PACE - Process & Control Engineering - October 2014

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OCTOBER 2014 | VOL.67 NO.9

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INSIDE PACE

Water

Safety

Automation

Yarra Valley Water benefits from mobile SCADA system

Understand HAZOP of machine systems to reduce hazards

An insight into the industrial Ethernet

Australian access control system wins global acceptance

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CONTENTS

Publisher: Martin Sinclair Email: martin.sinclair@cirrusmedia.com.au Editor: Kevin Gomez Tel: (02) 8484 0976 Fax: (02) 8484 0722 Email: kevin.gomez@cirrusmedia.com.au Group Sales Manager: Tim Richards Tel: (02) 8484 0829 Mobile: 0420 550 799 Email: tim.richards@cirrusmedia.com.au QLD Sales Manager: Sharon R. Amos PO Box 3136, Bracken Ridge, QLD 4017 Tel: (07) 3261 8857 Fax: (07) 3261 8347 Mobile: 0417 072 625 Email: sharon.amos@cirrusmedia.com.au Graphic Designer: Dave Ashley Email: david.ashley@cirrusmedia.com.au Production Co-ordinator: Tracy Engle Tel: (02) 8484 0707 Fax: (02) 8484 0722 Email: tracy.engle@cirrusmedia.com.au

IN THIS ISSUE News 6

Industry Roundup Solutions unveiled at HUG Symposium; NSW tops robotics competition Insight 8

Virtualisation Benefits of de-coupling automation software from specific hardware Innovation 10

Equipment Safety AccessPack technology reduces OHS and risk associated with industrial equipment use SUBSCRIPTION: $99 pa incl GST OVERSEAS SUBSCRIPTIONS: NZ: $A109 pa & OS: $A119 pa CUSTOMER SERVICE: 1300 360 126

Case Study 14

Water Treatment Yarra Valley Water benefits from mobile SCADA system upgrade Industry Update 16

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

Synergy Invensys completes our solutions says Schneider Electric Engineer’s Corner 18

HAZOP How to methodically examine a proposed design and operation to assess the effect of changes in the design conditions

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Design Focus 21

META Hub New hub links businesses to each other and to researchers to help transform firms by aligning internal pocesses with customers’ demands Conversation 22

Connectivity Visiting UK expert Peter Thomas sheds light on common industrial Ethernet misconceptions New Products 24

7 of the Best D1 repeater; Linear position transducer; Safety hinge switches; Coriolis flowmeter; Compact actuator; Miniature stepper motor drivers; Rugged CompactDAQ Controller Management 26

Software ERP can help process manufacturers stay ahead of the competition

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AccessPack reduces risks associated with equipment use

OCTOBER 2014 | VOL.67 NO.9

OFFICIAL MAGAZINE OF:

INSIDE PACE

Pa ge

Water Yarra Valley Water benefits from mobile SCADA system

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Average Net Distribution Period ending Mar ’14 5,709

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AN Australian access control system is winning the support of leading companies around the world. The inexpensive AccessPack technology reduces both OHS and business risk associated with industrial equipment use.

AccessPack uses smart card technology to prevent 5 /Australian 0 2access / 2 0 1 4 , 1unauthorised 0 : 4 9 : 3operators 5 A Mfrom using high control system wins global acceptance risk or critical equipment.

Safety

Automation

Understand HAZOP of machine systems to reduce hazards

An insight into the industrial Ethernet

The Future of Manufacturing

The system is different from typical access control systems that are designed to prohibit use by merely restricting perimeter access.

Not only do these systems need expensive communications infrastructure to work, once people have passed security, there is nothing to stop them from operating any individual machine.

(See page 10)

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OCTOBER 2014 www.pacetoday.com.au 3

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COMMENT

EDITOR’S MESSAGE

WHAT’S ON

Fundamentals of Process Safety 13-17 October 2014, Melbourne austcourses@icheme.org

Looming IoT challenges

HAZOP Study for Team Leaders and Team Members 21-23 October 2014, Perth www.icheme.org/hazopperth Certified Profibus and PROFINET Training 3 November - 5 December 2014, Perth, Brisbane, Sydney, Melbourne profibusaustralia.com.au

Kevin Gomez Editor

Next Issue

Chemical Engineering for Nonchemical Engineers 18-20 Nov 2014, Melbourne austcourses@icheme.org For daily updates visit www.pacetoday.com.au

• Test & Measurement • SCADA & MES • Motors, Drives & Motion Control • Asset Management & Maintenance

THERE have been many words written and spoken about Internet of Things. To some it is still a ‘thing of the future’.

The reality is that the capabilities and underlying technologies are already here – it’s a question of applying the technologies that are currently available.

Companies are already moving towards connectivity that can only be defined as ‘any thing, any time, any where’.

Asset management and maintenance is an early winner with companies collecting data from equipment, storing it in the cloud and then analysing it to garner useful information

to generate workflows for their maintenance departments.

Traditionally IT and automation have worked independently or collaborated uncomfortably. But with IoT, the two are converging and IT is deriving benefit from the connectivity and data analysis that is now possible.

Although in its infancy, we need to be aware some of the hurdles. The primary concern is security and early adopters are putting in place policies and procedures to reduce the possibility of security breaches.

There is also the challenge of making all the devices smart.

Currently, some devices are still

evolving and more work needs to be done on this front.

Capturing, managing and connecting mobile assets is curently quite difficult.

The internet too is another limitation and we may not have the bandwidth to handle big data.

For the user, software will the key to tying it all together.

We are interested to hear your opinion.

Email us, follow us on twitter and sound off on Facebook. kevin.gomez@cirrusmedia.com.au

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

OIL & GAS

BHP gets behind world’s largest FLNG project off WA

BY COLE LATIMER infrastructure, despite being granted ExxonMobil also reportedly as BHP has ended years of uncertainty government approval for the FLNG stating that “FLNG is considered the following its commitment this week to plant late last year. lead development option”. support floating LNG processing off Now Cutt has reversed his belief, If the project goes ahead, it will be Scarborough, in Western Australia. throwing his support behind FLNG. the largest FLNG facility in the world The plans for the $10 billion joint We’ve looked at all the different at 495 meters long, 75 meters wide and venture FLNG between BHP and technologies with ExxonMobil and we’re capable of processing between six to ExxonMobil began last year after plans now fully aligned with ExxonMobil,” seven million tonnes of LNG per year. to develop the gas through expansions Cutt said following his signing of a new ExxonMobil has previously said the of Woodside’s Pluto LNG plant and deepwater oil and gas joint venture with development would involve the drilling Chevron’s Wheatstone plant fell through.

Pemex. of 12 wells in two phases, starting with However, the partners were still “FLNG is the direction we’re seven over the period from 2018 to mixed on the processing option, after heading. We’ve got a lot of confidence 2019.

BHP’s petroleum head Tim Cutt still in the technology. The fact the gas is dry In addition to the gas treatment and P 4 M 1 1 -e 0 4 -technology 0 0 3 7 0 AA D0 _ 4 P a1 Apreference C_ E0 M0 E0 Tfor_ Adeveloping PE RT _ 2 1 2 -. p actually df 2 0 Phelps a 4 gfloating 2 7 0 T / 1 0 quite 3 :/ 4 1 2 :, liquefaction 5 + : 1 0 1 :facilities, P0 M the vessel would be highlighted the LNG through existing onshore a bit.” fitted with up to 10 storage tanks inside,

with an on-board storage capacity of around 380,000 cubic meters.

It is estimated 80-110 cargoes would be offloaded from the facility each year.

The two aren’t the only companies looking at FLNG off Australia’s coast line.

Australia is set to become the birth place of FLNG, with Shell currently building the world-first Prelude structure which is set to be moored off the WA coast by 2016.

Santos and GDF Suez are also looking into the development of a FLNG vessel for the Bonaparte Basin, 250 kilometres west of Darwin.

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NEWS

CONFERENCE

Solutions unveiled at HUG Symposium THE 2014 Honeywell Users Group (HUG) Asia-Pacific Symposium was recently held on the Gold Coast. More than 200 people attended the event, with the majority of attendees made up of users of Honeywell Process Solutions from across Australia.

The company used the event as a launchpad for a number of new releases, such as the oil and gas productivity and safety software suites and the Experion Orion console released on the first day of the event. It also officially launched Universal Cabinets for its universal input/output (I/O) modules.

The universal I/O modules allow operators to quickly and remotely configure channels as analog or digital I/O using Honeywell’s proprietary Universal Channel Technology software.

The Universal Cabinets incorporate Universal I/O modules and make the entire cabinet a standard part which can play a key role in on-time start-ups by removing I/O from the critical path. This can help project managers to reduce the impact of changes on automation project schedules, especially late in a project cycle.

Honeywell’s Lean Execution of Automation Projects (LEAP) processes were also highlighted during the show.

LEAP is a new methodology and philosophy in project execution. It uses cloud engineering and virtualisation methods to aid companies in implementing process solutions in their projects.

By using a cloud approach to engineering design, it decouples the software and the hardware, so they can be produced in parallel with one another, as opposed to sequentially, shifting formerly back-end processes to the front-end.

At HUG, Honeywell Process Solutions released Digital Suites for Oil and Gas, a set of software and services that can help oil and gas producers boost production performance by 3 to 5 percent while improving operational safety.

The offering, which has been validated through customer testing, allows oil and gas producers to turn 6 www.pacetoday.com.au OCTOBER 2014

data into digital intelligence that helps operators make critical decisions faster by capturing, managing and analysing the right production information at the right time.

“Upstream oil and gas producers tell us they have access to more realtime data than ever, but access to that data alone is not enough to improve performance – they also need digital intelligence to make sense of all the data being collected,” said Ali Raza, vice president and general manager, Honeywell Process Solutions.

“By using these new tools, operators can get better productivity, higher uptime and more efficient remote operations, and can produce a return on investment in as little as six months.”

Honeywell leveraged its experience in the oil and gas and related industries to develop this suite of solutions specifically designed for upstream operations. Digital Suites for Oil and Gas is designed to ensure that essential safety procedures perform as designed, operators are fully trained, alarms are managed and enforced, and production performance is instantly available to detect and mitigate unexpected events.

The solutions make collaboration through remote operations a reality, helping improve the safety of personnel, especially as upstream oil and gas production moves farther offshore and environmental conditions grow more risky.

HUG delegates view a 3D video of the RTU2020 Remote Terminal Unit – a modular and scalable controller capable of remote automation and control applications.

Digital Suites for Oil and Gas is a fully integrated offering, but each suite is also available separately, letting customers address the specific issues they face.

The six suites are: Operational Data; Process Safety; Production Surveillance; Equipment Effectiveness; Production Excellence; and Operational Performance.

The new offerings combine Honeywell’s technologies with new software and implementation methodologies delivered through its new oil and gas centre of excellence, which was recently established to better serve Honeywell’s customers in the upstream oil and gas industry.

Honeywell’s Universal Cabinets incorporate Universal I/O modules and make the entire cabinet a standard part.

Digital Suites for Oil and Gas works seamlessly with Honeywell’s line of integrated control and safety systems, instrumentation, and industrial products, and can be integrated into any multi-vendor environment.

Also at HUG, a team of chemical engineering students from Malaysia became the first ever group entry to win Honeywell Process Solution’s annual UniSim Design Challenge, demonstrating the power of collaboration to solve industry challenges. Kristy Nyagang, Aw Ying Yin, Wai Mun Chen and Chang Chung Min from Curtin University in Sarawak worked together to improve energy efficiency in a typical turbo-expander plant using an enhanced natural gas liquid recovery process.

In spite of the current market conditions, the mood at the event was positive overall.

“Despite the market being down, people have all been very positive here,” said Neil Wold, Honeywell director sales -Pacific.

“In fact the turn out was even better than last year,” he said.

Regarding the customer sessions, Wold stated that it was one of his favourite parts of HUG, as “it’s always exciting to see how our technology is being used”.

HUG will be held in Perth next year. www.honeywellprocess.com

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NEWS

AUTOMATION

NSW tops robotics competition UNIVERSITY of New South Wales Team Lab 202 defeated 26 teams from Australia and New Zealand to win the 2014 National Instruments Autonomous Robotics Competition (NI ARC) final, held at Macquarie University in Sydney last month.

Fellow university student team, University of New South Wales Mechatronics, came a close second, with teams from the University of Wollongong and University of Sydney making it through to the competition semi-finals.

In the knock-out style grand final, themed ‘Go, Sow, Grow!’, fully autonomous robots had to collect seeds, navigate to a farming area littered with obstacles, deposit the collected seeds in designated planting areas, wirelessly communicate within their environment, Victoria University of Wellington won the Best then navigate back to the home zone.

Robot Design award.

University teams of engineering students from multiple disciplines spent the last six months building their robots using the NI ARC development kit the importance of robotics in agriculture and helped including an NI myRIO hardware and NI LabVIEW students concentrate their skills to address the needs of system design software, featuring the LabVIEW the sector.

Robotics Module.

“Robotics has the potential to help transform and PMatej A 1 Krajnc, 0 1 4 _Managing 0 0 0 _ Director A M S for - National 1 2 0 1 4 - 0agriculture, 9 - 1 2 Tproviding 1 1 : 3farmers 2 : 0 with 4 + 1a more 0 : 0efficient 0 Instruments Oceania, said the competition highlighted productive way of working. Students who competed

in the NI ARC were able to demonstrate how robotics can play an important role in agricultural applications,” said Krajnc.

John Lam of the winning Lab 202 team, said three years of experience preparing for the competition yearon-year and a little friendly competition helped them finally take the title this year.

“We’ve been entering the NI ARC for the past three years, so this year we were able to build a more robust robot and very well organised LabVIEW code. We also tested in the same fields as the other UNSW team throughout the year, which really pushed us to be as competitive as we could be.”

Lab 202 was awarded the first place prize of $3000, University of New South Wales Mechatronics was awarded $1500 in second place, $750 to the University of Wollongong in third and a prize of $500 was awarded to last year’s winners, Victoria University of Wellington, who won the Best Robot Design award by the NI ARC judges.

All teams that successfully completed the competition final also get to keep the development kit which was provided by National Instruments. www.facebook.com/niroboticscomp

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OCTOBER 2014 www.pacetoday.com.au 7

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OPINION

Helping to put you in Control

IP65, 32K Reading LogBox RHT Dual channel data loggers with built-in temperature and relative humidity sensors.

They can be easily programmed via a handy infrared IR-link interface. Comes with 32K memory capacity.

Replacable internal battery.

SKU: LOG-005 Price: $159 ea + GST

AUTOMATION

Virtualisation

TagTemp - USB Temp Logger IP67 sealed temperature logger with replaceable internal battery.

1 year (typical) life. Micro USB interface and Windows software for configuration, download and charting. Price listed is a special price for September only.

SKU: NOD-050 Price: $49 ea + GST

Digital Universal Indicator

Panel mount process indicator accepts thermocouples, 0 to 75 mV, 4 to 20 mA, Pt100/RTD, 0 to 10 VDC signals. Isolated 24 VDC output, 4 to 20 mA analog output for retransmission and two alarm relays. 24 VDC powered.

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IP67 LED Power Supply

320.16 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. 24 VDC output at up to 13.34 A. SKU: PSL-3224 Price: $273.60 ea + GST

Small Cooling Thermostat Dead-simple DIN-rail mount thermostat usually used to switch a cooling fan on or off in an electronics cabinet. 0 to 60 °C setting range. 250 VAC @ 10 A switching capacity.

SKU: HEC-005 Price:$29.95 ea + GST

Wind Direction Sensor

Easy to use wind direction sensor with 4 to 20 mA signal output. With a 4-20mA signal output it can be easily connected to a PLC or RTU or datalogger to provide monitoring and control of systems according to the wind speed. 12 to 30 VDC powered.

SKU: FSS-010 Price: $170 ea + GST

BVS Pressure Sensor

Economical pressure sensor with input pressure range of 0 to 2.5 Bar. 2-wire 4 to 20 mA output. 1/4” Pt thread connection (Japanese thread type same as BSP). 18 to 30 VDC loop powered.

SKU: ALT-103 Price: $169 ea + GST

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8 www.pacetoday.com.au OCTOBER 2014

The largest benefit is de-coupling automation software from specific hardware, writes Harry Forbes.

V

IRTUALISATION is the separation of an IT resource from specific physical hardware. Since virtualisation today can only be applied to some parts of process automation systems, it can be difficult to assign specific economic value to the technology. Virtualization plays an important role wherever server hardware is used in the automation system. This is at levels 2 to 4 of the ISA-95 manufacturing model. Today’s automation suppliers offer system configurations that feature server consolidation.

Multiple HMI machines and other application servers are replaced by virtual machines. A small number of more powerful hosts support these virtual machines. Besides being more powerful, the new servers incorporate levels of redundancy with respect to power, storage, compute, and network resources.

Server consolidation benefits include removal of physical equipment, freeing rack or panel space in congested control areas.

Power requirements and system administration burden are also reduced (though the remaining administration work is technically more complex).

The largest benefit to end users of server consolidation in process automation systems is the decoupling of the automation software from specific configurations of PC or server hardware. For years, many HMI and other automation system functions have been implemented on PC hardware. Plant owneroperators and automation suppliers have struggled to support these systems due to the short lifecycle of PC products. By virtualising such a system, it can be more easily supported once replacement hardware is no longer available. This higher degree of hardware independence helps extend automation system life and reduces production interruptions due to automation system upgrades.

At lower levels (1-2) in the ISA-95 model, automation functions are implemented in embedded systems (e.g., process controllers, process I/O equipment, or field devices) that are managed by a real-time OS. While these devices can be simulated or

emulated, strictly speaking they cannot be virtualised as-is. Instead, their embedded software must be modified and/or ported to some degree to operate in a virtual machine environment. Most automation suppliers have developed products that now provide this functionality.

For the field devices and actuators at level 1 of the ISA-95 model, there is not much to report at present about virtualisation. Simulation software/hardware is available for some field networks. Several technologies are becoming available (EDDL, FDT, FDI) for managing field device parameterisation, configuration, and diagnostics. However the commissioning of field devices remains largely a field activity and has not yet benefitted from virtualisation or simulation to the same degree as other areas of process automation systems.

Virtualisation technology can bring significant value to their installed base of automation systems as well as to automation projects for new plants. For installed systems, the benefits come from replacing dedicated servers with virtual ones. In new installations, the benefits come from schedule compression resulting from the ability to develop the system configurations and applications in a virtualised environment. End users should evaluate specific benefits that accrue both during the design and build phase and the O&M phase of the plant asset lifecycle.

Benefits during the design and build phase center around two major areas. First is the reduced space and utility requirements of an automation system incorporating server virtualisation. These reductions can be dramatic and result in substantial savings in high-cost installation areas, such as offshore platforms. Note that to fully take advantage of such savings, these reduced requirements must be known during the early FEED stages of project engineering so that the project civil and mechanical engineering designs take advantage of the reduced system power and space requirements.

[Harry Forbes is Senior Analyst, ARC Advisory Group.] www.arcweb.com

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BEHIND THE SCENES

Australian access control system wins global acceptance The inexpensive AccessPack technology claims to reduce both OHS and business risk associated with industrial equipment use.

A

N Australian access control system is winning the support of leading companies around the world. The inexpensive AccessPack technology reduces both OHS and business risk associated with industrial equipment use.

First aimed at high risk equipment, it is now being installed on a huge variety of equipment across a range of industries around the world due to its simplicity and versatility.

Existing users of AccessPack include companies such as Schlumberger, BHP Billiton, Rio Tinto, FMG, Weatherford, UGL, Komatsu, Hitachi, Disney, Rolls Royce and Whiting Corporation.

AccessPack, from Western Australian company CASWA, uses smart card technology to prevent unauthorised operators from using high risk or critical equipment.

This improves OHS outcomes by requiring users to have current and appropriate ‘tickets’ including qualifications, accreditation, training and/or inductions in order to operate the equipment.

It records who uses the equipment and this creates and maintains a culture of operator accountability and typically improves availability as authorised users instinctively take greater care, says CASWA. It also provides HSE staff with access to information required for effective incident investigation and proactive training needs analysis.

AccessPack is radically different from typical access control systems that are designed to prohibit use by merely restricting perimeter access. Not only do these systems need expensive communications infrastructure to work (between the control point and a backend computer), once people have 10 www.pacetoday.com.au OCTOBER 2014

passed security, there is typically nothing to actually stop them from operating any individual machine they can get their hands on.

“AccessPack however, is fitted to the actual device you want to manage. So it will only operate for individual persons that have been authorised to do so, and only for the period that this authority is valid. Machines will simply not start for anyone else,” says the technology’s developer, Paul Kelly, Managing Director of CASWA.

Safety and environment benefits

“Controlling devices individually also enables us to tackle the difficult part of the HSE equation – the people part.

This is the bit that is typically ignored because, let’s face it, changing people’s behaviour is really hard. Maintaining it is harder still.

“AccessPack logs authorised use and thus achieves behavioural change by merely providing the means by which people can be held accountable. This change will often stay with the operator when they then use other equipment.

It’s cultural change you can buy off the shelf.”

“Also, because it doesn’t need rely on any communications system to operate, it can be installed quickly and inexpensively on a wider range of equipment.

“With AccessPack, you can finally control access to mobile and battery powered equipment that isn’t bolted down and can easily wander in and out of Wifi or 3G range,” says Kelly.

This unique feature has allowed AccessPack to become a universal solution for all types, makes and models of equipment, he says. Organisations are now finally able to employ a single access control technology across

Paul Kelly drew on a lifelong interest in developing rocket flight control systems to form a technology company with a global safety and reliability agenda.

The system prevents unqualified personnel from being pressured into using hazardous equipment by time-stressed supervisors their entire operation, with only one associated management system.

The range of equipment commonly fitted with AccessPack includes cranes,

production critical machines, hydraulic power packs, lathes, presses, CNC plant and breakout machines, as well as vehicles such as forklifts, diggers and elevated lifting platforms. The system can also replace most logbook controlled cabinets or rooms by fitting an AccessPack to an electronic safe or door.

There is also no limitation to the number of units or different equipment types on a site. Installations can be a single machine on one site, a type of machine across multiple sites, or a total enterprise solution for all types of critical

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BEHIND THE SCENES

Equipment can also be tagged out if mandatory maintenance intervals are not done in the required period. or hazardous equipment. It is infinitely scalable without incurring any sunk cost along the way.

P“Most A 1 0importantly 1 4 _ 0 0however, 0 _ G Lour OB hardware is simple and hassle-free to

AccessPack has the ability to track when maintenance or servicing is due.

use. After you fit an AccessPack to a also prevents unqualified personnel from machine, the operator just replaces being pressured into using hazardous pressing a start-switch with swiping a equipment by over-eager or timecard.

1 2Thus 0 1 we 4 -don’t 0 9 get - 2much 9 T push 1 0 : 1 1 : stressed 2 8 + 1supervisors.

0 : 0 0 “So it’s win-win for back from users,” says Kelly. The system everyone.”

Multi-network connectivity within fieldbus and industrial Ethernet

Get connected!

Anybus gateways allow you to quickly and easily connect any machine to any industrial network.

You configure the communication in the Anybus Configuration Manager software.

No programming is necessary.

Connect. Configure. Done!

www.anybus.com.au 12 www.pacetoday.com.au OCTOBER 2014

Other features of AccessPack include the ability to track when maintenance or servicing is due, thus keeping equipment in good working condition and further ensuring operators’ safety. Equipment

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BEHIND THE SCENES

can also be tagged out if this is required for any reason, or if mandatory maintenance intervals are not done in the required period. In this mode, no operator, certified or otherwise, can physically use the equipment until it is safe to do so.

Administration is just as simple. A secure web interface enables access rights to be granted or changed using a few drag and drop actions.

Recently, CASWA signed a license agreement with the Whiting Corporation, a major manufacturer of overhead cranes, foundry equipment and rail maintenance lifting equipment in the US, for distribution throughout North America.

Whiting Corporation’s Product Director Joel Phelps says: “The technology is brilliant. It is simple to install and use and is already proven in service in some of the most challenging markets and physically challenging locations on earth. From Australasia, Asia, Africa PA 1 0 and 1 4 Russia _ 0 0 to 0 Western _ DEL Europe and the US, AccessPack is

The system can replace most logbook controlled cabinets or rooms by fitting an AccessPack to an electronic safe or door proving itself to be the Seventh Sigma of excellence in process improvement.

“We love it here because it pays for itself by easing compliance with safety regimes. Importantly, AccessPack also helps to eliminate downtime by empowering workers to take responsibility for the assets they use.

Quite apart from saving compliance headaches and avoiding downtime – which are major issues here – it prevents accidents from misuse of fixed and mobile plant that can kill people.”

CASWA

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2 0 1 4 -0809277 9 - 0900 1 5 jo@caswa.com T1 1 : 5 0 : 1 7 + 1 0 : 0 0 www.caswa.com

AccessPack reduces both OHS and business risk associated with industrial equipment use.

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BEHIND THE SCENES

Yarra Valley Water benefits from mobile SCADA system Yarra Valley Water identified the need to develop a more open and maintainable system with wide industry acceptance for increased future-proofing and to remove the dependence on a single vendor.

Y

ARRA Valley Water (YVW) is the largest of Melbourne’s three water corporations providing water supply and sewerage services to over 1.7 million people and over 50,000 businesses in the northern and eastern suburbs of Melbourne.

Its water network spreads over 4,000 sq km including over 9,000 km of water and 18,000 km of sewer mains.

Development in Melbourne’s growth corridor to the north is increasing the pressure on Yarra Valley Water to deliver sustainable water solutions.

YVW’s 30,000 point SCADA system monitors approximately 550 sites including 11 treatment plants, 67 water pump stations, over 100 sewer relief facilities, over 96 sewer pump stations and 102 sewer flow control facilities.

Legacy system

YVW was looking to upgrade its legacy system, which was commissioned in 2001. The system had received minimal updates in functionality since that time. It had no graphical interface and relied on a text and tabular displays to show alarms and current status, with basic graphical trending capability for historical analysis.

The system was used largely as an alarm system, from which the control room generated work requests for the field crews. Having no graphical context made finding the information needed time consuming and was not very user friendly.

There was a large reliance on external knowledge and support services for this legacy system, which were largely provided by a single vendor, as the system was not in widespread use.

Yarra Valley Water identified the need to develop a more open and maintainable system with wide industry acceptance for increased future-proofing and to remove the dependence on a 14 www.pacetoday.com.au OCTOBER 2014

Yarra Valley Water staff now have a modern SCADA system that allows them to monitor the distributed assets and perform predictive and reactive maintenance. single vendor for support. Bringing the support in-house was a key objective.

The new system also had to provide a high level of security, with a secure architecture and current generation security concepts.

The telemetry communications system was no longer meeting YVW’s needs. The system was a mix of analog radio network,

NextG, PSTN and GSM dial-up/dial-in modems, spread across its many sites.

Separate to the SCADA host upgrade works, a parallel project was needed to upgrade the radio network.

Graphical User Interface Schneider Electric replaced Yarra Valley’s legacy SCADA system

with StruxureWare SCADA Expert ClearSCADA, which is Schneider Electric’s telemetry SCADA system for the water industry. Schneider Electric’s solution included over 800 detailed schematics for zones and all of Yarra Valley Water sites.

The GUI (Graphical User Interface) is a critical aspect of any SCADA system

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BEHIND THE SCENES

and the “look and feel” of the GUI was co-developed by Yarra Valley Water and Schneider Electric’s Telemetry Competency Centre to incorporate end user needs and industry best practices.

The completed system comprised a redundant server configured in Main/ Standby setup, with the standby server operating from the disaster recovery site.

A third level of resilience is provided with a server that can be run in a standalone mode, independent of IT infrastructure.

Specific configuration

The SCADA alarm system included alarm notifications and acknowledgment via SMS and email. Concerns over the reliability and timeliness of email and SMS mean they were largely used for less critical notifications. To ensure reliable delivery of alarms to operators using smart phones or tablets the ClearSCADA Mobile system is used.

The ClearSCADA Mobile client requires very little specific configuration to work. Once connected to the main SCADA system it provides a full alarm client interface to allow notification of alarms, viewing of all alarm details, acknowledgement (with comment if desired) and short term alarm disablement to manage nuisance repeat alarms.

Data from anywhere in the system can be browsed so that other statuses can be easily checked by the operator if needed. They can decide how they want to respond to the alarm without having to spend time powering up a laptop and connecting into the system.

Schneider Electric established custom data exchange interfaces between Melbourne Water and YVW that used the format of the legacy system. An application was built to handle the export/import process that exchanges data between YVW and Melbourne Water’s database every 3 minutes, updating over 700 points.

This interface has been so successful that it has been extended for use with other systems, and now also exports approximately 1200 points or about 83,000 values to a 3rd party leak detection application every hour.

By using the extensive template feature set of ClearSCADA, Schneider Electric was able to deliver a system that any of YVW’s approved System Integrators can work on without fear of compromising the integrity of the

Host SCADA system. To help achieve this, the Schneider Electric project team implemented a test and development server regime.

Operational environment

This offline test and development (T&D) environment allows for offline configuration and testing prior to roll out on the production servers. This ensures the integrity of the operational environment is maintained at all times and that contractors do not need to be granted full administration privileges to access the production system.

YVW is now using the SCADAPack E Series RTUs, where the configuration of the RTU is included in the ClearSCADA objects and can be downloaded to the RTU remotely.

YVW has adopted these as their standard RTU to deliver large savings on field system configuration. Templated standard SCADA sites include the RTU configuration. Changes can be made in the SCADA system and downloaded to the RTU remotely, avoiding the need to waste time in travel.

This integrated RTU management improves system configuration

management for the RTUs, as all changes are tracked and managed in the main SCADA system. With the new system there are no more unidentified changes made on site or and there is no longer the potential to lose the RTU code.

A third level of resilience is provided with a server that can be run in a standalone mode, independent of IT infrastructure YWV also upgraded its communications systems with over 200 Schneider Electric Trio Digital radios and 6 new radio base stations. This included fully redundant base stations and the capacity to later add diagnostics across the whole network.

As part of the upgrade project, a trial project was undertaken for a sewerage treatment plant to be fully integrated into the main Host SCADA system, allowing operators to have full

access to their own plant information and also visibility across the whole SCADA system. This allows for better management of the inflow and outflow process. This trial was successful and will ultimately be rolled out to the remaining treatment plants on a programmed basis.

Benefits

Yarra Valley Water staff now have a modern SCADA system that allows them to monitor the distributed assets and perform predictive and reactive maintenance, and be better able to respond to incidents, such as environmental spills, in a timely manner.

The user interface and open database tools allow real time and historical information to be made available to operations and strategic planning staff for informed decision making.

Some of the tangible benefits that the project produced include: reduced maintenance support cost; alarm capability and mobile data access; advanced alarm analysis and business reporting.

Schneider Electric 1300 369 233 www.schneider-electric.com OCTOBER 2014 www.pacetoday.com.au 15

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Invensys completes our solutions: Schneider Electric The Synergy Industry User Conference highlighted the complete automation offering that draws on the combined strengths of the two organisations, writes Brent Balinski.

O

NE of the major stories globally in automation last year was Schneider Electric’s acquisition of

Invensys.

Schneider, the French energy management specialist, acquired a significant control system and software capability when it agreed to buy Invensys for $US 5.2 billion.

“This acquisition brings significant synergies, enabling Schneider Electric to add a major process DCS and a leading safety line to its portfolio, as well as a large DCS and instrumentation installed base, and provide additional coverage in the heavy process industries, such as oil & gas,” said one analyst after the acquisition was completed in January this year.

According to Schneider Electric CEO Jean-Pascal Tricoire, Invensys added “a very significant brick of technology, which completes our solutions.”

Schneider Electric/Invensys recently held their Industry User Conference titled Synergy, for obvious reasons.

Broadly speaking, Vice President of Industry Business in Australia for Schneider Electric, Philippe Rambach, said there were three major benefits for the customers from the merger.

A “full, absolute, complete automation offering” pooled the strengths of each organisation, and was able to cater to the need for discrete automation, process automation and hybrid automation.

“The reality is even if your customer is more process or more discrete, at some stage in these factories in his company, he will need some of the rest of automation,” Rambach told PACE.

Gigantic trend

Other advantages were in terms of software offerings, and, crucially, a greater ability to convert users’ data into 16 www.pacetoday.com.au OCTOBER 2014

The common StruxureWare look and feel across the product suite delivers a consistent user experience between Schneider Electric software applications. information, the need for which is a “gigantic” trend.

“We have now, everywhere in the factories, in the automation, in the PLCs, in everything, we have that data available,” said Rambach.

“The question is how do we bring this data into useful information for the customer. And the combined software of Invensys and Schneider we will be able to bring to the customer information based on the data that comes from the automation. And that is absolutely key.”

The “data to information” issue is often mentioned when the Internet of Things is discussed, which happens with increasing frequency.

“Everywhere in the factories, in the automation, in the PLCs, in everything, we have that data available,” said Rambach.

“And with the combined software of Invensys and Schneider Electric, we will be able to bring to the customer information based on the data that comes from the automation.”

A recent release from the company, the Altivar Process variable speed drive (with embedded Ethernet), is an example of a response to the data-toinformation issue, as well as theimpact of the Internet of Things on industry.

Each of the new drives has an embedded web server, and data/ information on them can be viewed on a web browser.

Among the benefits of the drive claimed by Schneider are optimised cost savings through the detection of efficiency drifts and a 20 per cent reduction in downtime through “predictive, conditionbased maintenance.”

Meaningful data

Fundamentally, the Internet of Things and devices based around it are about collecting and making data meaningful, for reasons including predictive maintenance and optimised efficiency.

“Because the internet of things is bringing so much data that at the end it can mean nothing,” explained Rambach.

“This is really what we have at heart: information accessible everywhere, anytime in a very simple way and with useful information.”

Neil Smith, Country Manager Legacy, Invensys (acting) cited the benefits of connectivity (and sped-up decisionmaking) through an example involving a SCADA alarm notification at a plant.

“The traditional response was the operator gets an alarm, the operator sees they have a fault on an instrument, he

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IN FOCUS

then phones his operations tech, he then has to go off and look at it,” he told PACE. The worker might be an SOP contractor. He must enter the incident, do the permits, and follow a set procedure to see what has gone wrong.

“Now with the interconnectivity or the Internet of Things providing all that information, you can actually pull up the moment that alarm comes up, you can do that automatically – if it says it’s a maintenance alarm it could have already dispatched the work order to the maintenance department,” said Smith.

“It may have already checked your Philippe Rambach is Vice President Neil Smith is Country Manager of Industry Business at Schneider Legacy Invensys (Acting) at Schneider inventory. ‘Do you have a spare part Electric.

Electric. in place? If you haven’t: expedite...’ So you’re integrated from your controller automated processes, eliminating human into your MES and even into your ERP. system automatically downloads the error, and increasing the effectiveness of “So you’re connected up to SAP, correct configuration, and calibration both the operator and the plant’s assets, you’re releasing orders, you get a information, and he’s back up and with reduced downtime. notification of when the part has come running again.”

According to both Smith and in, and the maintenance guy goes Reduced downtime Rambach, major issues among customers and collects that, takes it out, maybe picks up10the 7 1calibration 4 _ 0 0 files 4 - 0 9 6 - in 9 T0 1 9 1 : 1 2 8 1 : 5 4 (Rambach’s PA 0 3 0 _ that I D he E 1 Great 2 0improvements 1 3 1 productivity 8 6 + 1 0 : 0brief 0 covers MMM, food could be achieved through simplified, and beverage and waste/wastewater) needs as well, presses download, the

include high operational costs and trying to extract as much value as possible from assets.

Within Schneider, other, broader shifts the company is trying to meet are around the shorter average tenures among operators, digital natives among the workforce, which is itself ageing.

Smith believes the merged companies are in a better position to meet all of these demands, as well as demands such as the need to bring products to market faster.

“There’s a combined operation to bring the expertise and the pedigree of Schneider Electric in energy management and if you think of Invensys, there’s a very strong offering around operational management,” he said.

“We now can address all of those industry trends around the ageing workforce, the need for customers to do more with less, to have green credentials, so it’s an extremely powerful offering.”

Schneider Electric 1300 369 233 www.schneider-electric.com

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Web: Web: www.idec.com/australia www.idec.com/australia OCTOBER 2014 www.pacetoday.com.au 17

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IN FOCUS

HAZOP of machinery packages The HAZOP methodically examines a proposed design and operation to assess the effect of changes in the design conditions and operational procedure, writes Amin Almasi.

T

HE HAZOP is a structured study technique, which methodically examines a proposed design and operation to assess the effect of changes in the design conditions and operational procedure. Hazards are the focus of HAZOP studies.

The HAZOP is best suited for assessing hazards in machinery packages, equipment, facilities, and processes. A hazard is a potential source of harm.

Deviations from mandatory design codes or established operational procedures may constitute or produce a hazard. A single hazard could potentially lead to multiple forms of harm.

The HAZOP review is employed to assessing the machinery package design and the operational capability to meet mandatory codes (such as API codes), client specifications and safety standards.

This is intended to identify weaknesses in a machinery package or its systems.

Operational and procedural controls are also the focus of a comprehensive HAZOP which would include assessing engineered controls (for example, a package automation), sequences of operations, procedural controls (for instance, human interactions), etc. This should cover evaluations on different operational modes such as start-up, standby, normal operation, unsteady situations, normal shutdown, emergency shutdown, and others.

The HAZOP is intended to be a cross-functional team effort, and relies on specialists and experts from various disciplines with appropriate skills and experiences who display intuition and good judgment. Experts should be carefully chosen to include those with a broad and current knowledge of deviations for the system or the package under study. The HAZOP should always be carried out in a climate of positive thinking and frank discussion.

An important factor is defining HAZOP study boundaries and key interfaces as well as key assumptions that the assessment will be performed under.

The HAZOP process systematically 18 www.pacetoday.com.au OCTOBER 2014

An example of a gas turbine package (Source: Siemens). questions every part of a package (or a unit) by nodes and lines to establish how deviations from design intents and established operational rules can occur. The causes and consequences of each deviation are then analyzed using worksheets to determine if they would have an adverse effect upon the safe operation of the process or machinery packages.

In a HAZOP, the identification of deviations from the design codes and operational intents is achieved by using predetermined “guide words” or “key words”. The role of the “guide word” (or “key word”) is to stimulate imaginative thinking, to focus the study and elicit ideas and discussions.

Risk and risk assessment

Risk is the combination of the consequence severity or harm that can result from a hazardous event and the

probability/likelihood of that event actually occurring. In other words: Risk = Consequence (severity) × Probability (likelihood) Having identified the potential hazards, measures should be taken to reduce residual risk to the tolerability region (or say within acceptable limits).

A process, a package or a plant may have a number of protective layers that work independently of each other.

Examples include mechanical relief devices to protect against overpressure and over-speed protections for some rotating equipment (for instance, steam turbines).

A mixture of quantitative, semiquantitative and qualitative methods can be used for the risk assessment. The most appropriate method should be selected based on the application. For most of machinery packages, a semiquantitative method is the best option.

In IEC-61511 (which is widely employed for machinery packages as well as plants), the risk assessment is known as the SIL (Safety Integrity Level) determination, and the standard also provides a scale. A SIL as defined by IEC-61508 is a discrete level (one out of a possible four) for specifying the target level of safety integrity.

This is given a range from SIL-1 to SIL-4, where the SIL-1 represents the lowest integrity requirement and the SIL-4 the highest integrity requirement.

Each SIL corresponds to a range of numerical target failure measures, known as the “Probability of Failure on Demand” - average (“PFDavg”).

The SIL assignment method that has been usually selected for machinery packages is the LOPA (“Layer of Protection Analysis”) method (a wellknown semi-quantitative method).

The LOPA method is a recognized SIL assignment method and complies with the requirements of IEC-61508 and IEC-61511.

This method has been deemed the most appropriate method for the SIL assignment of machinery packages.

This method considers all identified “Initiating Events” (IEs) and ensures there is a focus on high severity impact events. This also considers the effectiveness of each “Protection Layer” (PL) and ensures consistent allocation of the “Risk Reduction Factor” (RRF) to each PL. The LOPA method is a semiquantitative approach that relies upon a project’s risk acceptance criteria and the development of a set of guidelines that are to be applied consistently throughout the LOPA. In other words, this method can provide the opportunity to use the codes and academic details as well as opinions of subject matter experts and operators with experiences in the packages under study in the form of project’s risk acceptance criteria and other inputs.

This can guarantee a right mixture of academic data (often generic) with experiences and knowledge applicable to

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IN FOCUS

the machinery packages under review.

Risk acceptance criteria are also used to derive target risk frequencies which form the basis for determining the adequacy of risk reduction throughout the LOPA.

HAZOP focuses

The HAZOP review ensures that the level of the integrity of the package is as high as reasonably practicable at all times. In addition this confirms that risks to people on an installation (packages and surrounding facilities) arising from matters of integrity, are kept as low as reasonably practicable. This can include the design, modifications, operation and maintenance.

In a HAZOP review, a thorough search for deviations is carried out in An example of a machinery package. a systematic manner. All reasonable situations which are expected should be identified and subsequently challenged comprehensive methodology to identify performance and behaviours play very to determine if they are “credible” and resolve all important hazards with important roles in packages and plants. andAthen detail.

D _ they P A are C Eassessed D WY in MA R _ 1 2 . p focus d f onPthe a gtwo e followings: 1 1 0 / 0 1 / 1 2 , • Hazards 9 : 4 0that AareMdifficult to detect, The HAZOP is a systematic and • Hazards rooted in human operator analyse, isolate, count, and predict.

These hazards might be missed in safety checks during normal design reviews and ordinary safety reviews.

Existing protective devices that prevent or safeguard against the adverse consequences of hazards are considered and actions are raised where the protection is considered inadequate.

These actions could be: 1. To remove the cause 2. To mitigate or eliminate the consequences Where it is not possible to remove the cause, additional safeguarding is required. In such a case, a “Safety Instrumented System” (SIS) can play a significant role in preventing or mitigating major hazardous accidents.

A HAZOP review demands detailed recording and reporting to demonstrate that the rigor of process has been thoroughly carried out.

Operational feedbacks should confirm that the HAZOP assessment and control steps are adequately addressing the risk questions. Often the assumptions made about the level of

OCTOBER 2014 www.pacetoday.com.au 19

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IN FOCUS

residual risks should be re-evaluated after the HAZOP items closeout.

Residual risks are risks that are expected to remain after risk control strategies have been exercised. New risks might arise from risk control practices.

Sometimes risks that were not originally identified or may have been filtered out during the initial risk assessment can become aggravating factors due to the implementation of risk control measures.

Practical issues

A difficulty in current HAZOP studies is that these studies are usually carried out late in design when it is too late to make fundamental changes and all can be done is add on equipment or an item to control the hazard. To design inherently safer packages or plants it is needed to carry out a HAZOP study much earlier in design than in the past, at the flow-sheet stage and, even earlier, at the conceptual or basic-design stage, when deciding on basic configurations and parameters.

In this regard, it could be recommended to perform two HAZOP reviews, one at the basic-design (preferably before the order of the machinery packages) and another at the detailed-design (for instance, at around 80% of the design progress).

One of the potential problems in machinery packages is the conservatism in this industry. Design and manufacturing on what is already proven with operating references (what was used in previous similar plants) could bring swifter results with greater confidence than launching into radically new machinery designs that evaluated theoretically to offer inherently safer operation than previous ones.

Generally there is feeling by many plant operators that rotating equipment is unreliable. The reference checks play an important role in the machinery selection probably more than any other equipment in a plant. The organizations of clients and EPC contractors play also important roles in this regard.

Some new machinery designs such as oil-free compressors, hermetically-sealed compressors and others could be slightly cheaper and inherently safer compared to traditional designs.

However, as a proportion of the total capital cost of a project, this saving might be relatively small and safety advances might also not be evaluated significant overall. Project engineers and 20 www.pacetoday.com.au OCTOBER 2014

business managers are understandably reluctant to use new technologies for a small percentage saving in cost and slightly better theoretical safety in case there are unforeseen difficulties that could prevent or delay the achievement of the design output.

One of the common issues in many plants and machinery packages is the large inventories of hazardous materials.

A good question that should always be asked is “should the inventories have to be so large?” Often it would be possible to design machinery packages and plants that use less hazardous materials (or safer materials instead) or use the hazardous material in a less hazardous form. Such packages or plants are said

Optimum configuration

to be inherently safe as the hazard has been removed (rather than controlled by added-on protective equipment which can fail or can be neglected). The best way of preventing safety issues and risks is to use safer materials instead or so little of the hazardous materials that it hardly matters if they leaked or misused.

Most accidents were said to be due to human error (human failing). However, besides the slips and lapses of attention, some so-called human error (or human failing) are the result of inadequate training or instruction. This is an important issue for complex and unique machinery packages.

A critical aspect of HAZOP reviews (and particularly multiple HAZOP meetings at the basic-design, detailed design and final design) is the raise of the profile of safety. This can move the safety higher up the agenda and managers, experts, designers and operators pay more attention to the subject.

can handle. The higher the alarm rate, the lower the probability of the operator noticing it and responding effectively.

As the first few alarms sound, the human operator moves quickly from vigilance mode through analysis to action. Once into the action mode, people rarely re-evaluate their initial analysis, even if subsequent information clearly indicates that the initial analysis was wrong. In other words, once into the action mode, there is a powerful human operator tendency to “confirm”, rather than to falsify hypotheses and re-think about the situation. This bias which can be created by too many alarms could cause operational problems.

Alarms which repeatedly activate then clear can be seriously distracting to the operator, particularly during upset conditions when they can make a significant contribution to alarm floods.

Large proportions (typically more than 60%) of alarms are caused by a small

“Too many alarms” is bad and “too many shutdowns” is disaster. Humans are not particularly good at vigilance tasks. Human operators do not cope well with alarms. They suffer from a condition called “cognitive overload”.

In simple terms, an operator should not be presented with more information (in this case alarms) than he can process and act upon in the time available.

In modern plants, when an upset or something more significant does happen, the transition from normal to abnormal can be rapid. The result is many alarms in a short time. As an indication, the sustained rate of about two alarms per minute is as much as a typical operator

number of alarm points. Repeated alarms are generally caused by faulty instruments, alarm limits set too close to normal operating conditions, the ineffective use of dead-bands, repeat timers and similar mechanisms. The alarm flood is one of the most disturbing situations.

It is quite common for 100 alarms to occur in the first four minutes following an upset on a complex plant. Alarm rates of one alarm per 3 second are not unusual in an upset. The result is that the operator effectively abandons the alarm system, acknowledging alarms without looking at them. Not only is he likely to miss important information as a result, he may also misinterpret the information.

An important consideration is that the usefulness of alarm is extremely scenario-dependent. In other words, an alarm which, in one scenario, might give useful early indication of an incipient upset can be just one of many consequential alarms in another.

Furthermore, this dependence can often be chaotic, with slight differences in scenario giving rise to differing outcomes with respect to which alarms are useful and which are not.

In a HAZOP or a design safety review, a package or a small section of a plant is studied at a time. The scope of study in each HAZOP usually contains between 30 and 300 of measurement instruments and sensors. When a team study this small section in isolation, it is easy to conclude that adding a few alarms can make it safer. However, when the team look at a bigger picture, where the overall operation comprises many such sections, the picture is quite different.

This is an important consideration in any HAZOP. There should be an optimum number of alarms for any package or unit. Based on experiences, it simply costs less to add an alarm than to discuss whether it is needed or not.

In many HAZOP reviews, for any issue the first and simple recommendation has been put an alarm and leave it to operator. This is a fake solution that has been used for decades.

[Amin Almasi (amin.almasi@ymail. com) is a rotating machine consultant in Australia. He specialises in rotating machines including centrifugal, screw and reciprocating compressors, gas turbines, steam turbines, engines, pumps, condition monitoring and reliability.]

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Hub promotes global competitiveness The hub aims to link business to each other and researchers to help transform firms by aligning their internal organisation and pocesses with their customers’ demands, writes Brent Balinski.

A

NEW collaborative hub aims to spread the adoption of design led innovation (DLI), a “whole-of-business” approach based on a deep understanding of customer needs.

The META Design Thinking for Export & Competitiveness Hub was officially launched last month at the University of Technology, Sydney, which has partnered with META for the initiative.

“Design thinking is not a new concept. It was already around in the 50s; it’s just been re-applied,” Professor Sam Bucolo, a DLI expert at UTS, told PACE. “That whole notion of you put out your shingle and make something good doesn’t stack up any more in a global environment.”

The hub aims to link business to each other and researchers to help transform firms based on the concept, aimed at increasing competitiveness through strategies that will “align… internal organisation, processes, business model and culture with their customers’ demands.”

According to Bucolo, the idea’s time has come due to the shift in Australia’s cost structure in recent years, as well as the open economy. He said it had already been promoted and adopted successfully in Scandinavian countries, the UK and New Zealand.

“Australia has been left standing, for lots of different reasons,” he said. “Our role is actually to quickly accelerate it.”

The design-led innovation framework is outlined in a report co-authored by Bucolo and Peter King of the CSIRO and released

The philosophy of design-led innovation was consistent with META’s message of promoting business excellence across the whole of the value chain in June, Design For Manufacturing Competitiveness.

The study of 14 companies, including Enware, Centor, and RODE Microphones, identified an approach common to these globally successful manufacturers. It involved design principles applied to all aspects of what these companies do.

Membership of the hub was worthwhile for the support during the difficult task of transformation, explained Nigel Spork, managing director of Centor and one of two success stories presented as case studies at the launch.

“Design integration done well is something that you don’t dabble in,” Spork told PACE. “You’re embarking on a journey into the future, and that’s a scary place.

“So if you’re able to have others who are there to help you along that are there along the journey, not just to learn from others, but to learn from and share in the experience, it’s much more reassuring and it’s much more productive.”

Nick White, CEO of Gourmet Gardens, agreed.

“There’s not many forums where you can do that,” he said.

“So hopefully with some good case studies and mentors on board, there’ll be a platform for people to engage on.”

META’s managing director Zoran Angelkovski said the philosophy of design-led innovation was consistent with his organisation’s message of promoting “business excellence across the whole of the value chain”.

META has launched several

collaborative hubs this year, beginning in May with a Carbon Fibre Hub, based at Deakin University, and including others themed around industries such as commercial aerospace and prefabricated housing.

The Design Thinking hub was one of “more than 20” to be launched according to Angelkovski, who said he remained hopeful that META could continue to exist after December 31, when its federal government funding ends.

“What we’ve been doing through these activities and many others is positioning META to be considered as part of the National Innovation Competitiveness Agenda that addresses a whole range of issues about business and business becoming globally competitive,” he said. meta.org.au OCTOBER 2014 www.pacetoday.com.au 21

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CONVERSATION

AUTOMATION

Inside the industrial Ethernet UK Industry Automation expert and trainer, Peter Thomas, will visit Australia in November to conduct Profibus Association of Australia’s 3-day Certified PROFINET Engineer course. Here he sheds light on common industrial Ethernet misconceptions.

He also discusses network security requirements and controlling process applications through P A1 0 1 4 _ 0 0 0 _ CON industrial Ethernet.

What is PROFINET and how does it is not a multi-drop network but uses differ from PROFIBUS? four-core, twisted pair screened cable PROFINET is the Industrial Ethernet to connect one device to another using standard developed and supported switches. Termination, to prevent worldwide by PROFIBUS and reflections, is no longer an issue as the PROFINET International or PI for resistors are already installed in each short. At the end of 2013, 7.6 million device.

PROFINET devices, from a wide range Again, unlike PROFIBUS, of vendors, had been installed and the PROFINET is not a master-slave protocol number continues to grow. but uses full duplex communication at Most manufacturing sites are 100 Mbit/sec which means that devices used to using fieldbus technology like can read and write at the same time. It PROFIBUS and Ethernet side by side. makes use of existing IT standards, but PROFINET merges the two together unlike IT systems, PROFINET is a real with obvious benefits. time, deterministic protocol capable of PROFINET is based on established, achieving guaranteed cycle times. well-proven, Ethernet technology but There are two implementations of with the added robustness demanded PROFINET that can work side by RT for the 1for use 2 0in1an4 industrial - 0 9 - automation 2 6 T 0 9 : 0 8 : 2side.

4 +These 1 0 :are0 PROFINET 0 environment. Unlike PROFIBUS, it most common automation applications where cycle times of 10mS are more than acceptable and PROFINET IRT, standing for Isochronous, for use in high-speed applications such as multiaxis drives where cycle times as low as 31.25µS can be achieved.

Although PROFINET is not PROFIBUS over Ethernet, there are many similarities with this fieldbus technology and many of the features have been enhanced. Those people used to developing and supporting PROFIBUS systems will feel quite comfortable with the new technology although PROFINET-specific training is recommended. A Certified PROFINET Engineers course with world-wide recognition is now available.

Most importantly, PROFINET does not make your existing PROFIBUS installation redundant.

PROFIBUS will continue to play an important role but a gradual migration over to PROFINET will allow you to benefit from features only available using 21st century technology.

Is is possible to integrate PROFINET with an existing PROFIBUS installation?

Because PROFINET uses

22 www.pacetoday.com.au OCTOBER 2014

standard Ethernet technology as well as the enhancements required for use in an Industrial Automation environment, it offers several benefits that cannot be achieved with PROFIBUS. These include: • High-speed, deterministic, cycle times as fast as 31.25µS • Automatic compatibility with existing Ethernet standards such as SNMP, LLDP, DHCP and HTTP • More flexible topology options including star, tree, line and ring • The use of user-friendly, applicationspecific, device names instead of numeric addresses • Automatic neighbour recognition allowing devices to be replaced with a minimum of technical expertise • More detailed diagnostics about the network • IO Devices with integrated switch capability • The ability to communicate wirelessly • Access to web-based functionality • Safety and Redundancy functionality when required • One cable for all applications Collectively, these make better use of your resources, increase your productivity and allow more scope when developing innovative solutions.

Integration with existing PROFIBUS installations, and many other older technologies, is catered for by use of a device known as a PROXY. These devices are available from a wide range of suppliers and provide a low-cost option for protecting your investment in these older technologies.

Fortescue’s Herb Elliot Rail & Port Facility.

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CONVERSATION

Non time critical communications Profiles

Real time communications Profiles

PROFINET Application Layer

Not used

Not used

TCP/UDP

PROFINET Real-time channel

IP

Standard fast Ethernet

It is these enhancements that allow PROFINET to be classed as a realtime, deterministic Industrial Ethernet solution that can be used with complete confidence. It is also the reason why so many organisations are now using the technology.

on a day to day basis it will not be necessary to go down to this level. This is because PROFINET is a diagnosticrich protocol that builds upon the capabilities of PROFIBUS in this area.

As well as giving access to devicerelated diagnostics down to the module and channel level, PROFINET makes use of the SNMP protocol to allow you to monitor the health of the network components like switches.

SNMP stands for Simple Network Management Protocol and is a protocol that will be familiar to people working in the IT world. This information could be used to produce a SCADA page showing the status of the network with disconnected cables changing colour.

Many of the organisations that produce tools for PROFIBUS are doing the same for PROFINET and these range from software tools for use on a conventional laptop to permanently installed diagnostic monitoring devices with web interfaces.

What skills and tools will I require to configure and support a PROFINET system?

The line between industrial automation and the IT world is becoming blurred and automation engineers now need to be conversant with a lot more IT-related functionality than was the case in the past.

So a working knowledge of things like MAC addresses, IP addresses, Ethernet protocols and the ability to configure Ethernet switches are just some of the tools that a 21st century automation engineer will require.

In terms of support, there are free tools that allow you to go as in-depth as monitoring A D _ P the A CEthernet E P L Aframes A P Rpassing _ 1 2 . pdf back and too along a cable. However

P Profibus a g e Association 1 1 4 / of0Australia 3 / 1 2 , www.profibusaustralia.com.au

Profinet uses a dedicated and prioritised communications channel.

What about security?

In the past, automation networks were normally isolated from other IT networks. In addition they used specialist protocols and operating systems that helped to create a protected and secure environment. With the widespread use of Industrial Ethernet the situation has dramatically changed.

Highly interconnected systems using standard operating systems and protocols are becoming the norm. As a consequence security is now an essential consideration in automation systems such as PROFINET. Security systems can help protect your plant from malicious and accidental damage but It is not just a matter of locking things down. Threats must be identified, responsibilities need to be established and security policies need to be implemented and maintained. Industrialgrade firewalls are recommended on all PROFINET installations.

These firewalls will: • Control access to the protected network and its devices.

• Only allow authorised traffic to and from a protected network.

• Conceal the network and devices from outside the protected area.

• Record information useful for traffic monitoring and intrusion detection.

• Restrict access for firewall setup and maintenance.

Virtual Private Networks, or VPNs, are another method of improving the security of your network, especially when remote access is required.

Is it a good idea to control an industrial process using Ethernet?

Well, whilst it is perfectly possible to get a PROINET-enabled PLC to communicate with remote IO using conventional CAT5 cables and off-theshelf switches, this is not going to be suitable for an industrial automation environment. We are all aware of the annoying delays experienced in file opening times, file transfer times or the time taken for web pages to open.

Clearly, these are completely unacceptable for industrial automation and to overcome this, PROFINET defines the required specifications for cables, connectors and switches.

It also uses a dedicated, prioritised communications channel that by-passes several of the time-delaying layers of the 7-layer OSI model to transmit IO data in real time.

OCTOBER 2014 www.pacetoday.com.au 23

1 0 : 0 6

AM

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SPOTLIGHT

7best of the

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

Miniature stepper motor drivers

With the release of the TESK from Schmersal, the fourth generation of Safety Hinge Switches is now available. With this new series the switching angle is freely adjustable over the whole of the working range. The user can select different contact configurations with up to four contacts and the option of cable connection or plug connection. The construction of this safety switching device allows it to be mounted on the hinge side of the rotating guard. This replaces a conventional hinge and at the same time takes over monitoring the position of the guard. Safety hinge switches offer protection against tampering as the safety switch is not visible to the operator, being an integral part of the guard. Additionally, the machine builders benefit because their machines and enclosures can be constructed with the commercially available aluminium profile systems. With the sleek appearance of the TESK, the new safety hinge switch is the perfect solution for the position monitoring of protection doors on design-oriented machines. Even double swing doors can be monitored with this new hinge switch.

UIM240XX Miniature Stepper Motor Drivers are miniature, high performance stepper motor drives. They can be mounted onto NEMA 17/23/34/42 series stepper motor seamlessly through corresponding flanges.

The thickness of these drives is less then 17mm. The UIM24002 supplies 0-2A adjustable phase current, the UIM24004 supplies 1.5-4A adjustable phase current and the UIM24008 supplies 3-8A adjustable current. Their mixed-decay current control reduces the back-EMF effect under high motor speed and improves the performance. Except that UIM24002 takes 10-35VDC input, UIM240XX series drivers work on 12-40VDC input. The enclosure is made of die-cast aluminium which provides a rugged, durable protection and improves that heat dissipation.

Control Logic 07 3623 1212 www.control-logic.com.au

Motion Technologies 02 9524 4782 www.motiontech.com.au

Safety hinge switches

Rugged CompactDAQ Controller NI recently released the CompactDAQ 4-slot controller. By integrating the processor, signal conditioning and I/O into a single CompactDAQ system, engineers can reduce overall system cost and complexity while increasing measurement accuracy. Integrated measurement systems reduce the number of components, connections and wiring needed, where noise and additional costs are often introduced, to ensure high-accuracy measurements. The CompactDAQ controller features an Intel Atom dual-core processor that can run either industry-standard Windows Embedded 7 or NI Linux Real-Time for ultimate system reliability. By pairing industry-standard OS options with LabVIEW system design software, customers can port LabVIEW code from existing measurement systems to these CompactDAQ controllers.

Engineers can combine LabVIEW and over 60 sensor-specific I/O modules for CompactDAQ to customise data acquisition systems to meet their application needs.

NI 1800 300 800 info.australia@ni.com 24 www.pacetoday.com.au OCTOBER 2014

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

Compact actuator

Linear position transducer The UniMeasure ZX series is a compact wire drawn linear position transducer (string pot) with a 38mm measurement range and is available in two versions.

The ZX-PA-1.5 is the world’s smallest string pot and it utilises a long life co-moulded potentiometer with essentially infinite resolution. The ZX-HM-1.5 has a slightly thicker body and incorporates a non-contacting internal hall effect sensing device, which gives a ratiometric voltage output with a resolution of approximately 0.04mm. Both models have wide operating temperature ranges (-40°C~+125°C for the ZX-HM version), delivering a long service life without output signal degradation. The tiny footprint, makes the ZX series suitable for applications where space is at a premium and performance is required such as in robotic, biomedical, aerospace testing and automotive applications.

ADM 03 9551 6922 www.admtech.com.au

D1 repeater In partnership with PROCENTEC, I S Systems has released the D1 Repeater.

The PROFIBUS D1 repeater is suitable for creating reliable PROFIBUS DP networks in IP 66 environments where persistent dust and water are constantly present. By means of male-female M12 connectors, technicians can shape a PROFIBUS DP network. An additional M12 connector makes it possible to connect ProfiTrace to a running system by means of an adapter.

This results in increased uptime and optimization of the entire production process.

The advanced 12 Mbps core of the B1 is identical to the one in ProfiHubs; it can be cascaded without limitations and has increased RS 485 strength. It is immune against the short-circuit bug and the data is constantly monitored for glitches which are digitally filtered out. Every channel has on-board switchable termination and is able to drive 31 devices.

I S Systems 02 4964 8548 sales@issystems.com.au

The compact actuator LA25 from the LINAK TECHLINE division offers reliable performance under extreme conditions. Applications in different industries are required to deliver reliable performance relentlessly, even under extreme conditions. Failure is not an option in applications within, for example, mining, agriculture, construction, industrial automation, pergola solar shading or marine where failure means downtime and downtime means loss of money. In many of these applications the space can sometimes be limited even though the requirements for power, IP protection and integrated intelligent features are still high. The new actuator LA25 from LINAK provides an optimum combination of power, compact design, robust aluminium housing, high IP66 and IP69K protection and iFLEX - integrated intelligent control.

This leads to reliable performance regardless of weather conditions and an actuator that is easy to build into your application even when the space is limited. The actuator LA25 is available with iFLEX options. LINAK actuators with iFLEX all feature an integrated H-bridge which is why iFLEX solutions require less space and fewer cables than traditional actuator solutions. The control box is built into the actuator making installation convenient.

LINAK 03 8796 9777 www.linak.com.au

Coriolis flowmeter Emerson Process Management has introduced the Micro Motion ELITE CMF350 Coriolis flowmeter for line sizes from 3.5 to 4.5 inches (DN sizes of 90-125).

The CMF350 features an optimum level of scalability and standardization for the best fit in applications where flow rate accuracy with low pressure drop and high turndown is critical. Specifically, this meter delivers 0.05% optional liquid mass flow accuracy and volume accuracy, ±0.35% gas accuracy and ±0.0002 g/cc liquid density accuracy. Maximum flow rates for this sensor reach 409,000 kg/h. This meter is applicable in the oil and gas, refining, chemical and power industries. It is suitable for applications such as cementing, custody transfer of liquid and gas, production separation, basic and specialty chemicals, ethylene and crude production and manufacturing processes. CMF350 meters are available with Smart Meter Verification (SMV) which provides advanced diagnostics of meter health and performance without removing the sensor from the line or interrupting the manufacturing or measurement processes.

Emerson Process Management 03 9721 0200 www.micromotion.com OCTOBER 2014 www.pacetoday.com.au 25

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THE LAST WORD

ENTERPRISE RESOURCE PLANNING

Streamline with ERP ERP can help process manufacturers stay ahead of the competition, writes Mike Lorge.

P

ROCESS manufacturing industries are among some of the most heavily regulated, so it’s hardly surprising they’ll use whatever means necessary to make operations easier.

There are few industries that were immune to the effects of the global financial crisis and in many respects, process manufacturers are just starting to get back on their feet again.

This doesn’t mean, however, that there aren’t still challenges to be faced.

Ageing infrastructure and high costs are just two of the issues that need to be overcome on a daily basis.

Process manufacturers are also facing difficulties when it comes to complying with new environmental and safety regulations. Companies are expected to be proactive in their approach to these issues, which isn’t always easy.

With inaction no longer an option, the process manufacturing industry will need to evolve to cope with these issues – and ERP solutions could be just what’s required to make this happen.

What is process manufacturing?

Perhaps the best way to understand the issues facing process manufacturers is to understand exactly what their operations entail.

Simply put, they create products that following the manufacturing process, are unable to be returned to their original form. This includes everything from wine and soft drink production through to the creation of plastic products.

While each company will come up against its own specific challenges, there are some common problems that affect the industry as a whole.

What challenges are process manufacturers up against?

One of the greatest difficulties faced by process manufacturing companies is the need to stay ahead of the competition.

As with many other industries, the market is highly competitive, leaving 26 www.pacetoday.com.au OCTOBER 2014

ERP software gives ultimate visibility into projects enabling process manufacturers to enhance the efficiency of their operations while reducing the risk of failure businesses desperately looking for a point of difference.

This comes at a time when customer demands are growing – people are expecting more for their money, as well as top quality customer service to match.

Process manufacturers need to delicately balance the need to provide a great service with cost controls. Spend too much and the bottom line will be affected, invest too little and quality could be jeopardised.

Quality control must be at the centre of everything a process manufacturer does, but strict environmental and safety standards may mean this isn’t easy.

Every stage of the process is subject to heavy scrutiny, so companies need a means of gaining a complete overview of their operations that enables them to meet all the necessary regulations.

Why are ERP solutions so popular?

With inefficient infrastructure to compete with and the need to constantly stay ahead of the game, it’s hardly

surprising companies are looking for ways to enhance their industry specific business processes.

ERP software gives ultimate visibility into projects, enabling process manufacturers to enhance the efficiency of their operations while reducing the risk of failure.

In turn, customers can be more satisfied with the products and services they receive, giving manufacturers that head start they so desperately need.

There are many challenges faced by the sector, so a good ERP solution should address all of them and generally make the company more streamlined and efficient.

[Mike Lorge is Managing Director of Sage Business Solutions.]

13 72 43 www.sagebusiness.com.au

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Are you in Contact with your Future?

New generation of energy efficient contactors for the new generation of factory … just the start of your journey to Industry 4.0 … all produced from Siemens Amberg, one of the most advanced factories in the world. www.siemens.com.au/futureofmanufacturing

It takes a world-class factory to produce world-class industrial controls. Siemens is in a unique situation in that we are one of Germany’s largest manufacturers and we are also manufacturing things designed to improve the efficiencies of others.

Siemens is redefining manufacturing with advanced automation technologies such as SIMOCODE pro V, the smart, compact and Internet-connected motor management system. This is just one of the offerings designed to get you on the journey to Industry 4.0.

At our award-winning factory in Amberg, not only do we produce the new generation of energy efficient contactors, but also advanced automation and control products including SIMOCODE pro, our intelligent motor management system.

Industry 4.0

Siemens Amberg provides a window into the future of Industry 4.0 where we can demonstrate the integration between the virtual product generation and its actual production. Products already communicate with production machines and IT systems control and optimise all processes.

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

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

Scan QR Code to download a case study of the Siemens Amberg Factory.

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

SIMOCODE pro V You ask: How can faults in automated processes and costly plant downtimes be prevented? What is the best way to avoid faults in your system or detect pending errors at an early stage?

We answer: Smart motor management with SIMOCODE pro – a reliable partner since 1986 and now with the aid of an Internet browser you can access all diagnostic and service data relating to your motor feeders from anywhere via network connection and the web server. What’s more, it’s easily integrated into your automation solution using TIA Portal, an extremely user-friendly software providing one integrated engineering framework.

To find out how SIMOCODE pro can help your business switch on to the future, call 137 222 or email manufacturing.au@siemens.com

Answers for industry.

PA0514_000_KEL

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2014-02-12T11:03:55+11:00

Probably the World’s smallest Pressure Transmitter

Compensated pressure transmitters (≥ Ø 11 mm) with hermetically protected sensor electronics.

The unique combination of smallest size, outstanding performance and media compatibility.

Pressure Ranges: 0,3…1000 bar / Accuracy: 0,15 %FS

/ Stainless Steel Housing

Analog C-Line (Series 4 LC…9 LC)

Digital D-Line (Series 4 LD…9 LD)

- Output 0,5...4,5 V @ 5 V supply (ratiom.)

- Digital interface: I2C

- Sampling rate: 2 kHz

- Ultra low power: 11 µW @ 1 SPS and 1,8 V

- Operating temp. range up to 150 °C

- Up to 250 samples/sec

- Protected up to ±33 V

- Pressure- and temperature Information

www.keller-druck.com