representation of data that is physically attached to a product and stores information about that object.

Originally, barcodes conveyed data by varying the widths and spacings of parallel lines, presented in linear or one dimensional shapes – similar to what one sees on a retail product. In recent years, barcodes have evolved to include rectangles, dots, hexagons and other two-dimensional shapes for increased application compatibility and readability. However, barcodes are read only, therefore users cannot add to the information written on to the barcode as production continues.

Though barcodes have progressed, they still face challenges that limit their suitability for many industrial applications. For instance, to obtain readings and access data, barcodes

require line-of-sight with the reader, which means a product must be properly aligned in order for a barcode reader to identify the product by its code.

Though barcodes are not ideal for all industrial and pro¬cessing applications, they do provide the necessary performance capabilities required for commercial use. They are typically less expensive and simplistic, and they are a universal technology for commercial applications.

RFID As an alternative to barcode, RFID offers a more sophisticated approach for track and trace applications. RFID is capable of intelligent, advanced data management that enhances product visibility throughout production and distribution.

Further, since RFID enables users to both read and write information on the tag – even at diverse distances – RFID

provides the capabilities and flexibility to accommodate a wider range of applications.

RFID systems contain three parts: the tag, transceiver and the interface.

Tags can be active (uses a battery) or passive reflecting the signal back to the transceiver, which is often called a reader. The interface is the means of communicating the data from the tag to a screen or a data collection device such as a computer or a controller.

The transceiver is used to read the RFID tag, and an I/O device will communicate information on the tag with the enterprise or higher-level control system. RFID tags contain internal circuitry that respond to a radio frequency field that is provided by the transceiver. During operation, when the RFID tag passes through the field of the transceiver, it detects the signal from

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the antenna. This activates the RFID tag, signaling it to transmit or receive information on its microchip.

RFID allows manufacturers to optimise data management.

Additionally, RFID data carriers also provide a large quantity of read or write Advantages of RFID operations with high speeds, ultimately The versatility in performance increasing tracking capabilities to improve capabilities offered with RFID enables operations. RFID offers increased this technology to be used in situations memory storage over barcode options, Learn more at where barcodes or other optically read with FRAM data carriers processing www.turck.com.au alternatives are impractical. Unlike data up to ten times faster, enabling it to conventional track andStrace write | Coperations, E N Smethods, O R S | N E T Wwithstand O R K S | more RFID O N N E C Tsome IVITY | INTRINSIC SAFETY RFID tags are not required to be placed even up to one billion cycles. on the surface of an object because they RFID’s ability to monitor materials so do not require line-of-sight to obtain an closely during production eliminates the accurate reading. risk of human error during production.

Instead, RFID tags can be embedded By tracking one product through the into the product, which still offers the entire manufacturing process, users can desired reliability without being subjected quickly identify if a component has to environmental elements. Additionally, skipped a stage. Further, storing detailed RFID tags are offered in a wide range of information about a given product sizes and come in virtually any housing prevents counterfeit materials from style, and offer read and write abilities that entering the stream of commerce. can also be read from diverse distances.

This advantage can be especially Barcodes face challenges that limit their suitability for many industrial applications.

In addition to its longevity and important in applications that durability, RFID is also fast and accurate directly impact the health and safety Prior to implementing RFID into – increasing efficiency and productivity. of consumers, such as food and can be completely erased and reused, any manufacturing application, users The read time is typically less than 100 pharmaceutical manufacturing. Plus, by they reduce equipment costs. should consider several aspects of the milliseconds, allowing large quantities ensuring consistent product quality, RFID Deciding if RFID is right application to decide if RFID is the right of tags to be read at once rather than can aid in preserving a business’s public for your application solution for their needs. scanning item by item. Further, each impression and customer satisfaction.

While RFID does offer advanced TURCK Australia tag contains a unique serial code, While barcode technology offers a 1300 132 566 monitoring capabilities, it may not be which allows a product to be scanned read-only solution, RFID can provide www.turck.com.au ideal for all applications. and tracked throughout the entire users with read and write flexibility. manufacturing process.

This allows information to be added/ With its communication capabilities, edited on the tag as it moves through RFID can provide real-time tracking production rather than having to include to allow for maximum data availability a new tag for each additional variable. and accessibility. By integrating Further, since read/write tags can with common industrial networking store more information, it enables faster protocols, such as PROFIBUS-DP®, processing, satisfying today’s high-speed DeviceNet™ and Industrial Ethernet, applications. Plus, since read/write tags

Mil-Spec Cordsets

Overmolded and made-to-length for robust connectivity in the harshest applications.

RFID provides the capabilities and flexibility to accommodate a wider range of applications.

Users cannot add to the information written on to the barcode as production continues.

MAY 2014 www.pacetoday.com.au 25

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PACE ZENITH AWARDS 2014 ENTRIES Proudly sponsored by

Project of the Year NOMINATIONS

A big thank you and good luck to all the entrants to the 2014 PACE Zenith Awards. You have done your companies proud and turned the spotlight on the innovative work that is being done right here in this country. This is shaping up to be a very close contest with very little separating the entrants. After the judges have done their work and the scores tallied, there can be only one overall winner. Here, we celebrate our overall project winners from 2012 and 2013.

PACE Zenith Award: Overall Project of 2012 Aurecon Hatch’s NCIG Coal Export Terminal Control System Aurecon Hatch was engaged to provide total engineering design, procurement and construction management (EPCM) services to NCIG for all stages of the Coal Export Terminal Control System. This included providing entire control systems engineering services, as well as system design, function specification for PLC and SCADA configuration, factory testing, site commissioning, performance testing and operator training.

As part of the EPCM services, Aurecon Hatch project managed 11 different supply contracts, including HV switchgear, transformers, 415V MCCs, HV cables, power factor correction equipment, wagon vibrator, conveyor drive units, pulleys, conveyor belting, vibrating feeders, and sample plant modifications. The project was completed early and under budget. The controls design and controls capital works were also finished under budget.

Andrew Hepburn, Principal Engineer Automation at Aurecon Hatch outlined some of the difficulties involved in the project, specifically when it came to timing.

“We were given an overall schedule for the project and we knew our target dates and our durations. We planned the various steps of the work from design to installation and commissioning to work out and meet the end date of the overall program.”

The NCIG Coal Export Terminal is a plant rated at 66Mtpa and was developed in three stages of 33, 45, and 66 Mtpa. The plant involved a rail receival system, conveyor system, coal stacking, reclaiming and sampling as well as shiploading.

The expansion to 45Mtpa and 66Mtpa represented a much more challenging task and involved both greenfield and brownfield works. In response to market pressure, NCIG required expansion to 45Mtpa to occur over a period of just two years and to 66Mtpa one year later. “The control system usually comes at the WINNER 2012: Aurecon Hatch’s Andrew end of the project and we had Hepburn (L) receives the Project of the Year to almost work from negative award from Martin Sinclair, Publisher of program,” said Hepburn.

PACE. 26 www.pacetoday.com.au MAY 2014

PACE Zenith Award: Overall Project of 2013 Countermeasures Manufacturing Facility SAGE Automation successfully designed, developed and installed a new aircraft countermeasures production facility for Chemring Australia in the regional Victorian town of Lara near Geelong.

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

The $11 million new production facility was considered essential for the fulfilment of the contract. Constructed in four stages, this is the first automated countermeasure manufacturing plant constructed in the southern hemisphere.

The project was a unique combination of manual and automated processes and required SAGE Automation to consider issues such as delicate product handling techniques, functional safety requirements, machine guarding, hazardous areas and high operating temperatures of up to 85°C. SAGE invested heavily in the first stage of the program to develop a solution which met the requirements of the project, especially a combination of hazardous areas and high temperatures.

Both mechanical and electrical requirements within the manufacturing environment, products and control architecture were researched, locally and off-shore, to source and trial the appropriate equipment to develop a solution.

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

Additionally, the facility was developed to keep people outside of the danger blast area – thus requiring full automation of systems.

In addition, all the machinery and systems employed WINNER 2013: Garry Mahoney (L), Pacific

by SAGE had to meet Director, Honeywell Process Solutions exceptionally high standards congratulates winner Adrian Fahey of SAGE of safety operation.

Automation.

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dare to discover

100 years of innovation Honeywell has been a respected pioneer in oil and gas for over 100 years. From the UOP thermal cracking process that set the foundation for oil refining in 1914, to the first SCADA and DCS systems in the1970’s, to first-ever universal I/O in 2012, Honeywell develops and implements technology that delivers an unmatched combination of performance and safety.

Discover today’s processing, instrumentation, automation and advanced software solutions to help you drive more value out of your oil and gas operations.

Discover Honeywell.

For more information about our solutions for Oil and Gas visit www.honeywellprocess.com © 2014 Honeywell International Inc. All rights reserved.

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PACE ZENITH AWARDS 2014 ENTRIES

Proudly sponsored by

Food & Beverage NOMINATIONS

Rheology Solutions The OnLine Rheometer for enhanced process monitoring and control The project was to commercialise, in two years, novel technologies for an online process control instrument that delivers real-time data to afford better quality control for production processes, initially in the food, personal care and, later, mining and other sectors.

The instrument is an ‘OnLine Rheometer’ (OLR), which measures and delivers a characteristic flow curve for a liquid in a pipe in real time. Our vision is to displace time consuming laboratory-based QC visocsity measurements, and to advance from incumbent on-line viscometers which often fail to discriminate between in-spec and out-of-spec recipes.

The market need for this instrument is acute, and there are no direct competitors.

Across key sectors e.g. food technology, personal care, mining, and petrochemicals, product quality is verified by measuring flow properties (rheology) of liquids. Currently, these measurements are either through laboratory analysis which is highly accurate but adds significantly to process time (hindering change from batch to continuous production), or real-time, through in- or on-line viscometers, where low quality data compromises reliable discrimination for process control.

The OLR can deliver high quality data (comparable to a laboratory rheometer) in real time (comparable to an on-line viscometer), maximising the benefits achieved with high accuracy, real-time process control.

Treasury Wine Estates Treasury Wine Estate Global Packaging Optimiser project In 2013, Treasury Wine Estates (TWE) engaged Schneider Electric to implement a global supply chain network optimisation tool - the StruxureWare Supply Chain Operation SCNO (formerly SolveIT Software) - a Simulation/ Optimisation tool to answer the strategic business question of “what to pack where” and to determine the lowest total cost solution to TWE’s wine packaging and logistics operations.

With production in four continents, over 100 packing routings and greater than1,900 individual product lines, the sheer complexity of TWE’s supply chain meant the historical manual approach to supply chain solutions was no longer viable.

The solution that was planned, implemented and delivered by Schneider Electric was TWE’s Global Packaging Optimiser - designed specifically to address these “whole of business” business problems. The resulting supply chain network optimiser (SCNO) solution provides TWE with a strategic decision support tool that is used to optimise and reduce costs across the global packaging network.

Since going live with the Global Packaging Optimiser TWE have reviewed numerous scenarios, this has enabled TWE to identify significant cost saving opportunities for the future and the optimiser is currently being used as an integral part of the strategic planning and budgeting process. TWE expects to deliver material savings in F15 and beyond.

Columbus Group Thompson & Redwood Software Implementation Thompson & Redwood, an animal feed manufacturer partnered with Siemens Solution Partner, AP Automation, to modernise its manufacturing plant.

Initially, the idea was to find a solution that would see the plant grow in line with its modern requirements, become more efficient, consume less energy and comply with food safety regulations of tracking and tracing, while being robust enough to handle the repetitive grinding and batching functions.

For Thomson & Redwood, the key attraction of the Siemens solution was its ability to adapt to any grinding or batching application and its advanced diagnostics capability.

The solution was based on proven and tested software libraries which can be tailored for any application and consequently provide Thomson & Redwood with the flexibility to produce various product lines efficiently.

According to the company, the improvement in efficiencies is due to fine tuning of the new system and reduced down time.

As a result, the company has achieved a 7 percent increase in production and reduced its energy consumption by 2 percent.

Flat surface mix and make systems Mixing is a fundamental process in many manufacturing outcomes, from processed food production to making building materials like concrete and pavers.

The components for such mixing procedures usually have a mixing container, mixing implements, equipment to add ingredients, addition of heat and cold to advance the mixed materials and methods to move the mixed materials to the next stage.

Columbus flat surface mix and make systems incorporates these components in an interactive tessellation auxetic robust surface that is easy to clean.

The system works by raising containment profiles and moving paddle mixing profiles under movement software. More than one mixing action can happen at the same time on the same surface. Materials to be mixed are added in a similar way. Electro thermal cell heating and cooling can further process (cook) the mixed materials. Finally the completed mix can be moved away from the mixing surface by software controlled ‘dozer’ blade-like profiles.

With all the profiles and paddles ‘disappeared’ back into the flat surface, cleaning is an easy wiping process. The flat surface can be a shallow undercounter drawer or standalone robust panel. Tablet zigbee remote control also holds the ‘recipes’.

EDITOR’S NOTE This is a selection from all the nominations received at the time of going to press.

Once judging is complete, Finalists will be announced on www.pacetoday.com.au.

They will also be individually notified.

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PACE ZENITH AWARDS 2014 ENTRIES Proudly sponsored by

Manufacturing NOMINATIONS

SmartRider Escape Breakaway Stirrups The company offers two types of horse breakaway stirrups. The SmartRider ‘Classic’ Breakaway Stirrup are manufactured using the lost wax method, so are therefore produced offshore, by a quality, large capacity manufacturer, as economically it was not viable to produce them here in Australia.

However all research and development was done entirely in Australia. Was years in the making, with every detail checked by engineers to ensure that our stirrup is effective and affordable. It is made from 316 marine grade stainless steel.

The ‘Classic’ Stirrups have been tested in accordance with international standards by the “TUV-Testing facility in Munich”. When a rider is thrown wearing normal stirrups, the foot can become trapped. With the SmartRider ‘Classic’ Stirrups the inner bar is released, freeing the rider.

The SmartRider ‘Escape’ Stirrup is a Two-Part Stirrup that disengages, setting the rider free when in a position of danger. The SmartRider ‘Escape’ Breakaway stirrup is Australian in invention, design, development and manufacture.

It is the first ever Two-Part Stirrup to be made in a high-tech material. The design incorporates UV protection and can be produced in a vast array of colours. It also has the added provision, that when tilted to a 180 degree angle this system doubles as a ladder.

The company currently has a prototype for the SmartRider ‘Performance’ Breakaway Stirrups, aimed at the racing industry. SmartRider were actually approached by this sector and requested to develop a Breakaway Stirrup tailored for their specific needs.

Orora St Regis Bates Software Implementation Orora St Regis Bates (Orora SRB) specialises in fully tailored packaging solutions across a broad range of dry powder and granular markets including milk powder, flour, mineral, building and more.

The company commenced a major Productivity Improvement Project across three plants in Perth, Sydney and Melbourne.

The technology used in the project is the OFS Solution, supplied by Operations Feedback (OFS), a Melbourne based OEE software developer. OFS also delivered execution, implementation and training services for the project.

Having a manual production recording and monitoring method meant the company was waiting on information that was usually late and often wrong. The vision was to find a solution that did this work for them.

The OFS software suite was deployed to all three manufacturing facilities between December 2012 and February 2013, which included comprehensive onsite training by the software supplier.

As a result, labour costs were reduced by 14 percent and setup/changeover time was reduced by 21 percent. There was also an increase in AVA and an increase in engagement from the factory floor.

Hoshizaki Lancer Lancer Soft Drink Superchiller The Lancer Soft Drink Superchiller is the main soft drink equipment platform of Australia’s on-premise, fast food restaurant, cinema and convenience store outlets.

Superchillers enable multiple chilled soft drinks to be distributed through the one unit and are the system of choice for beverage customers such as Coca-Cola Amatil, Pepsi and Schweppes, fast food and convenience outlets including Hungry Jacks and On The Run as well as entertainment venues.

Superchillers and their associated carbon dioxide (CO2) regulator assemblies are manufactured at the Hoshizaki Lancer facility in Adelaide.

Lancer recently undertook a major redesign of the Superchiller and CO2 Regulator Board to improve cost and energy usage.

As a result, Lancer has been able to reduce energy consumption for the Superchiller by 34 percent, lower the price by 15 percent and eliminate the highest field failure cause from 9 percent to zero.

The redesign of the regulator has enabled Lancer to achieve price savings of 35 percent and reduce failure rates from 2percent to zero. The redesign has also significantly improved the robustness of the system.

Black Widow Enterprises Black Widow Easy Slide The company specialises in drawer systems for the rear of 4WD vehicles. These drawer systems are typically used as touring vehicles for people travelling around Australia.

A common application is to mount a portable fridge on top of the drawers.

However, a common issue faced by many people when mounting a portable fridge to the top of drawer systems is the access height. The opening of the fridge is often at eye level for most people meaning to see in the fridge is very difficult. Commonly people will carry a small ladder or step to gain access to the items in their fridge.

Black Widow currently produces a fridge slide to bring the fridge out from inside the vehicle so the user doesn’t have to climb up in the vehicle to access their fridge.

However, the access height issue still exists.

The obvious solution is to have the slide lower down to the vehicle floor height (approximately 30cm) when in the pulled out position to give better access.

This problem and solution has been one identified by Black Widow early in the company’s history and one the 4WD industry as a whole has also been looking for.

Making this product a reality is not as simple. Up to 6 companies have been trying to develop a product to meet this need for approximately the last 10 years.

Black Widow finally overcame the inherent issues associated with this application and identified an appropriate mechanism about three years ago. The release of the Easy Slide is the culmination of over two years work.

EDITOR’S NOTE This is a selection from all the nominations received at the time of going to press.

Once judging is complete, Finalists will be announced on www.pacetoday.com.au.

They will also be individually notified.

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Making things right Industry 4.0

Don’t you love it when everything just works?

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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PACE ZENITH AWARDS 2014 ENTRIES Proudly sponsored by

Fieldbus Implementation NOMINATIONS

Fortescue Metals Group & Profibus Australia Herb Elliott Port and Rail Infrastructure Fortescue Metals Group (FMG) selected Anderson Point (Port Hedland area) in Western Australia as the location for its Herb Elliott Rail and Port shiploading facility due to its close proximity to mining operations at Cloudbreak and Christmas Creek in Fortescue’s Chichester Hub. The Chichester Hub is located 263 km south of Port Hedland and 150km north of Newman Against the backdrop of an emerging minerals resources boom driven by the economic transformation of China and India, plus, restricted access to existing rail and port facilities, Fortescue was forced to build its own rail and port infrastructure to take advantage of Asia’s growing demand for Iron Ore. In partnership with WorleyParsons, construction at the Herb Elliott port commenced in November 2006 on reclaimed swampland, and first deliveries of iron ore from Cloudbreak mine were unloaded and stockpiled ready for export in April 2008.

The working name given to FMG’s initial rail and port construction project was T45, representing the expected tonnage of iron ore (0-45 million tonnes per annum) Fortescue expected to export between 2007–2010.

In 2011, Fortescue sought to triple Herb Elliott’s port loading capacity from 55 Mtpa to 155 Mtpa. This second phase of development at Herb Elliott was called the T155 Port Anderson Expansion Project 2011 – 2013.

WorleyParson’s Systems Engineers specified Profibus as the preferred communications protocol throughout the entire port facility in conjunction with a small number of Devicenet networks which were later phased down toward the end of T45.

The processing facilities designed, constructed and controlled by Profibus networks were completed in record time to take advantage of China’s growing need for iron ore.

Profibus Technology, particularly Profibus DP was able to provide reliable and stable network communication in harsh operating conditions characterised by extreme heat and high noise levels. The applications controlled by Profibus networks in the initial T45 Project included an inbound train unloader, conveyor belts, stacker and reclaimer, a ship loader, belt weigher, metal magnets and a Stockpile Management System (SMS) to analyse the composition of the iron ore before loading onto the ships.

Columbus Group Automated chute and bin cleaning systems Mining and transport systems can use a lot of ore chutes, holding bins and tanks as part of the movement and storage configurations. Installations are usually made of static hard surfaces and sharp corners that can attract clays, slimes and other deposits that build up and clog.

With chutes, ores with clay can cause heavy deposits on sides and corners, eventually blocking chutes and requiring considerable manual intervention.

By changing chute surfaces and corners to multiple solenoid cells covered by flexible, continuous tessellation surfaces, then the fieldbus control can weigh the static elemental loads, plus build up an automated plan for appropriate cleaning action and timing as to when to do it. Of particular note is the software management for clearing corners. Here an active ‘squeezing together and releasing pressure’ action is employed on nearby surfaces based on localised benchmarking to learn the fastest cleaning process. Cell movement height, frequency and timing are variable.

Another action of the pushing out cells in sequence, can be a ‘Mexican’ wave effect, so the broken material can be ‘pushed’ down and away. And then as part of the clearing action, the software can divert and trap unwanted material from the main processing path.

32 www.pacetoday.com.au MAY 2014

UGL Eastern Tertiary Alliance The Tertiary Upgrade Project at the Eastern Treatment Plant, Melbourne is a landmark wastewater and recycled treatment project for Australia, due to advancements in tertiary treatment. Through this project Melbourne Water has been able to achieve its two key objectives being the improvement in treated water discharge to the receiving marine environment as well as producing a new high quality Class A recycled water for the benefit of future generations.

The integration of the new tertiary treatment step with the existing secondary treatment plant, the high standard of output water quality required, and the requisite high level of reliability of the plant dictated the need for a very sophisticated control and communication system. The control system processes developed during the Alliance achieved outstanding results in terms of value for money, timeliness and operator satisfaction.

The objective was to provide Melbourne Water with a control system that combines robustness and high availability to be able to operate under demanding conditions in a 24/7 environment. For seamless integration with the new plant, the Siemens PCS7 platform was selected.

The highly complex plant required a reliable control system for high availability and to deal with the enormous amount of data communicated over the plant networks.

Several fieldbus technologies are utilised around the plant, including Ethernet, Profibus and HART.

Columbus Group Water meter management systems Smart electricity meters are being installed worldwide to remotely control domestic energy supply and peaks; get better value from infrastructure and introduce ‘user pays’ and premium rates to ‘educate’ end users.

By signalling through their grids, electricity suppliers easily transfer consumption data for billing.

Water utilities have not enjoyed the same. Sending data by tapping pipes isn’t practical. And meeting water demand at peak periods plus managing seasonal consumption has been best done by PR spin, abuse fines, and varying delivery water pressures.

Columbus water meter management systems are waterflow self-powered dual metering installations with low cost unique numbered radio Zigbee microprocessors in daisychained meters, to transfer data with a centralised data management and billing system.

Also, in each meter, there’s CANBus control of the plugged together flow through plus takeoff valve modules, together with USB sockets and smart phone NFC apps for setup/monitoring.

The hardware is suited to high and low supply pressures including potable, recycled, onsite bores and rain water tanks; has prioritised metered water outlets for peak/off peak water supplies; monitoring for potential leaks; water hammer reduction; other revenue features; and quick and easy retrofit of existing metering.

EDITOR’S NOTE This is a selection from all the nominations received at the time of going to press.

Once judging is complete, Finalists will be announced on www.pacetoday.com.au.

They will also be individually notified.

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PACE ZENITH AWARDS 2014 ENTRIES Proudly sponsored by

Young Achiever NOMINATIONS

Gavin Oakes Honeywell Process Solutions Gavin looks for new and innovative solutions to problems in everything that he does. As a result of this, he has gained the confidence of his customer and is considered a trusted advisor in wellhead controls.

Beyond his development of the RTU system, Gavin has also been responsible for designing software that completes 113 checks of the RTU systems manufactured in the Honeywell factory. This innovative approach to systems manufacturing has reduced the cycle time by approximately 20 hours and has significantly improved quality.

His in-depth knowledge of the wellhead monitoring environment enabled him to play a critical role in the development of Honeywell’s RTU2020 controller. Previously, Honeywell’s solution in this space required a third party controller built in to the overall RTU system. Gavin was also instrumental in developing a Local Operator Station that allows field operators to start up an RTU wellhead without requiring telemetry systems to be active.

Andrew Beal Hydrix Services Andrew Beal is a Senior Electronics Engineer working as part of the engineering team at Hydrix for over three years. He is responsible for many aspects of the product development lifecycle, from initial stakeholder discussions through to architecture, design, regulatory compliance and manufacture.

He is solely responsible for the manufacture and production of the complex and highly sophisticated Radio Interface Unit (RIU). The $3m RIU device, designed, manufactured and to be supplied by Hydrix, forms a key part of the high profile Digital Train Radio System (DTRS) project being built by for Siemens and the Victorian Department of Transport.

Originally from an automotive background, Andrew has designed and manufactured many products across many industries, including automotive, biomedical, consumer and rail, many of which are visible in the market today. In addition to his design role, Andrew has been autonomously working in a project management capacity, ensuring critical manufacturing pipelines remain fed to maximise production throughput.

Paul McCaffrey Unilever During 2013, Paul completed his three-year Unilever Future Leaders Program (UFLP). Throughout the UFLP, Paul was given opportunities to take on various challenging roles across different functional and operational areas of the business ie: role in Sales/Marketing, Supply Planner 3P, Process Engineer, Production Leader – Liquids.

Following the completion of his UFLP, Paul was recently promoted to the role of Senior Production Leader – North Rocks. In this role, Paul is responsible for all aspects of production in the Liquids area of the North Rocks factory.

As a Production Leader at North Rocks, Paul has four shift teams reporting through to him directly and his team has responsibility to manage a varying number of contract labour to ensure all production requirements are completed in as efficient 34 www.pacetoday.com.au MAY 2014

manner as possible. As a Production Leader at North Rocks, Paul has a vital role to help shape the high-performance, lean culture of the site through his leadership and driving the continuous improvement mindset and capability through Focused Improvement and Autonomous Maintenance pillars.

Bryan Emmerson Machinery Automation & Robotics The automation projects that Bryan has worked on during his 18 months at MAR since graduating have been: 3D modeling project for the Red Meat Industry; iPad Apps for the Red Meat industry; Product development of Bandsaw operator aid for the Red Meat Industry to reduce the risk of serious injury.

Bryan researched and utilised commercially available 3D modeling software to create 3D models of meat cuts, primal and carcasses. The ability to produce these 3D models has supported and assisted MAR with the development, adoption and commercialisation of automation within the Red Meat processing industry.

Bryan also developed three iPad applications aimed at providing support to management and maintenance staff by enabling them to successfully keep their systems functioning with minimum assistance from MAR service.

Bryan has also developed early generation software for Bladestop to the point where the Bladestop product has now been commercialised.

Daniel Hodges Austube Mills Daniel’s role as Reliability Engineer for the site sees him developing strategies, tools and standard operating procedures for use by all personnel in order to improve equipment uptime. Daniel does not allow the demands of his role prevent him from getting heavily involved in safety improvements and initiatives at the same time. Daniel is responsible for coordinating the lubrication and monitoring of two mill departments, a slitting department and despatch.

Other responsibilities taken on by Daniel include coordinating the installation of new items of plant for trialing and commissioning a new process, as well as leading multiple safety investigations to drive practical outcomes that will grow the safety of the site. Daniel has managed to juggle this workload with the demands of a part-time Mechanical Engineering Degree, which he successfully completed in November 2013.

In his Reliability Engineer capacity, Daniel has formed a Lubrication Team that did not exist on the site prior to his employment; and in the ensuing 18 months has taken a Lubrication Technician and Mechanical Cadet with no prior specific experience in the area to a world class level. The team has taken the actionable fault level from 15 percent down to a steady 1-0 percent.

EDITOR’S NOTE This is a selection from all the nominations received at the time of going to press.

Once judging is complete, Finalists will be announced on www.pacetoday.com.au.

They will also be individually notified.

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GHG-CONTROL: MEASURE RATHER THAN CALCULATE GREENHOUSE GASES

GHG-Control is the in-situ solution to measure CO2 , CO or N2O emissions ‒ and the direct method for determining annual greenhouse gas emissions. The accurate measurement of the complete system ensures total uncertainties of less than 2.5% ‒ without complicated calculation methodologies of single source streams. For more information please visit www.sick.com/ghg-control or call 1300 405 807.

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PACE ZENITH AWARDS 2014 ENTRIES

Proudly sponsored by

Machine Builder NOMINATIONS

Ryan Aerospace Blackhawk Helicopter Simulator for mission rehearsal Ryan Aerospace has developed a relatively low cost Blackhawk Helicopter Simulator to be used for mission rehearsal and military combined arms training exercises.

The machine is designed to be in a classroom situation to train pilots.

Being robust and relatively small (whilst not compromising the 1:1 scale of the real helicopter) it can also be deployed into a theatre of war where pilots can collectively practice real, upcoming practice missions without having to spend millions of dollars on expensive, high-end simulators or worse still, practice in the real helicopter where it’s too dangerous to fly, fuel is limited or helicopters are limited.

Whilst it’s based on a Blackhawk transport helicopter, it can be reconfigured to virtually any helicopter type.

Ryan Aerospace has customers in the US that can switch between the Blackhawk transport helicopter and the Apache Attack Helicopter just by changing the flight control grips and instrumentation panel which takes only a few minutes.

Columbus Group Columbus 3D MasterMAKER™ 3D printers usually build structures in layers, slowly, and often require additional finishing.

The Columbus 3D MasterMAKER™ printer has: multiple material-addition heads supported with material-substraction, (fine and coarse milling); standard X,Y,Z linear drive movements of the depositing heads are replaced by multiple robotic arms with many degrees of freedom and tool-like purposes, plus there are two depositing tables can move with 5 degrees of movement in the X,Y,Z directions plus tilt and revolve.

With the new hardware setup comes optimised software for true rapid manufacturing of completed 3D structures, big and small.

3D printed circuit boards and fitted parts all in housings become possible with the Columbus 3D MasterMAKER™.

Additive multi-head 3D printers (with conductive lead-free SAC and insulating filaments), plus subtractive milling, component placement, physical and magnetic grippers, metal forming pliers and closeup video inspection that ‘do the lot’ with realtime testing and fixes if needed.

Benefits include improved circuit interconnections, reliability, security, impact resistance, unique shape forms and compactness in one, that can be resistant to corrosion, flooding, crushing, vibration and explosions.

Structures can be light enough to fly, crawl and swim, with total versatility, particularly related to defence, mining, transport and oil & gas demands.

Engi-O Pty Ltd Heat Detector Assembly Machine This project is to automate the assembly of heat detectors used in the dairy industry.

The assembly currently takes seven people an hour to make 1000 parts.

This nine-station assembly machine does not require an operator and produces the same quantity per hour. There is no other machine of its type.

The project required creative thinking in the complex task both mechanically and programmatically.

B&R stepper motors and control have been used. Of particular note is the fact that Engi-O have used “virtual screen” technology where by any handheld smartphone or tablet can be used to communicate to the machine wirelessly.

This gives the operator freedom and the machine designer flexibility with regard to cabinet positioning.

Festo pneumatics have been used and the interesting technology used is the very precise flow meter use for leak detection.

This method is fast and reliable detecting remarkably small differences in flow quickly.

Hisen High Frequency welders have been used for the PVC welding. EMC technologies were used to conduct the RF hazard measurements.

CKAS Mechatronics CKAS Full Driving Simulator The CKAS Full Driving Simulator (FDS) is a world first in driver safety development, incorporating most of the features of multi million dollar flight simulators into a driving simulator, which offers the industry a training platform which is unprecedented, all at an affordable price.

The CKAS FDS features a real vehicle surrounded by a unique 360° visual system (offering total immersion and perspective correct mirrors), professional control loading on the steering wheel for realistic road feel, genuine servo controlled transmission for realistic gear changes, a completely functional vehicle interior, all mounted on a professional six degree of freedom (6DOF) motion system.

This combination of features makes the simulator completely unique around the world for driver safety training.

The CKAS FDS is an exportable technology which shall save lives on our roads and abroad, especially in younger drivers.

EDITOR’S NOTE This is a selection from all the nominations received at the time of going to press.

Once judging is complete, Finalists will be announced on www.pacetoday.com.au.

They will also be individually notified.

36 www.pacetoday.com.au MAY 2014

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PACE ZENITH AWARDS 2014 ENTRIES

Proudly sponsored by

Mining & Minerals Processing NOMINATIONS

Eagle Alternatives Pty Ltd Blast Suppressor (JK Jigger) As an electrician working in the mining industry John Keane’s hands on experience showed him a reoccurring problem existed.

He saw that solid shafts were the main cause, and could be modified to prevent this common problem in underground mines where 1000 volt isolator handles can be damaged on relocatable power and control boxes used in an underground mining environment due to blasting pressures.

Isolator handles are often damaged on power boxes, both in Australia and internationally in underground mining, rendering the box useless and unsafe. No mining can proceed until the 1000 volt handle is replaced.

By fitting, the Blast Suppressor in the underground box, with its unique function, it will prevent the handle from being damaged.

It replaces a solid shaft, absorbing the pressures like a shock absorber. In the split second of a blast, the power box handle is protected from being damage.

This reduces the amount of times electricians access power and control boxes unnecessarily, protecting workers and ensuring the highest level of safety, as well as reducing “lost opportunity” and associated costs whilst increasing production.

Columbus Group Automated chute and bin cleaning systems Mining and transport systems can use a lot of ore chutes, holding bins and tanks as part of the movement and storage configurations. Installations are usually made of static hard surfaces and sharp corners that can attract clays, slimes and other deposits that build up and clog.

With chutes, ores with clay can cause heavy deposits on sides and corners, eventually blocking chutes and requiring considerable manual intervention.

By changing chute surfaces and corners to multiple solenoid cells covered by flexible, continuous tessellation surfaces, then the fieldbus control can weigh the static elemental loads, plus build up an automated plan for appropriate cleaning action and timing as to when to do it.

Of particular note is the software management for clearing corners. Here an active ‘squeezing together and releasing pressure’ action is employed on nearby surfaces based on localised benchmarking to learn the fastest cleaning process.

Cell movement height, frequency and timing are variable.

Another action of the pushing out cells in sequence, can be a ‘Mexican’ wave effect, so the broken material can be ‘pushed’ down and away. And then as part of the clearing action, the software can divert and trap unwanted material from the main processing path.

Bonfiglioli Transmission Australia Coal conveyor touches lightly on the environment A 2 km coal conveyor system that combines engineering innovation and efficiency with built-in safety and environmental excellence has been completed by the Ellton Group for Rio Tinto Coal Australia’s Coal and Allied Hunter Valley Operations.

The 1400 mm belt conveyor system rated at 2400 TH – driven by Bonfiglioli Power Pack drives - includes an overland conveyor and a skyline stacker conveyor system that eliminates the previous need for heavy trucks to transfer coal from another load out facility during peak production.

The unique conveyor design also overcomes numerous environmental and structural challenges as it traverses reclaimed and subsidence-prone land to deliver high volumes of coal to an existing stockpile facility through a cost-efficient design that incorporates recycled previous structures and which was delivered safely and within budget.

“One of the many unique aspects of the design was the complete incorporation of an existing skyline gantry system contained within the new structure,” said the Managing Director of the Ellton Group, Mark Elliott.

“The old gantry had a tripper running through it. We built our new, higher capacity structure around the existing tripper gantry, running the conveyor in the opposite direction but sharing a radically improved and strengthened structure that easily and safely handles higher conveyor loadings but is designed to minimise additional mass and wind loadings.

Ausenco Isaac Plains CHPP sustainable cost saving project Ausenco reviewed the existing Coal Handling and Preparation Plant (CHPP) Operations and Maintenance Service Agreement for the Isaac Plains CHPP and identify and implement a sustainable cost saving of 20 percent across the CHPP, without impacting its reliability and availability.

Ausenco audited the operations and maintenance processes which revealed opportunities to reduce unplanned maintenance by adopting Reliability Centred Maintenance (RCM) practices, and by basing routine maintenance activities for each component on operating statistics and actual failure modes.

The company designed the maintenance strategy which enabled them to better plan and schedule maintenance activities. The net result was a reduction in the number of regular shutdowns per year from 17 to 10 and a reduced reliance on subcontracted labour required for the maintenance of the plant.

Despite reduced maintenance spend, plant availability increased from 91 percent in 2012 to 95.1 percent in 2013. Importantly, unplanned maintenance decreased from 33.1 hours/month to 23.8 hours/month over the same period.

Overall, Ausenco implemented a revised labour model, supply agreements and maintenance regime through which they helped IPCM attain an increased return on capital expended by achieving a 24.08 percent reduction in Operations and Maintenance services cost-per-tonne, with no negative impact on plant performance.

EDITOR’S NOTE This is a selection from all the nominations received at the time of going to press.

Once judging is complete, Finalists will be announced on www.pacetoday.com.au.

They will also be individually notified.

38 www.pacetoday.com.au MAY 2014

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PACE ZENITH AWARDS 2014 ENTRIES Proudly sponsored by

Water & Wastewater NOMINATIONS

UGL Eastern Tertiary Alliance The Tertiary Upgrade Project at the Eastern Treatment Plant, Melbourne is a landmark wastewater and recycled treatment project for Australia, due to many ground-breaking advancements in tertiary treatment.

Through this project Melbourne Water has been able to achieve its two key objectives being the improvement in treated water discharge to the receiving marine environment as well as producing a new high quality Class A recycled water for the benefit of future generations.

The integration of the new tertiary treatment step with the existing secondary treatment plant, the high standard of output water quality required, and the requisite high level of reliability of the plant dictated the need for a very sophisticated control and communication system.

The control system processes developed during the Alliance achieved outstanding results in terms of value for money, timeliness and operator satisfaction.

Tahmoor Coal (Glencore) Tahmoor Coal Recycled Water Treatment Plant Glencore and SKM have developed a fully automated Air Quality Control System believed to be a first for the Hunter Region’s mining sector.

The AQCS is enabling Glencore’s open cut sites across the Upper Hunter and Ulan to better manage air quality and noise issues through increased awareness of environmental management among employees and daily mine planning informed by detailed environmental forecasting.

The key component of the AQCS is an environmental forecast summary emailed daily to more than 120 Glencore representatives, who provide this information to their respective sites.

The email includes general five-day weather forecasts, wind conditions for the next two days, predictions of daily dust risk and predicted noise risks at specific locations.

Used in conjunction with extensive noise and air quality monitoring in place at each site, it is helping to minimise impacts from Glencore’s open cut operations.

Implementation of the system has contributed the following benefits: Higher employee awareness of potential environmental issues; An increase in the number of employees empowered with responsibility to manage these issues; Productivity improvements due to identification of favourable environmental conditions; No exceedances of project specific air quality criteria at sites; Providing community and regulators with additional confidence that Glencore is proactively managing impacts.

The AQCS was introduced in 2012 as part of a broader company project to improve air quality management across Glencore’s coal operations and was based on years of research across Australia and overseas, as well as detailed analysis of concerns associated with air quality.

Columbus Group Water meter management systems Smart electricity meters are being installed worldwide to remotely control domestic energy supply and peaks; get better value from infrastructure and introduce ‘user pays’ and premium rates to ‘educate’ end users.

By signalling through their grids, electricity suppliers easily transfer consumption data for billing.

Water utilities have not enjoyed the same. Sending data by tapping pipes isn’t practical. And meeting water demand at peak periods plus managing seasonal consumption has been best done by PR spin, abuse fines, and varying delivery water pressures.

Columbus water meter management systems are waterflow self-powered dual metering installations with low cost unique numbered radio Zigbee microprocessors in daisychained meters, to transfer data with a centralised data management and billing system.

Also, in each meter, there’s CANBus control of the plugged together flow through plus takeoff valve modules, together with USB sockets and smart phone NFC apps for setup/monitoring.

The hardware is suited to high and low supply pressures including potable, recycled, onsite bores and rain water tanks; has prioritised metered water outlets for peak/off peak water supplies; monitoring for potential leaks; water hammer reduction; other revenue features; and quick and easy retrofit of existing metering.

Rediscovering Pykrete for hard rock mining Columbus Group Pykrete is a mix of sawdust and ice developed in the period of WWII to make robust large aircraft carrier-like floating structures to provide protection for supply shipping in the Atlantic.

And SMA (shape memory alloy) will change shape to a predetermined configuration if heated or cooled to specific temperatures. While SMA is often in wire form, it can also be in wide sheets or narrow chisel-like forms that can transform between two shapes, based on sheet temperature. Specialised 3D printing can produce the shape changing SMA mechatronic consumables at the rock face.

By combining SMA with injected Pykrete (to ‘amplify’ the ore seam breaking effect), then continuous mining without explosives is feasible.

The broken ore is intentionally shaped into tetrahedrals and octahedrals for the best volume efficiencies (with the robust extending extraction conveyor systems) and save energy in the crushing phase. Real time assaying at the rock face is compared with the changing ore data records using the inhouse CYAEIP Software, so guiding the ore body mining direction for optimised profitability.

The technology package has been developed to suit old gold mine reworking where stope timbers can be converted to sawdust and the underground waters frozen to form pykrete.

EDITOR’S NOTE This is a selection from all the nominations received at the time of going to press.

Once judging is complete, Finalists will be announced on www.pacetoday.com.au.

They will also be individually notified.

40 www.pacetoday.com.au MAY 2014

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INSPIRING ANSWERS | Type 8905 – Online Analysis System

“Who‘s to say that you have to constantly keep an eye on a number of different meters to guarantee clean drinking water?“ With our new Online Analysis System Type 8905, this is no longer just wishful thinking.

Compact and modular, it meets all water sensor system needs from a single source – at a single glance. www.inspiring-answers.com

www.burkert.com.au 1300 888 868

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Australian Mining, Manufactures Monthly and PACE Magazine invites you to attend the 2014 Women in Industry Awards in Melbourne. 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 www.miningaustralia.com.au

Supporting partner

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IN FOCUS

Biometric access control Biometric switches eliminate security risks associated with lost, forgotten or stolen keys, cards and passwords, writes Sam Bakshi.

I

N A dynamic and constantly evolving industry, successful manufacturing organizations understand that it is paramount to use the right mix of people and technology.

They invest heavily in their people by training those responsible for operating their expensive and carefully optimised machinery and processes.

Safety systems and standard operating procedures (SOPs) are then implemented but statistics show that they don’t deliver adequate asset protection.

The Australian Bureau of Statistics (ABS) and Safe Work Australia estimate that the annual injury rate amongst plant and machine operating staff is still at a high 86 per 1000 people and the annual cost of work-related injuries is a whopping $57 billion.

A complete operational system should take into consideration, one of the most neglected pillars of efficient production – access control.

After all, given the investment, wouldn’t you want to ensure that your workplace remains safe and your specific machines, zones and proprietary information are used only by trained and authorised staff?

Biometrics

Token-based access control systems prove highly defeat-able with the vast majority of organizations encountering the familiar instances of lost/forgotten/ stolen keys/cards/passwords.

With these short-comings becoming increasingly frequent and jeopardizing the safety and productivity of operations, a more sophisticated and reliable system of access control has become prominent – Biometrics. Physiological

characteristics such as fingerprints are unique and form the basis of Biometric authentication.

Use in industry

The Harmony XB5S is a fingerprint reader switch which allows industry to limit access to specific and/or dangerous machine functions to trained and authorised operators.

Biometric access controllers are now available even for use in harsh industrial environments.

Some offer ruggedized characteristics such as high ingress protection, a wide operating temperature range and good shock and vibration resistance, etc.

You can also benefit from smart functionality such as user database management, multiple clearance levels, and recording of access attempts (i.e. who operated what and when).

These solutions tend to easily integrate into new and existing installations, be expandable, and work well in conjunction with certified safety systems and standard operating procedures. So, now is a good time to

Fingerprint based access control systems are gaining popularity due to their quick touch and go simplicity and reliability jump on board and secure your assets if you haven’t already done so.

Fingerprint based access control systems are gaining popularity due to their quick “touch and go” simplicity and reliability.

They have earned a rightful place in industrial applications and contribute to maximizing productivity and minimising safety risks and costly unplanned downtime directly impacting the bottom line.

[Sam Bakshi is Product Manager – Control & Signalling, Schneider Electric (Australia)] www.schneider-electric.com MAY 2014 www.pacetoday.com.au 43

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SPOTLIGHT

7best of the

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

Dual sensor electromagnetic flow meter

Wireless transmitter delivers two process variables

Process and plant engineers contending with swirl and other flow disturbances in the line will find the new FPI-X Dual Sensor Electromagnetic Flow Meter from McCrometer delivers accurate and repeatable measurement under extreme flow conditions unachievable with other technologies. The McCrometer FPI-X flow meter reliably achieves Âą0.5% accuracy under the most severe swirling flows.

Designed for use in close proximity to cascading or multiple pump arrays, this meter delivers the advantage of accurate measurement where no flow meter previously could serve. Whether installed near pumps, valves, elbows, headers, or any other equipment that makes it impossible to create a symmetrical velocity flow profile in the pipe, the FPI-X will outperform traditional mag meters. The FPI-X mag meter provides measurement in difficult sites that otherwise require multiple meters in various locations, saving customers both money and installation time. The FPI-X also eliminates the expensive flow conditioners and piping modifications necessary with other meters. Multi-point sensing technology makes this mag meter suitable in cramped, retrofit and new construction pumping stations or in any constrained space areas with limited straight pipe run availability. The sensorâ&#x20AC;&#x2122;s body is hermetically sealed and protected by NSF certified 3M fusion-bonded epoxy coating. With no moving parts, the FPI-X requires little to no maintenance for years of worry free operation.

The Rosemount 3051S MultiVariable Wireless Pressure Transmitter is designed to directly measure two process variables in one installation so users can gain greater insight into their process without increasing installation costs. The more devices in a facility, the greater the required cost and time investments for installation, scheduled maintenance and downtime. Because the transmitter measures differential and static pressure, users can reduce pipe penetrations and impulse piping along with their associated costs.

The static pressure sensor is available as either true gage or absolute which allows for reduced maintenance and calibration costs. Users have visibility to their measurements through a WirelessHART monitoring system. Users can monitor more assets throughout their facilities with greater than 99% reliability and at 40 to 60% cost savings over wired installations. The Rosemount 3051S MultiVariable Wireless Pressure Transmitter delivers a decade of maintenance-free performance with a 10-year stability specification.

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

Emerson Process Management 03 9721 0200 www.emersonprocess.com

Tablet dissolution testing and HPLC analysis John Morris Scientific have introduced Gilsonâ&#x20AC;&#x2122;s Automated Double Dissolution System (ADDS). This innovative system has been designed to address the need for increased dissolution testing by HPLC and will control the sampling and HPLC analysis of active drug components in dissolution media. The dissolution media is circulated in a closed loop system by a Minipuls peristaltic pump and samples are taken at the specified time intervals through the use of flow-through HPLC vials. Samples are collected and either injected on to the attached HPLC or transferred to capped HPLC vials for analysis at a later date. The ADDS features five pre-programed modes which can be run individually or together for unmatched flexibility. Sample lists can be imported from other software data packages or created by the user. Standards and samples can be run together in bracketed sample lists. The system is designed on a tried and tested liquid handling platform and comes complete, with a liquid handler, software, racks and sample pumps.

John Morris Scientific 1800 251 799 www.johnmorris.com.au 44 www.pacetoday.com.au MAY 2014

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

Temperature calibrators deliver high accuracy Fluke has introduced two single function calibrators for simulating process temperature sensors. For technicians who don’t want the complexity of multifunction test tools yet need highly accurate temperature calibration, the Fluke 712B RTD and 714B Thermocouple Temperature Calibrators let instrument, process and plant maintenance technicians quickly and easily test process temperature instrumentation. The Fluke 712B measures and simulates 13 different RTD types and resistance and the 714B measures and simulates 17 different thermocouple types as well as millivolts, to verify process sensors by direct comparison of measured versus reported temperatures. The calibrators also measure 4 to 20 mA signals with 0.001 mA resolution while simultaneously sourcing a temperature signal with both readings displayed on the large, backlit display. They can scale the measured mA to the programmed 0 and 100 percent temperature settings to verify the 0 and 100 percent values scaled in a temperature transmitter.

They also feature linear ramp and 25 percent step auto-ramp based on 0 and 100 percent settings. Settings at power down are saved for easy restart of tests when the calibrator is powered back up.

Fluke Australia 02 8850 3300 www.fluke.com.au

Compressometer for strength tests on concrete The CM compressometer from TML, Japan is designed to conduct a strength test on concrete. It measures the axial strain on a cylindrical concrete specimen placed in and secured by screws to the inner chamber of this compressometer. It uses a high-sensitivity strain gauge to take strain measurements, and by multiplying a measurement by a certain factor, the amount of strain can be calculated as a numerical value. Contrary to ordinary strain gauges, this compressometer is simple and easy to operate and can be used repeatedly. It cannot, however, be used to conduct breaking tests. Breaking strength tests can be conducted with the CM-H model, a destructive compressometer. It measures the compression strain similarly to the CM, with a block 10 cm in diameter and 20 cm in length. Both the high-sensitivity strain gauge and cylindrical concrete specimen are provided with coverings to protect them from damage.

Bestech Australia 03 9540 5100 www.bestech.com.au

Pneumatic control unit with position feedback Bürkert’s type 8697 pneumatic control unit with position feedback, with LED status indication, has been released to fit all Classic and Element valves. The IP65/67 8697 head has mechanical or inductive position switches, and an integrated pneumatic pilot to control single-acting actuators. This innovation replaces the type 1062, offering one-button commissioning for decentralised automation for small drives. Designed as a more compact version of the type 8690, Bürkert’s latest innovation boasts a larger scope than its predecessors. The new type 8697 is available as a pneumatic unit or feedback for ELEMENT valves with 50mm actuators, as well as a pneumatic control unit for CLASSIC valves with actuator sizes 40/50/63mm. The head can also be used as a feedback for CLASSIC actuators of all sizes, 40-225mm. The type 8697 replaces the type 1062, which previously offered position feedback (but no pilot) for CLASSIC valves. Beyond a replacement, the type 8697 offers original advancements such as an integrated pilot valve with manual actuation and LEDs for indicating device status. Integrating this head is the simplest way to create a decentralised automation device, improving overall process speed and allowing independence and therefore creativity in process design. The type 8697 asserts itself with mechanical self-adjusting valve position switches as 2 and 3 wire inductive or micro switches. LED integration illustrates switch position.

Bürkert Australia 1300 888 868 www.burkert.com.au

Multiprotocol Ethernet in-cabinet block I/O stations TURCK is expanding its line of In-Cabinet, Block I/O stations with the addition of the FEN20 I/O stations for Industrial Ethernet. This station incorporates TURCK’s Industrial Ethernet multiprotocol technology into a fixed, economical, in-cabinet I/O product suitable for applications where digital I/O needs to be elevated to an Industrial Ethernet layer such as EtherNet/IP, PROFINET or Modbus TCP. This first release in a family of FEN20 I/O stations is available with 16 configurable I/O, with power isolation between I/O zones, an embedded Ethernet switch to support a variety of application topologies. The station can be addressed via an external rotary switch or via a webserver which makes troubleshooting easier, quicker, and more cost effective. The FEN20 supports

DHCP, LLDP, and includes LEDs for status and basic troubleshooting. TURCK’s Industrial Ethernet multiprotocol technology is an innovative approach to Ethernet applications. A single station can operate on a Modbus TCP, EtherNet/IP or PROFINET network.

Upon power-up, the station automatically recognizes the protocol of the master that tries to connect to it, and dedicates the outputs to that master while still allowing other protocols to access the input data and diagnostic information. The FEN20 in-cabinet I/O modules employ a unique housing that makes it suitable for uses in light tower, push button, or operator panels.

TURCK 1300 132 566 www.turck.com.au MAY 2014 www.pacetoday.com.au 45

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OPINION

TRENDS

Top 9 emerging technologies The following technologies will play a major role in the evolution of automation, writes Paul Miller.

A

RC Advisory Group analysts track a broad range of emerging technologies related to manufacturing, infrastructure, industrial automation and IT, and enterprise applications.

This special ARC report highlights selected technologies that will have significant impact over the next several years, if not well into the future. While far from a comprehensive list, the following hot technologies provide a good “feel” for the overall landscape.

1

Proliferation of Intelligent Devices and the Emerging Internet of Things As microprocessors and other electronics become increasingly smaller, more efficient, and less expensive, we’re seeing intelligence being embedded into more and more consumer, commercial, and industrial devices.

Increasingly, these devices communicate with each other via the emerging “Internet of Things” (IoT).

This brings what the industry previously referred to as machine-to-machine (M2M) communications to a whole new level.

In 2012, there were more than ten billion Wi-Fi-connected devices, with projections for more than 50 billion devices to be connected by 2020. This will include more than five billion smartphone and internet users, most cars, and many home appliances. Free or inexpensive mobile platforms will dominate the market.

2

Predictive Analytics: Gaining Value from Big Data Interest in analytics and business intelligence (BI) software has surged over the last few years. Leading software providers offer full analytics suites for enterprises to use to monitor, analyze, and manage a wide range of business activities. But while many industrial enterprises already use business analytics packages, their successes are primarily in customer-facing activities like sales, marketing, and product 46 www.pacetoday.com.au MAY 2014

development. As a result, many question the applicability of using analytics to improve other critical, but more inwardfacing industrial processes like operations and asset management.

3

Cloud Computing and ServicesBased Solutions The technology disruption that cloud computing represents centers on information technology (IT), rather than operational technology (OT). Cloud represents a new model for IT, challenging an organization’s established IT practices in every area; new platforms, new services, new deployment, licensing, and support models. Cloud forces an IT organization to examine each application within its portfolio and reevaluate the way the application is currently deployed.

4

Virtualization Virtualization, a computing approach that decouples hardware and software, is rapidly gaining traction in the traditionally conservative automation and control industry.

While initially met with skepticism for industrial applications, this is no longer this case as end user demands to reduce costs and make more efficient use of computing resources drive suppliers to incorporate the technology.

5

Augmented Reality, 3D Simulation, and NUI An increasing number of companies in the energy and process industries use 3D virtual simulation and visualization tools to help address some of the many challenges they face. This technology allows plant engineering and operations groups to create very comprehensive and accurate virtual environments that represent the complete physical plant/ facility. These are used to help to plan operational procedures, train operators and maintenance technicians, and meet health and safety requirements; all within a computer-simulated 3D environment. Increasingly, planners

also take advantage of this advanced technology to improve their scheduling activities. High-fidelity operator training simulation software is designed to exactly replicate the specific plant or process, creating an interactive environment in 2D or 3D. The simulator uses a first principle or empirical model of the specific plant and/or process. The training can take place either on the plant’s actual control system, or on an off-line personal computer or tablet that incorporates an image of the actual control system running.

6

Mobility and “Wearable” Technologies New technologies often provide the key enabler for process re-engineering and business process optimization that can significantly enhances performance.

For maintenance, mobility can provide major improvements in its primary objectives: uptime, asset longevity, safety, and cost control.

The vast majority of maintenance personnel – technicians, supervisors, and stock keepers – are mobile during their typical work routines. Mobile devices and the associated software applications offer im-provements in the associated work flow and business processes.

They also improve data integrity by eliminating paper forms and the delays for manual data entry.

7

BYOD The trend toward BYOD (“bring your own device”) – driven by the today’s profusion of commercial smartphones, tablets, and other handheld computing devices – is another enabler for mobility in industry.

Increasingly, plant personnel at all levels prefer to use their own familiar handheld devices while on the job.

In many process industries, field devices must be certified to operate in hazardous locations, a requirement that excludes consumer devices from consideration. For industrial service,

smartphones, tablets, and other mobility devices require enhanced ruggedness, hazardous location certification, and – in some cases – dedicated higher performing interfaces for barcode scanning or other job-specific capabilities.

8

Remote Operations Management In the past, the focus on operating remote industrial facilities had been to maintain steady-state operations despite frequent disturbances, with operators doing whatever was required to keep the facilities running and meet production schedules in a safe and environmentally acceptable way. Although some remote facilities still operate in this mode, the nextgeneration of remote facilities will not.

Tighter production specifications and the need to maintain supply reserves, plus more stringent process safety measures, cyber-security standards, and environmental regulations further challenge this dynamic environment.

9

Additive Manufacturing Emerging additive manufacturing (3D printing) technology provides product design teams the ability to perform rapid prototyping to speed product design and reduce costs.

Additive manufacturing systems, driven from CAD models, can use a variety of different build materials; including metal, polymer, or sand to build prototypes.

Manufacturers are finding tremendous value in additive manufacturing as a prototyping tool since there is no penalty for design complexity or detail, although most prototypes will require post-production finishing. Using the original CAD models, additive manufacturing systems can fabricate either complex or simple prototypes in one process.

[Paul Miller (PMiller@ARCweb. com) is Content Director, ARC Advisory Group.] www.arcweb.com

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TICKETS NOW ON SALE Celebrating its 11th year, the 2014 PACE Zenith Awards ceremony will take place on Thursday 12th June in Melbourne and will bring together some of the biggest names in the industry to celebrate, recognise and award companies and professionals within the Process and Control Engineering industry.

DATE:

12 June 2014

TIME:

6.30pm pre dinner drinks, 7pm dinner

VENUE:

Zinc, Federation Square Melbourne

TICKETS: $155 per person or $1,430 for a table of 10 (inc. GST).

Tickets include a three course dinner and beverages

Categories • Manufacturing • Food & Beverage • Machine Builder • Mining & Minerals Processing • Oil & Gas • Power & Energy Management • Lifetime Achievement Award • Water & Wastewater • Young Achiever • Best Fieldbus Implementation • Project of the Year

To book your tickets to the PACE Zenith Awards dinner please contact alice.wearne@cirrusmedia.com.au or phone 02 8484 0822.

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

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© 2013 Swagelok Company

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A flexible way of joining two connections together with Swagelok reliability – Swagelok’s line of hoses Thermal, static and chemical performance you can count on, day in and day out. Made with core materials that can include stainless steel, PTFE, PFA, nylon and polyethylene. We’ve built an amazing range of sizes and options for your demanding specifications. Getting serious performance into tough places is now just that much easier – amazing flexibility, what else would you expect? For more information, please visit www.swagelok.com/hose.

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