PACE - Process & Control Engineering - October 2013

PA1013_001.pdf

Page

1

24/09/13,

4:42:02

PM

AEST

OCTOBER 2013 | VOL.66 NO.9

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

Post Print Approved PP255003/00539

INSIDE PACE

Engineering

Mining

Oil & Gas

Manufacturers must seek alternatives to conventional production methods

Augmented reality and automated processes will change the way we operate

Understand ISO 15156 to select the optimal fluid system component

PA1013_000_MET

-

1

2013-09-19T14:14:29+10:00

MT313a Process & Control Engineering Megaliner Full Page Advertisement October 2013.indd 1

18/09/13 2:04 PM

PA1013_003.pdf

Page

3

24/09/13,

4:39:24

PM

AEST

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

IN THIS ISSUE

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

18

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

6 SUBSCRIPTION: $99 pa incl GST OVERSEAS SUBSCRIPTIONS: NZ: $A109 pa & OS: $A119 pa CUSTOMER SERVICE: 1300 360 126

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

11

7

News 6

Management 10

Application 21

HUG 2013 Highlights and notable launches from the 2013 Honeywell Users Group Asia Pacific event

Embrace BYOD Integrating BYODs into practices and tools used is an investment in business success

Sour gas Material selection of fluid system components in sour gas environments is complex

Insight 8

Engineer’s Notes 16

IICA Corner 26

Factory fieldbus flexibility Field Device Technology plays an important role in achieving product flexibility

Optimise energy consumption A holistic approach can create greater energy efficiencies and intelligent building systems

Legal advice Using a lawyer wisely means knowing exactly what you want from the situation

ON THE COVER

OFFICIAL MAGAZINE OF: OCTOBER 2013 | VOL.66 NO.9

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

Average Net Distribution Period ending March ‘13 6,424

Engineering

Mining

Oil & Gas

Manufacturers must seek alternatives to conventional production methods

Augmented reality and automated processes will change the way we operate

Understand ISO 15156 to select the optimal fluid system component

Post Print Approved PP255003/00539

INSIDE PACE

Fluke is proud to announce the addition of the new 700G Series pressure gauge ranges to its existing 700G pressure products.

The 700G Series is a compilation of 28 precision pressure test gauges with pressure measurements ranging from 10 inH20 to 10,000 psi (20 mbar to 690 bar) and 0.05% accuracy. With the suite of pressure products now available, users can solve all their pressure

test needs with one reliable and accurate line of products from Fluke’s trusted brand.

Notable additions include absolute pressure measurement ranges and reference class accuracy gauges.

The 700G Series offers you portable, highquality round pressure gauges for fast and accurate results. www.fluke.com.au

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

The new Allen-Bradley® PowerFlex® 525 is ideal for a wide spectrum of applications. This drive installs and programs easily, delivers all the communications, energy savings and standard safety features you need in a cost-effective compact drive.

Find out more, visit:

www.ab.com/powerflex525 Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. PowerFlex is a trademark of Rockwell Automation Inc.

OCTOBER 2013 www.pacetoday.com.au 3

PA1013_004.pdf

Page

4

25/09/13,

10:17:38

AM

AEST

COMMENT

EDITOR’S MESSAGE

WHAT’S ON

TĂœV Functional Safety Engineering Course 8-11 October 2013, Perth mirek@iesystems.com.au

Use locally developed IP to support our SMEs

IICA Perth Technology Expo 17 October 2013, Perth wa@iica.org.au IICA Cyber Security Seminar 30 October 2013, Sydney nsw@iica.org.au

Kevin Gomez Editor

Profinet & Profibus EXPO 6 November 2013, Brisbane www.profibusaustralia.com.au

Next Issue

For daily updates visit www.pacetoday.com.au

• 60-year Special • Test & Measurement • SCADA & MES • Motors, Drives & Motion Control • Asset Management & Maintenance

WITH a new government in power there was hope that the engineering fraternity’s contribution would be tapped for nation building. But we soon learnt that there is no science minister in the new cabinet. This has caused concern among several organisations including Science & Technology Australia and a rather vocal Member of Parliament, Dennis Jensen, who has expressed an interest in the job. Dr Jensen’s credentials? “I’m the son of a scientist, the grandson of a scientist, I’ve always loved science. I base my politics around the facts of science.�

It will be interesting to see whether this government will embrace engineering

and particularly support the country’s small and medium enterprises - the source of much ingenuity. Emerging technologies such as additive manufacturing and custom production can neutralise many of Australia’s perceived and real weaknesses.

There is a lot of innovative work being done in our universities and research organisations. Sometimes, these do not progress to commercialisation. In many cases, these efforts are snapped up by overseas companies.

A lot of taxpayer dollars go into university funding and there is a case to be made for a more beneficial use of research that comes out of our institutions.

If we wish to truly support local entrepreneurs, it will be wise to offer intellectual property emerging from universities to small and medium-sized enterprises across the country. Universities must be encouraged to work with the SMEs to further develop and commercialise their technology.

This will offer real world experience and possible jobs for some student members on the university team.

We have several successes in developing pioneering new technologies; it’s about time we use this to grow our industrial capabilities. kevin.gomez@cirrusmedia.com.au

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

TECHNOLOGY TRENDS

Top disruptive technologies that threaten to change the world

BY JIM PINTO WHAT technologies will most radically transform human life in the next twelve years, to 2025? The McKinsey Global Institute has narrowed the most potentially disruptive down to a dozen.

They are, in order of size of potential impact: Mobile Internet – defined as increasingly inexpensive and capable mobile computing devices and Internet connectivity Automation of knowledge work

– intelligent software systems that perform knowledge work tasks involving unstructured commands and subtle judgments Internet of Things – networks of low-cost sensors and actuators for data collection, monitoring, decision making and process optimisation Cloud Technology – delivered over the Internet, as a service Advanced Robotics – increasingly capable robots with enhanced senses, dexterity and intelligence, used to automate tasks or augment humans

Autonomous and Near-Autonomous Vehicles – driverless cars Next Generation Genomics – fast, low-cost gene sequencing, advanced big-data analytics, and synthetic biology Energy Storage 3D Printing Advanced Materials – nanotechnology Advanced Oil and Natural Gas Recovery Renewable Energy According to McKinsey, the Mobile Internet, which could change the lives of more than five billion people around

the globe, the automation of knowledge work, and the Internet of Things would have by far the largest economic impacts.

All together, the above technologies could generate $14 to $33 trillion. Much of that growth will be at the expense of older technologies and even entire industries falling into obsolescence.

Leaders must be prepared to disrupt their own businesses and make the investments needed to effect change.

Nobody, especially business leaders, can afford to be the last to change.

Jim@JimPinto.com

*+0 #0#)'4 5 7.6+ '55+10 14' THINMANAGER.COM

ThinManager offers technology for IT professionals seeking better security and configuration of their thin client networks.

Our MultiSession core technology allows multiple sessions running anywhere on the ThinManager network to be viewed through one thin client.

ThinManager can “tile� these screen views based on your settings. You can dictate which tile shows which session. You can set it to run in screensaver mode so that certain “tiles� are constantly updated with different sessions. Multisession allows you to view displays from different applications on the same monitor.

#.. 10&'49#4' 7564#.+# 10 EGNN EGL LFI 14 8+5+6 174 9'$5+6' 999T910&'49#4'T%1/T#7 4 www.pacetoday.com.au OCTOBER 2013

AD_PACEMET2APR_12.pdf

Page

1

20/03/12,

8:34

AM

• Get your artistic side that craves performance • Make engineering look easy • Become an engineering superstar

HMI and Beyond...

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

PA1013_06.pdf

Page

6

24/09/13,

2:10:14

PM

AEST

NEWS

HUG 2013

Honeywell focuses on productivity

FLUXUS® F808 The non-intrusive ultrasonic flow meter IECEx / ATEX Zone 1 approved f Measures all kinds of hydrocarbons and chemicals f Rugged solution for any environment f No media contact, no wear and tear, no risk of leaks f No process shut-downs for installation f Very reliable and virtually maintenance free f Highly accurate, zero point stable and drift free

www.flexim.com

6 www.pacetoday.com.au OCTOBER 2013

CONTEXT: The Collaboration Station is a view-only control station linking operators at multiple sites with business information.

BY BRENT BALINSKI THE shift among miners to get the most out of their assets by improved business processes has emerged as a focus for Honeywell Process Solutions.

“The biggest issue at the moment is productivity,” explained Garry Mahoney, Pacific Sales Director for Honeywell Process Solutions, when discussing trends among customers of the automation control company.

“All our major clients are looking at capex, which has really dried up; but at the same time, there is a drive, and we see it across the board, to get back to a pre-GFC cost structure. That typically means a 20 to 25 per cent reduction in operating costs, in the operating budget.”

He told PACE during last month’s Honeywell Users Group (HUG) Asia Pacific that he’d seen a big change – not a revelation, he added, with the slowdown a frequent topic of discussion in the industry – for miners to get their operations back to pre-GFC cost structures. The difference,

however, was that there wasn’t so much panic or rush to cut as many staff as possible, but to try and make sustainable improvements in the way businesses are run.

In 2008 and 2009, there was a bigger problem regarding the availability of cash, with banks reluctant to lend. Things may be tightening up now, but there’s a big difference in one very important regard, according to Honeywell.

“The majority of the industry has cash,” said Mahoney, the majority of whose clients are in the three Ms (mining, minerals and metals), as well as oil and gas. “But at the moment they’re holding cash to maintain the share price. But if there’s a project with a payback of three months, six months, that type of period, they’re investing. That’s why I think there’s a mindset not just to slash and burn and manage labour numbers.”

Two of the productivityboosting solutions Honeywell had on show at HUG 2013 were its Belt Asset Inspection System (available as a product and a service) and its Experion

Collaboration Station.

“We’ve had that in play on pilot sites for a couple of years,” Mahoney stated. “We can provide industry with a low-cost way of monitoring belt condition, early awareness of a belt problem.” The monitor constantly collects and assesses data on defects – such as tears, gouging and splice problems – and their severity, visualising this for the user.

According to Honeywell, the payoff is that the life of belts can be more accurately determined, enabling the user to get the best run out of them before replacement, rather than just guessing at when this is needed.

Another item Honeywell was eager to talk about was its Collaboration Station, a view-only control station linking operators at multiple sites with business information at various points along a supply chain. “It’s not about a big LCD screen, it’s about being able to pull the data and present it in a context that makes sense for people to manage that incident,” Mahoney said. www.honeywellprocess.com

PA1013_07.pdf

Page

7

24/09/13,

2:10:14

PM

AEST

NEWS

TRAINING

Cyber security seminar in Sydney THE IICA has partnered with PACE to bring together experts to present leading edge applications and case studies on Cyber Security.

The keynote speaker for the seminar is Dr Christopher Beggs who will present “Towards 2020 Readiness: Changing the Focus of Industrial Control System Security”.

Dr Beggs is the principal ICS security risk specialist at SIS; the only national organisation solely dedicated to the security and safeguarding ICS/ SCADA networks. He holds a PhD in Cyberterrorism and SCADA security awarded by Monash University and is a Certified CSSA and SANS-GIAC Security Professional.

Other speakers are Nick Howarth and Mitchell Hewes from IT Security at ANSTO, and Robert Hicks of Rockwell who will speak about “Scalable Secure Remote Access Solutions”.

According to Hicks, by providing a scalable platform that can accommodate multiple applications, Ethernet-based automation systems can help increase flexibility and accelerate deployment of new applications, providing companies with a

future proof network that can help them achieve their productivity goals.

Exposing process networks to a wider audience raises valid security concerns. Due to their isolation, traditional fieldbuses inherently brought some level of security; although accessing data on these networks could be difficult. As industry moves toward a converged Ethernet network, security becomes a prime concern.

Warwick Black of Schneider Electric will present on “Cyber Security – Is your Industrial Control System Prepared?”

The seminar is fully catered. The cost for members is $145.00; non members is $195.00 and students is $50.00. The event is sponsored by Rockwell, iOpen, Schneider Electric and Daanet.

The IICA Sydney Technology Expo will be held on the smae day and venue and will feature over fifty suppliers demonstrating their instruments and solutions. Delegates may participate in a free tour of the Sydney Water Malabar Treatment plant.

To register email nsw@iica.org.au or phone 0410 334 333.

OCTOBER 2013 www.pacetoday.com.au 7

PA1013_008.pdf

Page

8

24/09/13,

2:16:32

PM

AEST

OPINION

Factory fieldbus flexibility FDT plays an important role in achieving product flexibility, writes Harry Forbes.

T

RADITIONALLY, FDT (Field Device Technology) had been associated largely with process automation and process field devices, but this is no longer the case. Suppliers in the factory automation space are now adopting FDT because they find it affords them the technical flexibility needed to deal with the wide range of product configurations their customers demand.

Factory equipment suppliers and machine builders, even major ones, must comply with the system specifications demanded by end user manufacturers. As a result, they must deliver their products to support one of many different combinations of factory automation system and fieldbus.

ARC spoke with one major equipment supplier that now uses FDT to increase product flexibility without adding permutations to its product design.

As the owner-operators, end user manufacturers create the specifications for their factory production systems.

Their specification decisions flow “up” the value chain, while the products that equip the factory flow in the opposite direction. This complicates matters for the equipment and device suppliers further up the chain who must serve a large number of end user customers, each with its own specifications. One major technical challenge they face is to

8 www.pacetoday.com.au OCTOBER 2013

customise their equipment as demanded by each end user without creating a large number of product permutations that would be prohibitively expensive to develop, maintain, and support.

Equipment suppliers must usually support user-chosen factory automation systems as well as user-chosen factory fieldbus technologies. End users usually prefer to standardise on one automation platform and as few fieldbuses as possible. This greatly simplifies the end user’s operating and maintenance tasks over the operating life of the equipment, but the machine builders can find themselves “sandwiched” between their customer’s automation and fieldbus choices. This places a premium on a supplier’s ability to be flexible. Complex machines will likely contain one or more embedded controllers supporting proprietary machine features. So the machine builder must integrate its own embedded control technology with whatever else the end user specifies.

FDT, the IEC 62453 standard, is a software interface specification for inter-operability between field devices and automation systems. Its design basis is such that FDT-enabled applications within the automation system can manage field devices regardless of the device’s manufacturer and regardless of the fieldbus protocol employed. This is achieved by equipping each device

with a unique software element called a Device Type Manager (DTM).

FDT-enabled applications called “FDT Frame Applications” contain a fully defined interface to DTMs, providing interoperability between any pair of Frame Applications and DTMs. Frame Applications typically operate in a Microsoft environment.

End users prefer to standardise on one automation platform and as few fieldbuses as possible

The scope of the FDT interface includes more than operating data communication. DTMs can be used over the device’s entire life cycle.

Functions for device parameterisation, messaging, health monitoring, interactive functions, and online help can be integrated into a DTM. Effective implementations can provide support from commissioning to repair.

ARC Advisory Group interviewed one large (over $1 billion annual revenue) global supplier of factory equipment that has begun embedding

FDT into its equipment controllers.

The supplier asked to remain anonymous. The supplier’s decision to use FDT was driven by its customer’s demand to support several different PLCs for factory automation and over six different fieldbuses to the various devices that are used with their equipment. The supplier’s FDT implementation presents fieldbus-independent process data both to its controller and to higher level automation systems.

The company has embedded FDT into its controller to such a degree that the end user does not see it, but can use the technology to configure, commission, monitor and debug all connected devices regardless of fieldbus.

The supplier has integrated FDT into its internal product management.

Each customer order now ships with a pre-configured FDT project within the equipment. Built automatically by its order management system, this covers all the manufacturer’s components in the shipment. System integrators receiving this equipment can add their own custom components to the FDT project when they integrate the equipment into a production line or machine. FDT extensibility is also a plus.

[Harry Forbes (HForbes@ARCweb. com) is Senior Analyst, ARC Advisory Group.] www.arcweb.com

PA1013_009.pdf

Page

9

24/09/13,

2:25:28

PM

AEST

IN FOCUS

How to bring BYODs into the fold Businesses have much to gain by embracing BYOD. Many organisations have yet to address the multitude of effects that BYOD can have on enterprise WLAN performance, security and compliance.

B

USINESSES have much to gain by embracing the bring-your-own device (BYOD) trend.

While most organisations are already moving in this direction, many have yet to fully understand and address the multitude of effects that BYOD can have on enterprise WLAN performance, security and compliance.

It is essential to factor smart devices, including BYODs, into the full wireless LAN (WLAN) lifecycle to reap the benefits of BYOD while addressing its associated challenges.

Today’s BYOD challenges are to: find effective methods and tools to discover smart devices used in the

workplace; assess their impact on the corporate network; reduce unwanted side-effects; and facilitate trouble-free, business-appropriate use.

Ignoring the BYOD impact on corporate networks can degrade business efficiency and increase operating costs.

Until organisations acknowledge and address these challenges, they can’t harness the business benefits such as using BYOD to reduce monthly telecom spend and liability for personal use of corporate phones.

Corporate networks IT initiatives to tackle BYOD challenges often focus on mobile device and data

management. Those measures can be critical for successful BYOD adoption.

For example, using a mobile device manager to provision secure WLAN settings and remove them after device loss, theft, or retirement.

However, these do not completely address the many ways in which BYOD affects corporate networks.

Unplanned devices compete for scarce airtime and drain WLAN capacity.

Network planners have traditionally designed for the capacity required by corporate assets such as the number of IT-procured laptops.

However, the number of smart devices carried by each individual continues to grow, surging in

unpredictable ways.

When employees return to work after a holiday with new BYO smartphones and tablets, capacityplanning assumptions can be blown out quickly.

Not only does competition for shared channels grow, but Wi-Fi chipsets in consumer electronics differ.

BYODs behave in unexpected ways, degrading overall performance. When IT departments select a smart device, network planners can first verify interoperability and isolate constraints like unsupported Wi-Fi data rates or modes that cause some clients to use more airtime.

However, IT has little control

Wireless and battery-less pushbuttons Significantly reduce your installation time and achieve cost savings of at least 20 per cent Maximise efficiency with Harmony XB5R wireless and battery-less pushbuttons.

> Increase flexibility and freedom of movement > Control your plant operation over distances of up to 100m

> No battery to replace, recharge or recycle > Quick and easy to install with wireless technology Give yourself a competitive edge… Increase the productivity of your people and equipment.

Discover more

Harmony Ø22mm XB4 Metal and XB5 Plastic Pushbuttons

Harmony Ø22mm Fingerprint Recognition Biometric Switch

Use our FREE calculator to determine the time and cost savings for your application using Harmony XB5R pushbuttons!

Simply visit www.SEReply.com and enter key code 53401K www.schneider-electric.com.au | Call 1300 369 233 © 2013 Schneider Electric. All Rights Reserved. SEAU26885

OCTOBER 2013 www.pacetoday.com.au 9

PA1013_0010.pdf

Page

10

24/09/13,

2:25:28

PM

AEST

IN FOCUS

over BYOD selection. Most BYODs are less-robust, consumer-grade devices.

For example, although iPads support 5 GHz, they aggressively prefer 2.4 GHz, which can lead to unexpected starvation of Wi-Fi phones and other single-band devices sharing limited 2.4 GHz channels. Android tablet and smartphone Wi-Fi behaviours are even more varied.

BYODs may operate insecurely, jeopardising corporate assets. Today, virtually all Wi-Fi-certified smart devices, including BYODs, are capable of supporting WPA2-Enterprise security.

However, corporate WLANs secured with WPA2Enterprise are sometimes off-limits to unapproved BYODs that aren’t enrolled in directories or issued certificates for 802.1X authentication.

These unapproved BYODs may then resort to using open guest WLANs where they expose traffic to eavesdropping and various man-in-the-middle attacks. When IT does not monitor BYOD activity, such exposures go undetected.

Even approved BYODs can be difficult or costly to troubleshoot. Consumer-grade smart devices often lack remote diagnostic interfaces and tools for help desks to investigate and resolve problems.

For example, remote control agents supported on laptops and Windows phones are unavailable for iPhones and iPads due to Apple iOS restrictions.

While some Android original equipment manufacturers (OEM) offer proprietary extensions for logging and diagnostics, the vast majority of Android BYODs support very limited administrative application programming interfaces (API) that don’t help IT troubleshoot remotely.

As a result, malfunctioning BYODs often remain a mystery, sapping WLAN performance indefinitely.

Further, BYODs have grown so numerous that IT departments may not have sufficient staff to troubleshoot them.

Here are some tips for melding BYOD into the WLAN lifecycle effectively.

Wi-Fi planning and design Today’s enterprise WLANs should be designed not just for laptops, but also to meet anticipated BYOD coverage and capacity needs.

Build in extra bandwidth and higher client density to accommodate inevitable BYOD growth. Optimise the network for expected BYOD device use based on known devices.

When positioning access points (APs), plan ahead for the shorter reach and lower data rates associated with battery-powered consumer electronics that have 1x1 MIMO antennas.

Allocate available RF spectrum while bearing in mind that most contemporary BYODs don’t support 5 GHz or 40 MHz bonded channels.

Intrusion Prevention System (WIPS) to continuously monitor corporate airspace for all smart devices, no matter who owns them.

Take advantage of WIPS to auto-classify and respond to BYOD-induced threats and security policy deviations, logging all activity 24/7 to better understand BYOD use and satisfy regulatory compliance and reporting needs. Make sure a solution that will allow for device classification is in place.

It is important to have visibility into the smart devices on the network and be able to differentiate between a smart device and a regular 802.11 station.

This will save hours of troubleshooting by being able to immediately identify rogue BYODs.

Deploy tools that can routinely monitor and deliver actionable visibility

Proactive performance assessment CHECK: The OneTouch AT Network Assistant can help network professionals address the entire lifecycle of managing BYOD.

true user experience, measure business application performance in both upstream and downstream directions. Results are likely to differ and often do not correlate directly to signal strength.

Measure performance at every location where smart devices can connect to the corporate network to get a complete and accurate picture of real-world results.

Use all of these survey results to offer guidance on recommended or banned BYODs and help employees make personal product choices that improve overall network and individual user productivity.

Troubleshooting Deploy tools that can routinely monitor and deliver actionable visibility into the physical and link layer interference that can be caused by smart devices carried by employees and guests.

Develop diagnostic practices to proactively isolate BYOD-induced anomalies and Wi-Fi connectivity problems, helping administrators cost-effectively spot and remediate new interferers before help desk calls begin and productivity suffers.

Deployment and verification

Wireless security monitoring

Follow initial planning and deployment with site surveys, conducted with IT-issued laptops and handsets and a representative set of BYODs. To verify the

Without adequate tools and automation, BYODs are difficult to monitor for possible security breaches.

Take steps to backfill this by using a Wireless

10 www.pacetoday.com.au OCTOBER 2013

Augment reactive troubleshooting with continuous active wireless testing to proactively detect network congestion, growing error rates, degraded data rates and other problems caused by unexpected increases in the number, density and diversity of Wi-Fi devices.

With BYODs, frequent unplanned change is a virtual certainty. Trend analysis can be an effective way to assess emerging impact and adapt plans and policies to satisfy demand and avoid BYOD troubles.

Investment in efficiency In summary, integrating BYODs into practices and tools used throughout the wireless LAN lifecycle is an investment in business success and efficiency.

For example, iPad and Android tablet sales are growing, but many enterprises have not yet embraced these popular BYODs. It makes sense to consider the presence of all personal smartphones and tablets carried by employees.

Proactively watch for RF interference caused by iOS and Android mobile hotspots and continuously test your WLAN to detect and evaluate their business impact.

When rolling out new APs, include consumer devices in site surveys, planning layout and spectral allocation to ensure coverage.

When the time comes to embrace these consumer tablets for business, your WLAN will be wellpositioned to do so without costly redesign.

Fluke Networks 02 8850 3333 www.flukenetworks.com

PA1013_011.pdf

Page

11

24/09/13,

2:29:15

PM

AEST

BEHIND THE SCENES

Unconventional production technologies Confronted with a range of challenges and sluggish productivity growth Australian manufacturers must seek alternatives to conventional production methods, writes Hartley Henderson.

W

HILE some 99 percent of Australian manufacturing industry consists of SMEs that often have low volume, high value production runs, current industrial automation is largely designed for high volume, low variation processes. To meet their needs, SMEs generally require more flexible, lower cost approaches to production.

A recently released White Paper from the CSIRO Future Manufacturing Flagship focuses on the need for affordable investment in technology.

It points to recent advances in robotics and information and communications technology, and the need for close collaboration between worker and robot

to achieve optimum outcomes.

More affordable new approaches to automation are required including assistive automation to provide flexibility in support of high variety low volume production runs. CSIRO’s Dr Peter Kambouris says we need to change the way we manufacture by providing companies with more flexible systems to deliver customised products.

“Avenues are being investigated to introduce appropriate automation into SMEs with a view to adding value and assisting the worker through autonomous solutions, rather than replacing the worker,” Dr Kambouris said.

“This is a very unique paradigm shift for Australia that involves providing the

robot with perception so that it knows what is around it and can navigate through its environment to grasp and manipulate items in the production process.

“There is a need for new thinking to look at manufacturing processes in a different way, where the robot assists the worker or is directed by the worker.

CSIRO is working on building a robot to assist the worker, incorporating the use of information systems to provide knowledge to help the worker to do complex tasks, which in turn will lead to enhanced quality control and improved productivity.

“Significant productivity improvements could also be achieved

by looking at how data and information is linked and transferred in the supply chain. New systems are required to handle information.”

The CSIRO White Paper emphasises that to maximise competitiveness, Australian manufacturers need to seek alternative affordable investment solutions that provide flexibility to respond to volatile demand.

To assist in the way ahead, significant technological advances are being made in a new generation of lightweight robots with advanced vision systems that are particularly suited to the requirements of SMEs. These robots form a key component of CSIRO’s Lightweight Assistive

LUMIFA LF1D SERIES LED LIGHTS MINI and LONG Types (IP69K)

KEY FEATURES

Rugged construction suited to use in harsh environments

LF1D Mini (LF1D-C): - Compact at only 100 x 50 x 25mm - Single LED module eliminates multiple shadows - Distributes light over a wide area ( 120˚ ) - Available in Cool White - Power saving: Only 4.6W at 24V DC - Brightness at 1.0m = 180 lux

LF1D Long (LF1D-H/J): - Available in Two lengths: 365mm and 510mm - Flat design reduces glare and multiple shadows, improving visibility from a distance - Distributes light over a wide area ( 120˚ ) - Available in Neutral White - Power saving: Max 28W at 24V DC - Brightness at 1.0m = 560 lux (LF1D-H), 840 Lux (LF1D-J)

IDEC AUSTRALIA PTY LTD Phone: 1800 68 4332

Email: sales@au.idec.com

Web: www.idec.com/australia OCTOBER 2013 www.pacetoday.com.au 11

PA1013_012.pdf

Page

12

24/09/13,

2:29:15

PM

AEST

BEHIND THE SCENES

Manufacturing Solutions (LAMS) concept that is designed to work with and make work easier for humans and to deliver a potential new era of flexibility and agility to Australia’s manufacturing industry.

Wearable technology CSIRO has developed wearable technology that provides workers with access to a virtual pair of expert eyes and hands to guide them through difficult tasks via a head-mounted camera. The system consists of a helper unit and an operator unit, both of which use a wearable computer, a head mounted camera, and a near eye display with video screen.

Through a shared visual space between the helper and the operator, the operator can virtually see the helper’s hands pointing and gesturing to objects visible through the near eye display.

Developed initially for use in the mining industry, the ReMote system is currently being trialled in manufacturing industry in the USA and in a Melbourne manufacturing company.

Kambouris believes that by providing access to expert helpers in real time, the new ReMote technology has the potential to make SMEs more agile and more competitive.

In Singapore, manufacturing accounts for some 20 percent of GDP, and key sectors include electronics, chemicals, precision engineering and biomedical.

The country is currently experiencing full employment and a shortage of manpower, and as a result, there is a strong focus to boost productivity and one of the ways is on the continuing development and uptake of industrial robotics.

A new breed of industrial robots is emerging that is easier to teach and programme, interfaces more with humans and is easier to operate.

The Singapore Institute of Manufacturing Technology (SIMTech), a research institute of the Agency for Science, Technology and Research (A*STAR), is playing a key role in carrying out collaborative research with academic institutions, co-developing automation equipment and machines with companies, transferring technology, and conducting training for manufacturing industry.

With more than 360 engineers and scientists employed, SIMTech is 12 www.pacetoday.com.au OCTOBER 2013

SMOOTH: An example of a precision motion system is this decoupled planar positioning system.

PRECISE: A robotic polishing system. proactively assisting SMEs to move up the value chain through a variety of programs backed by a combination of government and industry client funding sources.

According to Dr Guilin Yang, senior scientist and group manager of mechatronics at SIMTech, there is a strong focus on high value manufacturing, and the human-

robot interface where robots become co-workers, particularly in relation to carrying out manual and repetitive tasks.

“Robots with an increasing number of axis are being developed to undertake a greater range of tasks.

Generic manipulators can be equipped with different tools to work with high mix, low volume products,” Dr Yang explained during a recent interview in Singapore.

“Robots are being reconfigured to handle different products in unstructured environments which provides greater flexibility in production processes, and a lot of development is going into ease of programming and control.

“Significant advances in robotics technology for manufacturing industry include precision mechtronics (mechanical engineering combined with electronics) featuring high speed and high accuracy as well as high dexterity and adaptability. This makes these robots easier and safer to use in a human-robot interface.

“Key areas of research include hybrid force-motion control and integrated manipulator and sub-system design, together with sensors to identify objects and improve safety at the workstation.

“Mobile manipulators are also being developed that are proving very useful

for materials transfer on the shop floor as well as flexible systems of automation and autonomous vehicles to handle different products.”

Dr Yang says some 65 percent of SIMTech clients are SMEs that are provided with a range of assistance, including the T-up technology upgrading scheme, where researchers are attached to SMEs to identify needs and help in developing technologies to meet those needs.

SIMTech and the National University of Singapore Faculty of Engineering recently launched joint research laboratories in precision motion systems and industrial robotics geared towards high value manufacturing and improving productivity.

The joint laboratories aim is to boost industry automation by enhancing the capability, performance and intelligence of precision machines and robotic systems to allow for higher throughput, higher accuracy, and greater humanmachine co-operation on unstructured manufacturing shop floors.

CSIRO peter.kambouris@csiro.au www.csiro.au SIMTech +65 67938383 www.SIMTech.a-star.edu.

PA1013_000_RSC

-

1

2013-09-19T16:13:15+10:00

GIFT OF INVENTION

WITH DESIGNSPARK MECHANICAL At RS Components we know that you want the shortest possible time between having an amazing idea and creating the prototype design. But getting the right design software to realise your ideas is often expensive and the programs can be time-consuming to learn.

That’s why we’re making our professional 3D solution DesignSpark Mechanical available for all.

DesignSpark Mechanical is the first FREE and fully functional 3D design package to feature intuitive Direct Modelling techniques, helping you to generate world-changing designs more easily, quickly and creatively than ever before.

Download DesignSpark Mechanical For Free Visit www.designspark.com/mechanical

BROUGHT TO YOU BY

PA1013_014.pdf

Page

14

24/09/13,

2:30:59

PM

AEST

BEHIND THE SCENES

Optimising energy consumption BuildingIQ overcomes communication challenges with MatrikonOPC Server for BACnet.

TO monitor and optimise energy consumption, BuildingIQ’s software depends on reliable connections to building management systems (BMS) and their underlying control layers.

BuildingIQ needed a cost-effective solution to support communication with BMS that use BACnet and other communications protocols.

The MatrikonOPC Server for BACnet enables BuildingIQ’s software to communicate with BACnet devices and other protocols including LonWorks, Modbus, SNMP and Johnson Controls.

BuildingIQ is a young, rapidly growing Sydney-based in Australia that offers a Predictive Energy Optimisation System that can reduce energy consumption and costs in commercial buildings.

To create an optimised running profile, the company’s software needs to connect to the management and control systems in each building. Through that connection, the software gathers data that is then used, in addition to external data such as weather forecasts, to optimise HVAC operations.

The key challenge for BuildingIQ was establishing a connection to the BMS in buildings that lacked an OPC server.

Most of the buildings relied on BACnet or LonWorks communication protocols — protocols with which BuildingIQ’s software could not communicate.

MatrikonOPC solution creates connections BuildingIQ considered expensive hardware-based solutions to its communication challenges, before finding the MatrikonOPC Server for BACnet, which provides secure, realtime data access between OPC-enabled systems and BMS. “MatrikonOPC came highly recommended,” said Peter Dickinson, vice president of operations for BuildingIQ. “We tested it using the free demo, found that it ran reliably, and implemented it without any difficulty at a number of our sites.”

Following an installation process that took less than one hour, BuildingIQ’s software was able to communicate efficiently with BACnet devices and 14 www.pacetoday.com.au OCTOBER 2013

CUSTOM DRIVER PROBLEM: Each application requires a device or protocol specific driver to allow it to communicate with each respective device.

Drivers are not re-usable between applications because each application uses its own data format(s).

COMMUNICATION: Multiple applications using OPC to communicate with a Device without directly using its native protocol.

The OPC Server for BACnet utilises the BACnet protocol to natively communicate with the BACnet Device.

work in parallel to the BMS. The company also has the flexibility to communicate with numerous other protocols, including LonWorks as well as Johnson.

MatrikonOPC’s local support team assisted BuildingIQ with initial setup, and has since helped the company address additional communication challenges, including DCOM issues that were quickly resolved with OPC Tunneller.

Benefits of MatrikonOPC BACnet offer sseveral benefits including: Single operator workstation for all systems; Full compliance with BACnet specifications; No lengthy configurations — just need to activate the OPC Server; and Easy

integration into existing control systems.

“The support we’ve received has been fantastic,” Dickinson said. “When we’ve come across obscure systems and other concerns, we’ve received immediate follow-up and solution support. It’s been a great relief to have one less thing to worry about.”

The BACnet OPC Server from MatrikonOPC provides secure and reliable real-time data access between all BACnet objects/devices and any OPC-enabled applications such as Historians, HMIs, and SCADA ...etc to maximise control over one’s Building Automation Systems.

The BACnet OPC Server automatically generates the server’s configuration to make it easy for building automation professionals to control and monitor their: HVAC systems, Lighting Control, Security systems, Fire detection and alarm, Smart Elevator Controllers.

MatrikonOPC info@matrikonopc.com www.MatrikonOPC.com

235mm

297mm

PA1013_000_MOO

-

1

2013-09-09T11:12:08+10:00

When Your SIS is Your

Last Line of Defense

Moore Industries Is There Like a good goalkeeper, a Safety Instrumented System (SIS) is your dependable “last line of defense.” This means you need reliable Functional Safety products to anchor your team.

You can count on Moore Industries with FS Functional Safety Series products designed for Safety Instrumented Systems and to IEC 61508 standards. Our alarm trips, relays, isolators and splitters help your SIS perform at its highest level. With approval from exida for use in SIL 3 and SIL 2 environments, you can install our products with condence.

Looking to add more reliability to your SIS roster? Our FS Functional Safety Series products...

•

Are exida certied with reviewed FMEDA reports

•

Warn of and prevent potentially hazardous conditions

•

Add layers of protection to existing safety systems

•

Isolate an SIS from a basic process control system

•

Share, split and pass valuable HART data

Great teams are condent their keeper will make the big save with the game on the line. Shouldn’t you feel the same about your safety instrumentation?

Contact Us at 1800-784-899

Demand Moore Reliability Watch videos, download white papers and datasheets to learn more about our safety products at: www.miinet.com/safetyseries

PACE_2013-10_SafetyFam Ad_FullPg_Moore_Industries_Australia.pdf

PA1013_016.pdf

Page

16

24/09/13,

2:32:36

PM

AEST

BEHIND THE SCENES

Diamond standard in medical research Adelaide’s SAHMRI building demonstrates how a holistic approach can create greater energy efficiencies and intelligent building systems for the long term.

M

EDICAL research generates new ideas and innovation every day.

To swiftly incorporate these developments into healthcare delivery, the South Australian Health and Medical Research Institute (SAHMRI) is building a 25,000-square-metre facility to foster creativity and productivity.

Together with Schneider Electric Life Sciences solution experts, SAHMRI will realise its vision of an intelligent and responsive facility.

Key to the building’s success was early engagement with Schneider Electric and the company’s EcoStruxure architecture which

16 www.pacetoday.com.au OCTOBER 2013

provides users with a clear view across process, building control and physical security during the design phase.

EcoStruxure integrates SAHMRI’s building systems into a single platform that includes heating and cooling, energy management, security, and lab controls, to provide efficiency and flexibility throughout the facility’s lifecycle.

Icon status Already destined for icon status on the Adelaide city skyline, SAHMRI’s diamond shape construction, elevated on flower columns, also features a pine cone inspired transparent skin to allow in plenty of natural light into the building.

It features wet and dry laboratory areas, modern research areas and even a medicinal garden.

“We need environments that encourage creativity, the right temperature, right lighting and right systems to ensure researchers are at their best, most creative and productive,” says Professor Steve Wesselingh, Executive Director, SAHMRI. It is a theme reiterated by Michelle Gheorghiu, SAHMRI Project Director, “We are creating a hub of knowledge to instill passion into the young generation about research.”

The backbone of the EcoStruxure architecture is the Integrated Building

Power interruptions have the potential to create data loss and hardware damage to communication equipment.

PA1013_017.pdf

Page

17

24/09/13,

2:32:36

PM

AEST

BEHIND THE SCENES

System (IBS), providing efficiency through a collaborative design, construction, and delivery process.

The system design utilises 3D building information modeling software to avoid design changes and rework. Because all components communicate with one another, the system allows the facility manager to monitor and control heating, ventilation, air conditioning, humidity, lighting, access control, video, lifts and other security features across the facility.

Integrated security The control of access and security was of critical importance for SAHMRI’s objectives. Schneider Electric’s integrated security offering including smart card access control, close circuit video management and high-definition cameras, and monitoring provided a safe, flexible and secure solution.

The Video Management System designed for SAHMRI deploys the latest in Pelco by Schneider Electric’s high-definition cameras.

These offer increased capabilities for video analytics and identification – more than standard resolutions.

Lighting control Another key component of the EcoStruxure architecture is Clipsal

by Schneider Electric’s DALIcontrol lighting control system, designed to maximise energy efficiencies in the building. Although there are key scenes programmed into the building, the system also allows for customised programming in research areas that require constant lighting to simulate daylight levels of light.

DALIcontrol also includes an emergency lighting solution. Test sequences have been scheduled into the operation and provide reports to the facility operator to confirm that the evacuation lighting is functioning properly. Clipsal has also supplied energy efficient exit light fittings for the entire building.

Emergency power supply It is critical in medical facilities to have the assurance that the backup power system will perform in an emergency.

Schneider Electric’s Emergency Power Supply System (EPSS) test solution provides automated analysis and accurate reporting as well as complete

design team including electrical services consultant, Aurecon also ensured sub-metering was installed strategically in specially designed distribution boards, to separately meter the power and lighting chassis.

Partnership

SAHMRI: The facility features wet and dry laboratories and research areas. power system information. It tests the back-up generator supply and gives reports on the precise timing of transfer switches, the condition and health of the generator, monitors EPSS load levels and duration of test.

It makes manual testing obsolete, saving time and also collecting data during real outages. This ensures that the system is healthy and will perform if and when needed.

Power interruptions also have the potential to create data loss and hardware damage to communication and computer equipment.

With 18 communication hubs located throughout the SAHMRI building, Schneider Electric is providing uninterruptible power supplies (UPS) to maintain power continuity and protect vital communications equipment.

monitor their entire installation from the Utility Grade Power Quality (PQ) Meter on their main incomer, to the PQ meters on their Sub sectional feeders; and via low voltage Masterpact air-circuit breakers and Compact NSX moulded case circuit breakers fitted with Micrologic control units installed on key sub mains. SAHMRI’s project

Schneider Electric partnered with local energy solution integrator AZZO to deliver this integrated technological solution to maximise the functionality and efficiency of the SAHMRI’s electrical distribution network.

A facility such as SAHMRI requires an enormous number of pumps, fans and motors to ensure the HVAC system is operational.

These consume vast amounts of energy, however the SAHMRI design team has conserved as much energy as possible with the addition of Schneider Electric’s Altivar variable speed drives.

These will limit energy usage on start up and allow for the precise control of heating and cooling through the IBS. www.schneider-electric.com.au

Energy monitoring Many clients are now asking for more functional energy monitoring and reporting capabilities as part of their electrical distribution network and SAHMRI is no exception.

Schneider Electric included their new StruxureWare Power Monitoring 7.0 (SPM7) energy management software platform to better integrate SAHMRI’s energy metering.

To achieve even better Power Quality and reliability outcomes for SAHMRI, Schneider Electric collaborated with electrical contractors, Nilsen, to upgrade the metering hardware to allow for better Power Quality event diagnostics and therefore ensure a shorter ‘mean time to repair’ should any electrical network issues arise.

SMP7 will allow the SAHMRI to OCTOBER 2013 www.pacetoday.com.au 17

PA1013_018.pdf

Page

18

24/09/13,

2:35:01

PM

AEST

IN FOCUS

Additive manufacturing adds up New localised niche markets can be developed through additive manufacturing to provide low cost design and quick response to consumer requirements, writes Hartley Henderson.

T

HERE is a lot of discussion about the potential of additive manufacturing, (otherwise known as 3D printing or layer manufacturing) and whether it could even lead to the next industrial revolution.

A recent meeting in Melbourne, hosted by CSIRO, facilitated the establishment of an Additive Manufacturing Network by bringing together the research and development, service provider and end-user communities to share information and visions for the future of this emerging technology.

Keynote speaker at the meeting, former CEO of Siemens Australia and New Zealand, and current chair of Manufacturing Excellence Taskforce of Australia (known as META), Albert Goller, believes that too many Australian manufacturing companies today are focussed on customers within only one industry.

“There is a need for manufacturers to adapt to servicing across a diverse range of different industries, including textiles, rail and defence,” he said.

“We must develop greater flexibility with a focus on mass customisation, shorter cycle times in developing a product and bringing it to market, and sustainability by bringing the supply chain under control.

“Much greater attention must be given to agility, connectivity, collaboration, and creativity in order to provide a flexible solution for manufacturing industry in this country.”

At Monash University’s ARC Centre of Excellence for Design in Light Metals there is a focus on the utilisation of laser melting additive manufacturing machines. The Centre is pursuing a joint program with CSIRO and Deakin University to manufacture a small engine utilising additive manufacturing technology.

Director of the Centre, Prof Xinhua Wu, believes that additive manufacturing will revolutionise 21st Century manufacturing industry

18 www.pacetoday.com.au OCTOBER 2013

BENEFIT: Shown here is a conventionally machined aircraft component in titanium (left) and the topology optimised and additively manufactured version from titanium powder (right). The topology optimised part is around 50 percent lower in weight.

SAVINGS: A hinge manufactured in stainless steel by Breseight demonstrates the 3D printer’s ability to reduce several subtractive manufacturing processes to a one-process operation.

through a range of benefits including very short lead times and low manpower requirements.

“However, there are also some challenges that need to be addressed in commercialising additive manufacturing, such as material properties, repeatability and the ability of shop floor engineers to redesign,” she said.

“There is a need for close collaboration between experts in materials, design, engineering and commercialisation. Historically Australia has not been good at such collaboration

and there is a need to create a win/win situation between stakeholders.”

Launched in 2011, RMIT University’s $20 million Advanced Manufacturing Precinct includes a key focus on the advancement of both metal and polymer based additive manufacturing technologies.

RMIT’s Prof Milan Brandt says additive manufacturing research includes topography optimisation in design, manipulation of structures, materials research and manufacturing process optimisation.

“The global market for additive manufacturing is said to be growing at about 16 percent per annum and is projected to reach US$3.5 billion by 2015,” he said. “Our additive manufacturing research in the Precinct is focused in four main areas: aerospace and automotive engineering, bioengineering, sports engineering, and design.

“In current projects we are working on the development of direct manufacturing of small scale components, as well as repair

PA1013_019.pdf

Page

19

24/09/13,

2:35:01

PM

AEST

IN FOCUS

technologies for aircraft systems, such as landing wheels.”

At Swinburne University of Technology a new Manufacturing and Design Centre is being built that will include a ‘Factory of the Future’ which is scheduled to open in 2014 and include five studios with advanced equipment including 3D printing.

Michael Edwards, general manager, Boeing Research and Technology Australia, says the company, which manufactures various aircraft components in Australia, is focused on innovative ways to reduce lead time and the cost of development programs.

“We are looking at additive manufacturing and digital design, together with a major investment in up-skilling, as solutions to shortening the supply chain. This could play a significant role in assisting to develop the very big markets of Asia on our doorstep,” he said. “There is a need for change and to make a paradigm shift in development programs because they are getting longer and more expensive.”

Edwards sees additive manufacturing as the start of a potential new industrial revolution, but emphasises the need for industry sectors to work more collaboratively, and for stronger strategic alliances between industry and R&D organisations.

Advanced manufacturing A number of companies are now providing additive manufacturing services, including AMS (Advanced Manufacturing Services, part of the Breseight Group), which has a range of advanced manufacturing machines including those that the company says are capable of building in metals such as cobalt chrome, stainless steel, aluminium and titanium, as well as plastics.

Breseight’s CEO, Marc Perez, says that the range of additive manufacturing applications and solutions is set to expand, including in the areas of medical, military, police, injection moulding, food customised process handling, aerospace, jewellery, automotive and renewable energy.

“Increasingly in the future, it will not be the big companies that eat the small, but the quick enterprises that eat the slow,” he said.

Following the CSIRO-hosted meeting, an Inaugural Committee has been formed to come up with future arrangements for the establishment

and operation of a national Additive Manufacturing Network, to be driven by all stakeholders.

Dr Swee Mak, Future Manufacturing Flagship director, says CSIRO’s objective in initiating the Additive Manufacturing Network is to facilitate greater engagement between Australian industry and advanced technical resource providers.

“We use our Arcam facility to partner with interested Australian manufacturers to facilitate the uptake of additive manufacturing technologies in their businesses,” he said.

John Barnes, who leads CSIRO’s Titanium Technologies, believes that additive manufacturing has reached its tipping point. “While it is unlikely to fully replace conventional manufacturing technologies, thanks to the savings in time, risk, and materials it offers, future factories are just as likely to include 3D printers as conventional milling machines, presses, foundries and injection moulding machines,” he said.

At the National University of Singapore (NUS) significant additive manufacturing research and education programs are underway. Prof Ian Gibson, at NUS’s Engineering Design and Innovation Centre, points out that a major benefit of additive manufacturing is in waste reduction because of its layerby-layer additive process, compared with traditional metal machining that takes away layers to form an object and can result in substantial waste.

“Often, no assembly is involved with the additive manufacturing process, which is capable of producing rapid prototypes, and people are now also

AUTOMATED: Robotic assembly of a Dreamliner 787 outboard flap at Boeing Aerostructures Australia.

realising that this technology is feasible as a direct manufacturing process,” he told Manufacturers’ Monthly during a recent interview in Singapore.

“Three major industries have evolved through the use of additive manufacturing. The automotive industry has shortened product development processes in parallel with manufacturing processes, and in the aerospace industry additive manufacturing is used to deal with engineering complexities involving external as well as internal geometry.

“In the medical field, 3D models are being created of individual patients to enable the development of custom designed implants.

“New localised niche markets can be developed through the use of additive manufacturing to provide low cost design and quick response to the requirements of consumers. Mass production and mass customisation have got to work hand in hand.”

Breseight Australia www.breseight.com.au

Control Components

See… it’s that

,EVEL -EASUREMENT

easy!

Reliable, energy-free level measurement solution for storage and process applications

WEKA VISUAL LEVEL INDICATORS s 6ISIBLE ,EVEL READINGS AT METRES s ,OCALLY MANUFACTURED FOR SHORT LEAD TIMES s 3WITCHES TRANSMITTERS FOR %X APPLICATIONS s ,ONG MAINTENANCE FREE LIFESPAN s !VAILABLE IN 33 #06# 506# 06$&

TAKE CONTROL

CCEZY.COM.AU 02 9542 8977 OCTOBER 2013 www.pacetoday.com.au 19

PA1013_020.pdf

Page

20

24/09/13,

5:08:44

PM

AEST

IN FOCUS

Next level for mining automation In the future people will no longer be situated in the mine as more processes become automated and augmented reality will change the way we operate as tele-remote operators will be able to feel everything with that additional layer of information, writes Cole Latimer.

I

t is a universally accepted truth that a mine seeking innovation will in some way implement automation. Whether they are putting tele-remote vehicles on site, semi-autonomous loaders, or going completely driverless for their fleet, automation is undoubtedly the next step in mining.

And with the current downturn in mining forcing many companies to re-evaluate what have in time become bloated or cost heavy operations, they are now obligated to be seeking new ways to achieve more cost efficiencies and better productivity, and one of the ways in which they can do so is through automating processes.

Australia is at the forefront of much of this automation, and as Caterpillar’s Carl Hendricks said during a recent Brisbane event: “Australians are often very keen to implement new technology on site”, but where is automation headed?

We already have driverless trucks running in the Pilbara; LHDs roaming underground tunnels picking up and dumping pre-set tonnages by themselves within a laser defined area, all the while reporting back every aspect of their operation; we also have the technology to remotely control vehicles from thousands of kilometres away, as ably demonstrated by both Rio Tinto and BHP’s remote control operations centres in Perth.

The next great leap, though, is not exactly known. We have this existing technology, so where to from here?

According to Schneider Electric’s solutions vice president for mining, minerals and metals (MMM) Diego Areces, the next step is likely to change the reality of mining itself.

Catching up with Areces at AIMEX earlier this year, he explained to PACE that the next great leap will be less on the capital equipment itself and more on the technology progression side, seeing the full integration of Informational Technology and Operational Technology, more simple

20 www.pacetoday.com.au OCTOBER 2013

plug and play process, and most remarkably, augmented reality.

Examining the market Areces started by explaining that despite the current predictions of a downturn, “the concept of a mining slowdown isn’t 100 per cent correct, and in reality it is the way that companies are investing in mining that has changed, and as they are investing in a different way the levels of investment have changed which is forcing miners to invest in optimisation”.

“In the past miners focused simply on being the biggest of the lot, but now this has changed; they are focusing on being the best, the most efficient, the most optimised,” he told PACE. Automation will play a major part in this. “We don’t need to pull back now; we need to invest more into optimisation.”

Going on to describe Schnieder Electric as a company that supports organisations to optimise their operations, he said this is even more important as the scale of the mining has shrunk compared to the previous years and while the longterm fundamentals

remain the same, population growth, urbanisation, the push for sustainability, and the scarcity of reserves will force these economics to change.

Automation and the options this offers miners will allow them to be more flexible as “commodity price volatility will become more prevalent”.

The changing factors Six factors were given by Areces as the new focus for miners in the next technological age, and he explained how automation was to play an either direct or indirect role in them.

He listed off the upcoming IT/OT convergence, which makes automation technology and hardware easier to use and implement in existing processes; the focus on overall process optimisation and automation’s role in ensuring accuracy in all aspects; workforce management and how automation is changing job roles and creating new ones while reducing the need for others; the rising importance of ICT for mining and its link back to the IT/OT convergence and the plug and play model for miners; remote control

and the increase in mobility in mining; the crucial aspect of energy management; and finally automation and social licence.

He pointed to mobility as one of the bigger game changers, and how in automating processes and allowing for remote control operation miners can now access their site, modify or fix issues while off site and have a greater ability to analyse data from their machines.

The opportunity for developing mining in Australia lies thoroughly in optimisation and in turn automation “as Australian operations aren’t at the level they should be for the levels of knowledge it has locally, it has a huge amount of engineering knowledge and process facilitation.”

Mining is going to use automation to take it to the next levels of operation.

“It will be more pragmatic, as it moves to a more sustainable mining model and miners use sustainability as a yardstick to measure their operations,” he said.

“We can expect more remote operations and greater mobility and this is even likely to spawn augmented reality in mining - where operators are replicating, remotely, the environment of the site for remote control operators so that they can get a better understanding of the conditions they are operating in, not just watching through a screen, but getting more layers on information (potentially through using something such as Google Glass) such as the humidity and temperature of the area, hardness of rocks, GPS, and other aspects that are currently not recorded or provided but directly affect operations,” he told PACE. Areces added that in the very near future “people will no longer be in the mine as more processes become automated or tele-operated, and augmented reality will change the way we operate as tele-remote operators will be able to feel everything, with that additional layer of information, but without the safety risks of actually being in the mine”.

PA1013_021.pdf

Page

21

24/09/13,

2:58:47

PM

AEST

IN FOCUS

Helping to put you in Control LED Power Supply

Components for use in sour oilfields Choices surrounding material selection and manufacturing of fluid system components for service in sour gas environments are complex, writes Gerhard Schiroky.

T

HE conditions under which oil and gas are brought from their reservoirs to the surface can be outright hostile to many common materials used in fluid system components employed in the industry.

Potentially dangerous mechanisms include localised corrosion, stress corrosion cracking (SCC), and sulfide stress cracking (SSC). SSC has become increasingly dominant as more sour reservoirs are being developed.

Aging reservoirs can also turn sour as abiotic and biotic reactions take place. This article describes how to select the optimal materials of construction for components that need to perform reliably for many years in the demanding sour environments of oil and gas exploration and production.

Chloride concentrations Pitting corrosion or crevice corrosion occurs when the chromium-rich passive oxide film on an alloy surface breaks down in a chloride-rich environment.

Higher chloride concentrations, more acidic environments, and elevated temperatures all increase the likelihood for breakdown of this passive film.

The higher an alloy’s Pitting Resistance Equivalent Number (PREN), the higher its resistance to localised corrosion.

The most frequently used relationship for calculating PREN is: PREN = %Cr + 3.3(%Mo + 0.5%W) + 16%N Values of PREN for frequently used alloys with typical compositions are as follows: Alloy

PREN Value

316

24

317

29

2205

35

2507

43

254SMO

43

AL6XN

44

825

31

625

51

C-276

74

Stress corrosion cracking In the presence of chloride ions, e.g., in a marine environment, certain alloys are susceptible to SCC, or chloride-ion induced SCC. The chloride ion interacts chemically with the material at the very tip of a crack where tensile stresses are highest, making it easier for the crack to propagate.

This failure mode can destroy a component at stress levels that are below the yield strength of an alloy, and final failure can occur suddenly.

Three conditions For SCC to occur, three conditions must be met simultaneously: the material must be susceptible to SCC; the fluid must be capable of inducing SCC; and a tensile stress must be present that is greater than a critical tensile stress.

Some alloys are considerably more prone to SCC than others, with nickel content playing a major role. Austenitic stainless steels like 304 (8 to 10 percent nickel) and 316 (10 to 14 percent nickel) are particularly susceptible.

Carbon steels, nickel base alloys, and duplex stainless steels are highly resistant to SCC.

Sulfide stress cracking Raw oil can be contaminated with undesirable compounds. When H2S and large quantities of carbon dioxide (CO2) are present, the unrefined fuels are said to contain “acid gas” because these gases form acids when mixed with water.

The term “sour gas” is used for unrefined fuels containing H2S, a very corrosive, toxic, and flammable gas. The requirements for SSC to occur include: a susceptible material; a sufficiently sour fluid (H2S concentration above a threshold); and a tensile stress above a critical level.

Material properties An increase in the following parameters can contribute to the rate at which SSC occurs: material properties such as tensile strength and hardness; hydrogen ion concentration in the fluid (i.e., pH-value); H2S partial pressure; total tensile stress (applied and residual); temperature; and exposure time.

40 W, IP67 power supply with Australian standard plug on 1.8 m lead. Designed to work as constant voltage or constant current for driving LEDs. Cooling by free air convection. 12 VDC output at up to 3.33 A. Other models are also available.

SKU: PSL-0412 Price: $106.20 each + GST

Flow & Batch Controller GLJLW ÀRZ UDWH WRWDOLVHU batch controller meter with NPN/PNP pulse or 4-20mA analog input. RS-485 interface with Modbus RTU protocol. 4 relay outputs that can be used for alarms or batch control. 24VDC powered.

SKU: AXI-060 Price: $449.00 each + GST

Universal Double Level Terminal SKJ universal DIN rail double level Screw terminal offers a wire section of 4mm² with 4 side cable entry.

Rated to 1000 V @ 41 A. Can be mounted on standard hat type railway.

Other sizes are also available.

SKU: TRM-011 Price: $1.69 each + GST

Mini PLC - Arduino Compatible Fitted with Ethernet, USB & RS-485 interfaces, our new controller features; 8 relay outputs, 4 opto-isolated inputs and 3 x 4-20 mA or 0-5 VDC analog inputs.

Windows, Mac OS X and Linux compatible.

Accepts XBee form factor expansion boards.

12/24 VDC powered. DIN rail mountable.

SKU: KTA-323 Price: $185.00 each + GST

1-port, Modbus Gateway MB5001C provides an interface between Modbus serial slave devices and hosts running Modbus/TCP on Ethernet networks.

Supports RS-232, RS-422 & RS-485 interfaces. 10/100 Mbps fast ethernet full duplex auto negotiation.

SKU: ATO-161 Price: $189.00 each + GST

4-20 mA Loop Powered Calibrator 2-wire, 4-20 mA loop powered output signal to test PLCs, indicators or other controllers.

Selectable 4 mA, 20 mA or any value in between via switch & potentiometer. Available with backlit LED or standard LCD display.

SKU: KTA-266 Price: $129.00 each + GST

4-20 mA RHT Wall Mount Sensor Highly accurate & stable sensors that measures both temperature and relative humidity whose information is converted to linear loop powered 4-20 mA output. 0-10 VDC output, wall or duct mount are also available.

SKU: RHT-003 Price: $189.00 each + GST

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

OCTOBER 2013 www.pacetoday.com.au 21

PA1013_022.pdf

Page

22

24/09/13,

2:58:47

PM

AEST

IN FOCUS

STRESS: Cross-section of 316 stainless steel tubing showing deep corrosion pits on the outer surface.

On an atomic scale, SSC is a special case of hydrogen embrittlement.

Hydrogen diffusion When a susceptible metal surface comes into contact with sour gas, the H2S molecules react to form metal sulfide and hydrogen atoms.

The latter diffuse into the material at the tip of the crack at which tensile stresses are highest.

Hydrogen diffusion and accumulation in the lattice, on interfaces and on grain boundaries reduce the material’s ability to deform plastically, leading to hydrogen embrittlement that facilitates crack propagation.

In sour environments such as mixtures of oil + seawater + H2S, SCC and SSC can pose a synergistic threat.

Crack propagation caused by the chloride ion interaction with the tensileloaded crack tip may proceed more readily if the material ahead of the crack tip has been embrittled by atomic hydrogen.

The term environmental cracking describes the synergistic actions of SCC and SSC.

WEAKNESS: Photomicrograph of chloride-induced stress corrosion cracking in 316 stainless steel (100x magnification).

Metallic materials This standard gives requirements and recommendations for selecting and qualifying metallic materials for service in equipment used in oil and gas production and in natural gas sweetening plants in H2S-containing environments.

It addresses all mechanisms of cracking that can be caused by H2S, including SSC and SCC, and other forms of hydrogen-induced cracking.

Pre-qualified materials listed in the standard can be used for the intended service without performing additional laboratory testing.

22 www.pacetoday.com.au OCTOBER 2013

Environmental conditions All listed materials with documented microstructural characteristics (for example, annealed or strain-hardened) and properties (for example, hardness) have performed satisfactorily in field installations or in laboratory tests carried out under defined environmental conditions.

In this standard, alloys are identified by material groups, and within each group, by materials type or as individual alloys.

Acceptable metallurgical conditions and environmental limits are given for which alloys are expected to resist cracking.

Environmental limits are given for H2S partial pressure, temperature, chloride concentration, in situ pH, and elemental sulfur.

Downhole applications Key points for general and downhole applications are summarised for the material groups of austenitic stainless steels, highly alloyed austenitic stainless steels, solid solution nickel-based alloys, and duplex stainless steels.

Austenitic stainless steels comprise one material group that includes common alloys 304, 316, 317, 321, and 347.

In addition, alloys 309, 310, Nitronic 50, and cast alloys such as CF8 and CF8M are part of this material group. Free-machining austenitic stainless steels which have elevated levels of sulfur are specifically excluded.

In terms of environmental limits, a maximum use temperature of 60ºC is permitted along with a maximum H2S partial pressure of 100 kPa with no limit on the maximum chloride concentration.

Partial pressure

Selecting materials Petroleum and natural gas industries — Materials for use in H2S-containing environments in oil and gas production (ISO 15156), an international standard published in 2003, consists of three parts: • Part 1: General principles for the selection of cracking-resistant materials • Part 2: Cracking-resistant carbon and low alloy steels, and the use of cast irons • Part 3: Cracking-resistant CRAs (corrosion-resistant alloys) and other alloys

Austenitic stainless steels

End users should understand ISO 15156 requirements to select the optimal material of construction of a fluid system component.

When the maximum chloride concentration is limited to 50 mg/L, the material can be used without restrictions on temperature and H2S partial pressure.

ISO 15156 provides more detailed guidelines for austenitic stainless steels that are used to produce valve stems, seal rings, and gaskets, and as components in compressors or in subsurface applications.

Strain-hardened 316 stainless steel may be used in surface applications for compression fittings, instrument tubing, and control line tubing without restriction on temperature, H2S partial pressure, chloride concentration, or in situ pH in production environments.

The standard cautions that some combinations of the values of these parameters may not be acceptable.

Highly alloyed steels Highly alloyed austenitic stainless steels comprise another materials group. If used for any equipment and components, alloys like 254SMO and AL6XN are permitted in their solution-annealed state.

For downhole tubular components, the alloys must have been solution annealed and may be in the cold-worked condition with a maximum hardness of 35 HRC. These alloys may be used in surface applications for compression fittings, instrument tubing, and control line tubing without restriction on temperature, H2S partial pressure, chloride concentration, or in situ pH in production environments.

Nickel-based alloys ISO 15156 defines five material

PA1013_023.pdf

Page

23

25/09/13,

10:28:46

AM

AEST

IN FOCUS

types for solid-solution nickel-based alloys based on the Cr, Ni, Mo and W content of the alloy and its metallurgical condition, i.e., solution annealed or cold-worked.

Commonly used alloys 825, 625, and C-276 can be used in the solutionannealed or annealed condition for any equipment or component at any combination of temperature, H2S partial pressure, chloride concentration, and in situ pH occurring in production environments.

For downhole tubular components, cold-worked alloys 825, 625, and C-276 can be used if their hardness does not exceed 40 HRC and their yield strength is not above specific limits. Alloy C-276 can be used at higher temperatures and H2S partial pressures than alloy 625, which in turn is qualified for higher operating conditions than alloy 825.

Duplex stainless steels Duplex stainless steels are divided into material types with lower PREN between 30 and 40 and higher PREN above 40 to 45.

If used for any equipment, the alloys must be in the solution-annealed and liquid-quenched state, and have a ferrite content between 35 percent and 65 percent.

Maximum use temperature is 232ยบC for both material types.

Maximum H2S partial pressure is 10 kPa for alloys with PREN between 30 and 40, and 20 kPa for alloys with PREN above 40. If used as downhole tubular components, the materials can be in strain-hardened condition with a maximum hardness of 36 HRC. The lower PREN alloys can only be used up to a maximum H2S partial pressure of 2 kPa, and the ones with PREN above 40 up to 20 kPa and a maximum chloride concentration of 120,000 mg/L.

Manufacture of components Producing fluid system components that comply with all aspects of ISO 15156 requires the use of high quality raw materials, careful testing, and prudent choice of manufacturing methods.

Alloys must have gone through a controlled solution annealing process, and their microstructural quality must be assessed with tests such as ASTM A262, which probes austenitic stainless steels for intergranular corrosion, or

ASTM A923, which qualifies duplex stainless steels for absence of detrimental intermetallic phases.

Austenitic stainless steels should be free of martensite and contain ideally no, or at most 2 percent, ferrite because these phases are more susceptible to hydrogen embrittlement than austenite.

Maximum hardness A sufficient number of hardness measurements must be performed and an average hardness value calculated, which must not exceed the respective allowed maximum value.

No individual hardness reading is allowed that is greater than 2 units on the Rockwell C hardness scale above the allowed maximum hardness.

When components are welded, care must be taken to perform hardness measurements on the welds following the procedures described in ISO 15156. Where solution-annealed materials are required, any cold drawing of bar or cold rolling of plate must be avoided.

Cold deformation of surfaces is acceptable only if it is caused by processes such as burnishing that do not impart more cold work than typical machining operations.

Identification stamping with low-stress stamps is acceptable, but sharp V-stamping should not be performed in high-stress areas.

Beyond material properties, several factors affect the susceptibility of a material to cracking in sour fluids: H2S partial pressure, in situ pH, chloride concentration, presence of elemental sulfur, temperature, galvanic effects, mechanical stress, and time in contact with an aqueous solution.

End users should understand ISO 15156 requirements to select the optimal material of construction of a fluid system component.

When a customer orders a specific valve, fitting, or other fluid system component for sour gas service, the manufacturer should perform a product review in which all wetted parts are evaluated against standard requirements, e.g., for type of material, manufacturing processes, and maximum hardness.

[Gerhard Schiroky is Senior Scientist, Engineering, Swagelok Company.]

M Rutty & Co 1883

www.swagelok.com OCTOBER 2013 www.pacetoday.com.au 23

PA1013_024.pdf

Page

24

24/09/13,

2:42:21

PM

AEST

SPOTLIGHT

5best of the

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

Non-contact inspection for extruder bores With compound extrusion lines, continuous wear signs occur in the bores caused by abrasive raw materials, temperature and pressure. Exact maintenance intervals are therefore necessary in order to prevent expensive failures. The idiamCONTROL

by Micro-Epsilon detects the wear in the bores by non-contact internal inspection.

The sensor unit – with integrated capacitive sensors arranged opposite to each other – measures the diameter of the bore. By turning the cross rollers by 40° clockwise or counter-clockwise the bore can be measured in 6 tracks altogether. For exact positioning, the sensor is centered on both ends by spring-loaded rollers. Several metal pins prevent the measuring cylinder from turning. The new controller unit equipped with a touch screen displays the measuring results graphically. The measuring signal is shown as a diameter over the complete bore length and any tolerance deviations are immediately displayed. The diameter values of several test cycles can be saved. By comparing the individual diameter values, the extruder wear is calculated. For the data output the device is provided with a USB interface. A calibration control checks the functionality of the measuring system.

Bestech Australia 03 9540 5100 www.bestech.com.

Junction box connects up to 8 signals in harsh environments Turck’s stainless steel process junction box has the ability to consolidate up to eight individual, localised analog or discrete signals into a single device, this junction box streamlines connectivity requirements. The signals are then routed to a control unit through a single homerun cable. The stainless steel process junction boxes provide a robust connectivity solution in harsh environments such as oil and gas exploration, offshore drilling platforms and pharmaceutical plants. The junction boxes feature FM approval for Class 1, Division 2, Groups A, B, C and D hazardous locations, and ingress protection of IP67— including the junction boxes receptacles as long as the ports are covered/connected. Additionally, Turck stainless steel process junction boxes have cast 316 stainless steel electropolished housing to ensure optimal performance in areas that present severe environmental conditions.

TURCK Australia 1300 132566 www.turck.com.au

3 Find

24 www.pacetoday.com.au OCTOBER 2013

Evaluate

Select

PA1013_025.pdf

Page

25

24/09/13,

2:42:21

PM

AEST

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

Schubert’s Transmodule continues its evolution

Air/gas mass flow meter with dual averaging The ST102A Air/Gas Thermal Mass Flow Meter from Fluid Components International (FCI) features a dual-element averaging system, improving installation repeatability and accuracy for larger diameter pipes and ducts. Flow measurement applications involving line sizes 12 inches (305 mm) or greater can realise improved installation accuracy and repeatability by averaging the flow rates of two elements. Distorted and non-repeatable flow profiles can result in decreased accuracy of single point meters. It is often impractical or impossible to provide the required straight-run for a fully developed flow profile in large lines. The Model ST102A overcomes these flow profile concerns with a simple dual-element averaging system. The transmitter electronics average the input from two independent flow elements into a single output. Each flow element can be independently configured for insertion length and process connection to allow installation flexibility.

One flow element can be integral with the flow transmitter, or both can be configured as remote for easier access and visibility to the digital display/ optical four button user interface. The flow transmitter also provides independent information for each flow element, saving time when performing service checks.

In its short history, the Schubert Transmodule – also known as the world’s first transporting robot – has taken on new tasks and functions giving packaging machines additional flexibility. This third generation has been reworked and used in Schubert machinery from mid 2013 – which is represented in Australia by Selpak. The company is deploying approximately 200 transmodules across 10 packaging lines within the next six months across a diverse range of industries. Transmodule 3.0 combines all of the new functions, ideas and experiences gained over the past three years into its development. The transmodule controls the product to package perfectly from collating to carton erecting to closing and directly to palletising. They allow Schubert packaging machines to be smaller, compact, flexible and have a higher efficiency than traditional machine transport systems. It takes its signal wirelessly and power inductively – no cables, wires, chains or sprockets connected to it. Initial ideas for the fourth generation of the Schubert Transmodule have already been formulated.

Selpak 02 9585 8811 www.selpak.com.au

COMbricks Profibus DP slave module In partnership with Procentec, I S Systems has released the Profibus DP Slave module as an addition to the COMbricks family. It is the only available DP Slave device with a 3-in-1 functionality: Profibus DP Slave; Permanent busmonitor; Modular repeater. The DP Slave device enables the largest multiple cross gateways between ProfiNet and Profibus modules which are placed in the backplane. Simultaneously it permanently monitors the segment/network and acts as a repeater when it is used in combination with other communication modules. It may be used to establish communication between multiple ProfiNet and Profibus controllers that manage their own specific network. The gateway works the same way as regular DP/DP and PN/ DP couplers. Application areas include: Linking of different DP Masters controllers; ProfiNet to Profibus gateway; Migration from old control systems to new control systems; COMbricks has the advantage that up to 10 ProfiNet/ Profibus modules can exchange information. The DP Slave module can also be mixed on the backplane with other COMbricks modules like Profibus PA, Fiber Optic and DP Repeater modules.

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

I S Systems 02 4964 8548 www.issystems.com.au

The easiest way to find products and suppliers

Manufacturing | Mining | Industrial

askferret on 1300 156 836

OCTOBER 2013 www.pacetoday.com.au 25

PA1013_026.pdf

Page

26

25/09/13,

10:13:43

AM

AEST

CONNECTIONS

5

minutes with...

I started designing a small personal vehicle that weighed a few hundred kilos

Trevor Bloch, BlochTech Engineering How did you come to be in this industry?

My first job out of university was for a company providing control systems for the water and wastewater industry. From there I spent a few years in software development, building applications for mass transit ticketing and train emergency braking systems before returning to control systems integration. I felt I could do things better than the company I was working for and that motivated me to start my consultancy.

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

A few years ago, I started working on a small lightweight personal electric vehicle. Most car trips are single-person trips over relatively short distances and people will use a five seater car to make these trips. I thought this wasn’t a very optimal use of energy so I started designing a small personal vehicle that only weighed a few hundred kilograms and could make the short trips using a fraction of the energy of a conventional car.

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

The biggest opportunity for our industry is centralised remote automation. Water utilities are already accustomed to monitoring hundreds of remote sites from a single central operations centre but this idea is essential for countries like Australia to be competitive.

Our high labour rates mean that it is not competitive for us to have large numbers of plant operations staff “on the ground” and these people are likely to be replaced by a higher level of plant automation and by centralising a number of plants into larger operation centres.

What’s the greatest challenge in your job?

Balancing the managerial and technical aspects of my work is the greatest challenge. Being an engineer I find it all too easy to dive head-first into the technical aspects of projects and somewhat ignore the management requirements.

Over the last few years I’ve realised that my business only works if I spent the majority of my time managing so when I find myself knee-deep in technical work I know that it’s time to hire more technical people so I can get back to doing the things that keep the business running.

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

I would definitely be a ski bum! You can’t beat the freedom of hiking through the mountains and picking your own line to snowboard down – it uses a completely different set of skills to those that I use every day. It would be great not to have to worry about project deadlines or budgets and wake up every day with absolutely nothing planned. If it’s any consolation I do manage to squeeze two snowboarding trips in a year to keep me sane.

[Trevor Bloch (trevor.bloch@blochtech.com) is Director, BlochTech Engineering.] www.blochtech.com

What to do when things go wrong Using a lawyer wisely means knowing what you want from the situation, writes Melissa Kirby.

CALIBRATING process controls, automating critical life-safety systems, or pinpointing the errors in diagnostics – automation and control engineers have a tough job that often requires resilience and innovative thinking.

When problems occur, engineers often take a DIY approach using the tools they have learned.

But sometimes, problems need a different skill set. Most people don’t like involving lawyers unless absolutely necessary, and in automation and controls, it can be very challenging to find a lawyer who understands the technical, operational, commercial and strategic dimensions of the industry.

Using a lawyer wisely means knowing 26 www.pacetoday.com.au OCTOBER 2013

what you want from the situation: do you want to get money recovered, find out the facts, find a way to solve the problem without ruining the commercial relationship or win your argument at any cost? That’s something you have to be clear about, and not wait for a lawyer to make the decision for you.

If the lawyer you work with can only argue to win and doesn’t give you any options, then you might not have the right person for the job.

Instead of winning at all costs, there are a few things that a good legal professional can do. For example, lawyers can help to negotiate a mediation session between parties who have a dispute and want to avoid court. This allows

the parties to a dispute to formulate a solution through negotiations mediated by a neutral third party. Unlike court, mediation offers the chance to come to a win-win solution.

Similarly, when equipment fails, and disputes about costs occur, sometimes the threat of a law suit gets thrown around. Instead of litigation, it is possible for parties to enter into ‘without prejudice negotiations’, where both parties negotiate a settlement in good faith – and where any admissions made during these negotiations are not permitted to be used in litigation if the negotiations fail.

Without prejudice negotiations allow each party to aspects of the problem that

may have contributed to the cause; such as an equipment installer admitting the failure was their fault, or the end-user admitting that they may not have been properly maintaining the equipment.

This allows for a clearer analysis of what may be causing the problem – hopefully leading to a solution. It also allows for even-handed distribution of culpability when negotiating reparation.

So, when things go wrong, and you think you need a lawyer, pick a legal professional understands IC&A and who helps you find a solution that works for your business.

[Melissa Kirby is IICA Melbourne Branch Committee Member.] admin@iica.org.au www.iica.org.au

PA2957_60th_FP.pdf

Page

1

13/09/13,

10:08:46

AM

AEST

This November, PACE celebrates 60 years of serving and informing the engineering community with meticulously researched process, control and automation engineering news.

This souvenir issue will focus on the evolutionary developments in fields such as motors and drives, sensors, control systems, process instrumentation, security systems, and robotics & machine control, among many others.

Profile your company’s progression and impact among the elite in the industry!

CONTACT US TODAY TO LEARN ABOUT SPONSORSHIP AND CATEGORY PACKAGES Ph: 02 8484 0940 M: 0415 869 176 email: maksym.kolomiiets@cirrusmedia.com.au

PA1013_000_AUM

-

1

2013-09-13T14:01:33+10:00

Modular concepts, accurate control – designs for all applications AUMA do not manufacture standard actuators. Whether in the processing industry, the food industry or even afloat in the shipbuilding industry, all applications are individually addressed by AUMA. Combined with the state-of-the-art AUMA actuator controls, solutions to virtually any industrial requirement can be provided.

■

AUMA’s modular concept ensures perfect integration

■

Appropriate for all valve types and mounting positions

■

Integration with all conventional DCS concepts

■

Worldwide service and extensive experience

Actuators for industrial valves

Global expertise in automation

BARRON GJM Pty. Ltd. • P.O. Box 792 • Artarmon NSW 1570 • Tel. +61 294361088 • info@barron.com.au • www.barron.com.au