PACE - Process & Control Engineering - September 2012

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Mine of the Future Rio Tinto’s Remote Operations Center in Perth manages 14 mines in the Pilbara 1,400 km away.

Feature 17

Little on size, Large on performance Little onthe size, Large on performance performance Little on size, on Introducing new Large L Series programmable controller

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Introducing the the new new L L Series Series programmable programmable controller controller Introducing

Little on size, Large on performance

Post Print Approved PP255003/00539

Introducing the new L Series programmable controller

www.mitsubishielectric.com.au proven performance / global strength / cost effective solutions www.mitsubishielectric.com.au www.mitsubishielectric.com.au or call us on 02 9684 7777

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The simplest way to integrate safety technology: TwinSAFE.

www.beckhoff.com.au/TwinSAFE TwinSAFE from Beckhoff: the universal safety system from I/Os to drives.

The TwinSAFE I/Os for the EtherCAT Terminal system make optimum use of the high performance offered by EtherCAT: Compact: Safety PLC in a 12 mm terminal block Powerful: up to 128 safety devices per Safety PLC Versatile: integrated function blocks for emergency stop, protective door, two-hand control Modular: standard and safety I/Os integrated in a single system Flexible: “fieldbus-neutral” communication, eliminates dedicated safety networks Certified: solution up to SIL 3 according to IEC 61508, EN 954 Cat. 4 and DIN EN ISO 13849 PLe

Safety inputs

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CONTENTS

Published monthly by Reed Business Information Pty Ltd

Tower 2, 475 Victoria Avenue Chatswood NSW 2067 Locked Bag 2999 Chatswood DC NSW 2067 Tel: (02) 9422 2999 Fax: (02) 9422 2977 ABN 80 132 719 861 Associate Publisher: Martin Sinclair Email: martin.sinclair@reedbusiness.com.au Editor: Kevin Gomez Tel: (02) 9422 2976 Fax: (02) 9422 2722 Email: kevin.gomez@reedbusiness.com.au

IN THIS ISSUE

Deputy Editor: Isaac Leung Tel: (02) 9422 2956 Email: isaac.leung@reedbusiness.com.au Group Sales Manager: Tim Richards Tel: (02) 9422 2818 Mobile: 0420 550 799 Email: tim.richards@reedbusiness.com.au

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Copyright © Reed Business Information 2012 All rights reserved. No part of this publication may be reproduced or copied in any form or by any means without the written permission of the publisher.

31 Industry Watch 7

Industry Application 21

Viewpoint 16

Engineering Update 29

HUG 2012 Reports and interviews from the recent Honeywell Users Group Asia Pacific Symposium held on the Gold Coast.

Extend your control Companies that take up the industrial digitisation challenge drive more effective and ultimately profitable businesses.

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07

Dust control made simple Process dust is a huge problem in many industries but taking control can be simple as a fertiliser plant discovered.

Technology Report 31

Torque monitoring Measurements from a torque monitoring system at Qenos showed power losses occurring in the compressor rather than in the turbine.

IICA Corner 38

Drive down energy costs Escalating demands to save energy have lead suppliers to develop new, more efficient motor and drive systems.

IC&A careers Instrumentation and automation courses feature low down the priority list for students.

ON THE COVER

OFFICIAL MAGAZINE OF:

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Mine of the Future Rio Tinto’s Remote Operations Center in Perth manages 14 mines in the Pilbara 1,400 km away.

Feature 17

Little on size, Large on performance Little size, Large on Little on onthe size, on performance performance Introducing new Large L Series programmable controller

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Introducing Introducing the the new new L L Series Series programmable programmable controller controller

Little on size, Large on performance

Introducing the new L Series programmable controller

Average Net Distribution 6,849

Post Print Approved PP255003/00539

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www.mitsubishielectric.com.au proven performance / global strength / cost effective solutions www.mitsubishielectric.com.au www.mitsubishielectric.com.au or call us on 02 9684 7777

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THE L series is a powerful but compact modular controller with many features built-in to the CPU itself. With its excellent cost performance and usability it is ideal for use in mid-size control applications.

The rack-free design promotes high system flexibility with minimum form factor. The singleEthernet and 1 3 CPU / 0 8architecture / 1 2 , includes 5 : 5 2built-in PM Mini-USB interfaces, a SD/SDHC memory card

slot for program storage and data logging, and 24 digital I/O for simple high-speed counting and positioning functions.

The high-performance CPU also includes a CC-Link V2 Master/Local station for connection to the powerful open field network CC-Link.

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COMMENT

EDITOR’s MEssAGE

Olympics boosts engineering Kevin Gomez Editor

Next Issue • Instrumentation • Discrete Control • Process Control in Mining • Process Control in Building Automation

SADLY, Sydney has lost its crown. While Britain basks in the afterglow of what many say is the ‘best Olympics ever’ a lot of the attention is now turning to the people behind the achievement.

No doubt the architects and builders will get credit for the amazing structures but emerging from the shadows are the engineers who designed and automated the grand show.

Invisible to the spectators were cables, communications systems, wireless devices and control systems that worked together to create a marvel-

lous spectacle. As they say, the attention turns to engineers and designers only when things go wrong.

Except for the fiasco with a flag, the spotlight shone firmly on the athletes. And the flag mix-up, they say, was human error, not engineering’s fault.

There’s even hope that the winner of the inaugural Queen Elizabeth Prize for Engineering will come from the Olympics talent pool and there must be several strong contenders in the ranks. The winner will get a prize of one million pounds (A$1.5 million). Check out

http://qeprize.org – the competition isn’t confined to the UK but open to international entrants.

Talk of the skills shortage in Australia inevitably leads to discussions about the PlayStation generation and the lack of interest among the younger generation who are unwilling to ‘soil’ their hands with an engineering job. Well, things are changing – and for the better.

At the Honeywell Users Group Symposium, the company demonstrated its Collaboration Environment – a remarkable audio visual

representation of a plant’s integrated operations, applications and tools to support decision-making in real-time.

The large-screen set-up that was demonstrated, is capable of live interaction with remote colleagues and separates the control function from the support function.

This is an innovative way to operate control rooms or collaboration environments where multiple systems and personnel are involved. And certainly more familiar and appealing to the next generation of automation engineers. kevin.gomez@reedbusiness.com.au

COMMuNITIEs

element14 unveils microsites for key technology segments ELEMENT14 has introduced new Design tools and resources, featured element14’s Medical microsite covers Robotics, Medical and Industrial products, white papers, training videos the innovative use of analogue signal Automation microsites for the Asia and articles can be accessed online to chain, embedded processing and Pacific region. The three new microhelp design engineers accelerate their sensing technologies and products sites will cater to the latest emerging design cycles and reduce time-to-market. from suppliers such as Altera, Fischer, technologies in the region and add to element14’s Robotics microsite Panasonic, Texas Instruments and XP the company’s established microsites features products and training videos Power. Medical imaging has a strong covering Wireless, Sensing, Lighting, from manufacturers like Freescale, presence in Asia Pacific with displays Alternative Energy, Transportation and Microchip, Omron Industrial and multimedia embedded products Instrumentation & Measurement.

Automation, STMicroelectronics and such as DSP and FPGA. Also growing element14’s team of technology Vishay to accelerate the adoption of in popularity are low-power devices and experts have combined proprietary robotics solutions. wireless communications for mobile intelligence with information from the High performance, highly accurate medical devices.

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Schneider and TE Connectivity are covered on element14’s microsite, including PLC, temperature and process PID control, variable speed drive control, and even electromechanical relay, timer, and counter control.

Engineers can link from the sites to the appropriate group in element14’s engineering Community to collaborate with industry peers and experts. element14’s online Community offers engineers the opportunity to find impartial, independent knowledge on technical issues. au.element14.com

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nEWs

industry

Beckhoff sets up in New Zealand Beckhoff Automation has established a new subsidiary in New Zealand.

The new Beckhoff office is located in Albany, considered the new technology center of Auckland.

Fifty-six percent of the total turnover from the Germany-based Beckhoff Automation was accounted for by exports in 2011. “This positive result bears out our strategy of continually expanding our international presence through the establishment of strong subsidiary companies,” says Kai Ristau, Head of International Sales and Business Development at Beckhoff.

“Although New Zealand is primarily

known for tourism and agriculture, there is an interesting industrial structure that is ideal for our products, such as food processing, the timber and paper industry, the textile industry, machine building as well as means of transport, logistics, mining,” adds Ristau.

“New Zealand’s dynamic economic growth, particularly in the automation market, has prompted Beckhoff to increase its local commitment in order to gain new customers and tap into new fields of business.”

Beckhoff automation technology has been represented in New Zealand since 2000 by the distributor CSE W.

Arthur Fisher.

The Economist recently profiled Germany’s economic prowess and singled out Beckhoff as a case in point. This is what the report had to say: “Omnipresent but obscure, family owned but by no means puny, Beckhoff is among thousands of ‘hidden champions’ that account for much of Germany’s prowess as a manufacturer and exporter. Its sales leapt 34% to €465 million (A$560million) last year. It is aiming for €2 billion (A$2.4 billion) by 2020. Beckhoff exports more than half its output. But its manufacturing is mainly in high-wage, rule-

bound Germany. Largely thanks to its Beckhoffs, Germany looks like a bright exception to the dispiriting rule among developed economies.”

Neil Pearce, Country Manager of Beckhoff New Zealand explains: “With the opening of our own Beckhoff New Zealand branch office, we aim to intensify our business activities and improve sales support to our customers as well as technical support and service.”

Auckland is home to mechanical engineering companies from diverse branches of industry as well as to system integrators and OEM customers. www.beckhoff.com.au

distribution

SMC and RS Components extend global partnership RS Components has extended its tion of pneumatic equipment including global partnership with the SMC actuators, fittings, filters, regulators, Corporation into Australia and New lubricators, tubing, control valves, blow Zealand. RS Components will offer guns, silencers, pressure gauges and flow 4,600 SMC products across the region control equipment. and more than 2,200 of these are RS Components is the trading brand stocked locally in Australia for nextof Electrocomponents and SMC is a day delivery. high service distributor of electronics AD_ PACET URSEP_ 1 2 . p d f Pa ge 1 8 / 0 8 / 1 2 , The range comprises a broad selecand maintenance products and a

specialist in pneumatics and automation.

Through the RS Components eCommerce platform, customers have instant access to SMC products with the ability to view product models in 3D, and to place orders 24 hours-a-day. RS Components also offers fax and phone ordering services.

3 : 5 3 PM RS Components and SMC will

continue to extend their trading partnership over the next few years, incrementally adding SMC pneumatics products to the ANZ range.

The RS Components and SMC Corporation partnership now extends globally throughout the UK, Europe, the USA, Asia and Oceania. www.smcaus.com.au

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CONVERSATION

HUG 2012

Focus on Sustain.Ability Garry Mahoney, Pacific Director, Honeywell Process Solutions took time out at the Symposium to speak with PACE about key aspects of the company’s technology solutions. By Kevin Gomez.

The Honeywell Users Group Asia Pacific Group Symposium 2012 was held on the Gold Coast in August.

The focus was on helping users achieve optimal sustainable processes and business performance with a holistic approach for the entire lifecycle of an industrial plant.

process – there’s design, construction, helping cash flow. The bigger saving long lead time, a lot of effort and investis delaying the design team’s final ment in the early period. The design of decision of allocation of I/O and the control system is usually one of the addressing information. last things finalised.

Part of that same solution suite is Universal I/O allows projects to make Virtualisation. The Virtualisation of all those decisions much later in the piece. our software applications now lowers the With the combination of Universal I/O cost of ownership for customers. and Virtualisation, we’re able to test, Instead of having a large system validate and acceptance test those tasks with 30 or 40 PCs you’re now down to What are the key solutions Honeywell much later in the project cycle. Because one or two. is displaying at HUG 2012? it’s virtualised, you can load the software Another area is the production, Looking at it from a client point of at the back end of the project. planning, scheduling, management view, the key elements are: how do you The first thing you do on a normal and manufacturing and execution layer execute projects, speed up schedules, project is order your PCs and start to (MES). This is really a step change reduce cost and ensure that you still get load your software. as many sites have many islands of a quality thea lead A D _ result.

P A C E P H O S E P _ 1 2 . p d fBut P g e time 1 could 1 3be/ 12 0 8or/181 2 , information.

9 : 2 2 Now A MIntuition allows In a greenfields project it’s a serial months – we can delay that investment, you to visualise, or provide a common

Easy to clean

environment to the user.

Then there are solutions in the area of operator effectiveness which allow customers to build their collaboration centres and some of the tools around that.

There’s wireless infrastructure as well. As part of collaboration you need information. You can get that by running cables and wires.

But the cable is the expense, not the transmitter or the information.

So a wireless infrastructure allows you to bring back a lot more data and reporting, often at a much lower cost.

All this helps you maintain a safe, optimised environment efficient.

In summary, I’d say the key focus > is on the MES layer or Intuition,

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CONVERSATION

Visualisation and then a suite of solutions of varying levels around operator effectiveness.

Technology is the enabler and we need to be solving those business issues for our customers as opposed to just delivering products.

How do you see these technologies evolving in the future?

The technologies are really there to support a business requirement. We will see collaboration centres evolve in whatever form, whether it’s remote operations, remote support, remote decision support, remote planning, an so on. different information depending on the In collaboration centres, multiple situation they’re managing. people from different disciplines need to A lot of our development and interact on business decisions.

R&D is built around VOC – voice of It is important how you present the customer. information and data to them so that Through the UIS, (User Input they’re efficient in data analysis.

Subcommittee), we understanding the It is recognising a business need and business pains and drivers of our users. developing technology to solve that We try and solve those needs problem. We see a collaboration centre – some with new technology, others as more than pulling people together with existing solutions we have in with a bunch of PCs. different industries.

It’s more than a data projected on a Different industries have varying wall. It is a screen where multiple people levels of automation development and canAbeDtogether _ P A CtoElook A E at C the S Esame P _ 1 2 . p sometimes df P awe g adapt e 1the 8base / 0technology 8 / 1 2 , thing in real time and be able to pull solution from another industry.

tss12_Pace_OL.indd 1 8 www.pacetoday.com.au September 2012

Will the slowdown in Australian mining impact your business?

I don’t think it’ll change our business.

We will definitely see a slow-down but no change of direction. This slow-down is being driven by economic conditions in Europe and US, as opposed to any fundamental flaw in our strategy. We still see a strong future in core business as it is today, but do expect a slow-down over the next 12 months.

What is Honeywell’s key strategy in the area of instrumentation?

On the instrumentation side, the area where we can differentiate is wireless.

We have a strong wireless portfolio in terms of understanding the ISA100 standard. It’s about moving information around and our field instruments portfolio is quite mature and robust.

In fuel, oil and gas markets, we have quite an extensive portfolio.

Custody transfer and temperature gauging, are specialised areas, whether it’s 3 : land 4 9 or marine.

PM So we have a strong presence in those

markets where we don’t necessarily focus that much on say food and beverage, where it’s very much discreet control, batch control and low cost instruments in place. That’s another market and it’s a bit smaller, that’s all there is to it.

How does HUG 2012’s Sustain.

Ability theme tie in with Honeywell’s road map?

Going forward, the future is about understanding and solving the business issues that clients have around the automation space. Automation is the information from sensor to boardroom.

That’s the value Honeywell brings to the table. We have solutions from the sensor to the operator; from the control room to the MES layer and production reporting.

If you look at that space – production planning, reporting, scheduling – we are the only integrated solutions provider across the whole portfolio.

The majority of our competitors play in one of those spaces. I guess that’s our legacy from being strong in

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INTERACTION: The Demo Room allowed users to get up close and personal with A MHoneywell’s solutions.

Oxygen Analysers, Thermal Conductivity Analysers, NDIR Analysers, Multigas Analysers, OEM Analysers

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the refining oil & gas sector and bringing that automation knowledge, production, planning and scheduling knowledge into other industries.

Overall, sustainability is key. How do we sustain site operations, keep the plant running, maintain knowledge while being buffered by the churn of people, whether retiring or leaving. Sustainability is about having the right cost structure to operate, so Virtualisation is about lower cost.

Universal I/O is about lowering cost of a facility to operate. Abnormal situation management is about ensuring operators are supported so they are able to operate and maintain the plant and assets without downtime periods. That about sustainability as well.

These are the solutions, the business solutions, we’re trying to address, as opposed to technology.

Technology is the enabler. We need to be solving those business issues for our customers as opposed to just delivering products. www.honeywellprocess.com

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convERSAtIon

IntuItIon ExEcutIvE

Tool for intelligent operations Analysing data in motion leads to faster decision making says David Dickson. By Kevin Gomez.

Intuition Executive is considered the flagship product of Honeywell’s new Intuition software portfolio.

David Dickson spoke with PACE about the key elements of this new software product and its applications in industry.

What are the key elements of Intuition Executive?

Intuition Executive is a deployable software product that we have built using our Intuition family of technology. It’s a set of software services that are specifically designed to best support operations in the resource industry and process industry.

In Australia, it extends to conventional and unconventional gas and oil, both very focused operations that are asset intensive in business. The objective is to deliver enterprise wide information management, decision support services and to be an enabler in supporting improved collaboration and business functions within an organisation.

It’s really a set of software services that we stitch together – blend information from the plant or from the field and support the delivery of composite applications.

We’ve adopted a forward-facing position on technology, using semantic modelling. This ensures people get the information they want in a format that’s meaningful to them and in a very scalable and flexible manner.

Once we’ve measured it and put it into a format that’s readily recognisable for the people, we then support it with another layer of analysis and reporting services for engineering and some business intelligence type analytics and reporting.

Then we present and visualise that information, and this is where we adopt Microsoft SharePoint as our both content management and visualisation portal. But we take it beyond the use of SharePoint in enterprises and integrate that with real time industry visualisation information and really extend the concept of collaboration.

So, we’re measuring the current 10 www.pacetoday.com.au September 2012

state. We’re putting it into a usable format; providing tools to drive analysis, anticipate problems; then presenting and visualising it.

The critical point is we’ve taken it further to provide orchestration services.

Once they have all that information, traditionally, organisations really haven’t done much with it. They’ve invested an awful lot of money in creating some great analytics but not actually doing anything with it. So it’s basically shelf-ware.

So we want to extend that and we’re providing an orchestration layer where we support a work flow environment that can, “orchestrate” - conduct, different processes and functions, work flows that span multiple business functions. So you get end to end visibility and actions and ultimately measurable outcomes. So this is an operational excellence feedback loop, this is Intuition Executive support.

Organisations need reliable and real time access to operational data in a flexible and scalable environment with actionable and auditable outcomes.

What is the principles behind Intuition Executive?

We’re going through something of an information revolution. Information was doubling every 20 to 40 years a hundred years ago, but now it’s doubling every six months.

We’re living in an age where we’re drowning in a deluge of data and the process industry is no exception. Operators need to drive the practices, processes and examine key business-determining information. And currently, it’s case of trying to find a

needle in a haystack.

Take the coal seam gas industry as an example. Typically in conventional oil and gas extraction, you’re talking about 20 to 100 wells. With coal seam gas, you’re talking somewhere between 3,000 to 10,000 wells per field making them incredibly asset intensive enterprises. To determine key information out of the volumes of data is a real challenge. It’s an ecosystem of data out there.

So we went to Gartner about four or five years ago and asked them what’s important to businesses and they came back with all the typical principles.

A lot of it comes down to anticipation – businesses need to be able to understand what the problems are before they arise. Resource retention, workforce expertise retention and gleaning knowledge from subject matter experts is a real challenge. You’re coming back to enabling open standards and interoperability, being able to capture that information.

We want to improve workforce effectiveness too by providing tools, an environment and enabling technologies to support collaboration. It’s based on this concept of the Single Source of the Truth. Organisations need reliable, real time access to operational data in a flexible, scalable environment with actionable, auditable outcomes.

This is a very important consideration with so many assets in, say, coal seam gas, especially considering the increasing environmental and security related concerns. It is all about taking the right decision and then executing it.

If you imagine a scenario where some of coal seam gas operators have 30,000 assets. This is going to scale over the next three to four years to 300,000 to 400,000 assets. That’s an enormous quantity of data that needs to be proliferated through the organisation in various ways. It’s got to go to financial asset registers. It has to go to an engineering master data management record.

It has to go a asset management system, a condition based management system and so forth.

You can imagine as this change is going on, in order to be able to manage the transfer of that information throughout the organisation in a timely manner and know where those assets are in their life cycle, who owns the assets, what land they’re on, if there are any disturbances on that land or other issues, the operators need to have a good handle on that information. This is that interoperability piece. This is open standard, so that my engineering data management system talks to my Intuition Executive system talks in the same data format to my asset management system.

Are you able to quantify the benefits?

We’ve done quite a few studies for the tier one super majors in the oil and gas industry, local gas companies, as well as mining companies. A lot of the challenges are around retention of intellectual property. Over the next decade western oil and gas companies are predicting to lose about 75 per cent of their intellectual capital. Typically these people have worked in functional silos. If you take an upstream oil and gas environment you might have geophysics, drilling, reservoir, production, engineering, planning, finance and so on, all working within different pressure constraints and timelines.

We’ve got reports based on work we’ve done that shows a reduction of 66 per cent in terms of freeing up workforce by automating procedures.

A reduction from about 36 core functions to about five repeatable functions through the adoption of improved work flow, through the adoption of collaboration technologies, examination of business processes, improved data connectivity and access to that data.

So there is a quite a lot of recognised value. Another super major has recognised that just in one function on one of their assets, they’re looking to save $5 million per annum. And that’s just on one function within one asset. They’re a super major, so extend that globally and you’re talking significant savings.

www.honeywellprocess.com/digitalplant

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COnVERSATiOn

Mining

Remote operation centres The term remote collaboration centres in mining means different things to different people.

Andy Sherring weeds out the misunderstanding and presents the hard facts. By Kevin Gomez.

Andy Sherring is Independent Consultant at Sherring Consulting and specialises in the design and implementation of Integrated Operations Centres. He played a key role in setting up Rio Tinto’s Iron Ore operations centre project in Perth, and now consults to major mining clients to apply these same principles to their respective operations. Following is an extract from his presentation on Global Trends in Remote Operations & Collaboration delivered at the recent Honeywell Users Group Symposium.

Remote operations misunderstood I see a lot of confusion about the subject.

I think people are talking about different things and aren’t necessarily clear on the goal. This isn’t helped by different terminology – so you hear remote operations, remote operation centres, remote collaboration centres, collaborative decision making environments, monitoring centres. All of these have got a place, but it is rather confusing.

I prefer to use the term ‘integrated operations’ and ‘integrated operation centres’. For me that’s a much more positive term for the broader strategy and goal of what we’re trying to achieve here. Remote has got a negative connotation – it’s about distance, out of touch.

Integrated means positive, trying to make it better. So integrated operations and IOC is integrated operation centres.

Although I talk quite a bit about integrated operation centres, the goal is not to have a centre. The goal is to drive improvement through better integration of the operations. It’s not uncommon to have an organisation seeing a centre somewhere and saying ‘I want one of those’ and it’s about a centre. There are examples of beautiful centres that people from all over the world come to see, but these centres actually aren’t adding a lot of value.

That’s a real problem. It’s easy to see what’s wrong out in the mining world, but how do you practically improve it?

14 www.pacetoday.com.au September 2012

The key is to be really clear about what you’re trying to achieve and make sure it’s about improving. Most importantly, it’s about sustainability of that value.

For me one of the greatest crimes is when a mine reaches the pinnacle of excellence, they cannot sustain it. One particular mine I’ve been involved with in the past was at that level, at the very cutting edge, but became an absolute basket case. Technically, they just lost all their skills and knowledge. The key is the sustainability of the models we put in place.

Companies in the mining industry are becoming larger, more complex organisations. Mines are getting bigger, deeper, holding lower ore grade, and are more remote. Yet we carry on trying to do things the same way. A business that starts off with one or two mines, grows to 10 or 15 mines within its complex, frantically tries to do things the same way and expecting to live with the same efficiencies. It just doesn’t work.

It is not just moving chairs around but about driving substantial improvement that is sustainable.

We also need to take into account the reducing pool of expertise.

Knowledge tends to gravitate to the cities. Teams at the front line are trying to reinvent the wheel, and we’re not very good at connecting that knowledge in the cities with the mines. So it is very hard to leverage that experience.

Then there’s the challenge of expectation as people aspire to move to a more technology focussed future. It’s very different operating an automated, high technology mine, to the current set up. If we’re struggling so much with a simple, basic operation, why are we so confident that we are actually going to be able to operate an automated, high

technology mine? The Collaborative Research Centre, Optimising Resource Extraction group looked at productivity.

Australian mining companies have seen a 30 per cent fall in productivity over the last 10 years. About half of that can be put down to declining ore quality.

With regard to the other inefficiencies, I’d say the head is buried in the sand and the issues are not getting addressed.

Need for a comprehensive strategy Because it addresses these major challenges facing the industry. Because it delivers enormous value.

We’ve been in a growth market, we are still hopefully in a growth market, there’s the momentum there. But if the market turns, this is probably more applicable. We’ve got to get to grips with those efficiencies we’re avoiding at the moment and focus on capital.

Importantly, this isn’t rocket science, most of the principles are extremely simple and can be applied in a relatively low cost, low risk way. Really, the question should be why wouldn’t we do this?

First of all, what is meant by integrated operations? If you look at a typical value chain and you can look at this actually within a mining department, you know, drill, blast, load, haul.

You could look at this as multiple businesses within a broader business unit.

Integrated operations is about optimising the individual parts. It is also about optimising the value across the whole value chain. We don’t standardise, we don’t plan particularly well, and when we do plan well, we don’t tie it in from longer through to short term planning. So you get great long term planning but the short term plan is doing something totally different.

Typically there’s no one charged with optimising the whole value chain, except the GM at the top. He’s got a thousand things on his plate, he hasn’t got time really to give it the attention it deserves. So you end up with the mining department focusing on optimising the mine, which is tonnes.

The processing guys try to get them

to provide better material to get more metal or products out the door. But the mining department is not interested in that – their KPIs are in tonnes. Different KPIs. This issue is typically not addressed organisationally in a business.

Actually facilitating the integration between these two objectives is all part of the wholistic approach.

Integrated operations centre defined Most people would straight away say it’s something to do with a control room.

For me ‘it is an enabling environment for driving sustainable improvement’.

It’s an environment, it’s an enabler and it’s for driving, I mean forcefully driving improvement, not just allowing it to happen. There’s also accountability.

It does involve co-location of operations staff, planning team, technical support specialists and improvement experts in a custom-designed collaborative environment with fantastic visibility of the whole system, one truth data, but backed up with really clear accountabilities for driving that improvement.

The support functions driving improvement should have the same accountability as the do operations for meeting the plan. In any mining operation, the operations guys are absolutely nailed to the floor about production versus plan.

The improvement experts have a lot of care but not much responsibility.

There should be much more accountability for driving improvement and sustainable improvement. Some of the key touch points that really worry operations people are that it is going to take away their control. They believe this is centralised planning and “we know that doesn’t work”.

This isn’t a centralised control room, it’s not about sites losing control of their operations. Sites must continue to make and be accountable for those operating decisions. It’s not centralised planning, it’s integrated planning. These are really important distinctions.

[Andy Sherring’s profile on LinkedIn may be found at http://goo.gl/MIQ6G]

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NEWS ANALYSIS

NETWORKS

Security is key

By Cole latimer SeCUrity is more than just a bit of a byword on site. Whether it is securing your actual mine from trespassers, activists or potential illegal miners (in the case of South america and africa), or just trying keep the wrong people out of your computer network, security is key. and with automating processes and getting a single network for all of a business’ operations the goal of many companies right now, ensuring your information is secure is becoming even more important.

But one of the main hurdles in the industry at the moment is the fact that many companies do not recognise or realise the importance of network security and how the wrong people accessing their networks can have long ranging affects, particularly in this age of greater interconnectedness.

Sourcefire’s australian-New Zealand regional director Chris Wood, explains that companies have to pay attention to who has access to their networks, and how. While it may seem a little unrelated to the mining industry, cyber security is starting to become as vital as ensuring your machinery is operating at full capacity, particularly SCaDa networks, which can be more vulnerable. “most of our job now is actually trying to educate the mining companies of this risk,” Wood told PACE. He explained that “there has been an increasing number of mines using SCaDa, and their networks are now more iP-centric than before, so the delineation that existed between the corporate and the work networks has now gone”. as more mining companies utilise remote operation control centres, such as rio tinto’s mine of the Future centre, which is located more than 1,000 kilometres away from the mine itself, total control of your remote and SCaDa networks becomes more critical.

However “a lot of them don’t realise the security risks of their networks, and that their networks need to be able to detect changes and also users.” there is currently an evolving threat from cyber attacks and network disruptions right across the digital landscape. examples such as the affects of the apparently government sponsored

Stuxnet and the havoc it wreaked, particularly as it spies on and subverts industrial systems, and was designed to target SCaDa networks and fake industrial process control sensor signals, cause concern for miners. on top of this is Duqu, related to the Stuxnet worm, which enables attackers to steal data from manufacturers of industrial control systems and then use this data to exploit SCaDa and PlC systems. “you can shut down a mining company’s email with malware and it can keep operating, but you can’t keep operating if your trucks or coal loaders have been shut down.”

What makes the issue even more concerning is that “no one says who the bad guys are, who wants to illegally access these networks, but we know they’re out there,” Wood said, “there are vulnerabilities people are exploiting.” there is also the danger from employees misusing the network. “in a recent investigation we carried out we found that one worker had actually used a wireless USB with open access on his computer so he could work away from his desk, and work while in the cafeteria. “as miners’ process control systems come on to the network you want to know who does what and where they are,” Wood said.

However some have recognised the danger. “there is one company we are working with who are carrying out security scans every few months,” he said.

Wood stated that the company has a few miners as customers as these companies have recognised that they need to know who is doing what, and from where, on their SCaDa and process control networks. “it’s about greater control. “you need software and hardware that continually monitors your networks and traffic, mapping the traffic, destinations, and lets users know what has changed.”

Wood explained that information security “is about having more information about the workings of your network than the bad guys.

“Because if a miner doesn’t have control over their trains, scheduling, trucks, and processing, how are they going to work?”

“ We’ve made radar level measurement even easier for you.”

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www.sourcefire.com September 2012 www.pacetoday.com.au 15

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oPInIon

IndustrIal dIgItIsatIon

Extend your control Companies taking up the digitisation challenge drive more profitable businesses, writes Alison Koh.

T

HE industrial automation space has traditionally been conservative, with a focus on reliability and high availability. Today, many production plants, facilities and industrial businesses expect real-time, connected and mobile digital experience combined with the traditional principles of data resilience and availability in order to meet their production needs.

Consider this industrial scenario: during morning planning, an operations manager is reviewing the plant’s overnight performance on their tablet.

They notice that the site’s weekly Overall Equipment Effectiveness has dropped significantly. One touch data mining enables them to drill into this KPI and identify the origin of this drop in productivity. Additionally, the operations manager can pinpoint the common cause of these failures discovers it is due to breakdown of a critical process pump motor and flags it for action.

Continuing this scenario, the operator at the centralised operations centre is reviewing the control screen and notices the action flag from the operations manager. After confirming the failures on the critical process pump motor, a single click takes the operator to the motor’s temperature and control history.

This information allows the operator to easily identify a consistent problem of fluctuating high temperatures.

To rectify the situation, a maintenance engineer is required on-site to troubleshoot the problem whilst the over-temperature situation is occurring. With a second click, the operator drills down into the associated variable speed drive configuration and sets a high temperature alarm that will trigger before the motor trips. This alarm will alert the maintenance engineer and allow enough time to access the site for troubleshooting. The operator initiates a work order request to advise the maintenance engineer, describe the issue and the actions he has taken in setting the high temperature alarm.

The scenario continues on the actual

16 www.pacetoday.com.au September 2012

Centralised control embeds standardisation in automation across the demand chain emphasising the need for common visualisation and control standards. production site where the maintenance engineer views his tablet to register the work order request that the operator initiated. Without wasting time, the engineer continues with his routine maintenance until he is notified of the high temperature alarm. On arriving at the critical process pump, the engineer accesses the remote control station.

With a touch, the motor control data for the pump is visible. The engineer confirms the fault and the motor controller is quickly replaced, detected automatically on the process control system, and the 100 plus complex parameters are downloaded as the engineer watches. The engineer restarts the plant and confirms the motor performance on the remote control station.

The above scenario encapsulates a complicated yet typical workflow between three roles within an industrial business; a process that is streamlined through the use of technology. Not only are the multiple workflows of the different roles managed in the digital domain but the seamless interoperability across the entire process control system enables the rapid identification of production losses, root cause and immediate rectification of the fault – all minimising process downtime, the key contributor to profitability. These integrated solutions featuring enterprise-wide centralised control, mobile technologies and industrialised PCs at local control stations form the backbone of industrial digitisation. Putting it simply with industrial digitisation, what used to take

hours (if not days), now takes minutes.

The first critical piece of the industrial digitisation architecture is enterprise-wide centralised control. This can be achieved through the consolidation of disparate site-based monitoring, control and operations intelligence solutions into one holistic production management system that operates across all sites in the demand chain. While obviously decreasing the cost of ownership of the automation assets, increased collaboration across the systems, processes and personnel leads to higher operational effectiveness and broader collaboration in maintenance, scheduling and planning.

Centralised control also embeds standardisation in automation across the demand chain – emphasising the need for common visualisation and control standards. For example, when multiple sites have the same pumps performing the same task, each pump requires both identical visualisation in the SCADA and also common control functionality to ensure they are operated correctly, and safely, from the centralised control centre.

The second critical piece of industrial digitisation leverages the strength of mobility solutions, such as tablets and smart phones, which provide the flexibility necessary when consolidating operations for centralised control. In the scenario above, operations managers and maintenance engineers access information remotely, make decisions and act based on real-time information at the right time. Using these wireless devices to provide data in real-time enables higher operational performance. When considering mobility, the security, in addition to the accessibility of information, must be embedded within the system.

Critical to centralised control and the strength of this industrial digitisation model is the localised, industrialised PC (iPC) in local control stations. As the historical, site-based control rooms are replaced by enterprise-wide centralised control, the need for on-site visibility into the process control system remains critical. To fill the local gap, control moves from the site-based control room

into the production process itself. This extends the monitoring and control capability directly into the plant. This delivers visibility of both the SCADA production data and the environmental or physical input required for operations or maintenance teams on-site. This is the third key piece of the industrial digitisation architecture, and is particularly critical for production processes requiring high maintenance activities together with the need for digital visibility (SCADA).

For digitisation to be directly located with the physical process (which is often dusty, wet or subject to high vibration), iPCs have evolved into rugged, strengthened, rust resistant solutions.

In addition, particularly in the mining industry, iPCs are required to have high visibility touchscreens that can be viewed in direct sunlight. These requirements are becoming standard across iPCs, and targeted iPCs are being bundled and pre-built with operating system and SCADA software.

Enterprise-wide centralised control combined with mobility solutions and local control stations (iPCs) architectures are the fundamental building blocks for industrial digitalisation. With these in place, industrial businesses are leveraging the rapid paced digital world - effectively combining the real-time, connected and mobile, digital experience with traditional industrial automation principles of data resilience and high availability.

Industrial companies that take up the industrial digitisation challenge drive more effective, agile and ultimately profitable businesses as their workflows are streamlined across their operations.

These architectural building blocks form the beginning, not the end, of the industrial digitisation story. The next step is to understand the significant importance of interoperability, information transparency and the critical nature of open standards, together with digital security.

[Alison Koh is Solutions Marketing Manager, Schneider Electric.] www.schneider-electric.com.au

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BEHIND THE SCENES

‘Mine of the Future’ is here Rio Tinto’s Yandicoogina mine has been designated as the ‘Mine of the Future’ and ongoing development is delivering significant benefits, writes Hartley Henderson.

C

ONTINUING development by Rio Tinto of remote control of its iron ore mining operations in the Pilbara is delivering significant productivity benefits.

Previously, most of the mining operations were managed on site with logistical processes segmented across key areas such as plant, rail network and ports.

Now, the various mining and logistical operations are increasingly managed from an operations centre located 1,500 km south of the Pilbara next to Perth airport.

The 1,800 sqm operations centre is connected to three different ports in the Pilbara via a series of fibre optic cables.

Extra fibre and satellite connectivity provide further redundancy.

Over 500 personnel, including controllers, schedulers, and technical planning staff are brought together at the centre where there are 325 PC work stations which are divided into pods to monitor and manage a range of operations.

Dual electrical paths are provided to all IT equipment, and all IT loads are backed up by a 300kVA/240kW (per unit) uninterruptible power supply.

Some 4,800 control network points are connected by 79 km of Cat6 and 22 km of fibre optic network cabling.

Five physically diverse fibre optic cable connections have been installed to three separate telecommunications carriers in case one goes down. These provide 224 MB of ATM backhaul communications capacity from Perth to the Pilbara, 10 GB connections in the Perth metropolitan area, and a permanent 6B satellite segment connection.

REMOTE: Rio Tinto’s Operations Centre, near Perth airport, manages 14 mines, 1,500 km of railway, shiploading, stacking, car dumping, infrastructure and utilities, and most other significant functions in the Pilbara from 1,400 km away to the south.

Operators can override automated processes by remotely operating the machinery from their desk.

Video wall

A fully redundant IP radio system with 34 touch panel controls and a supporting Tetra digital trunk radio solution is provided to allow operators to have fully secure radio mobility in and around the operations centre site.

Two 15m x 2m automated video

walls made up of twenty 70-inch large panel rear projection monitors have also been installed to provide personnel with the big picture of operations in real time.

From this huge display, and from smaller duplicated monitors around the

operations centre, operators can instantly see stockpile levels at port or mine plants through live closed circuit TV feeds, as well as ore quality, the progress of loading trains or ships, and the time the next ship or train arrives.

This high tech operations centre also boasts fully automated electric lighting and day-lighting control that combines the benefits of daylight with the stringent glare requirements of the control centre environment. In addition, an underfloor displacement air conditioning system provides low energy cooling and massive outside air supply.

Key functions of the operations

centre include pit control and mine care, crushers and plant control, train control and scheduling, port operations and scheduling, and control of power stations and network.

If power goes down due to adverse weather, power network controllers communicate with the scheduling team to establish what the most critical operations are with a view to restoring them in order of priority.

Standardisation

There is a strong focus on standardisation and integration. Due to the > similarities of sites controllers are September 2012 www.pacetoday.com.au 17

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BEHIND THE SCENES

typically able to control two different sites, and potentially more as skill sets further develop.

If necessary, operators can override automated processes by remotely operating the machinery from their desk, such as via control sticks for train loading or via their screens for plants.

A remote online monitoring system has been introduced to determine asset health and send data, such as oil pressure levels, from the mining equipment to prevent potential maintenance failures.

A new GPS system has also been developed which enables the operating centre to track the movement of workers onsite, thereby providing a safer working environment.

Fully autonomous mine

Rio Tinto recently launched its first fully autonomous mine in the Pilbara. According to the company’s spokesman, the Yandicoogina mine has been designated as the ‘Mine of the Future’, A D _toPbe A eventually C E E L Efully S E autonoP _ 1 2 . p VISION: df P aRio g eTinto’s 1 operations 8 / 0 8 / centre 1 2 , also 3 features : 4 4 fully P M automated electric lighting and day-lighting control that combines the benefits of daylight with the glare requirements of the control centre environment. mous with trucks, trains and drilling

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All the Tools You Need for Embedded Measurements and Control, in one rugged box.

CONTROL: A driverless 930E Komatsu truck being loaded at Yandicoogina mine in the east Pilbara, one of the 160-odd driverless trucks Rio Tinto will have operating across the Pilbara over the next three years. rigs managed remotely out of the Perth operations centre.

“At the operations centre there is a big emphasis on improving efficiency by closely integrating different parts of the business, eliminating or mitigating bottlenecks that previously restricted production and throughput,” he said.

“In the operations centre we can now better plan and activate tactics to, for example, prioritise certain technical specification grades of ore that are required for blending and shipment, and those trains can be scheduled and brought forward in the schedule.

“Autonomous drilling, which has been successfully trialled at the West Angelas mine in East Pilbara to establish the density of ore, is also being introduced at Yandicoogina. In addition, we can operate remotely controlled crushers for rock breaking from the operations centre, replacing manually operated jack hammers.

“Formerly, only 80-85 tonnes of ore used to be fitted into each rail car, but now each car will generally accept 115 tonnes due to better planning and crushing to maximise loads.”

GPS devices will be utilised extensively at the Yandicoogina mine to control the fleet of driverless trucks equipped with highly accurate sensors that can identify where the edge of a road is, and enable obstacles such as rocks to be avoided. Required clearances can then be programmed in.

Sensors on haul trucks enable the operations centre to tell the condition of

components such as bearings and brake pads, which enables maintenance to be monitored, planned and prioritised.

Rail car dumping is also managed from the operations centre. Using automatic positioning, a huge onsite clamp enables ore to be dumped from rail wagons without human intervention, and ship loading is also being progressively automated.

Significant benefits

The company spokesman says that although some challenges had to be overcome, including old mindsets and traditional resistance to change, the continuing introduction of remotely controlled autonomous systems via the operations centre has resulted in a wide range of benefits.

“Most importantly, we now have whole-of-system visibility. There is improved access to information, production response times are faster, asset health has improved, production systems are more reliable, there is greater consistency across the system, quality variability has improved, and there is greater scheduling reliability,” he explained.

“Pioneering initiatives, involving the introduction of leading edge technology, are transforming the business and providing enormous future potential.”

Rio Tinto Iron Ore 08 9327 2000 www.riotintoironore.com

Q

Graphical Software

Q

Sensor Connectivity

Q

Signal Analysis

Q

Control Algorithms

Q

Custom Timing

Q

Custom Triggering

Q

Actuator Connectivity

Q

Embedded Storage

Q

Industrial Networks

Q

Expansion Systems

The NI CompactRIO hardware platform can handle your embedded measurement and control applications, and do it in a way that outperforms other off-the-shelf systems so you don’t have to spend time developing a custom solution.

The range of high-quality measurements, coupled with an extremely rugged design and the ability to modify the hardware using NI LabVIEW system design software, gives you all the benefits of customization with the convenience of an off-the-shelf platform.

To learn more about CompactRIO, visit ni.com/compactRIO

Australia: 1800 300 800 New Zealand: 0800 552 3 322

©2012 National Instruments. All rights reserved.

CompactRIO, LabVIEW, National Instruments, NI, and ni.com are trademarks of National Instruments.

Other product and company names listed are trademarks or trade names of their respective companies. 05309

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NEW PRODUCTS

Rotronic wireless data logger Redundant I/O platform The 1715 Redundant I/O platform requires no user programming code or add-on instructions, special wiring or additional hardware to operate. It supports multiple configurations and applications, in standard and extreme environments, with a single product. Unlike other I/O platforms, 1715 I/O lets users put redundancy where they need it. It offers the flexibility of simplex (non-redundant) or duplex (redundant) module operations. Modules offer native device intelligence so that they can monitor their own health with internal diagnostics. The modules perform multiple samples of a single signal using different criteria to alert users to issues such as open and short circuits, unexpected rate of change and thresholds.

Rockwell Automation 03 9757 1111 www.rockwellautomation.com.au

Stainless steel valve system Bürkert has released a modular valve and block package designed to make systems quickly and easily. The INOX solution incorporates an all stainless steel pneumatically actuated valve, and standard block modules with eight standard port channels. The ports are drilled open in accordance with block channel design, bolted together, and valves screwed in to complete the block system.

Strainers, check valves, and sensors are easily included in block construction. INOX block systems support media to 180°C, 16 bar and 600 mm2/s viscosity, and has high chemical resistance for process media including water, alcohols, oils, fuels, hydraulic fluids, salt solutions, alkali solutions, organic solvents, steam, air and more.

Bürkert Australia 1300 888 868 sales.au@Bürkert.com

The LOG-HC2-RC and LOG-PT1000RC wireless data loggers can fulfil a wide range of humidity and temperature monitoring tasks. The USB wireless adapter LOG-DS-EXT serves as an interface to a PC. It is possible to program and download information of the wireless data logger via the HW4 software. Using an existing Ethernet infrastructure and the wireless interface, remote data loggers can be accessed from any networked PC. The connection between the PC and the remote wireless logger is done via the LAN interface.

Pryde Measurement 1800 688 211 info@pryde.com.au www.pryde.com.au

Laser distance measurement sensor Schneider Electric has released its range of advanced laser distance measurement sensor, the OsiSense XUE Laser, which is an addition to its Telemecanique Sensors brand. The XUE Laser is designed for applications that require long range detection.

The sensors also offer enhanced accuracy over distance and long distance back ground suppression. This includes measuring the positioning in automation applications such as precise robot control, coil diameter monitoring, error proofing, overhead cranes and anti-collision systems. Key features and benefits of the OsiSense XUE Laser include: Flexible optical systems including diffuse and reflex measurement for enhanced accuracy, repeatability and long detection range; Diffuse measurement of over six metres on white objects with background suppression, and up to 30 metres for use with reflector for reflex model; and Multiple programmable outputs that provide extended flexibility through two configurable discrete NO or NC outputs (PNP), and a 4-20 mA analogue output. OsiSense XUE use visible red Class 2 lasers.

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

AS-i safety monitor with USB interface The AS-i safety monitor enables the transmission of safe and non-safe I/O signals via the same AS-i bus. The safety-related extension is fully downward compatible and can be retrofitted on existing installations. All masters, power supplies and bus components can further be used. The AS-i safety monitor can be integrated into the AS-i system at any position. Several AS-i safety monitors can be operated via one AS-i master. Parameter setting of the functions known from the safety relays such as “E-STOP”, “stop categories 0 or 1”, “two-hand control” or “enable switch” can be done via the software using the USB interface. One AS-i safety monitor replaces many traditional safety relays. When a device is replaced the data can be saved on a chip card. The device has 4 safe inputs or 8 standard inputs/outputs, plus two safe semiconductor outputs and 6 triggerable outputs in the field. It is certified to EN 62061 / SIL3, IEC 61508 / SIL3 and EN ISO 13849-1 / PL e. ifm efector sales.au@ifm.com 1300 365 088 20 www.pacetoday.com.au September 2012

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BEHIND THE SCENES

Dust control made simple Process dust is a huge problem in many industries but, as Tasmania’s Impact Fertilisers plant found, taking control can be simple, writes Sarah Falson.

FILTERED: The dust collector, which receives dirty air (righthand pipe), and emits the clean air through the pipe on the left. The pMCi controller can be seen at the very top of the dust collector.

T

HE dust produced through materials processing can pose serious occupational health and safety (OHS) and environmental hazards, as well as diminishing the quality of the finished product.

As most processes emit dust as a by-product, including mining, metalworking, food and fertiliser, ‘collecting’ the dust to purify the air is a key step in meeting modern quality and safety standards.

One company that recently upgraded its dust collection operation is Tasmania’s Impact Fertilisers, which operates 24 hours a day, seven days a week, to produce Single Superphosphate (SSP) fertiliser products for Australia’s farmers.

The business called on process monitoring and control solutions provider PTronik – which specialises in industrial air filtration and dust collection projects

Dust collectors operate like giant vacuum cleaners with a number of collection bags.

– to update a legacy controller which had fallen below par in monitoring and controlling the plant’s ‘dust collector’ system which was tasked with filtering the dust-laden air produced from the fertiliser component.

Monitor and control

Impact Fertilisers required a control system that could also monitor the dust collector for mishaps, including blockages in the air ducts where the dust entered and the clean air was emitted.

The team at PTronik, including managing director, Robert Bosshard, retrofitted the company’s pMCi controller – a system that provides remote monitoring, sensors to detect air pressure loss, air pulsing operation and the ability to monitor the clean air outlet to make sure that there are no dust leaks.

“Dust is everywhere; we estimate that 20,000 dust collector units are operating in Australia – and this is a very conservative figure,” Bosshard told PACE.

Maintenance challenge

Impact Fertilisers’ dust collector is 10 metres high, and incorporates over 350 filter bags. For such a large system, maintenance had become a challenge.

“Maintenance to change the bags is quite time consuming. Our system can indicate the location of the potentially-damaged bags, as well as the

state of the air pressure valves – whether they are OK, if they use an open circuit or short circuit coil and which one it is,” explained Bosshard.

“When and if the bags have an excess of dust load, the pMCi will detect this state and increase automatically the number of air pulses; then, when the dust is cleaned, it will either slow down or even stop pulsing until there is a need.

“All this is done by constantly monitoring the DP (differential pressure) across the bags; when DP crosses a high level the pulsing starts, and when DP goes below a low level it will stop pulsing. A DP alarm is also available is case there is a blockage.”

Efficiency benefits

Industrial dust collectors work by employing either tubular filter bags or cartridges to retain fine dust particles, > September 2012 www.pacetoday.com.au 21

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BEHIND THE SCENES

We estimate that 20,000 dust collector units are operating in Australia and this is a very conservative figure.

Bosshard explained.

“Dust collectors operate like giant vacuum cleaners with a number of collection bags, called baghouses.

Dust particles are drawn into fabric bag filters and are trapped by the walls of the filter bag. For the bags to filter at an optimal level they must be cleaned regularly.

ONSITE: PTronik engineers installing the pMCi control board to control the dust collector.

Filters blasted

In order to provide continuous filtered compressed air (for example, between air, dust particles trapped by the filters every 10 to 30 seconds depending on need to be removed whilst the plant is the type of dust). operating,” Bosshard said.

A D _ P A C E I N S S E P _ 1 2 . p d “The f Pdust a gparticles e 1 then 1 3fall/ from 0 8 / 1 2 , “The filters are blasted with the filters and are collected below in a

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Training courses from IChemE

The Institution of Chemical Engineers (IChemE) annual training programme features comprehensive, quality-assured courses to support the career-long development of chemical, process and related engineers.

CONNECTED: The pMCi display, complete with programming pushbuttons, driver boards and Ethernet connectivity.

HAZOP study for team leaders and team members 3–5 September, Perth, WA Fundamentals of process safety 22–26 October, Brisbane, QLD Project engineering - fundamentals of a project lifestyle 12–14 November, Melbourne, VIC Introduction to process safety 25–27 November, Melbourne, VIC Particle technology - the science of powder handling and processing 27–29 November, Melbourne, VIC Visit www.icheme.org/courses for full details.

Email austcourses@icheme.org for the 2013 programme.

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22 www.pacetoday.com.au September 2012

ADVANCING CHEMICAL ENGINEERING WORLDWIDE

hopper which is regularly emptied.

“Too much shaking is to be avoided where possible as it can cause unnecessary wear to the filters.

“The rows of filters are pulsed with high pressure air jets (duration 100 ms) sequentially.

“In the case of the fertiliser plant there are 30 rows divided in five chambers (six rows and six valves per chamber).

“The first chamber is isolated (no air blowing through) and the first six valves are pulsed sequentially then the second chamber is isolated (all the others are open to air flow) and the next six valves

are pulsed and so on.”

The solution PTronik installed to the control the dust collector included the pMCi – which acts as the main controller for the system – along with a DS10C Dust Sensor from PCME, and a 8498 Series Pressure Sensor (which operates up to 10 bar) from Trafag.

Constant control

According to Bosshard, as the dust collector’s pulse rate is now controlled constantly, compressed air usage has been lowered by 50 percent.

Also, the total energy consumption has been reduced by 40 to 70 percent,

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and filter bag life by up to 30 percent.

The system also suffers less downtime, and maintenance costs are decreased, he says.

The pMCi system provides: ‘on demand’ cleaning; broken filter row detection; manual single valve pulsing; electronic fault detection on each solenoid; and mechanical fault detection on each valve. Data logging; filter state tracking; remote set-up, monitoring and diagnostic control via Ethernet; and wireless control of up to one km are also made possible.

Bosshard says the controller is easy-to-use and, with operation performed using only three push buttons, little or no operator training is required.

PTronik 02 4578 9611 www.ptronik.com

AD_ PACEUNI SEP_ 1 2 . p d f

Pa ge

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1 6 / 0 8 / 1 2 ,

9A :D 1_ 5P A A CM EABSJ UL _ 1 2 . p d f

OPERATING: The Impact Fertilisers dust collector working to process the super phosphate.

Impact Fertilisers P a g e 1 2 81300 / 0727 6 /815 1 2 , www.impactfert.com.au

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www.absolutefilters.com.au September 2012 www.pacetoday.com.au 23

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IN FOCUS

Improve compressor efficiency Optimising air treatment helps minimise energy consumption of compressors, writes Richart Tuft.

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MAJOR component of many manufacturing and industrial processes is compressed air. To ensure effective and efficient operation of equipment or a process, it is important to know the air quality level required.

A diverse range of air treatments can be utilised within an industrial compressor system. The primary air treatments include air receivers, air dryers and filters. Ancillary treatments include moisture separators, drains and after-coolers. Air treatments can be combined in a variety of ways in order to achieve a regulated supply of compressed air of the required quality and pressure.

Prior to purchasing a new compressed air system, or upgrading an existing system, it is important that all available options are carefully considered. According to William Chan, Gas and Special Projects Manager at Compressed Air and Power Solutions Australia (CAPS), it is important to carefully plan a compressed air installation to create the appropriate quality air in the most cost effective and efficient manner.

“You must think about what you need to do with the compressed air and how you want to achieve the compression and the environment the compressor is to be used,” Chan said.

One of the first decisions to be made is the quality of air that is required for a process—the purity of the air in terms of particulates, moisture and vapours.

After that the volume and flow rate must be determined.

Stabilising usage

Air receivers – pressure vessels that allow compressed air to be stored prior to use – are a key part of any industrial air system. They are useful adjuncts to many applications as they can be added to allow for the output capacity of a compressor to be temporarily exceeded so that short-term spikes in demand can be met.

Installing a larger receiver tank can sometimes allow a smaller capacity and less expensive compressor to be utilised.

24 www.pacetoday.com.au September 2012

CAPTION: The usual sequence of air treatments in a compressed air installation consists of the compressor connected to a storage vessel. After storage, the compressed air is filtered, dried, and then often filtered once more before usage.

Receivers also create more stable pressure conditions, working to dampen compressor pulsation, separate out particles and liquids, and make the compressed air system easier to control.

Air receivers can be supplied in a variety of sizes and strengths to meet specific customer requirements. A number of standards cover the certification of pressure vessels depending on where and how they are used.

Australian standard AS1210 sets out the requirements for the materials, design, manufacture, testing, inspection, certification and despatch of pressure vessels. The standard was developed to ensure safe and proper functioning of pressure vessels in order to minimise potential injuries to people using the equipment. All pressure vessels should comply with AS1210 as a minimum requirement.

In certain environments, a standard pressure vessel is inadequate and, potentially, a safety hazard. For example, if a compressor is required to operate in a cyclone prone area, a special, reinforced design is required. “Australia is a country with geological and climatic extremes,” Chan added. “A compressor could face Antarctic winds, earthquakes, cyclones

and ambient temperatures from -40 to +60 degrees.”

There are several ways to dry compressed air depending on the type of process for which it is used. For example, air guns and blowers used in a car workshop would typically use only a refrigerant dryer. In more critical applications, such as on an oil rig and hightech manufacturing – such as electronic manufacturing, CD/DVD printing or food processing – a desiccant dryer must be used because no moisture can be allowed to touch the product.

Refrigeration dryers employ two heat exchangers, one for air-to-air and one for air-to-refrigerant. The compressors used in this type of dryer are usually of the hermetic type and the most common gas used is R-134a. The goal of having two heat exchangers is that the cold outgoing air cools down the hot incoming air and reduces the size of compressor required. At the same time the increase in the temperature of outgoing air prevents re-condensation.

In a desiccant dryer, compressed air is passed through a pressure vessel filled with an absorbent media such as activated alumina, silica gel, or similar mate-

rial. The desiccant adsorbs vapour moisture in the compressed air. Two vessels with desiccant material are used: while one is drying the air, the other vessel is being regenerated. Automatically operated solenoid valves are the usual way to control the switching of the vessels and the regeneration sequence.

Additionally, an air receiver can also act as a secondary cooling device. By locating the receiver prior to the dryer, the moisture content of the air entering the dryer is reduced, increasing efficiency of the dryer. Multiple air receivers may also be utilised, with one receiver prior to the dryer and others closer to where the air is used. Such an arrangement can further reduce any pressure drop across the system providing smoother overall operation.

Filtration for safety

It is recommended that compressed air be filtered to remove particulates and lubricant droplets in order to prevent damage to downstream equipment.

Filters are available in a variety of grades designed to remove different sizes and types of contaminants.

It is also possible to combine a high flow rate with highly effective particulate and oil removal in the one unit. For example, Ingersoll Rand’s NL Module filter captures particulates down to 0.1 microns and filters oil from 2 ppm to 0.01 ppm, all with minimal loss of pressure.

The usual sequence of air treatments in a compressed air installation consists of the compressor connected to a storage vessel. After storage, the compressed air is filtered, dried, and then often filtered once more before usage.

It is important to have a clear understanding of what filters are needed for a specific application, how dry the air must be and whether demand will be relatively constant, or fluctuate during the course of operation. Once these are known, the sequence of filters, driers and other ancillary equipment can be determined.

CAPS Australia 03 8527 6815 www.capsaust.com.au

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IN FOCUS

Consistent information flow Users should take advantage of communication opportunities provided by HART signals.

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ANUFACTURERS and users in the area of process engineering are familiar with the HART protocol. This technology modulates an analog 4-20mA signal to a digital signal in accordance with the FSK (Frequency Shift Keying) process for the purpose of performing configuration work or collecting diagnostics data.

This is possible not only during commissioning but also within the scope of maintenance and operation. A precondition is that all devices involved are HART capable. Experience has shown that the procedure is commonly known but rarely used.

Statistics from the HART Communication Foundation (HCF) show that around 64.9 million devices were installed throughout the world in 2008. Some 58 percent of these devices are equipped with communication capabilities such as HART or a fieldbus interface. The great majority (some 30 million devices) are HART capable.

Although users want to know more about devices in terms of a secure, efficient and sustainable process, HART capabilities are used for only about 10 percent (approximately 3 million) of the devices. The majority of users thus not only forgo the option of simplifying commissioning and maintenance but also miss out on the ability to gather important diagnostics data.

Networked environments

One reason for this is that many planners were initially only interested in the device’s 4-20 mA signal. Its HART capabilities, while not being considered a bother, were not included in any list of requirements. HART-capable I/O cards were rarely installed.

However, the communication capabilities of devices are playing an ever-greater role.While increasingly networked production environments provide many advantages, they also require a consistent information flow.

In other words, what is the use of a smart device if the relevant data is not available? In this context, HART

A HART multiplexer organises bi-directional data exchange between a maximum of 32 field devices and a separate PC or controller communication represents an interesting option.

When it comes to configuring and maintaining individual devices, users can perform the necessary tasks with a HART modem or a HART handheld.

The disadvantage of this approach is that users are only able to access HARTcapable devices and, when using a handheld, only temporarily.

While these restrictions are tolerable for configuration, the procedure is not viable for the ongoing maintenance and monitoring of multiple important field devices.

If the HART signal is to be put to more comprehensive use at a later time, normal I/O cards need to be replaced with HART-capable cards to enable communication with the higher-level asset management system.

Replacing a number of cards is, however, highly expensive and has repercussions on the existing equipment and its function.

An alternative solution is HART multiplexing. A HART multiplexer organises bi-directional data exchange between a maximum of 32 field devices and a separate PC or controller. Users need to wire the 4-20 mA signal to the controller and also implement a link to a transfer board.

This does not impact the 4-20 mA signal in any way due to capacitative decoupling of the information.

The HART multiplexer takes up the decoupled HART signal and relays it via an RS485 interface. This enables consecutive communication with the devices via the HART multiplexer. If the connection volume is not sufficient,

the transfer board can be extended by a second board.

The available concepts for communication between the multiplexer and PC depend on the application scenario: Implementation using an RS485to-RS232 interface converter and Data exchange with the Comserver via Ethernet TCP/IP. After the HART multiplexer has been connected to the PC via Ethernet by means of the Comserver, the operator can call up the Comserver web interface for system configuration. The Comserver enables communication with multiple multiplexers.

The operator will also require a HART A DOPC _ P Aserver C E which V A L supports S E P _ all 1 2 . basic and general HART commands. In

addition, the manual entry of devicespecific HART instructions for parameterising is also possible if the manufacturer supports this function.

The operator can finally save the HART information using a suitable commercial software.

The HART multiplexer enables improved use of the HART signals for optimising both new and existing systems. By exchanging data with the HART devices in the field based on a multiplexer, operators gain more complete information on the process and are able to visualise the data, for instance via TCP/IP, at any desired location. pdf

Phoenix Contact P a g e 1 8 / 1300 0 8786 / 1411 2 , www.phoenixcontact.com.au

September 2012 www.pacetoday.com.au 25

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IN FOCUS

Fast load shedding for oil & gas The oil & gas industry’s electrical infrastructure may be improved by applying IEC 61850 communications technology, writes Greg Finlayson.

R

ELIABLE electricity supply transient instability conditions, such as is critical for oil and gas sudden loss of generation or a threeoperations. IEC 61850 is a phase short circuit. This means that standard for the design of at any given point in time, the load electrical substation automation. consumption will be balanced with the It allows the development of software generation capabilities. architecture based on Ethernet networks A loss of generation or grid fault will linking all electrical protections, meascreate an immediate instability condiurement units, PLCs, energy managetion which has a direct impact on the ment system and local HMIs. process rotating equipment. A worst case One advanced application for the oil scenario if an electrical grid becomes & gas industry that benefits from IEC unbalanced is a black out. Fortunately 61850 is distributed Fast Load Shedding these threats can be mitigated through (FLS), which means managing multiple software architecture based on IEC substations and generation machines on 61850 technology. the same site.

An example of such technology is FLS is typically provided for modern Schneider A D _ P A C E P L A MA R _ 1 2 . p d f PElectric’s a g e PACiS 1 1software 5 / 0 2archi/ 1 2 , 1 1 : 2 9 : 5 2 AM AEDT CAPTION: PACiS architecture for the oil and gas industry. electrical power systems to overcome tecture. It provides operators with the

information they need to monitor, analyse and manage the whole electrical system.

PACiS FLS controls the plant stability, so that during a power source loss, it will shed the necessary loads in less than 80 milliseconds and maintain 26 www.pacetoday.com.au September 2012

the whole network stability in line with process priorities.

[Greg Finlayson is Product Application Engineer Substation Automation, Schneider Electric.] www.schneider-electric.com

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Terms & Conditions Your subscription may be tax deductible, ask your accountant. ABN 80 132 719 861. Please note RBI has a no refund policy, contact Customer Service for details on 130 360 126. *Based on previous $99 annual subscription price. All prices are quoted in Australian Dollars and GST inclusive. We are committed to handling your personal information in accordance with the Privacy Act www.reedbusiness.com.au/privacy.asp

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IN FOCUS

Driving down energy costs Escalating demands to save energy in manufacturing facilities coupled with rising energy prices have lead equipment suppliers to develop new, more efficient motor and drive systems. Sarah Falson investigates.

W

ITH the carbon tax in motion and energy prices rising by the month, there has never been a better time to assess factory equipment running costs.

However, taking in to account the array of systems used in production, it can be difficult to identify areas where savings can be made.

According to NORD Drivesystems AU regional sales manager Victoria, Tasmania & South Australia, Tony Sculpher, manufacturers should begin by auditing the energy-hungry equipment at the heart of the production line: the motor and drive systems.

“Here in Australia, the consumption of electric power by electric motors accounts for approximately one-third of all electric power generated. Electric motors are the single largest consumer of electric power as one identified group,” Sculpher told PACE. “This is why the Australian and New Zealand authorities created the Minimum Efficiency Performance Standard (MEPS), also known as the AS/NZS1359.5 Standard, which covers all three-phase electric motors between 0.73 kW and 185 kW.”

OPTIMISATION: Efficiency gains are there for the taking but manufacturers need to know where to look if they want to take advantage of these cost savings.

Know your system

A good way to start, Sculpher says, is to ensure factory equipment is properly matched to the job at hand. There are also products available to help minimise surplus energy use.

“An electric motor running continuously at full load current requires investigation to confirm its correct size selection. A frequency inverter with flux optimisation software can minimise the usage of full load current when it is not actually required,” he explained.

“Further consideration is required to ensure that the gearbox with the most efficient gear set is utilised, as this further enhances the efficiency of the total drive package.”

Sculpher says manufacturers often make the mistake of purchasing a drive system based on price, forgetting

A frequency inverter with flux optimisation software can minimise the usage of full load current when it is not actually required. the operating and maintenance costs throughout the life of the system vary depending on the unit.

“Many drive systems are often selected by a secondary source, for example an original equipment manufacturer or a design engineer, and these

decisions are based on their purchase cost, and for the selection to remain competitive against competition,” warned Sculpher.

“For a manufacturer or end-user who requires the most efficient drive system package, he must identify the efficiency goal for his installation, and communicate his preferences to the selection source. Many customers do not take enough ownership of this energy saving and efficiency requirement, simply assuming they will be offered the ‘best performance’ drive package by the supplier.

“Some do not appreciate that they do indeed have the power to specify what they exactly want. After all, the

one paying the bills for both the initial purchase and for the long-term running is the end-user!”

Taking advantage of the expertise offered by maintenance managers or an offsite contractor can help identify problems and advise where energy savings are possible, Sculpher says.

“Where there are a large number of drive packages onsite, the opportunity for efficiency and energy savings are greatly increased. Management must drive their maintenance providers for these efficiency and energy gains, and this will require communication, education, and a concentrated effort (read cost) to identify those drive packages which do not > meet their goals,” he said.

September 2012 www.pacetoday.com.au 29

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IN FOCUS

Invest to save

Bonfiglioli Transmission application sales engineer, Electronic Automation, Steve Dumbrell, recommends conducting a motor audit to identify areas for potential savings.

“Audit your plant to work out: what motors you have; what kW size; what application they are being used for; and whether or not the resultant effect of the motor is being reduced by other means – for example, pumps flow being reduced by manual flow valves after the motor,” he told PACE. “Once you have this basic information, I would look at the applications that the motor is running at full speed where the effect of the motor is being limited, as in a control valve limiting water flow or the motor continually being turned on and off due to it overworking the application. These will be the areas that have the largest potential to give the greatest return.

“If you find you have applications that are being restricted you are in a very good position to benefit from an external energy audit.”

Dumbrell also suggests using variable speed drives (VSD) to manage motor output: “VSDs are generally around 94 to 98 percent efficient. In many pumping applications it can be very cost-effective to replace the direct-on-line start with a VSD. This can see installation payback in some cases less than 12

months,” he said.

“Many manufacturers install VSDs to simply allow the machine to have a variable speed, but modern VSDs can also have a variety of industrial sensors connected to them to allow the drive to control the process better – with more control – and therefore save on the cost of a PLC [programmable logic controller] or separate controller.”

Dumbrell says suppliers are constantly updating drive designs to improve energy efficiency.

“Drive manufacturers are looking at ways to make their VDSs more appealing to the customer and are starting to design the drives with lowloss drive filters, sleep modes to reduce energy consumption when the motor is not running, and load monitoring which will optimise the motor current to the application to reduce energy supplied to the motor,” he said.

“Technology has improved greatly in the last 10 years with a large effort being spent on improving environmental footprint, meaning businesses can actually save a lot of money by reassessing how they use energy in the day-to-day running of their business.”

Dumbrell warns however that energy-saving products can be expensive, and calls on the government to provide assistance not only for equipment, but for services as well.

“I feel the government would be

better subsidising energy audits and once businesses realise how much they can save they will start to implement change themselves,” he said.

Assistance options

ABB energy efficiency manager – motors & drives, Shailesh Sharma, believes equipment funding delivers a compelling argument for manufacturers to begin reducing energy consumption, but also calls on government to provide other assistance options.

“Clean technology and energy efficiency grants from the government are the cost-effective way to apply replacement or upgrades of existing installations to support energy efficiency,” Sharma told PACE. “Being more energy-efficient makes economic sense because it lowers operating costs. From an environmental perspective, it is an effective way for businesses to cut carbon emissions.

“Energy efficiency represents a multiple opportunity for cost reduction, contribution to sustainability and environmental commitment. Short return of investment based on net present value is very attractive for any business-owner investing in energy efficiency projects.

“More publicity for government grants and incentives for the industry is required. Government should come up with loan options or such incentives for the industries that are not covered by

current grants. This would allow all sizes of industry to access capital to apply energy efficiency.”

A number of equipment grants are available, most recently through the Clean Energy Future scheme, which is part of a long-term plan to reshape Australia’s economy, cut carbon pollution, drive innovation, and help avoid the increased costs of delaying action on climate change.

The plan comprises three separate initiatives: the Clean Technology Investment Program; Clean Technology – Food and Foundries Investment Program; and Clean Technology Innovation Program – which are all open for registrations. Funding has also been designated specifically for supply chain initiatives and the steel industry.

ABB 03 8577 7114 www.abbaustralia.com.au Bonfiglioli Transmission 02 8811 8000 www.bonfiglioli.com.au Clean Energy Future 1800 057 590 www.cleanenergyfuture.gov.au NORD Drivesystems AU 1300 006 673 www.nord.com.au

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30 www.pacetoday.com.au September 2012

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BEHIND THE SCENES

Maximise steam turbine performance Measurements from a torque monitoring system at Qenos Altona showed power losses were occurring in the compressor, rather than in the turbine, write Daniel Phillips, Trevor Mayne and Mark Ellul.

A

LL turbo machinery is subject to degradation that, over time, will affect the system’s efficiency and operational performance.

Precise monitoring of turbo machinery performance with continuous torque-monitoring systems can be used to identify gradual efficiency loss, allowing a more focused maintenance scope to be developed to return the system to its optimum operation and efficiency.

Torque monitoring based on heat balance, energy balance, and other methods utilise numerous parameters such as pressure, temperature, flow rate, gas composition, which require precise instrumentation to properly measure with low uncertainty.

However, phase displacement technology can be used to accurately measure torque directly at the coupling to within 1 percent of full-scale torque, a combination of all electrical and mechanical sources of error.

This accuracy provides the lowest amount of uncertainty when computing efficiency, compared to alternative methods.

Power limitation

A system of this type was recently installed on a cracked-gas compressor train at Qenos Olefins in Altona, Victoria to determine the causes of a power limitation.

The Kop-Flex Powerlign system utilises phase displacement technology for long-term reliability, eliminating need for re-calibration.

Two rings with pickup teeth are installed on a torsionally soft spacer, and are intermeshed at a central location. Two monopole sensors 180 degrees apart are mounted on the coupling guard.

As the coupling rotates, the ferromagnetic teeth create an AC voltage waveform in the sensor coil, which is digitally processed using known calibration parameters.

Because of the intermeshed pickup teeth, the system is referred to as a single

FIGURE 1: The Powerlign system produces two independent torque signals.

Phase displacement technology can be used to accurately measure torque directly at the coupling to within one percent of full-scale torque.

channel phase displacement system, producing two independent torque measurements (Figure 1).

The Powerlign system will output

torque, power, speed, and temperature, which can be easily integrated with any DCS system (Figure 2).

At the Olefins plant the operating cycle of the steam-driven, crackedgas compressor train is seven to eight years.

During this cycle the plant reaches production limitations because this compressor train encounters a power limit.

Engineering debate

To determine the cause of the power limit as “turbine fouling” or “compressor fouling” or a combination of both was not confidently possible with the instru-

mentation installed.

The cause had long been the subject of an engineering debate between the Machinery group, Process Engineering group and Operations department.

One option to add more power by upgrading the turbine power rating from 7.5 MW to 9 MW was investigated.

This required a capital investment of $2 million. The plant elected to defer this investment and instead installed a torque meter at the major eight-year shutdown.

The installation involved replacing the existing coupling spacer and flexible halves with a “drop-in” torque > September 2012 www.pacetoday.com.au 31

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BEHIND THE SCENES

FIGURE 3: Existing coupling arrangement at top, and with retrofitted Smart Spacer, bottom.

FIGURE 2: Typical output from Powerlign system.

INSTALLED: Completed mechanical installation at Qenos Olefins, Altona.

SOLUTION: Smart Spacer retrofitted at the Qenos Olefins plant.

32 www.pacetoday.com.au September 2012

meter and integral flexible elements (Figure 3).

The torque meter assembly was dynamically balanced to API standards so it was not necessary for the user to return any coupling components for the retrofit.

The coupling guard was modified so that the two variable-reluctance sensors could be installed, completing the mechanical installation.

On restarting the plant and having completed a number of compressor efficiency improvements, the torque >

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PACE.SEP12.PG035.pdf

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BEHIND THE SCENES

The value of the torque meter has justified the installation of another system for the Olefins plant’s second steam cracking plant compressor train. meter clearly showed the 7.5 MW turbine did not require an uprate and that the major power losses were coming from the compressor.

The torque meter also allowed online tuning of the seal gas system of the compressor to establish the lowest power draw from the recycles that the seal system introduces.

An additional 200 kW of power was reduced from the turbine load with the manual adjustments made on the seal gas system.

Steam fouling

ACCURATE: The Powerlign system provides accuracy to within 1% of full-scale torque, utilising singlechannel phase displacement.

This would achieve increases in the operating envelope of the compressor.

The value of the torque meter has justified the installation of a second system for the Olefins plant’s second steam cracking plant turbine/compressor train in October 2012.

[Daniel Phillips (daniel.phillips@ emerson.com) is Manager, Field Service Engineering, Kop-Flex, Emerson Industrial Automation, Maryland, USA. Trevor Mayne (trevor.mayne@qenos.com) is Machinery Engineer, Qenos Olefins Australia. Mark Ellul (Mark.Ellul@qenos. com) is Qenos I & E Specialist, Qenos Olefins Australia.]

The torque meter is now being used to monitor turbine steam fouling issues and process related compressor fouling so that the corrective online washing can be activated as soon as issues arise.

The historical data collected from the torque meter will also provide a baseline of mechanical loading through the drive drain of the cracked-gas compressor over time.

Kop-Flex is represented in Australia by This data will be used to determine Rolling Bearings Company if increases in the maximum continuous 03 9553 1811 operating speed rating of the compressor andAthe D _turbine P A Ccan E SbeI accomplished C S E P _ 1at2 . p d f P a grbc@rollingbearings.com.au e 1 1 6 / 0 8 / 1 2 , 5 : 5 7 PM www.rollingbearings.com.au FITTED: Sensor installation in coupling guard. minimal costs.

W280-2

• Reliable detection on various colours and surfaces at high incident angles • Available in single switching output or duel switching output • Resistant to reflections from external shiny objects or highly reflective material Long Range Photoelectric Sensors.

For more information please visit www.sick.com.au or call 1800 334 802 (Tollfree).

September 2012 www.pacetoday.com.au 35

PACE.SEP12.PG036.pdf

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SPOTLIGHT

7best of the

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

Water sorption analysis The DVS Intrinsic offers a rapid, sensitive and accurate means for the determination of moisture sorption properties of solids. The research grade water sorption instrument provides fast high quality isotherms with minimal operator training. With a compact footprint it requires very little bench space. Water sorption behaviour is accurately determined on very small samples (1-20 mg) thus providing savings in the time required to reach water sorption equilibrium. The system can perform isoactivity measurements in which materials are kept under constant RH conditions while linearly or stepwise varying the temperature.

ATA Scientific 02 9541 3500 enquiries@atascientific.com.au www.atascientific.com.au

Stand-alone CompactDAQ System National Instruments has released a stand-alone NI CompactDAQ system, a high-performance embedded measurement and logging platform with a built-in dual-core Intel processor for running data acquisition, online analysis and logging software. With the NI CompactDAQ platform, engineers can customise a complete measurement system using LabVIEW or take advantage of over 600 companies in the NI Alliance Partner Network for a custom turnkey data-logging solution.

It features: Intel Core i7 dual-core processor, 2 GB RAM and 32 GB nonvolatile storage to run high-performance, mixed-measurement tests while logging data directly to the system, removing the need for an external PC. It is compatible with LabVIEW 2012 and features USB, Ethernet and serial ports. The 8-slot chassis enables more than 50 C Series I/O module options.

National Instruments 1800 300 800 info.australia@ni.com

Effective position control The Axioline I/O system from Phoenix Contact has been expanded to include the AXL SSI 1/AO 1 module for position detection. The terminal also has an analog output to control drives. The combination of position measurement via the SSI interface and simultaneous analog set point input offers a simple and fast positioning solution. The SSI interface of the module enables fast communication with encoders up to a transmission frequency of 2 MHz. The value transferred by the encoder can be directly converted into a position by the module. This functionality significantly shortens commissioning times. The automation 36 www.pacetoday.com.au September 2012

terminal has a resolution of up to 56 bits and supports Gray and binary encoders, making it sufficiently flexible for a range of applications. Additional functions include the synchronisation of the SSI values with the digital or analog inputs and outputs of the Axioline station as well as detailed diagnostics of the module and encoder.

The positioning solution is rounded off by the integrated analog output for specifying a set point. Users can define a set point position with standard voltage or current signals.

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

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

HMI touchscreen for harsh environments Certified safety encoder The Fraba Posital division has added a certified safety encoder to their OCD series of absolute shaft encoders. These encoders offer the advantages of increased personnel safety, minimal risk of machines malfunctioning, and reduced costs.

In addition to creating a safer environment, the transmission of “Safety Position” eliminates the need to install two separate encoders, and the complex development of validation monitoring logic in the PLC. The new encoders fulfil the requirements of IEC 61508, EN 62061 (SIL CL 3) and EN ISO 13849 (performance level e). Operated with protective extra low voltage (PELV), they are suitable for use in drive technology, lift applications, mobile machines, construction machinery, cranes and machine tools. Safety Specification: SIL CL3, PL e, Cat 4.

This OCD encoder uses a proven optoelectronic scanning method to measure absolute position values. The single-turn sensor provides a resolution of up to 16 bit per revolution (0.05°) and the multi-turn unit registers a maximum of 16,384 revolutions (14 bit), thereby covering an overall measuring range of 30 bit.

One of the latest products of the EXOR – UniOP 500 Series is the eTOP507G, a harsh environment HMI Operator Touch Screen. The high-brightness, contrast-enhanced ruggedised 7” TFT widescreen (16:9) display with a 800x480 pixel (WVGA) resolution has a fully dimmable LED backlight and support for 64K colours. It features an ingress rating of IP69K (front) and is able to operate in extended temperature ranges -20°C to +60°C. The two built-in dual 100Mb Ethernet interfaces with switch function enhance its communication capability. The Projected Capacitive Touchscreen is constructed with glass bonding assembly and anti-reflective glass surface treatment to deliver superior optical performance. The durable glass touchscreen operates with the human touch thus eliminating false activations. It will continue to work even if the surface is scratched or contaminated. This HMI unit carries ATEX and DNV approvals.

Tecno Platform csportiello@tecnoplatform.com.au 0401 747 403 www.tecnoplatform.com.au

Wireless monitoring system ZigSense wireless monitoring system is designed to monitor and record environmental, energy and refrigeration conditions in cool rooms, pharmaceutical laboratories, hospitals, supermarkets, and restaurants. The system is designed to assist in maintaining temperature, humidity and other records generally required for health and safety regulations associated with the food & drug industry. ZigSense system supports a variety of wireless sensing nodes. It includes a central monitoring, logging and display station.

The utilisation of wireless sensing nodes will reduce costs normally associated with installing long wires and cables.

Plant Control & Automation sales@pca-aus.com.au pca-aus.com.au

Conlab info@zigsense.com.au www.zigsense.com.au

Planetary gear units for low speed high torque SEW-Eurodrive Australia has added two sizes to their P-Series of standardised catalogue products, P072 and P082. The P-Series now covers rated torques up to 500 kNm. The planetary gear units are used in applications where low speeds and high torques are required. The P-Series of industrial planetary gear units is available in 11 sizes and covers torque range from 24 to 500 kNm. The gear units are designed so that the gearmotor is directly mounted in front of the planetary gear unit. This eliminates the need for couplings, intermediate flanges and adapter flanges, saving space and cost. Several different designs enable

the gear units to be optimised for the user’s application. SEW’s gearmotors offer a wide variety at the input. This results in precise gear unit ratio grades. It is possible to combine the designs with the planetary gear unit in helical or bevel-helical gear versions. The P-Series is designed to be short and compact. The gears feature high torsional rigidity and can transmit high torques. The CAD database DriveCAD makes it possible to create 3D models and 2D dimension sheets using DriveGate.

SEW-Eurodrive 03 9933 1000 www.sew-eurodrive.com.au SEPTEMBER 2012 www.pacetoday.com.au 37

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COMMUNITY

TOP TWEETS

WHAT’S ON

Overview of Grounding & Noise Reduction for Control Equipment 5 September 2012, Adelaide events@iica.org.au

Here’s what you may have missed this August if you weren’t following @pacetoday on Twitter: o A preview of tomorrow’s technology trends http://dlvr.it/1xVtX1

o How PLM Software built Curiosity [VIDEO] http://dlvr.it/1zCJm8

o Siemens and TrustPower to build largest wind farm in South Australia http://dlvr.it/1xkJDQ

o Honeywell launches Intelligent Management of Change for industrial manufacturers http://dlvr.it/1zCndt

Practical OPC Training Workshop Level 1 & 2 10-11 September 2012, Sydney jane.zhang@matrikonopc.com

o More funds for clean technology http://dlvr.it/1xkdnb

o Fieldbus Foundation updates device coupler test specification http://dlvr.it/20792v

Practical OPC Training Workshop Level 3 12 September 2012, Sydney jane.zhang@matrikonopc.com

o RS Components and SMC extend global partnership http://dlvr.it/1yvmmq

ANSTO Tour 6 September 2012, Lucas Heights, NSW nsw@iica.org.au

IICA @Home Event at Schneider Electric 18 September 2012, Sydney nsw@iica.org.au

o Honeywell turns spotlight on Sustain.Ability at AsiaPacific Users Group Symposium http://dlvr.it/1yQ2Ym

o Australian University develops salt based battery http://dlvr.it/1zCCZk o Madison Technologies acquires test and measurement company http://dlvr.it/1r3Wfw

For daily updates visit www.pacetoday.com.au

o OTEK delivers an Australian first to provide hi-res images of soil pollution http://dlvr.it/207t1C o Shell Prelude FLNG contract awarded to Wood Group http://dlvr.it/20LpNs o Residents in Australia’s capital cities’ drink treated sewer water http://dlvr.it/20cFlv o Queensland lays down the law on CSG water http://dlvr.it/20cVD5

Follow @pacetoday on Twitter for the latest news, analysis, new product information and commentary. And never miss out again.

IICA CORNER

Make IC&A careers attractive Instrumentation and automation courses feature low down the priority list, writes Brett Simpson.

AUSTRALIA is ideally suited to creating interest and aspiration for our young people in areas of science and technology in general, and instrumentation, control systems and automation (IC&A) in particular. After all, this country is blessed with myriad opportunities, not the least being those arising from the wealth of our diverse mineral and gas resources and even more importantly, from their allied value.

The question that the Institute of Instrumentation, Control and Automation Australia (IICA) has discussed over the years, is why aren’t our primary and secondary schools as well as tertiary institutions, as interested in offering courses and creating interest in these areas of national importance as we think they should be?

38 www.pacetoday.com.au September 2012

We know there are some problems in teaching science and technological subjects really well in schools. There is also the perception that science based and technological subjects are seen as ‘difficult’ by some students who have had this attitude unfortunately passed on from primary school and this has a knock on effect when students make their choices for courses for further study.

At universities, we see a further complication as they have tended to favour courses that have the lowest cost bases per student. This bottom line consideration has become more apparent as universities have had to operate as business organisations, especially when government funding declined to around 50 percent. Engineering and most sciences clearly felt disadvan-

taged by definition, as they must have laboratories, equipment and technical staff on top of the teaching academics.

Universities also had to factor in student popularity choices in deciding which courses to axe and which to retain.

So how do IC&A type of areas of study fare in competing in the popularity stakes at most universities? The answer is, not all that well. Most IC&A courses are add-ons to electrical engineering or other technological courses on offer. While there are a few that do offer standalone IC&A courses, these are the exception, not the rule.

We should also consider the fact that the Australian media, including social media, are not interested in anything scientific or technological unless it refers to ‘geeks’ or a unique happening like the

current Mars landing. It soon becomes apparent that right from primary school onwards, there is less information, knowledge, and understanding about the value of these critical areas to Australia’s future.

The fact that there are students who choose to enrol for these so called ‘hard and difficult’ courses is a tribute to their intrinsic love and passion for those subjects and certainly not because of any external encouragement.

I have raised some of the issues and problems in this article, because I believe they need airing and public debate. In my next article I will outline a sample of what the IICA has and is doing to publicise the opportunities and excitement of IC&A in schools and elsewhere.

[Brett Simpson is President IICA.] admin@iica.org.au www.iica.org.au

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HYDRAULICS

„It’s high time that hydraulic companies study advanced sensor technology and its impact on the market!“ Over 30 years ago, KELLER mediaisolated piezoresistive pressure sensors were introduced into the hydraulics market.

Today, the technology is widely ignored and hydraulic components vary little from one to another manufacturer.

When compared to competing technologies, the KELLER piezoresistive sensor in media-isolated housing provides a unique combination of benefits to the hydraulic system designer, including small size, high resolution, low hysteresis and high gauge factor.

Of increased significance in contemporary system designs is a wide dynamic range, typically required to be 2 kHz. Therefore the sensor must be small so it can be close-coupled to the pressure source. Also, in order to reduce noise influences, the signals should be digitized instantly.

KELLER’s “LC” line of integrated transmitters addresses every one of the aforementioned issues, in packages as small as 11 mm (0.433”) diameter! Not to be mistaken for only a sensor, the “LC” is the complete embedded system, providing a 0.5 – 4.5 VDC (ratiometric) output from a 5 VDC supply, with all components housed within the stainless steel module.

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In the case where digital signal transfer is preferred, KELLER provides the “LC” line with I2C interface. The addressing of the measurement points allows the coupling to a BUS system. In embedded systems (i.e. valve controllers) which do not require a fieldbus, the I2C interface provides faster and less complex data transfer compared to the CanBus. Placed adjcent to the pressure sensor inside the oil-filled stainless steel housing, the specialized ASIC handles digitization of the sensor output, performs mathematical error correction for temperature effects and handles all communication with the system master.

All design, testing and production are accomplished in our own facilities.

Engineers with extensive experience in hydraulics are available to coordinate customer’s requirements with our staff. A state-of-the-art hydraulics test bench, complete with Internet access for the convenience of our customers is now fully operational.

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