PACE - Process & Control Engineering - September 2014

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SEPTEMBER 2014 | VOL.67 NO.8

INSIDE PACE

Water

Sustainability

Management

SCADA upgrade boosts treatment plant’s efficiency and compliance

Applying anaerobic wastewater treatment changes cost structure

New business models must focus on productivity improvement

Post Print Approved PP100008186

Get to market quicker with Finite Element Analysis

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CONTENTS

Publisher: Martin Sinclair Email: martin.sinclair@cirrusmedia.com.au Editor: Kevin Gomez Tel: (02) 8484 0976 Fax: (02) 8484 0722 Email: kevin.gomez@cirrusmedia.com.au Group Sales Manager: Tim Richards Tel: (02) 8484 0829 Mobile: 0420 550 799 Email: tim.richards@cirrusmedia.com.au QLD Sales Manager: Sharon R. Amos PO Box 3136, Bracken Ridge, QLD 4017 Tel: (07) 3261 8857 Fax: (07) 3261 8347 Mobile: 0417 072 625 Email: sharon.amos@cirrusmedia.com.au Graphic Design: Blue Star Group Tel: (02) 8020 4400 Graphic Design: Dave Ashley Email: david.ashley@cirrusmedia.com.au Production Co-ordinator: Tracy Engle Tel: (02) 8484 0707 Fax: (02) 8484 0722 Email: tracy.engle@cirrusmedia.com.au

IN THIS ISSUE News 6

Industry Roundup Changes to Australian Standard AS 4024.1; Rockwell Automation collaborates with Cisco Engineering 7

Water Treatment An upgraded plant is now positioned to store data and records for 10 years Design 10

FEA Insights Finite element analysis enables the engineer to test a product design’s integrity Insight 13

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Oil & Gas A coordinate measuring machine completes inspection checks in less time

Automation 22

Robotics The automating of processes in manufacturing and other industries continues apace and robot sales have never been higher New Products 24

Boost Productivity Develop new structures and operational business models with a focus on productivity improvement

7 of the Best Hazardous area gear units; Inductive proximity sensors; Industrial measuring amplifier; Flow computer power module; Suspended solids density meter; Thermal mass flow meter

Innovation 19

Sustainability 26

Management 16

Food Processing A dairy plant constructed a local processing plant to reduce their milk-hauling costs while also reducing transport emissions

Water Week Strategic planning coupled with investments in technology and infrastructure can produce a radical change in water supply options

ON THE COVER PA0 9 1 4 _ 0 0 1

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Empower the product designer and engineer

SEPTEMBER 2014 | VOL.67 NO.8

INSIDE PACE

Water SCADA upgrade boosts treatment plant’s efficiency and compliance

FINITE element analysis enables users to shift the costs in the product cycle. The traditional peak at the end is moved to the beginning when more time is invested into the 3D CAD model and simulated analysis.

Once the product has been verified, the appropriate tooling and manufacturing can be setup. The reason why FEA reduces costs is that the peak costs of 3D design and analysis are dramatically less than the peak costs at the manufacturing end.

Some companies produce prototypes on their CNC machines and 3D printing has made this process easier.

However, the: process beMcostly and time-consuming relative to utilising CAD and FEA. 5 / 0 2 / 2 0 1 4 , 1 0 4 9 : can 3 5 still A (See page 10) Sustainability

Management

Applying anaerobic wastewater treatment changes cost structure

New business models must focus on productivity improvement

Get to market quicker with Finite Element Analysis

OFFICIAL MAGAZINE OF:

Average Net Distribution

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Post Print Approved PP100008186

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SEPTEMBER 2014 www.pacetoday.com.au 3

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COMMENT

EDITOR’S MESSAGE

WHAT’S ON

Honeywell Users Group AsiaPacific 2014 21-23 September 2014, Surfers Paradise apusersgroup@honeywell.com

FieldComm: users to benefit from merger

Chemeca 2014 28 Sep-1 Oct 2014, Perth austcourses@icheme.org Fundamentals of Process Safety 13-17 October 2014, Melbourne austcourses@icheme.org

Kevin Gomez Editor

HAZOP Study for Team Leaders and Team Members 21-23 October 2014, Perth www.icheme.org/hazopperth

Next Issue

For daily updates visit www.pacetoday.com.au

• Instrumentation • Discrete Control • Minerals Processing • Process Control in Building Automation

ONE of the major developments unfolding in the industry right now is the setting up of FieldComm Group. Fieldbus Foundation and HART Communication Foundation are merging to build a single organisation.

Given the current state of fragmentation, this can only benefit end users as well as automation vendors. The chairmen of both parties issued a joint statement which read: “For end users, a single organization that combines the power of both would provide a full solution that addresses every conceivable aspect of field communications and intelligent device management for the process industries.

“For suppliers, a single organization would create efficiencies in resource utilisation, consistency of processes and procedures, and would deliver significant improvements in member services and support.”

The two organisations have long worked together on the development of common international standards such as EDDL and, most recently, the development of the FDI specification. The merger offers potential to harmonise many aspects of the two protocols.

A combined organization could better leverage the complementary benefits of the technologies. FieldComm Group would have improved economies of scale through

merging training; registration and testing; participation at trade events; online presence.

Industry analyst and commentator for PACE, Jim Pinto, once remarked: “The parallel promotion of different industrial Ethernet standards increases confusion among end-users.”

Against that backdrop, the emergence of FieldComm Group can only be a step in the right direction.

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

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

INSTRUMENTATION

AMS has been appointed distributor for optek AMS Instrumentation & Calibration has been appointed exclusive distributor for optek’s range of analytical instrumentation in its territories.

AMS is now able to offer a full range of analytical instrumentation with the addition of the optek range in their product line-up.

For over 25 years, optek has focused on the development and P A 0of3inline 1 4 _photometric 0 0 0 _ Me t q support analysers for liquid and

gas-processing applications.

Headquartered in Essen, Germany, optek remains a familyowned company with a team of more than 100 professionals. optek has four main operations located in Germany, the United States, Singapore and China.

The company has developed a line of turbidity meters, colorimeters, UV absorption, and upH i p 2 conductivity 1 2sensors.

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in some of the roughest process conditions, in plants all over the world.

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New Historian and System Platform 2014

• Expanded 2 M Tags and multi-tiered configuration • New cloud Historian hosting on line data • Improved security for Multi Galaxy support • Improved robustness for High Availability & Disaster Recovery

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NEWS

TRAINING

SAFETY

Rockwell Automation collaborates with Cisco THE demand for skilled professionals who understand the exchange between information technology (IT) and operations technology (OT) is increasing as the industrial plant floor and corporate enterprise become more connected.

In response, Rockwell Automation, in collaboration with Strategic Alliance partner Cisco, has launched a new training course to help IT and OT professionals overcome the challenges of converging their network technologies.

The new training helps candidates prepare for the recently introduced Cisco Industrial Networking Specialist certification.

The hands-on, lab-based course – Managing Industrial Networks with Cisco Networking Technologies (IMINS) – provides the foundational skills needed to manage and administer networked, industrial control systems.

The first-of-its-kind course is designed to help control system and traditional network engineers in manufacturing, process control, and oil and gas environments to better understand the networking technologies required to enable a connected enterprise for more profitable, real-time decision making.

The demand for skilled professionals who understand how to interact with IT, networking and traditional control systems continues to grow. An opportunity exists here to re-skill system engineers.

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Changes to Australian Standard AS 4024.1 STANDARDS Australia announces several revisions to the Australian Standard AS 4024.1 Series – Safety of Machinery to align with global standards and strengthen workplace safety.

The revised parts have been individually issued at this stage with the entire standard due to be released as a 2014 version once the application guide (part 1100) is finalised later this year.

The AS 4024.1 series provides guidelines to designers, manufacturers, suppliers, employers and users of machinery to help reduce the risks of working with, or near machinery.

Pilz Australia Managing Director The principal task of the 2014 revisions was to consider the latest Scott Moffat explains that the Safety international standards. of Machinery Standard has grown in relevance over time, and has recently been adopted as an AS/NZS Standard.

1701-4, 1801&3, 1901-7); two new safety related control systems using The revision will closely align it Parts have been added (1303, 1503); ISO13849-1 and the Performance with the European machinery and four Parts superseded and withdrawn Level (PL) approach. Part 1501 safety standards.

(1101, 1202, 1301, 1802) with the (Category approach) remains in the According to Moffat, the revision application guide (1100) to follow. standard and the option is still open is a logical step to continue to update Key changes in the Australian to the designer; AS 4024.1 Series to European standards Standard AS 4024.1 include: • Parts 1602 (Interlocking Devices) as they lead the world in this area of • The risk assessment approach parts and 1604 (Emergency Stop) are now machinery safety.

1201 & 1303 (new) have been both direct text adoptions of their Standards Australia’s Technical updated to reflect the global standards international standards, ISO14119 Committee said the principle task of the of ISO12100 (Machine Safety, and ISO13850 respectively; 2014 revisions for the AS 4024.1 Series General principles of design, risk • Guarding Parts 1801 (Safety Distances) was to consider the latest international assessment and risk reduction) and and 1803 (Minimum Gaps) are also standards and incorporate these into ISO14121-2 (Practical examples of now both direct text adoptions of their the original 2006 Standard.

Risk Assessments); international standards, ISO13857 Overall, 19 Parts have been revised • A new Part 1503 that now gives the and ISO13854.

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BEHIND THE SCENES

Council upgrades to comply Hamilton City Council implemented an upgrade to their SCADA system at the plant, enhancing the ability of key stakeholders to improve performance efficiency and meet regulatory compliance.

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HE Waikato River – the longest river in New Zealand – supplies all of Hamilton city’s water supply. Water is treated, distributed, and managed by the Hamilton City Council to ensure that when water reaches consumers, it is free from harmful organisms and meets water supply standards.

Hamilton’s reticulated water supply system consists of one water treatment plant that provides potable water to eight different reservoirs located around the city through over 1000km of piping. The reticulated (piped) network delivers the water straight to the taps of consumers.

P A 0 7 Every 1 4 _second 0 0 0of_ each A Mday, S Hamilton City Council produces an

average of 2385 glasses of high quality drinking water to over 51,000 homes The plant is now and industrial premises. positioned to efficiently The council is also responsible for the operation of the Pukete Wastewater comply with water Treatment Plant (WWTP) – Hamilton’s regulations including the only wastewater treatment facility. This plant services a region that has grown storage of data and records rapidly in recent decades to have a for 10 years population in excess of 150,000. Like the city, the Pukete WWTP is continually developing, in its case to improve operational performance and maintain Hamilton City Council implemented compliance with a changing government an upgrade to their SCADA system at regulatory environment. the plant, enhancing the ability of key Leveraging the FactoryTalk stakeholders to make informed decisions, efficiency and 1 Integrated 2 0 1 4Production - 0 6 - 1and 3 TPerformance 1 4 : 1 2 : 1 improve 9 + 1 0performance : 0 0 Suite from Rockwell Automation, meet regulatory compliance.

Calibrations under control

In 2008, the New Zealand Ministry of Health issued revised drinking water standards. To comply with these regulations, it is the responsibility of water treatment facilities to track, save and provide monthly reports on water production, intake and discharge levels.

Crucially, the standards require that water treatment plants retain operating data for 10 years.

More than a decade ago Rockwell Automation provided the council with the software suite for its previous SCADA system. However, the RSView32 system had become outdated over time and inefficient for compliance with modern-day regulatory requirements set out by the New Zealand Government.

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BEHIND THE SCENES

NZ Drinking water standards compliance report.

With its previous SCADA system the council had often recorded data manually before transferring this information into Microsoft Excel spreadsheets for reporting. A faster, more accurate and automated reporting system was needed, and one that could rapidly generate pre-determined reports automatically for sharing with authorised groups.

“Our previous system was outdated and we required an upgrade to help simplify the process of complying with current water regulations in New Zealand. Not only that, but we identified the potential for improving operational efficiencies at the plant by implementing an integrated system that aims to increase productivity and reduce down-time,” said Gary Pitcaithly, automation and electrical manager at Hamilton City Council.

Operational efficiencies

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Monthly Compliance Report.

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A key aim of the upgrade was to deliver a system with the ability to retain 10 years of data in a stable and reliable manner. At the same time, the system would need to provide operational efficiencies compared with the previous operating system, while also maintaining a secure environment only accessible by authorised stakeholders.

To improve on this process, Hamilton City Council engaged Rockwell Automation to provide the latest versions of the FactoryTalk 2 0 1 4 - 0 8 - 2 6 T1 7 : 4 4 : 5 1 + 1 0 : 0 0 software suite as the integral element of an upgrade to its system.

According to Prasad Nory, industry manager – South Pacific at Rockwell Automation, “FactoryTalk Historian and FactoryTalk VantagePoint are increasingly becoming standards in the water/wastewater industry – especially with the need for compliance to changing drinking water standards.

Also, FactoryTalk Historian ME has been used by some councils in their pump stations to store data locally to take care of communication failures and meet compliance.”

“By upgrading to the FactoryTalk suite the key benefits identified by council included: superior reporting for compliance to government regulations, improved system reliability and stability, and reduced risk when contractors are onsite to undertake modifications or further expansions.”

The FactoryTalk software suite delivers a real-time exchange of information throughout organisations, a critical element that allows for more informed business decisions, improved responsiveness, increased productivity, reduced costs and ease of compliance with regulations.

Implemented in-house by Pitcaithly, Hamilton City Council upgraded the WWTP’s system over six months to include the Factory View (SE), FactoryTalk Historian, FactoryTalk VantagePoint, FactoryTalk AssetCentre and FactoryTalk ViewPoint applications.

The Rockwell Automation Customer Support and Maintenance team provided support to the council during

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BEHIND THE SCENES

the upgrade, particularly for the migration from Historian Classic to FactoryTalk Historian.

The long-term storage and reporting capabilities required to comply with water standards are provided by FactoryTalk Historian and FactoryTalk VantagePoint. Data is stored in the Historian server for the required 10 year retention period and is accessed for analysis and reporting purposes.

Another key result of the upgrade has been the flexibility it has added for personnel operating the system at the WWTP. “The FactoryTalk software suite has enabled our team to be more flexible with their time, as we are now able to edit or update reports as we go. We now simply store our data directly into Historian and the data spreads directly from the PAC (Programmable Automation Controller) to a human

interface. This data is incorporated into spreadsheets for us to interrogate, whether it is on a daily, weekly or monthly basis, to tell us if we’ve had a breach in turbidity or if chlorine levels aren’t what they should be,” said Pitcaithly.

The flexibility extends to the ability of system users to remotely access the software from tablet computers or smart phones. “The team has tablets and smart phones that can basically access FactoryTalk View anywhere in the world

– if they are out of the office or on-call the system can be easily accessed and key changes made,” concludes Pitcaithly.

With the FactoryTalk software suite delivering new found operational potential for the plant, the council is planning to continue to update and improve its system further in the coming years utilising these capabilities.

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The flexibility extends to the ability of system users to remotely access the software from tablet computers or smartphones FactoryTalk VantagePoint is used by the plant to schedule and produce automatically generated reports providing information on periodical water consumption, discharge, intake, water quality and storage levels.

FactoryTalk AssetCentre provides improved contractor control, change management and storage capabilities.

Most importantly, the plant is now positioned to efficiently comply with water regulations in New Zealand, including the storage of data and records for 10 years.

FactoryTalk VantagePoint Inlet screen flow comparison.

Delivering fresh water

The benefits of the new Integrated Architecture solution will help the plant supply fresh drinking water and a clean environment to residents of Hamilton for many years to come. According to Pitcaithly, historical and reporting data is now available more quickly and accurately following implementation of the FactoryTalk suite, as the council had envisioned prior to the upgrade.

“The upgrade has delivered greater ease of use of our system throughout the WWTP. The new Historian is superior in how it stores data and makes generating information for vital reports a much more efficient task to undertake,” explains Pitcaithly.

“The VantagePoint software allows us to develop reports at will, whether it is for compliance to water standards or for other needs. These reports can then be published as web-based reports that are available for anyone authorised to view them.”

Waste Water SCADA Screen.

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IN FOCUS

FEA is the key to saving time and costs Finite element analysis can save time and costs and can help companies get to market quicker with even more innovative products, writes Craig Hingston.

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INITE element analysis enables thing about this, and the reason why users to shift the costs in the FEA reduces costs, is that the peak product cycle. “The traditional costs of 3D design and analysis are peak at the end is moved to the dramatically less than the peak costs beginning when more time is invested at the manufacturing end,” he adds. into the 3D CAD model and simulated “If you are not going to rely on finite analysis,” explains Shigeaki “Steve” element analysis to test your design, the Kinoshita, FEA Simulation Applications alternative is to make physical versions Engineer at Sydney based CADspace. of every configuration until you get Once the product has been it right. Some companies produce verified, appropriate and P A 0the 9 1 4 _ 0 0 0tooling _ O Uand T 1 prototypes 2 0 1 4on - their 0 8 -CNC 2 7 machines T0 9 : 1 8 : 4 7 + 1 0 : 0 0 manufacturing can be setup. The great 3D printing has made this process easier.

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IN FOCUS

However, the process can still be costly and time-consuming relative to utilising CAD and FEA. “Furthermore, FEA gives greater insight into the behaviour of the product such as the various stress components experienced by the product. This insight empowers the product designer and engineer with tools to improve the design in the early stages. Although able to be used for testing, with standalone prototypes you may not be able to assess such parameters as easily.”

Steve says the tradition of relying on manual calculations and sound engineering is still essential and can never be forgone. However, the market is demanding more innovative products, some of which are complex to solve manually.

Multiple test runs

In such situations, FEA comes in very handy. If multiple test runs are required, analysis using manual calculations can be time consuming. Running a parametric study through SolidWorks Simulation would be a more efficient process.

FEA gives greater insight into the behaviour of the product such as the various stress components experienced by the product Steve, who used FEA to conduct parametric studies for his PhD studies, says another benefit of FEA is that it enables the product designer and engineer to test a product design’s integrity.

Using SolidWorks Simulation, the virtual 3D model can be subjected to extreme operating environments until it “breaks”. Fine tuning of a design can be conducted within Simulation, reducing production and testing of prototypes.

Trial and error in physical testing can lead to huge waste, he adds.

As described above, with the traditional design-to-manufacture cycle costs can ‘blow out’ in the latter stages if flaws in the product design are not identified and resolved in the early stages of the cycle.

Tooling and CNC machining are high cost processes. If a conceptual

part has to be changed numerous times those costs keep increasing.

“Outside of the research and development phase, I believe there is another benefit that SolidWorks Simulation offers to engineers: that is when they have to present their concepts to non-engineering stakeholders such as to corporate executives, investors or marketing and sales personnel.

“FEA is a highly visual tool and it can be used to prove the design, demonstrate its performance capabilities and verify the integrity of the product design to people who need more evidence than a standalone physical model.”

Professional training

At the end of the day, FEA is only as good as the person using it and Steve says it is imperative to get professional

training and to acquire experience with the tool.

“It’s no different to the first time you used SolidWorks CAD. In order to get the most out of it you were trained.

Practice and usage then adds and hones the skills. SolidWorks Simulation is a highly complex computer simulation.

“At CADspace, we will train people how to setup and analyse a FEA model using Solidworks Simulation.

Conversion of real life problem to an FEA model requires understanding of the problem, knowledge of FEA and engineering judgment. The inputs will dictate your outputs. When used properly, FEA has incredible benefits.”

Steve adds that validation of an FEA model is an important process in conducting simulation analysis.

“Validation of the model makes you more confident in your outputs.

I tell everyone to validate their FEA model, if possible. For example, it might require starting out with an experiment with a parameter at one extreme then another experiment with a parameter at the opposing extreme.

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IN FOCUS

“You can then conduct finite element analysis within that parametric range and, having determined your boundaries, you can go on to test other configurations of the model in the same range.

“With experience and knowledge, analysis outside this range can be conducted. Example of a validation may include comparison of strain results with field results obtained using strain gauges.

“Alternatively, you might determine a rather standard outcome using both computer and manual calculations and when they match you can then go to the FEA for more complex calculations.

This should give confidence with the workings of the FEA package. Once you have determined your process, the application becomes a powerful tool.”

Design analysis

Combination field/test data with simulation is a good practice and makes FEA a suitable and power tool in the design analysis. The model can be validated against strain

FEA is only as good as the person using it.

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The virtual 3D model can be subjected to extreme operating environments until it “breaks” gauge results and the FEA model used to obtain greater insight into the behaviour of the product.

This includes finding regions of high mechanical or thermal stress. The design can then be adjusted accordingly to meet the requirement such as thickening its walls to increase its robustness.

SolidWorks Simulation can help companies improve product quality and evaluate performance in a quicker and more cost effective manner. The fact that it is integrated into SolidWorks CAD means users achieve a more efficient work flow.

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BEHIND THE SCENES

Completing inspection checks in less time A coordinate measuring machine uses a ball probe at the end of the arm that is directed at various positions on an object to collect individual 3D data points that are then processed by CAD/CAM software.

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UBSEA is an integrated engineering solutions provider that serves the oil & gas industry through providing turnkey fabrication, machining services, non-destructive testing (NDT), and load testing.

The company’s service department also helps to repair, modify, and refurbish oilfield-related components and equipment. Incorporated in 2006, SUBSEA works primarily with major offshore oilfield services companies specialising in the field of drilling and subsea services.

For SUBSEA, its metrology needs include machine alignment and dimensional calculations for quality control, mainly for the

components that are fabricated and machined in its facility.

The team had always relied on hand tools such as Inside (ID) and Outside (OD) micrometres for its inspection needs. Typically, the subsea and surface components produced by the company ranged from 0.5 to 2.0m in measurement volume, 50 to 200kg in weight, and quality checks were vital on first articles and outgoing products.

In 2011, however, a search for better inspection methods was prompted.

“The team realised that existing hand tools lacked the desired level of precision they were gunning for,” said Choo Tuck Wah, Director of SUBSEA. He continued, “The tools led to human error and it did not allow our team to

maximise their productivity. After all, manual methods required more time and care. Plus, objects had to be moved from shop floor to measuring room, which made it labour-intensive.”

Coordinate measuring machine

At around that time, SUBSEA heard about FARO solutions – specifically the FaroArm – from its customers. The FaroArm is a portable, articulated-arm coordinate measuring machine (CMM) that offers accuracy, reliability, and convenience to users.

The ball probe at the end of the arm is directed at various positions on an object to collect individual 3D data points that are then processed by CAD/

CAM software. Instead of bringing parts to the device, the portable CMM can be deployed directly on the shop floor.

This offers savings on time, labour, and cost.

In that same year, SUBSEA purchased an 8-foot (2.4m) FaroArm to replace the hand tools for its inspection needs. Choo noted, “On top of all the benefits we knew we would enjoy, FARO came highly recommended by our customers and had a good reputation in the oil & gas industry. The choice to invest in this equipment made perfect sense.”

The SUBSEA team could now bring the measuring device to the shop floor, for measurements to be taken right at the production site. Not only does this SEPTEMBER 2014 www.pacetoday.com.au 13

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BEHIND THE SCENES

save time and labour, it also reduces the exposure of health risks on the personnel since the movement of large, bulky objects are involved. Choo revealed, “We were pleased to see tangible improvements since the switch. Our statistics show that inspection time has reduced by a significant 30 percent.”

As productivity increased, SUBSEA also noticed an improvement in accuracy and repeatability. The FaroArm is capable of achieving required tolerance levels of 0.00125 inch (0.03175 mm), and provides much better consistency even between technicians.

Choo further explained, “In the past, measurements had to be taken several times to ensure that they were accurate.

The FaroArm basically eliminates any concerns of human error and allows us to confidently show these figures to our customers to resolve any dispute.”

Dimensional calculations on components can be done directly on the shop floor with the portable FaroArm.

Subsea Structure’s 6500 sqm facility located in Singapore.

14 www.pacetoday.com.au SEPTEMBER 2014

Our goal is to expand our geographical footprint in order to become a global integrated engineering solutions provider

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BEHIND THE SCENES

Portable equipment permits high-precision 3D measurement and comparison of parts and compound structures within production and quality assurance processes Onsite inspections

The availability of digital data also means that reports can be generated for customers who require them.

Using the intuitive software that accompanies the FaroArm, technicians can generate reports to validate the dimensional accuracy and quality of outgoing components.

When asked about how SUBSEA’s customers played a part in their final decision, Choo said, “When our customers request onsite inspections in our facility, they have full assurance on the quality of the components we Reports can be generated with the software that accompanies the FaroArm. supply, because we speak the same language.”

Ultimately, even though customerand expansion plans are in the pipeline. coordinate measurement devices and driven quality had a hand in influencing Choo concluded, “Our goal is to expand software. Portable equipment from SUBSEA’s investment decisions, there our geographical footprint, in order to FARO permits high-precision 3D were several tangible benefits that were become a global integrated engineering measurement and comparison of parts obvious to the team, including better solutions provider. We are hopeful that and compound structures within productivity, precision, convenience, and our partnership with FARO can help production and quality cost-savings. us get there.” assurance processes.

PA0 9 1 4 _ 0 0 0 _ ADM 1 2 0 1 4 - 0 8 - 2 6 T1 7 : 4 8 : 0 7 + 1 0 : 0 0 Business is doing well for SUBSEA FARO develops computer-aided The devices are used for inspecting

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SEPTEMBER 2014 www.pacetoday.com.au 15

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BEHIND THE SCENES

Changed business model boosts productivity Australian industry must develop new structures and operational business models with a focus on productivity improvement, writes Hartley Henderson.

W

HILST South East Melbourne is one of Australia’s foremost industrial regions with thousands of companies providing over 108,000 skilled jobs, the loss of automotive assembly will have a significant impact on the region.

According to Adrian Boden, Executive Officer of South East Melbourne Manufacturers’ Alliance (SEMMA), South East Melbourne generates around 44 percent of Victoria’s manufactured product, provides 30 percent of the region’s 358,000 jobs, 16 www.pacetoday.com.au SEPTEMBER 2014

and more than 300 exporters are located in the region.

“There is a need to develop new structure and operational business models for Australian manufacturers with a focus on productivity improvement to ensure that companies survive, grow and prosper,” he said.

Assemco, located in the South East Melbourne suburb of Kilsyth, is a SEMMA member that employs some 50 people and provides assembly services for clients, including cabins for Kenworth trucks.

The company has achieved impressive productivity improvement results, particularly through the development and implementation of a unique flat-line management system where substantial responsibility is devolved to production workers.

People management costs The MyKPI online self managing tool was developed by Assemco’s Managing Director, Danny Vorhauer, with a view to ensuring that the company remains viable in a challenging environment.

“Once we had removed all middle management positions and embedded the MyKPI system into the company, a substantial reduction in people management costs was achieved coupled with significantly improved employee engagement,” he told PACE. “MyKPI is a self-directing and engaging work process system that promotes, encourages and drives cooperation, accountability and productivity improvement between staff at all levels throughout the business.

“It replaces the traditional and less effective hierarchy management systems

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BEHIND THE SCENES

that are often heavy on employing managers to oversee and drive staff.

This unique flat system has proved hugely successful with staff on average doubling their individual output of work in around 38 hours or less.”

Business outcomes

Vorhauer explains that MyKPI is based on delineation of clear work processes that are measureable (by some 450 KPIs), and that employees are trained in these processes with an emphasis on competency and the factors important to deliver core business outcomes.

“Employees have defined process accountabilities and are provided with appropriate resources and delegated authority to make decisions and deliver on their part of the system, resulting in greater ownership by each employee.

“A continuous improvement ethic is embedded into all work, which provides an umbrella above incremental improvement to stimulate significant productivity gains by directly rewarding individuals and group process improvements.

“Real time feedback is provided through the MyKPI online reporting system that allows each employee to access performance information and dynamically audit and steer their efforts to achieve best results. Thus the system

is able to respond to leading rather than lagging indicators and develop daily corrective actions in line with the demands of the business.

“Ensuring fairness and accountability go hand in hand with provisions for employees to interrogate and challenge performance data to substantiate their actions/outcomes.”

In addition to providing assembly services for client companies, Assemco is now producing its own shock absorbers (branded RedRoo Shocks) for trucks and 4WD vehicles with a strong focus on export markets.

According to Vorhauer, these products will compete primarily on quality and uniqueness, and are capable of delivering a 15–30 percent increase in the tyre life of trucks as well as improved ride and handling.

Vertical integration

SEMMA member company Maton employs around 70 people and manufactures a range of high quality acoustic and electric guitars that are recognised as one of the top brands in the world.

The company has a history of vertical integration that Production & Projects Manager, Patrick Evans, says was born initially out of necessity and has been carried through as a philosophy.

The system is able to respond to leading rather than lagging indicators and develop daily corrective actions in line with the demands of the business “One of the most important aspects of Maton’s identity is its uniqueness.

For example, we have always preferred to make our own pickups and this has helped to separate us from the pack. Our competitors mostly use readily available OEM products, resulting in a ‘sameness’ across different brands,” he said.

“On occasions this has been of enormous benefit, particularly in relation to the amplification of acoustic guitars. Rather than fit our guitars with the same systems as our competitors we have deliberately developed world leading systems that have put us in front of our competition.”

Tight tolerances

Maton also employs vertical integration in the seasoning, storing and treatment of raw materials, especially timber, to ensure quality of tone and reliability.

Evans points out that tolerances required in guitar making are much tighter than in other timber industries and that in the end, Maton’s vertical integration is a crucial part of its unique identity.

“A central focus at Maton is the realisation that the company must continue to evolve in order to remain competitive, and that this requires combining traditional craftsmanship with advanced manufacturing technologies. The aim is to retain quality while boosting production.”

Rare woods

The company has invested millions of dollars in a state-of-the-art controlled atmosphere factory that features locally designed computer programs and CNC machines to precisely cut valuable rare woods from around the world.

CNC machines include Biesse Rover C, SCM Routomat and Multicam. These machines have their own software that interfaces with Rhino for design, Edgecam for machining strategies and code, and Multicam Toolpath for creating machining cycles on Multicam.

“We have embarked on a strong continuous improvement program throughout our operations which is delivering outstanding results. This

At Assemco, the truck door finished assembly is ready for dispatch.

SEPTEMBER 2014 www.pacetoday.com.au 17

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includes the application of value stream mapping to identify areas that can be more efficient,” Evans says.

“CNC technology has assisted in reducing variation and ensuring that specifications are as tight as we can get them. Also, CNC set-up times have been reduced from one day to half an hour by improved record keeping, standardising, and applying templates to speed up changeovers.

“Our way of making guitars has been redeveloped by focussing on designing the ideal acoustic instrument and then working backwards to establish the methods required to achieve the goal. It is important that our approach to the market is quality driven because if we focus mainly on price then we are going to lose the battle with our competitors.”

Assemco 03 9761 4118 www.assemco.com.au Maton 03 9896 9500 www.maton.com.au SEMMA 03 9768 2524 www.semma.com.au

Tolerances required in guitar making are much tighter than in other timber industries.

Maton combines traditional craftsmanship with advanced manufacturing technologies.

18 www.pacetoday.com.au SEPTEMBER 2014

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BEHIND THE SCENES

Dairy benefits from wastewater A dairy plant decided to construct their local processing plant to reduce their milk-hauling costs while also reducing transport emissions and carbon footprint as a result of shorter transportation distances.

A

NEW dairy processing plant features advanced wastewater The fine gas bubbles are created by recycling clean effluent treatment technology that in which biogas is dissolved under pressure not only radically improves biomass recovery and effluent quality, but also harnesses green energy from waste streams to drive production Region, NY – decided to construct seeking to simultaneously achieve an processes and reduce its carbon footprint. their local processing plant to environmentally effective, energyThe Cayuga Milk Ingredients (CMI) reduce their milk-hauling costs efficient and cost-efficient solution. plant in New York – which is scheduled while also greatly reducing transport The GWE technology involved to commence production this year – will emissions and carbon footprint as a in the project is represented in Australia manufacture a wide range of dairy result of the shorter transportation and New Zealand by CST Wastewater products, such as pasteurised cream, distances involved.

Solutions, whose Managing Director, whole milk powder, liquid permeate, To achieve optimum environmental Michael Bambridge, says such condensed milk, skim milk powder, and efficiency benefits, CMI technology is suited to local dairy, beef non-fat dry milk and milk proteins. further decided to implement an and food processing companies who and profit benefits PCayuga A 0 7 Marketing 1 4 _ 0 0– 0a collective _ DEL 1 anaerobic 2 0 1 4treatment - 0 6 - process 2 5 T for 1 1 : 0 4 : 0 value 7 + 1environmental 0 : 0 0 of dairy farmers in the Finger Lakes their wastewater treatment facility, from production processes.

“In addition to generating valuable biogas to replace fossil fuels, the technologies installed at Cayuga provide exceptional benefits for biomass recovery that are also strongly applicable to Australasia,” said Bambridge, whose company recently installed GWE COHRAL technology at Oakey Beef Exports on Queensland’s Darling Downs, where it will extract green energy biogas from waste water streams to replace millions of dollars worth of natural gas currently consumed at the abattoir.

In the US, CMI selected Global Water & Energy (GW&E) as the engineering, procurement and construction (EPC) contractor to design,

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SEPTEMBER 2014 www.pacetoday.com.au 19 Delta industrial automation (122H x 210W).indd 1

2014/6/24 下午 06:21:34

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BEHIND THE SCENES

build and start up their new wastewater treatment facility, specified to achieve outstanding effluent discharge qualities while producing valuable biogas (methane) initially for future utilisation and electricity production. GW&E is the US branch of Global Water Engineering and results from a joint venture with Western Water Constructors.

Biological waste

Applying anaerobic wastewater treatment to a business sheds a whole different light on the cost structure of wastewater treatment infrastructure.

GWE has completed scores of successful waste-to-energy projects around the world, each one responding to the particular needs of plants ranging from sugar cane and cassava through to potato products, brewery products and any wastewater stream with a biological waste content,” says GWE Engineer Natascha Janssens.

“We determined that the ideal solution for wastewater treatment from a dairy plant such as Cayuga was provided by GWE’s FLOTAMET system,” says Janssens. “This unique GWE system offers high rate anaerobic treatment with GWE’s ANAMIX reactor (completely mixed continuous flow stirred tank reactor, CSTR) followed by biomass recovery in a combined sludge separation system consisting of GWE’s SUPERSEP-CF followed by GWE’s Dissolved Biogas Flotation (DBF) unit SUPERFLOT-BIOGAS.” The SUPERFLOT-BIOGAS is a

dissolved biogas flotation (DBF) system developed by GWE and used for high efficiency removal of anaerobic biomass from the effluent of an anaerobic treatment system. The anaerobic biomass is returned to the anaerobic system, thus increasing the sludge retention time.

Such systems allow anaerobic reactors to be greatly reduced in size.

In SUPERFLOT-BIOGAS systems such as that used by Cayuga, the biomass is separated by means of flotation. Solids are forced to float by fine biogas bubbles attached to these solids.

These fine gas bubbles are created by recycling clean effluent, in which biogas is dissolved under pressure. After injection into the lower part of the flotation tank, the pressure release results in formation of fine biogas bubbles.

Since biogas is used instead of air, the system has a completely enclosed design.

Convert to biogas

The Cayuga plant is designed to treat 950 m³/d of wastewater and 95 m³/d of whitewater, together resulting in a total COD (Contained Oxygen Deficit effluent pollution) load of 6,000 kg/d.

Approximately 80 percent of the COD load and 85 percent of the BOD (Biological Oxygen Demand) load and is removed in the FLOTAMET system, with the waste removed converted to biogas. This results in the production of up to 1,900 Nm³/d (at 75 percent CH4) of biogas, with an energy content of 590 kW. Janssens says the biogas will be used partially to heat up the wastewater in order to ensure optimal anaerobic digestion. As such, the anaerobic treatment plant does not create an additional energy demand to the factory for heating purposes. In a second phase it is the intended to use the remaining biogas to generate electricity in order to meet CMI’s goal to further decrease the carbon footprint of the factory.

The anaerobic effluent from the FLOTAMET system is treated in a conventional aerobic treatment by GW&E followed by a Dissolved Air Flotation (DAF) for solids separation.

The aerobic polishing of the anaerobic effluent ensures that the discharge from the plant to the local sewer will meet the strict discharge limits applying.

Anaerobic benefits The technologies provide benefits for biomass recovery that are applicable to Australasia.

20 www.pacetoday.com.au SEPTEMBER 2014

Anaerobic digestion facilities have been recognised by the United Nations

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BEHIND THE SCENES

The anaerobic biomass is returned to the anaerobic system thus increasing the sludge retention time.

development program as one of the most years – while achieving permanent useful decentralised sources of energy environmental benefits by replacing Anaerobic plants can also supply because they are less capitalfossil fuel, says the Chairman and benefit local communities intensive than are large power plants.

CEO of GWE, Jean Pierre Ombregt.

Modern anaerobic processes “One ton of COD (chemical by providing local energy can vastly concentrate the process oxygen demand) digested anaerobically supplies while eliminating in environmentally harmonious generates 350 Nm³ of methane, closed reactors, operated under ideal equivalent to approximately 312 the need for smelly lagoons temperature and process control to liters of fuel oil, or generates about optimise waste degradation and, in 1,400 kWh of green electricity.” need for large and often smelly and the process, generate large quantities Additional income environ-mentally challenging aerobic of methane (CH4) from the organic Anaerobic plants can also benefit and anaerobic lagoons commonly used materials in the wastewater. communities cost of - 1 local PSavings A 0 9quickly 1 4 _ repay 0 0 0the _ M ET 2 0 1 4 - 0 8 by - 2providing 6 T 1 7local : 4 6 : 0 outside 0 + 1 0the: USA. 0 0 energy supplies while eliminating the “Applying anaerobic wastewater anaerobic plant – typically within two

treatment to a food or beverage business – or any business with an organic wastewater stream – sheds a whole different light on the cost structure of wastewater treatment infrastructure,” says Ombregt.

“It can now actually become a substantial additional source of income for many factories and processing plants throughout the world, including the food, beverage and agro industry and other primary product processing.”

CST Wastewater Solutions 02 9417 3611 www.cstwastewater.com

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www.mt.com/pro SEPTEMBER 2014 www.pacetoday.com.au 21

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IN FOCUS

Automation: a challenge and an opportunity LBR iiwa is the first industrial robot to have force torque sensors on all of its seven axes.

Materials handling robots THE new Industry 4.0 robot was launched by German robotics manufacturer KUKA at the Automatica in Munich this year.

Designed to revolutionise the automation of materials handling, KUKA’s Industry 4.0 robot, called the LBR iiwa, is a 7kg or 14kg payload robot that supports the Human and Machine Cooperation (HMC) concept with features that allow the new range to work without traditional safety fencing.

Greg Sale, CEO of KUKA Robotics Australia , who was in Germany for the launch, explained that the user’s ability to start and stop the robot with a gentle touch of the hand takes the whole operator/machine relationship to a new level.

Features of the new generation Industry 4.0 robots include using the sensitivity of the robot to check the correct weight of the product being picked up; waiting for a product to bump it before picking it up, making redundant the use of external sensors; or closing a machine door just as a human would, with variable force, all without the need for external or add on devices.

Speaking about the safety factor, Sale recalled he was a little nervous the first time he put his hand into the path of the LBR assembling two halves of a gearbox; however the force was a gentle touch and the robot pulled back without even leaving a mark.

KUKA Robotics Australia 03 9939 9656 www.kuka-robotics.com/australia 22 www.pacetoday.com.au SEPTEMBER 2014

The automating of processes in manufacturing and other industries continues apace, and robot sales have never been higher. Brent Balinski talked to spokespeople from three Australian Packaging and Processing Machinery Association member companies about some recent trends.

I

N industry, the drive for higher levels of automation is undeniable.

“Demand for all types of robots is on the way up,” explained Bill Saylav, Engineering Manager at JMP Engineering, when PACE asked about demand for increasingly popular lightweight robots.

Automation has been a hot topic this year especially, featuring in debates

about growing economic inequality and efforts to completely automate container terminals.

According to the International Federation of Robotics (IFR), worldwide purchasing of industrial robots has never been more robust.

The IFR’s figures show about 179,000 robots were sold globally last year.

According to JMP Engineering, demand for all types of robots is increasing.

The standout country was China, buying nearly one in five of all robots sold. Combined, the next four most robot-happy countries, Germany, Japan, USA and Korea accounted for half of the total market.

Asia/Australia stood out as the leading region overall. A regional increase in installations of 18 percent – to roughly 100,000 – was seen.

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IN FOCUS

Another trend in effect is the need for lightweight and particularly collaborative robots In Australia, the rush to robotise was even used recently to explain an increase in joblessness after the ABS showed unemployment creeping up to a 12-year high.

Automation is, according to shadow treasurer Chris Bowen, among the “greatest unspoken challenges” in the national economy.

“There is a disconnect here,” he said at the Financial Services Council annual conference last month.

“Productivity is going up but employment is not following to the degree that it should.”

Stay competitive

The jobs that automation has replaced aren’t limited to those in logistics and factories, with plenty of examples including in agriculture, trading, and even journalism.

In manufacturing the unavoidable need to automate to stay competitive has been used to explain the decline in demand for lower-skilled jobs, and the overall decrease in manufacturing employment.

As reported earlier this year, recent demand in Australia for robot assistance has been strong, with one company telling this magazine earlier this year that units sold increased from 690 to 1214, “a 76 percent jump from 2011 to 2012.”

Are some workers worried?

“In short, yes,” Stuart Shaw, Innovations Manager, Machinery Automation & Robotics, told PACE. “Production line workers tend to have this view.”

Those positive about the increase in automation say it’ll liberate employees from tedious tasks.

“Robots will free workers from repetitive tasks enabling them to move to more interesting roles,” Mark Emmett, Managing Director of HMPS told Manufacturers’ Monthly.

Saylav said there was some time to go until every production line role has been replaced by a robot.

“We can see that Australia still has a long way to go before it’s saturated by total automation,” he said.

While all types of robots are in increasing demand, there are some particular trends that some are noticing among types of machines and segments of the manufacturing industry.

Mechanical systems

According to Emmett, the use of robots in food and beverage has doubled every year in the last five.

Also, “Robots are replacing conventional mechanical systems,” he said.

Saylav agreed that demand was particularly strong in the types of robots required in food and beverage, in “mid- to high-speed” varieties.

“Australians are definitely consuming more than ever before and expect the supermarket shelves to be full at all times,” he explained.

Robots will free workers from repetitive tasks enabling them to move to more interesting roles Another trend apparently in effect, pointed out by the IFR and others, is the need for lightweight, particularly collaborative, robots.

The CSIRO has pointed out that these types of machines can offer productivity and flexibility advantages while being safe to integrate into a production line.

“Smaller, lightweight robots are the fastest growing robotic segment,” said Emmett.

Shaw agreed.

“Interest is increasing as the awareness and capabilities of lightweight robots is disseminated,” he said.

“Interest is escalating for collaborative robots that can work safely alongside humans.”

Collaborative ability (including teachability), flexibility, safety and speed all come up in conversations about automation trends.

“High demands require high speeds,” said Saylav, adding that JMP had increased the speed of its offerings in June.

“High speeds [also] require high efficiency.”

JMP Engineering 03 9460 1219 jmp.co.nz Machinery Automation & Robotics 02 9748 7001 www.machineryautomation.com.au HMPS 08 8150 1000 hmps.com.au SEPTEMBER 2014 www.pacetoday.com.au 23

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SPOTLIGHT

7best of the

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

Thermal mass flow meter The ST75 Air/Gas Flow Meter from Fluid Components International (FCI), which measures fuel gas, process gas, inert gas, waste gases and air in small line sizes, is suitable for optimising natural gas flow control for industrial ovens, heat chambers and furnaces to reduce process and plant fuel costs. Two of the most common types of industrial ovens are the batch oven and the conveyor oven. Batch ovens support variable production load sizes, volumes and multiple temperature profiles where a high degree of process flexibility is desirable. Conveyor ovens, on the other hand, support highly repeatable temperature profiles with uniform, predictable volumes.

FCI’s ST75 Flow Meter helps process and plant engineers more accurately control their complex heating processes to optimise rise time, which lowers gas consumption and minimises plant energy costs. In addition, reducing natural gas consumption shrinks a plant’s carbon footprint to protect the environment. The ST75 Flow Meter is equally well suited for low flow and high flow operations in industrial ovens and operates over a wide flow range, from 0.01 to 950 NCMH depending on line size.

For variable process conditions, the ST75 is factory preset to a wide turndown range at 10:1 to 100:1.

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

Suspended solids density meter This sensor uses non-radioactive ultrasound to measure and monitor the density of mix tank inflow, process slurries, silt in raw water, and backwash/wastewater sludge in tanks, pipes, re-circulation loops and clarifiers, and automates sludge removal.

It helps operators to adjust fluid/particulate/ chemical amounts for preferred concentrations, allows them to program underflow pumps to automatically shut off before biosolids become too thin, and assists in determining polymer dosages for improved filter press/centrifuge/digester performance. Changes in density may warn of breaks in filtration material. This non-intrusive sensor is simple to install, calibrate and clean.

CHEMTRACK Water Technology Services 02 9587 4988 www.chemtrack.com.au 24 www.pacetoday.com.au SEPTEMBER 2014

Hazardous area gear units and motors Motors and gear units from SEW-EURODRIVE meet the requirements for equipment intended for use in potentially hazardous areas in accordance with IECEx standards (international). Additionally, SEW’s motors and gear units meet ATEX (Europe) and HazLoc-NA (Northern America) standards. Being certified according to these standards makes them suitable for worldwide use. The motors and gearmotors are offered in IECEx according to equipment protection levels (EPL) Gb and Gc (gas protection) and Db and Dc (dust protection). The combined gas/dust approvals for SEW gearmotors simplify the selection process for the relevant drive components, reduce the number of variants and allow you to use the gearmotors in combined gas/dust zones. The 4-pole motors of categories 2 and 3 (or EPL .b and .c) are suitable for operation on a frequency inverter and in field weakening operation. SEW motors and inverters are available as electrical equipment in protection types “e” (increased safety), “nA” (non-sparking) and tb and tc (dust explosion protection). The gear units as non-electrical equipment are certified in protection types “c” (design safety) and “k” (liquid immersion). The compact, performance-oriented properties of the standard drives from SEW-EURODRIVE are also included in the hazardous area motors, which are available in various designs in the power range of 0.12-75 kW. SEW-EURODRIVE 03 9933 1000 www.sew-eurodrive.com.au

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

Industrial measuring amplifier HBM has released an industrial measuring amplifier, PMX, which is designed to optimise production and testing processes. PMX enables rapid integration in complete system and machine concepts and delivers numerous web-supported operating options. Quality assurance and system integration of measurement technology are important cornerstones in industrial production and in end-of-line test benches for the success of a product, and PMX has been developed to provide this. With HBM’s PMX, production data can be access password-protected via a web browser using an Internet-capable end device. This guarantees an overview of the processes and ensures maximum security. In addition, the combination of Ethernet technologies and the internet enable uncomplicated remote maintenance. Plus it’s possible to access a test device at HBM in Darmstadt, Germany from around the world at pmxdemo.hbm. com. Users can parameterise the system within seconds, using an upgradeable sensor database in the data acquisition software. Measurements during start up and for quality control can be immediately visualised and recorded. In addition, the free driver package enables integration within existing software and therefore within the complete system or machine concept.

HBM Test & Measurement 02 9889 8070 info@au.hbm.com

PULS MOSFET Redundancy Modules

Inductive proximity sensors

PULS have released a range of compact MOSFET redundancy modules. Redundancy modules are used for building N+1 and 1+1 redundant power supply systems where it is critical that a control circuit remains powered even if a power supply was to fail. Some of the key features of these new modules are low power losses and voltage drop due to MOSFET technology, short circuit output protection, reverse polarity protected inputs, 160% overload capability for 5 seconds and a plug connector on the output of the YR40.245 model which means that the module can be hot swapped without the need to turn off power to the load. The range includes modules which have 2 x 20A inputs and 1 x 40A output, 1 x 40A input and output as well as 2 x 40A inputs and 1 x 80A output. Voltages range from 12 to 56 Vdc depending on the model.

The Allen-Bradley 871P VersaCube 4-wire inductive proximity DC sensors integrate both standard and specialty features into a redesigned 40 mm rectangular housing suited for an even wider range of general purpose and welding applications. The VesaCube combines features such as Factor 1 sensing, high IP67, IP68 & IP69K ratings, extended sensing ranges, weld field immunity, slag resistance, complimentary outputs and high visibility LEDs into one package. The VersaCube offers extended range, complementary (N.O. + N.C.) outputs and equal sensing distance for all metals. The VersaCube features a highvisibility status indicator that can be seen from a long distance at 360°. When coupled with the mounting flexibility of the VersaCube, installation, alignment and troubleshooting are simplified. For demanding applications, the 871P VersaCube can be ordered with ToughCoat, a patented weldslag resistant coating on the sensing face.

ToughCoat prevents the adhesion and accumulation of weld splatter, as well as the associated problems – including physical damage or “burn-through” to the internal components. The result is a sensor that lasts considerably longer than its standard weld field immune counterparts.

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

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

Flow computer power module Emerson Process Management has released a power module for the ROC800 and ROC800L RTU Flow computers. The PM-30 offers increased power delivery and the flexibility to install the ROC800 in either 12 volt solar installations or 24 volt rack mounted installations without needing to change the power module. The PM-30 power module auto regulates any voltage between 11 and 30 volts DC. It offers increased power delivery to the ROC800 I/O of 70 watts of power – exceeding the PM-12’s 60 watts and the PM-24’s 30 watts. The additional power enables users to expand the I/O in the ROC800 without concern regarding power consumption. This module also offers improved monitoring with LEDs indicating the status of the 12Vdc and 3.3Vdc on the back plane. The ROC800 series flow computers are suitable for a variety of applications for a wide-range of liquid hydrocarbons including crude, refined products, special application products, lubricating oils and light hydrocarbons.

Emerson Process Management 03 9721 0200 www.emersonprocess.com SEPTEMBER 2014 www.pacetoday.com.au 25

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THE LAST WORD

SUSTAINABILITY

Global water issues Strategic planning coupled with investment can change water supply options, writes Bob Gill.

T

HE sixth iteration of the Singapore International Water Week (SIWW) has emerged as a key event for the global water industry. Although Singapore is a popular location for international conferences and exhibitions, the fact that the country plays host to this large-scale event for the water industry has roots more in its own experience managing water resources and assuring water security than its location.

For a long time following independence in 1965, Singapore relied on imports from Malaysia to satisfy much of its water needs. Given the occasionally tense nature of relations, the Singapore government was well aware that this was hardly an ideal situation for water security.

Through deliberate planning and targeted investments in research and technology over the last two decades, Singapore has sought to develop a diversified water supply beyond the traditional local catchment and Malaysian imports.

This has recently been achieved through the addition of two major new sources: NEWater, which is water reclaimed from wastewater and purified using advanced membrane technologies and ultra-violet disinfection; and desalinated water, which is water treated and processed from seawater.

Reverse osmosis plants

The four NEWater plants constructed since 2003 now deliver around 30 percent of Singapore’s water needs.

Two large reverse-osmosis desalination plants provide a further 25 percent.

Going forward, by 2060, Singapore is expecting NEWater and desalinated water to provide 80 percent of its water requirements.

At the opening of the second desalination plant in 2013, the country’s Prime Minister could quite rightly boast of a strategic weakness being turned into a source of thought leadership and competitive advantage.

26 www.pacetoday.com.au SEPTEMBER 2014

Through the Environment and Water Industry Programme Office (EWI) set up in 2006, Singapore’s vision is to establish itself as a “global hydro-hub”, such that it becomes a base for a water industry ecosystem to which international water companies are attracted to establish operations and where local companies can develop and grow their capabilities.

Mentioned here are some highlights of SIWW.

Lee Kuan Yew Water Prize

This international accolade was awarded to Orange County Water District (OCWD) of California for its pioneering

the MELSEC System Q series. With a modular control concept, the MELSEC iQ-R is said to reduce development, maintenance, and operating costs and also has a number of security and diagnostics features.

Energy management

Mitsubishi also showed its GOT2000 Graphics Operation Terminal, which features tablet-like operation, highquality graphics, simplified connectivity to other automation devices, and an MES interface option; and AX Energy – an integrated energy management solution that provides and visualizes (via web) information on energy

Attention must be paid to environmentally safe and economically efficient processing of domestic and industrial wastewater work in groundwater management and water reclamation using advanced water reuse technologies. The judging panel also cited OCWD’s achievements in public policy and community outreach that have helped increase public acceptance regarding water reuse.

Water Expo

The majority of exhibitors at SIWW’s Water Expo exhibition are equipment suppliers and EPCs to the water industry, with companies in evidence this year including well-known companies such as GE Power & Water, Veolia, and Black & Veatch. The international flavor was bolstered by a large number (17) of country pavilions.

So while it is a case of “more pumps than PLCs”, large automation suppliers seen at each SIWW included Mitsubishi Electric, Schneider Electric, and Endress+Hauser. All three supply products and systems to Singapore’s municipal water authority (PUB).

Mitsubishi Electric displayed its new MELSEC iQ-R PLC, successor to

consumption, financial costing, environmental impact.

Schneider Electric exhibited the company’s new Altivar Process variable speed drive (0.75 kW model), which targets utilities and process industries and includes dedicated features for water and wastewater processes. The company is marketed this as a “servicesoriented drive”, designed to reduce OPEX as a result of its embedded digital services.

Schneider also demonstrated its remote SCADA solution based on the SCADAPack RTU, which targets the type of dispersed infrastructure found in the water industry. ARC also noticed a poster in the booth that announced “Invensys is Becoming Part of Schneider Electric”.

First time in Asia

Endress+Hauser prominently displayed its new Liquiline System CA80/CAT8x0 analyzer for monitoring and optimizing nitrification performance in wastewater treatment plants. While the company launched this product at Hanover 2014,

this was the first time it was shown in Asia.

Other suppliers the show floor included Bentley Systems (software for water facility design), Elpro (industrial wireless solutions for water facility monitoring), and Festo (pneumatic systems for water facility automation).

Industrial water

Not surprisingly, industry was also in the spotlight at the event’s Industrial Water Solutions Forum. We heard discussions on water interdependencies and opportunities in four industrial sectors: chemicals & refining, pharmaceutical, electronics, and mining.

To varying degrees, all these sectors are set to see increasing demand for water processing and wastewater treatment systems over the next four years. Each has its unique set of requirements in aspects such as water access, purity, and disposal.

Increasing demand for water

Population growth, the urbanisation trend and increasing industrialisation are driving up the demand for water.

Indeed, according to OECD, by 2050 global demand will be 55 percent greater than it was in 2000. At the same time, water is becoming a scarcer resource and subject to greater contamination threats.

At the other end of the use cycle, increasing attention needs to be paid to environmentally safe and economically efficient processing of both domestic and industrial wastewater.

The experience of Singapore, which has successfully transformed from a highly water insecure country to near self-sufficiency, shows how strategic planning coupled with judicious (and large) investments in research, technology, and necessary infrastructure can produce a radical change in water supply options.

[Bob Gill (BGill@ARCweb.com)is Southeast Asia General Manager, ARC Advisory Group]. www.arcweb.com

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