What’s New in Process Technology Apr 2013

$MART THINKING $6.2M OFF REDEVELOPMENT COSTS, MILLIONS OF DOLLARS PER YEAR OFF ENERGY AND CARBON LIABILITY COSTS AND OVER ONE THIRD OFF EMISSIONS.

CARBON EMISSIONS

STEAM AJ Bush & Sons have long been one of Australia’s largest rendering operations.

AJ Bush selected WILEY to design and build their facility in Beaudesert, Qld in late 1992, and to rebuild the facility after a fire in 2001. We are now working together on a process focussed project to improve production efficiency and cut energy cost throughout the AJ Bush operation to reduce its direct carbon liability.

Wiley is helping AJ Bush to turn an inconvenient waste product into a lucrative energy recovery system. This will mean a huge annual energy saving, a new stream of export revenue and has secured a $6.2M redevelopment grant from the Clean Technology Food and Foundries Investment Program.

An innovative initiative to cap and recover unexploited biogas from their Beaudesert rendering ponds will save millions on annual energy and carbon costs, reduce annual emissions by over a third and reduce the intensity of remaining emissions by a further 64%.

Ecofficiency means improved efficiency, productivity and profit with reduced impact on our environment. That’s creating a better future!

www.wiley.com.au

0413

ON THE COVER

WHAT'S NEW IN PROCESS TECHNOLOGY APRIL 2013

CONTENTS 4

Legacy systems and today’s safety standards

Ideally suited for use in mid-sized control applications, the MELSEC L Series has been designed with Mitsubishi Electric’s familiar high reliability, user-friendly operation and functional flexibility in mind.

The rack-free design promotes high system flexibility, and all the key features that

Two-thirds of programmable systems in the process industry were installed before today’s safety standards were published

engineers require as standard are built in

8

New products

engineering costs.

10

Hot products online

20

Building a bridge to safety

36

PAT gains traction

ethernet and CC-Link (master or local sta-

PAT implementation is growing in the biopharmaceutical industry

tion) interfaces and an SD/SDHC memory

42

Automation safety over a non-safe industrial network

As I see it The importance of standardisation

to the base CPU, minimising hardware and Features of the MELSEC L Series include 24 I/O, a 2-channel high-speed counter, 2-axis positioning up to 200 kHz, pulse catch and interrupt functions and built-in data logging. Communications features include

card interface is provided for data storage.

Using just a single MELSEC L Series CPU with a power supply provides users with a potent solution.

Each MELSEC L Series CPU can be configured with mix-and-match snap-on selectable power supplies, a snap-on display unit and up to 40 expansion modules for additional functionality, including intelligent modules for motion, positioning, high-speed counters, communications and networking.

The compact size, easy expandability, networking capabilities and the multitude of built-in high-powered functions make the MELSEC L Series ideal for both standalone machine control and as networked stations in larger applications.

Mitsubishi Electric Australia www.mitsubishi-electric.com.au

NOW in DIGITAL! Your copy of What's New in Process Technology is now available as an online eMag.

http://www.processonline.com.au/latest_issues

LEGACY SYSTEMS

AND TODAY’S SAFETY STANDARDS

© iStockphoto.com/36clicks

Luis M Duran, Product Marketing Manager Safety Systems, ABB

4 WHAT'S NEW IN PROCESS TECHNOLOGY - APRIL 2013

www.ProcessOnline.com.au

It is estimated that about 66% of the programmable electronic systems (PES) running in the process industry were installed before the publication of today’s commonly used safety standards (IEC 61508 and IEC 61511/ISA 84).

T

he economic growth of heavily regulated industries such as the oil and gas industry and the power industry, the increased demand for energy from BRICs economies, particularly China and India, and the increased acceptance of international functional safety standards, especially after major incidents, are driving the growth of the safety automation market in the process industries, with a growth estimated at 9% CAGR. This trend is likely to continue for the process industries as about 66% of the programmable electronic systems (PES) used in safety applications were installed between 11 and 30 years ago; before ISA 84, IEC 61508 or IEC 61511 were issued and recognised as good engineering practices.1 Many users have also extended the life span of their system beyond their supplier’s obsolescence notice. ibid Additionally, there are many relay-based safety systems that missed the initial wave of automation, or were left alone, as installing a digital electronic programmable system was not economically feasible for the plant in those applications at the time.

Prescriptive versus performance-based functional safety standards The international functional safety standard IEC 61508, Functional Safety of Electrical/ Electronic/Programmable Electronic Safety-related Systems is a general standard applicable to multiple industries. In addition to IEC 61508, there are industry-specific standards. For the process industries, the applicable international safety standard is IEC 61511; ISA has adopted IEC 61511 in its latest revision of ISA84. Although there are similar changes affecting the machinery safety standards, this article will only cover the process industries and IEC 61511.

IEC 61508 and IEC 61511/ISA 84 are known as performance-based safety standards, contrasting with previous standards

www.ProcessOnline.com.au

that prescribe the type of protective functions needed to reduce risk. Performancebased standards require an analysis of the hazards associated with the process, the risk reduction alternatives and the determination of the performance needed to reduce risk to an acceptable level.

Grandfather clause The concept of the ‘grandfather clause’ in ISA-84.01-2004-1 originated with OSHA 1910.119. The grandfather clause’s intent is to recognise prior good engineering practices (such as ANSI/ISA-84.01-1996) and to allow their continued use with regard to existing safety instrumented systems.

According to ISA-TR84.00.04-2005 Part 1 Guidelines for the Implementation of ANSI/ ISA-84.00.01-2004 (IEC 61511 Mod): “For existing SIS designed and constructed in accordance with codes, standards, or practices prior to the issuance of this standard (e.g., ANSI/ISA-84.01-1996), the owner/ operator shall determine that the equipment is designed, maintained, inspected, tested, and operating in a safe manner.” 2 The technical report highlights two essential steps: • Confirm that a hazard and risk analysis has been done to determine qualitatively or quantitatively the level of risk reduction needed for each SIF in the SIS. • Confirm that an assessment of the existing SIF has been performed to determine that it delivers the needed level of risk reduction.

According to ISA-TR84.00.04-2005 Annex A.2 2, if those activities have not been done, they should be scheduled for review at the “next appropriate opportunity”, which means if any of the following conditions is met: • Modifications are made to the process unit that impact process risk managed by the SIS. • Modifications are made to the control system that impact protection layers used to achieve safe operation.

APRIL 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 5

© iStockphoto.com/36clicks

Safety systems

• When an incident or near miss investigation has identified an SIS deficiency.

• When the review of another process unit designed according to similar practice has identified an SIS deficiency.

Where are the safety certificates?

In reviewing project specifications during the bidding phase of a project, it is common to find ISA 84 or IEC 61511 as a requirement for mandatory compliance.

Compliance to IEC 61511 implies more than a certified system, particularly at the time of design and implementation. On the subject of PES, this standard requires that components and subsystems selected for use in SIL 1 through SIL 3 shall either be designed in accordance with IEC 61508-2 and IEC 61508-3 or comply with the ‘Proven-in-Use’ criteria. Additionally, the system programming tool should use limited variability languages, defined in the standard as “software programming language, whose notation is textual or graphical or has characteristics of both, for commercial and industrial programmable electronic controllers with a range of capabilities limited to their application” 3.

As the reader might anticipate, the majority of the programmable electronic systems used before 1995 were not certified to the same criteria as those released to the market over the last 10 years. Legacy systems are likely to be general-purpose systems (like a standard PLC) or an early version of safety PLC/ PES (first-generation safety system).

Proven-in-Use In order to keep using a system that is not certified according to IEC 61508, the user must demonstrate ‘Proven-in-Use’ and such demonstration shall include: • The manufacturer’s quality management system.

• Adequate identification and specification of the components and subsystems.

• Demonstration of the performance of the components or subsystems in

similar operating profiles and physical environments.

• The volume of operating experience.

• The documented evidence shall demonstrate that the likelihood of any failure of the subsystem is low enough so that the required safety integrity level(s) of the safety function(s) is achieved.

Certified to IEC61508 If the system has an IEC61508 certification, then it is important to understand the criteria used by the third-party assessor for issuing such certification to a first generation safety system. The IEC 61508 standard recognises the following four criteria in the assessment of Safety PLCs/Programmable Electronic Systems: • Hardware safety integrity • Behaviour in the presence of failure • Safe failure fraction (SFF) • Systematic capabilities Most first-generation safety systems were certified on the basis of hardware safety integrity, which is related to redundancy and behaviour in the presence of failure, and these two concepts were sufficient to describe their performance that at the time included few and maybe limited software diagnostics. Many of these systems used relay ladder logic as a programming language, which was a representation relay-based logic and useful at the transition point between said technology and the emerging digital systems.

SFF and systematic safety integrity are new terms for many users, and particularly Systematic Capabilities is a new concept that many of the first generation of certified systems today do not support, although it is a requirement gaining more visibility in the newer edition of IEC 61508 published in 2010.

To release a certified system following the newer revision of the standards, the vendor needs to start by establishing a functional safety management system (FSMS) and having the development organisation certified by an independent assessor. The FSMS requires the design

6 WHAT'S NEW IN PROCESS TECHNOLOGY - APRIL 2013

process to document and track functional requirements, to review functional specifications and test against requirements, and to validate performance and results during the development of the product. Every step needs to be properly documented; the competence of the personnel involved in each step is also documented. It might be easier to understand for the reader if the FSMS is compared to a quality assurance process - it will be difficult, if not impossible, to assure or even test performance if the performance criteria are not well defined and documented.

Over time it will be very challenging for a product vendor to certify a system to the latest revision of IEC61508 if their development organisation was not previously certified and if their design practices lack the FSMS and the document trail explained in the previous paragraphs.

The reader is probably familiar with the discussions around the architecture of programmable electronic systems used in safety applications, as the majority of first-generation safety systems used redundancy (hardware safety integrity) to satisfy the requirements of low demand applications commonly found in the process industries.

Product developers in the safety automation market might adopt different design methodologies, but current functional safety standards encourage the use of software diagnostics and diverse technologies.

Diverse technology Technology has evolved to a point at which there are multiple options to address a similar technical problem. For example, by selecting two or more of these technologies, diversity can be embedded in the system design.

Examples of diverse implementation include using different operating systems and then using different teams to develop the software on multiple cooperating modules, or combining two different technologies (such as microprocessors or microcontrollers and field programmable

www.ProcessOnline.com.au

Safety systems

IEC 61508 AND IEC 61511/ISA 84 ARE KNOWN AS PERFORMANCEBASED SAFETY STANDARDS, CONTRASTING WITH PREVIOUS STANDARDS THAT PRESCRIBE THE TYPE F PROTECTIVE FUNCTIONS NEEDED TO REDUCE RISK.

gate arrays (FPGAs)) to perform the same functionality in parallel to each other.

Unlike traditional redundancy, the application of diverse technologies achieves a redundancy scheme with minimum or no common cause failures.

IEC 61508 Edition 2 There are other concepts added to IEC 61508 Edition 2 that might affect compliance and should be considered when choosing a PES. This article will concentrate only on the following three areas, but the author encourages the reader to seek additional information on the topic.

• Systematic capabilities • Competence • Security

Systematic capabilities Today it is well understood that a system can be designed following a very strict development process, using a rock-solid FSMS, and even certified by the best independent authority, yet the system can be programmed in a way that disables its safe action under some conditions.

Systematic capabilities should assist in the assessment of the programming tools to avoid this kind of situation.

Systematic capabilities is a concept developed to replace the term ‘effectiveness against systematic failure’ and is a measure (on a scale of 1-4) that the systematic safety integrity of an element fulfils the given safety function, considering the instructions stated in the product safety manual.

Competence Competence has been recommended in the previous edition of the standard; however, it is now mandatory for compliance (normative). The following are the requirements: • Organisations involved on safety system projects or activities shall appoint one or more persons with responsibility for one or more phases of the safety lifecycle (as per IEC61511).

• All persons, departments or organisations shall be identified, and the responsibilities clearly defined and communicated.

www.ProcessOnline.com.au

• Activities related to the management of functional safety shall be applied at the relevant phases.

• All persons undertaking specific activities shall have the appropriate competence.

• The competence shall be documented.

Competence is particularly critical in the management of functional safety and in the case of a functional safety assessment may apply to independent individuals or departments depending on the consequence of the hazard.

As concerning as the competence requirements may sound, it is important to highlight that there are competent resources available worldwide, either as independent consultants or associated with product vendors, and available to provide support throughout the implementation of the safety lifecycle.

Security Infrastructure security and network security have been the subject of several papers and blogs. The targeted attack of the Stuxnet worm in 20104 confirmed the industry concerns. The subject is recognised in the revision of the standard - not in the application specifics or to specify the requirements needed to meet a security policy - but advises potential security threats should be added to the safety requirements.

Section 7.4 (Hazard Analysis) of the IEC 61508 standard requires that in the case that the hazard analysis identifies the potential for malevolent or unauthorised action constituting a security threat is reasonably foreseeable, then a security threat analysis should be carried out.

Following this, Section 7.5. (Overall Safety Requirements) recommends that a vulnerability analysis should be undertaken in order to specify security requirements.

Summary This article explains some of the changes in the functional safety standards IEC 61508 and IEC 61511/ISA 84 and identifies the key elements to assess if a safety system

installed the late 1980s and early 2000s meets the certification requirements for applications in the process industries.

An existing installation is only covered by the ISA84 grandfather clause if the owner/operator can demonstrate that the equipment is designed, maintained, inspected, tested and operating in a safe manner. In addition, if a system is not be certified according to IEC61508, then according to IEC 61511 those systems should comply with the Proven-in-Use criteria. For those systems certified to the first edition of IEC 61508 only on the basis of hardware fault tolerance, there are technical challenges that might limit the ability of those systems to retain that certification when the industry moves to IEC 61508 Edition 2.

IEC 61508 Edition 2 also introduces additional criteria such as security and increases the importance of systematic capabilities and competence. The notion of competence requires organisations involved on safety system projects or activities to appoint one or more persons with responsibility for one or more phases of the safety lifecycle (per IEC61511) and the adoption of a functional safety management system.

References 1. A RC A d v i s o r y G ro u p , 20 1 0 , I N S I G H T # 20 1 0 - 53 E M P H Th e C o m i n g Wave of Process Safety System Migration 2. ISA Europe, 2005, ISA-TR84.00.04-2005 Part 1 Guidelines for the Implementation of ANSI/ISA-84.00.01-2004 (IEC 61511 Mod) 3. International Electrotechnical Commission, 1998, IEC 61508-4 Functional safety of electrical/electronic/programmable electronic safety-related systemsPart 4: Definitions and abbreviations 4. Byres E, Howard S, 2010, Analysis of the Siemens WinCC/PCS 7 “Stuxnet” Malware for Industrial Control System Professionals, Tofino Security ABB Australia Pty Ltd Contact info and more items like this at wf.net.au/T258

APRIL 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 7

NEW PRODUCTS

ULTRASONIC LIQUID LEVEL TRANSMITTER CONTROLLER The Series UTC ultrasonic liquid transmitter controller provides reliable, accurate, non-contact measurement of liquid level and open channel flow even under extremely harsh conditions. It overcomes vapours, agitators or light foam, with no moving parts to wear or jam.

It supports a full range of process monitoring and storage level measurement applications, such as high process tanks and large storage vessels.

PERMANENT FIELD MOTOR WITH INTEGRATED ELECTRONICS The DRC electronic motor series consists of a permanent-field synchronous motor and matching integrated drive electronics. The motor is also available as a brake motor, making it suitable for hoists and inclined conveyors. A bevel, helical or parallel-shaft gear unit can be mounted directly via the flange and output shaft.

The motor efficiency of the DRC surpasses the requirements of the highest efficiency class IE4 (Super Premium Efficiency), making it possible to save up to 50% of the energy costs compared to conventional electric drive technology.

SEW-Eurodrive’s Single Network Installation (SNI) technology requires only one 4-wire cable for power supply and communication. For standalone applications or systems with simple drive functionalities, variants with binary control and AS-Interface communication are available. The fourth variant is equipped with the CAN-based SEW system bus SBus, which provides flexibility for integrating various fieldbus networks, increasing system performance for the realisation of sophisticated drive tasks.

The DRC electronic motor series is available in two distinct frame sizes covering a power range up to 1.5 kW with a further 250% overload capacity. Available with an IEC flange option and a degree of protection up to IP66, the DRC motor can be used for stand-alone motor application in challenging environments. System emergency stop functionality can be easily realised in conjunction with the integrated Safe Torque Off

The UTC has a 6-digit LCD and a simple menu structure with multiple indications, making programming simple. Its dual part system allows for the control unit to be located up to 200 m away from the sensor (model UTS purchased separately), and installation is simple with an included mounting bracket.

In addition, this series also supports the Modbus RTU communication protocol and offers RS232 and 4-20 mA communications.

Featuring five independent SPDT relays and embedded firmware for volume and flow totalisation, this transmitter controller is suitable for liquid level and open channel flow applications.

Dwyer Instruments (Aust) Pty Ltd Contact info and more items like this at wf.net.au/S813

Safe Circuit - SIL3 according to IEC 61800-5-2:2007.

The DRC electronic motor covers a wide voltage range from 380 to 500 V at 50/60 Hz and meets all application standards, directives and efficiency regulations.

SEW-Eurodrive Pty Ltd Contact info and more items like this at wf.net.au/T097

ETHERNET SWITCH MONITORING Red Lion Controls has announced the integration of its Crimson 3.0 configuration software with N-View server software from N-Tron. With this announcement, all N-Tron and Sixnet industrial ethernet switches can be monitored from any locally mounted Red Lion G3 operator interface.

This offers users the benefit of using Red Lion operator interfaces as visible dashboards to monitor, display, log and alert on network status received from N-Tron and Sixnet industrial ethernet switches.

For users with N-Tron switches, the integration of Crimson 3.0 and N-View allows plant managers and IT staff to efficiently monitor a number of different network parameters - including data collisions, received packets, dropped packets, alignment errors and more - from a single dashboard. For customers with Sixnet switches, monitoring is accomplished via Modbus. Advanced data logging features offer users the ability to collect and review network performance history.

Email and SMS notification is also available to alert remote personnel of network issues.

Control Logic Pty Ltd Contact info and more items like this at wf.net.au/T008

8 WHAT'S NEW IN PROCESS TECHNOLOGY - APRIL 2013

www.ProcessOnline.com.au

MASONEILAN CONTROL VALVES and CONSOLIDATED SAFETY VALVES MASONEILAN LINEAR AND ROTARY CONTROL VALVE SOLUTIONS:• For Severe Service in Oil and Gas Applications; • For High Pressure and Temperature Media in Power Plants; • For Erosive and Corrosive Service in Mining Services; • For High Turndown in Contaminated CSG Fluids; • For Noise Control in Gas Transmission; • For Contaminated and Fibrous Pulp and Paper Plant Duties; • For Precise Control Performance in Food Processing Plants; • In fact, for any Modulating Control Application at all ...

CONSOLIDATED SAFETY RELIEF VALVES:• For ASME Section I and Section VIII Relief Valve Applications; • For Applications that require the highest level of Quality – without compromise; • For Duties that require unique Material Combinations; • For Processes that demand rugged and proven design; • There is only one Solution ... CONSOLIDATED!

LOCALLY ENGINEERED AND SIZED IN AUSTRALIA LOCALLY ASSEMBLED AND TESTED IN AUSTRALIA LOCALLY SERVICED AND REPAIRED IN AUSTRALIA ASME Section I and Section VIII Certification Coming Soon POWERFLO SOLUTIONS PTY LTD

AUTHORISED DISTRIBUTORS AND REPAIR PARTNERS FOR GE MASONEILAN AND CONSOLIDATED

Email: sales@powerflo.com.au Tel: 1300 658 701

HOT PRODUCTS

ON WWW.PROCESSONLINE.COM.AU THIS MONTH TESTING SOFTWARE VeriStand 2012 supports real-time model execution from a variety of modelling environments and has an open, extensible architecture.

National Instruments Australia

>

WF.NET.AU/T318

> TEMPERATURE INDICATORS The Noshok 820/821 Series digital temperature indicators are a suitable replacement for bimetal, liquid-bulb and glass thermometers.

AMS Instrumentation & Calibration Pty Ltd

WF.NET.AU/T236

>

ISOLATION AMPLIFIERS

>

VIBRATION SWITCH

The Series VBS vibration switch is compact and uses two easy set-up dials that adjust the maximum RMS velocity set point and false

The Phoenix Contact Mini Analog isolation amplifier series has

trip time delay.

been expanded with new modules.

Dwyer Instruments (Aust) Pty Ltd

Phoenix Contact Pty Ltd

WF.NET.AU/T399

WF.NET.AU/T178 10 WHAT'S NEW IN PROCESS TECHNOLOGY - APRIL 2013

www.ProcessOnline.com.au

Domino iTech

A tried&true way to LEAN your labelling and coding operations.

Domino introduces iTech: Common parts, software and control pads for all coding technologies.

Today’s business is about LEAN operations, process improvement and achieving 100% quality. The new Domino iTech range allows users to control multiple technologies from a single touch point, and provides maintenance staff access to common parts for all equipment.

Achieving LEANER operations, Domino’s iTech range allows the use of common parts, software and control pads for continuous ink jet, laser, thermal ink jet, thermal transfer overprint and print and apply technology.

Contact us to find out more about the Domino iTech range.

Phone: 1300 467 446

|

Email: sales@insignia.com.au

|

Web: www.insignia.com.au

NEW PRODUCTS

CONTROL SYSTEM Honeywell has upgraded Experion PMD, boosting the range and functionality of its automation

DIN RAIL POWER SUPPLIES The Meanwell SDR-960 series of DIN rail-mounted power supplies has built-in power factor correction, an input voltage range of 180-264 VAC and free-air convection cooling. These power supplies offer up to 94% efficiency, delivering full output power up to an ambient temperature of 50°C. The series features a 110 mm slim design, front panel DC voltage adjustment, and a LED power-on indicator.

The units also have a built-in parallel function, allowing for current share with up to four units, and can handle 130% of peak load for 3 s. A DC OK relay contact is provided, as well as short circuit, overload, overvoltage and overtemperature protection.

solution for controlling processes, machinery and drives through a single system.

The updated release of Experion’s integrated Process, Machinery and Drive control (PMD) widens the scope of the solution further, integrating Experion Alarm Management, Experion Integrated Historian, OneWireless and Digital Video Manager solutions for the first time. Release 800 also adds

Soanar Limited

a new Field Controller Express

Contact info and more items like this at wf.net.au/T164

(FCE) controller with over 60% more controller-point capacity, integrated Profibus and TotalPlant Alcont Upline/IOline highway interface, native peer-to-peer connectivity with Experion MX and the Experion PKS controller family through parameter connection and a single point of data entry.

PMD controllers can be used on all control levels for implementing advanced controls, fast machine controls and process controls.

A single, consistent set of engineering tools across these levels means lower capital costs and enables cost-effective execution of production line and plant-wide control. Benefits include reduced database maintenance, easier training, increased access to diagnostic information, single alarm and event logging, and faster control responses.

The release is fully scalable and also continues to support migration from Honeywell’s TotalPlant Alcont (TPA) systems. Users migrating to Experion PMD are able to re-use many existing TotalPlant Alcont assets to minimise costs, and commissioning and start-up times. Existing TotalPlant Alcont application solutions are converted to Experion using existing cabinets, I/O and wiring so the costs of implementation can be minimised while significantly extending the life of assets.

Honeywell Limited Contact info and more items like this at wf.net.au/T239

12 WHAT'S NEW IN PROCESS TECHNOLOGY - APRIL 2013

www.ProcessOnline.com.au

NEW PRODUCTS

E-STOP RANGE Banner Engineering has expanded its line of emergency stop buttons with the surface flush mount E-Stop. The 40 mm emergency stop buttons are designed to mount on a wall or other flat surface without disassembling or individual wiring. They are available with a non-illuminated base with four actuator styles: standard, illuminated actuator, lockable actuator and an illuminated lockable actuator; or with an illuminated base with a standard or a lockable actuator.

The illuminated-base e-stops feature Banner’s EZ-Light logic and are available with two colours (yellow or green and red lighting) or one colour (red lighting). Depending on the model, the highly visible LED illuminated-base changes from yellow to flashing red when actuated.

The lockable-style actuator can provide supervisory or personal control. It is intended to prevent unauthorised or accidental resetting by accommodating a padlock to secure the actuated button in place.

Multiple e-stops can be connected via the CSS Series hookup cordsets for system-wide control. By applying an external signal via the M12 QD connector, the illuminated-base models can change from a steady yellow light to a steady red indicator light when a stop condition exists. Models that interface with SafetyBUS nodes and gateways are also available.

The e-stop buttons have a safe break action to ensure the safety contacts will open if the contact block is separated from the actuator. The push-to-stop, twist-to-release or pull-to-release actuator and direct (positive) opening operation is compliant with ANSI B11.19, ANSI NFPA79, ISO 13850 and IEC/EN 60204-1 Emergency Stop requirements.

Micromax Pty Ltd Contact info and more items like this at wf.net.au/S835

DATA LOGGER PAC WITH SMS The WISE-5801 is an intelligent data logger PAC controller with SMS functionality from ICP DAS. WISE (Web Inside, Smart Engine) is a product series developed by ICP DAS that functions as control units for use in remote logic control and monitoring in various industrial applications. WISE offers a user-friendly and intuitive web interface that allows users to implement if-then-else control logic on controllers with a few clicks; no programming is required.

WISE-5801 provides data logging functionality to record the I/O channel of the controller by event trigger or at regular time intervals. It then sends the data files by FTP or email at a scheduled time to the control centre for further administration management or data analysis. WISE-5801 also features an SMS sending function for alarm messages.

The logger allows users to connect to a wide range of XW-Boards, I-7000 Remote I/O modules and Modbus RTU slave devices that enable users to freely choose the most suitable I/O modules, and provide users more flexibility for their application.

ICP Electronics Australia Pty Ltd Contact info and more items like this at wf.net.au/T094

www.ProcessOnline.com.au

APRIL 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 13

Gearmotors keep mining industry equipment working in the toughest of conditions Despite the strong Australian dollar, the electrostatic separation technology company OreKinetics is exporting over 60% of its revolutionary machines to titanium mining operations all over the world including China, India, South Africa, the US, Canada and Indonesia.

Research by Peter Gates, OreKinetics Founder and Managing Director, in 1999 led to the development of the company’s UltraStat conductive induction separator and the CoronaStat ionised field separator the following year.

“Our electrostatic mineral separators have been widely accepted as the new benchmark in their field, with installations on four continents testament to their rapid and ongoing acceptance.

Our machines can separate minerals better than any other.

That’s the reason for our success; impressive service coupled with innovative IP,” Gates explained.

“The separators greatly improve process efficiency, reduce plant complexity and allow separation of minerals not previously possible. Our machines are very robust and capable of processing five to eight tonnes of material an hour on a continuous basis; 8000 hours a year or more, in hot industrial mining environments, in truly tough conditions, where it is extremely dusty and gritty.

He explained that the UltraStat separators use a very different mineral charging mechanism to ionised field (corona) separators.

“A strong static electric field is used to selectively induce charge onto the conductive mineral particles (conductive induction charging).”

Gates said the mineral passes beneath a charged electrode that induces a polar opposite charge on the conductor particles; as a result, these charged particles are electrostatically attracted to the electrode and are drawn away from the grounded surface.

“A splitter located further in the separation zone separates the conductor particle and non-conductor particle trajectories dividing the feed into mainly non-conductor and conductor fractions.”

Gates also explained that the company’s CoronaStat machines utilise ionised field separator technology combined with a unique combination of three electrodes to achieve vast performance improvements over conventional HTR (high-tension roll) separators.

“Customarily, ionised field separators utilise a grounded roll that transports a feed material through a high-voltage ionising field (corona) which charges the mineral particles by ion bombardment. Conducting particles lose their charge to the earthed roll and are thrown from the roll by centrifugal and gravitational forces. Non-conducting particles are pinned to the roll surface and are transported further through the separation zone before their charge either dissipates and they are thrown off or they are removed by mechanical means.

“When it came to choosing the electric motors and the gearboxes to drive our machines, we went with SEW-Eurodrive right from the

14 WHAT'S NEW IN PROCESS TECHNOLOGY - APRIL 2013

beginning, and still only use their equipment now 13 years on. SEWEurodrive gives us high-quality, reliable service, plus the quality of the company’s products is excellent. They are good robust motors and gearboxes that can operate in extremely harsh environments.

“Our customers want an efficient, reliable machine. With SEWEurodrive for all our motors and gearboxes we get excellent support plus they offer us the ability to get our larger quantities directly from Germany, by the container load. We bought well over 1000 gearboxes from them last year.

“Another key advantage for us is their MEPS 3 higher efficiency motors. With high-efficiency motors we can set the machine’s overloads at a normal current setting with the benefit that we get slightly higher output torque giving us the capability to set higher brush tensions in our machines if required,” he added.

Wo r k i n g c l o s e l y w i t h OreKinetics, John Bel lert, Technical Sales Representative with SEW-Eurodrive, explained that the electrostatic separation technology company produces a range of machines demanding different quantities of gearmotors: “For example, on one separator there are eight Spiroplan W Series and six parallel shaft helical F Series gearmotors.

Bel lert said the reason OreKinetics chose their gearmotors is because of their reliability and their high efficiency compared to other gearmotors on the market.

“The Spiroplan gearmotors, for example, are economical, robust, right-angle gearmotors that feature incredible reliability, low operating noise and life-long lubrication. They feature steel-on-steel gearing, special tooth meshing relationships and an aluminium housing ensuring they are very quiet in operation, wear-free and lightweight,” Bellert said.

He said the F Series gearmotors were also very popular in the mining industry due their high power density, high permitted overhung loads and a multistage gear unit for low output speeds.

“These two- and three-stage, extra-slim parallel shaft helical gearmotors are very robust and are designed for heavy-duty applications, high torque and 24/7 operation. They are the perfect solution when space is limited.

“We also understand how important it is for companies in all industries to have minimal downtime. All of our components are still manufactured in Germany, with the gearboxes and motors handassembled here in Australia with excellent quality control.”

Bellert explained that every SEW-Eurodrive motor and gearbox has a unique serial number which allows customers, via a smartphone app, to instantly download a wide range of information on the equipment including type and quantity of oil required, maintenance procedures and spare parts list.

SEW-Eurodrive Pty Ltd Contact info and more items like this at wf.net.au/ T321

www.ProcessOnline.com.au

Our safety experts talk safety.

Our operators talk control. But when it comes to keeping our people and plant safe, we all need to speak the same language.

YOU CAN DO THAT Eliminate uncertainty, reduce your risk with DeltaV SIS. Emerson’s smart safety instrumented system provides an integrated, intuitive set of engineering tools and software that enables your team to handle configuration, alarms and device health monitoring–while maintaining the systems separation required by IEC 61511 and 61508 standards. The DeltaV SIS system reduces your training and lifecycle costs by eliminating complex data-mapping and multiple databases while helping to ensure that you’re meeting safety compliance. Learn more about safety processes and best practices by downloading the Safety Lifecycle Workbook at: www.DeltaVSIS.com/workbook

The Emerson logo is a trademark and a service mark of Emerson Electric Co. © 2012 Emerson Electric Co.

www.ProcessOnline.com.au

APRIL 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 15

NEW PRODUCTS

LASER MEASUREMENT SYSTEM FOR CASTING ROLLERS Simetal Opal from Siemens Metals Technologies provides operators of continuous casting plants with an integrated laser measurement system for exact alignment of strand guide rollers. The system achieves high measuring accuracy of ±0.07 mm, even under the hostile ambient conditions prevailing in a steelworks.

Simetal Opal registers the strand guide rollers’ current positions and, after quality control, saves the measured data in a log file. An intuitive user interface and automated measurement sequences make it easy to use locally and reduce measuring times. Saved measurements serve as the basis for condition-based maintenance of the strand guide system, which cuts maintenance costs. The system can be integrated into both new and existing plants.

The system uses a high-precision rotation laser, whose beams embrace a plane in space. This is used as the reference point for measuring the strand guide rollers. A laser receiver with an integrated microprocessor logs the measured values and transfers them wirelessly to a control unit where they are analysed and backed up automatically with the aid of the specially designed software. For each measurement, the system generates a test report that can be archived. This permits a precise comparison of target and actual positions. The system also features intelligent measured data management, which can be linked to monitoring the plant’s status. This helps the plant operator to observe the required maintenance intervals and creates the foundation for a condition-based maintenance strategy.

Siemens Ltd Contact info and more items like this at wf.net.au/T361

AUTOMATION CONTROLLER Based on the third-generation Intel Core i-series processors, the B&R Automation PC 910 (APC910) offers maximum computing power for complex tasks, such as sophisticated machine vision and multiaxis motion systems.

Industrial PCs are characterised by taking a standard ‘Wintel’ approach, and waving the ruggedising wand over the case and components; improving tolerance to vibration, and providing cabinet mounts. Add a solid state drive and its reliability is significantly enhanced compared to a workstation bought from an appliance retailer. The APC910 is fanless and cableless, and has the option of a built-in UPS. The B&R real-time operating system provides higher performance and reliability than COTS operating systems. Effectively an OS and PLC in one application, a PC-based controller accepts a PLC program download just like a traditional PLC. Hypervisor technology allows multiple operating systems to run on a single multicore processor. Thus a dual (or more) OS PC can be built - each OS is assigned a core and all run simultaneously. This powerful feature, effectively quarantining each OS and the applications within, allows a single PC to perform reliably as a controller, without the concerns that other applications could affect reliability. One core can run the realtime OS for control, while another can run Windows to host a SCADA server or client, reporting tools or just a desktop for web browsing.

Daanet Pty Ltd Contact info and more items like this at wf.net.au/T324

Now working with the

Industry Capability Network to maximise Australian content in major projects To find out more, or to register to use the Australian Made logo, visit www.australianmade.com.au or phone 1800 350 520 5809AM

16 WHAT'S NEW IN PROCESS TECHNOLOGY - APRIL 2013

www.ProcessOnline.com.au

www.ProcessOnline.com.au

APRIL 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 17

NEW PRODUCTS

PROCESS OPTIMISATION SOFTWARE Aspen Technologies has released the aspenONE V8 edition. The edition offers an enhanced version of Aspen HYSYS; solids modelling functionality integrated within Aspen Plus; a new version of Aspen Collaborative Demand Manager, and innovations in advanced process control, energy and economic analysis.

The edition features an updated version of Aspen HYSYS. This process simulator offers a redesigned interface, streamlined workflow and interactive analysis, to make it faster and easier to generate optimised process simulations for the hydrocarbon industry.

The integration of recently acquired SolidSim technology into Aspen Plus eliminates silos between previously disparate solids and liquids modelling processes. This makes it possible to optimise all chemical processes together.

Both Aspen Plus and Aspen HYSYS now incorporate an Activate function. This allows process engineers to quickly find energy and capital cost savings. Process engineers can quickly identify ways to change process designs to reduce energy consumption, saving design time and future operating costs.

The Adaptive Process Control functionality in the V8 edition automates many of the tasks that traditionally required costly control engineering resources. APC creates a continuous process of assessing plant model quality, collecting current data, and generating new models as the behaviour of the plant changes over time.

To support the additional functionality and increased data manipulation, an updated Aspen Collaborative Demand Manager provides the user with the information granularity needed to manage different forecasting requirements. Process manufacturers can improve demand forecast accuracy to increase customer service levels, reduce excess inventory, and provide better input to purchasing decisions.

Aspen Technology Australia Pty Ltd Contact info and more items like this at wf.net.au/T092

ULTRASONIC FLOW METERS Mass Flow Online BV has released the Sonic-View Series ultrasonic flow meters for water and aqueous solutions. The compact, non-obstructive instrument operates on the basis of two ultrasonic transducers, mounted on the outer surface of a straight, stainless steel tube. The flow meter does not contain any moving parts, causes virtually no pressure loss and can be mounted in any position, requiring no straight inlet or outlet runs. Its sensor housing is IP54 protected.

The inline ultrasonic flow meters are available in nominal sizes DN10 and DN20 for flow ranges of 1.5-30 L/min and 5-110 L/ min respectively. Both versions provide frequency and analog output proportional to the flow and an additional alarm output.

The alarm status is indicated by an LED and the alarm level can easily be adjusted by means of a rotary switch on the front cover.

Mass Flow Online BV www.massflow-online.com

18 WHAT'S NEW IN PROCESS TECHNOLOGY - APRIL 2013

www.ProcessOnline.com.au

Everything you need to order your FREE 2013 Schneider Electric Catalogue.

Australian Catalogue

13/14

Helping you make the most of your energy Electrical distribution Automation & control Services & support

Simply visit www.schneider-electric.com.au/catalogue and register to receive your printed copy.

Š 2013 Schneider Electric. All Rights Reserved. Schneider Electric and Make the most of your energy are trademarks owned by Schneider Electric Industries SAS or its affiliated companies. • www.schneider-electric.com.au CLIPCOM25792

www.ProcessOnline.com.au

APRIL 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 19

© iStockphoto.com/Baran Özdemir

BUILDING A BRIDGE TO SAFETY

AUTOMATION SAFETY OVER A NON-SAFE INDUSTRIAL NETWORK Zachary Stank, Phoenix Contact

Safety in today’s market has come a long way from the simple, single-function safety relays of the past.

Now engineers are left to question which is best for the efficient implementation of the prevailing safety requirements in their process: programmable, network-enabled safety controllers or spatially limited, configurable safety relays?

I

n machine automation, one of the primary objectives is the efficient and flexible integration of safety functions, and machine and plant engineers must observe functional safety standards, such as ANSI B11.19, EN ISO 13849 and IEC 61508, when they are constructing their equipment. Every automation system is different, but similar safety solutions are effective when comparing equally scaled applications. For smallscale applications, simple-to-configure safety relays are usually better suited, whereas large-scale applications usually employ highly integrated and networked failsafe PLCs. A new approach encompassing both flexible and easy network communications would bridge these two solutions and support machine builders during the realisation of an efficient, networked safety solution without the need for a full failsafe PLC.

20 WHAT'S NEW IN PROCESS TECHNOLOGY - APRIL 2013

Configurable safety relays Configurable safety relays are similar to hard-wired safety relays but contain the logical processing power required to configure multiple safety sensors using a single device. The logic configuration is typically done using a screwdriver on a selector dial, a simple on-board configuration screen or basic software configuration. Technological developments also allow these devices to report status back to a master PLC via an RJ45 or fieldbus module connection.

Easy configuration and communication with logical controllers have greatly contributed to the growth of configurable safety relays in hazardous applications. Customers can now have a customisable safety solution that requires less wiring time and can be integrated without special training or advanced classes in programming languages. This can reduce logistics costs, because one part number

www.ProcessOnline.com.au

Safety networks

can be stocked to handle all safety applications for all machines or processes. Even the safety program can be saved and transferred to replacement devices for easy repair.

Even with all these advantages, configurable safety relays still fall short of safety PLCs in distributed safety applications because they cannot communicate over a safe network. In a distributed safety application, safety inputs and outputs are needed throughout the machine.

To accommodate systems like this, there are two options: • The installer can run safe I/O wiring across long distances through the machine back to the configurable safety relay.

• Each remote safety application can use separate configurable safety relays. This will lead to increased wiring and set-up times, as well as inefficient use of configurable safety relay I/Os. Because of these shortfalls, the only efficient way to connect a distributed safety system is to use a safe PLC and its associated safety protocol.

Programmable safe PLCs While configurable safety relays replace simple relay solutions at moderate safety I/O counts, the programmable failsafe PLC

www.ProcessOnline.com.au

replaces the configurable safety relay at higher safe I/O counts.

A programmable failsafe PLC also has significantly more processing power and safety functionality. These specialised PLCs offer better integration, programming resources and a larger amount of usable safety signals for functions like safe motion and robot control. The failsafe PLC uses a standardised safety network to communicate to safe I/Os on the network. This allows direct control and monitoring of hazards.

Programmable failsafe PLCs offer increased computing power and functionality, but they also require certain preconditions that can present challenges in designing and certifying a system.

The first and most important precondition is that the PLC being used has a failsafe version. Though safety technology has grown significantly over the past decade, some PLCs do not have a failsafe version or add-on processor widely available yet.

Machine builders also need to consider that specific customer control requirements may vary from region to region, and different PLCs may be specified altogether. Designing systems for multiple PLCs can be time-consuming and expensive, especially considering change control within each system. If a change is made to the overall design, then each individual safety design must also reflect that change. This could lead to multiple versions of multiple controls systems being in the field at the same time.

If considering different solutions for different regions, then it is also worthwhile to consider the safety network and communication protocol each solution requires. A system that uses both Profibus and EtherNet/IP will require communication bus couplers, cabling and safety I/O for each of those protocols.

This increases the need for logistical control and stocking for these parts.

Another concern is customers who use their own ‘homegrown’ machine controls. Though they may be using a standard network, they are not using standard control software. Safe software tools and runtime technologies are available, but these components are based on safe hardware, which the machine builder must then develop.

The programmable failsafe PLC offers a significant advantage in safety functionality. The deep integration of safety logic and communication into the central PLC, however, means strong dependences on single-source providers, increased needs for engineering and logistic control, and inflexibility of components - all potential disadvantages.

Bridging safely - the distributed configurable safety relay Today, however, a different approach to distributed safety in an automated industrial network is available. New technology makes it possible to eliminate the strong dependencies between the failsafe PLC and the safety protocol by achieving two conditions: • The safe logic must not be an integrated part of central PLC, but rather decentralised and separated from the standard PLC as in the case of a configurable safety relay.

• The safe logic must communicate via special protocol over an already installed standard network to read safety input signals from distributed sensors and write safety outputs to actuators.

APRIL 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 21

Safety networks

Figure 1: The black channel principle separates safety from the standard communication protocol, effectively ‘bridging’ the safety application across the network.

• To reach these conditions, a special logic module can act as a standard network device. This logic module is distributed in the network and handles all safety logic processing on-site.

Processing this safety data is done via internally redundant processors, much like a configurable safety relay can process its own safety program. Unlike a configurable safety relay, however, the distributed logic module can communicate to its associated safe input and safe output signals via a special protocol on the standard network.

This safety protocol does not contain any network or PLCspecific dependencies, but operates on the ‘black channel’ principle, like that of a PROFIsafe system. The entire network, including the standard PLC and all infrastructure components located in the data path of the safety signals, is part of the black channel. Safety failure detection is only implemented at the end points of communication, which can detect failures within the black channel with a residual failure probability for the highest safety levels (PL e, Cat 4, SIL 3) (see Figure 1).

Using this communication principle, the safe I/O can be distributed throughout the network, while still communicating back to the same logic module. This creates even more system flexibility. Input and output devices can be wired where they are needed, eliminating the need for long bundled sensor and actuator wire runs throughout the system. Having the standard PLC on the black channel also brings about several advantages: • The standard PLC has direct readable access to all safe input signals coming from the input devices.

• The standard PLC has direct readable access to all safe output signals, which are mirrored as standard inputs by the safe output devices.

• The standard PLC can directly access all diagnostics information from all distributed safety modules.

• Standard I/O can be used inline with safe I/O modules.

22 WHAT'S NEW IN PROCESS TECHNOLOGY - APRIL 2013

From the user’s point of view, the safety logic module and its associated safe I/O modules are realised into one configurable safety relay function responsible for all safety functions.

A detailed network view isn’t necessary for the configuration of the safety function because of the black channel communication philosophy.

The SafetyBridge system from Phoenix Contact, for example, combines the advantages of safe network communication with the simplicity of configurable safety relays. Due to the strict separation of the safety functionality from the standard PLC and network, there is no need for changes on safety relevant configuration and parameters if the standard PLC and network configurations are changed or adapted. This means that an approved safety application remains unchanged and is re-usable in various machines with various PLC types.

Conclusion Bridging the safety data across the existing control network using a ‘black channel’ is a new approach to safe network communication in automation networks. The system can work independently of the relevant network and the standard control system used. Both simply act as a transport medium for safe data packets, which are exchanged between the safe input and safe output modules.

The safe inputs and outputs are distributed in the network and do not require a higher-level safety controller or a separate safety bus system. Therefore, instead of having to choose safe networks with safety controllers available accordingly, it is very easy for users to integrate into the systems or technologies they have come to rely on.

Phoenix Contact Pty Ltd Contact info and more items like this at wf.net.au/T319

www.ProcessOnline.com.au

www.ProcessOnline.com.au

APRIL 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 23

Holcim relies on drive technology from NORD Drivesystems Holcim Ltd, with its headquarters in Switzerland, is one of the largest construction material producers worldwide with around 80,000 employees and production facilities in about 70 countries.

Its products include additives of different aggregates along with cement, gravel and concrete. For a good 10 years, the corporation has been represented in Croatia with six concrete factories, a cement plant and three quarry systems. From the beginning, Holcim Croatia has mostly used drive solutions from NORD Drivesystems for the belt conveyor systems used in these facilities.

At the Sumber and Ocura quarries in Croatia, large stones are removed through explosions, transported through conveyor belts between the working floors and bunkers to the preparation facility, then crushed in stone crushers and graded to maximum grain sizes 3.3, 8.8, 16 and 32 mm.

After this, they are transported to the storage site through conveyor equipment. Different technologies are available for the transportation of the various materials, which each have their own challenges.

T h e co n ve yo r b e l t s t h a t transport the larger rocks must overcome inclines of up to 25° and minerals up to 250 µm in size are conveyed with bucket elevators. Fixed on a double or central chain, a sprocket chain or on a belt, large cup-shaped containers made of steel or plastic are continually loaded with material.

Screw conveyors are also used, with a helical screw running in a trough to transport the goods over several metres. Gravity and friction of the transported material on the trough walls make sure that the material does not rotate with the conveyor screw, but rather is continually transported longitudinally. If the friction on the wall is small with a high degree of filling, the material will only rotate at right angles to the screw axis and is not transported. Thus, with a vertical transport, wall friction must be created through centrifugal force, which requires high rotations in the order of 250 to 400 rpm.

The conveyed material can then be transported horizontally, inclined at an angle or moved vertically. All of this conveyor equipment is powered by NORD drive systems.

“We value the drive technology from NORD due to its high reliability and efficiency. Service and delivery availability are also the best. For good reason, we have been operating NORD products in our quarries for more than 10 years without experiencing problems,” said Nenad Mackic, facility manager in the Sumber quarry.

24 WHAT'S NEW IN PROCESS TECHNOLOGY - APRIL 2013

Variable-speed geared motors with frequency inverters are used for the small bucket elevators, while unregulated single-speed geared motors provide the higher performance required for larger systems. Because of the mass to be transported, gentle startup via a fluid coupling is essential, while a back stop prevents the conveyor equipment from running backwards. With an efficiency of about 95%, the gear units are available in shaft-, foot- or flange-mounted versions to suit the application. The maximum capacity is up to 200 kW with a maximum torque of 50,000 Nm. In the Holcim cement plant in Koromacno on the coast of Istria, NORD geared motors have also been used for more than 10 years.

The plant produces an average of around 500,000 t of cement per year; the maximum capacity is up to 750,000 t. Cement is produced according to a continual drying process, primarily using natural resources. The raw materials (normally limestone, clay, sand and iron ore) are mined in quarries, and after the extraction, a crusher mills the raw materials. In the cement plant, all raw materials are crushed and simultaneously dried together in a mill. The raw material resulting from this process is then fired into clinker in a kiln at temperatures of about 1450°C and then cooled to 200°C. The clinker is then crushed in a mill together with gypsum or anhydrite, yielding the finished cement product.

NORD drive solutions are used for all transportation and conveyor tasks in cement production. Some of the drives are designed for operation in explosive environments according to ATEX Zone 21 or 22. Primarily, mid-sized geared motors are used: helical, parallel and bevel geared motors up to 45 kW, mostly with protection class IP55, depending on the respective task.

Robert Tencic, head of purchasing, and Teodor Gobo, head of maintenance, of Holcim Croatia are very happy with the performance of the NORD products.

“We particularly value the high delivery availability and reliability, the very good price-performance ratio, the good service and the unique quality of the NORD products,” they said.

This is reason enough for Holcim to sign a three-year-contract, which says that Holcim will exchange older gear motors - independent of the brand - with NORD drive solutions in all factories in Romania, Bulgaria, Hungary, the Czech Republic, Slovakia and the countries of the former Yugoslavia.

NORD Drivesystems (Aust) Pty Ltd Contact info and more items like this at wf.net.au/S833

www.ProcessOnline.com.au

www.ProcessOnline.com.au

APRIL 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 25

NEW PRODUCTS

1D AND 2D CODE READERS Sick’s Lector620 series of 1D and 2D code readers provide reliable reading performance, rapid integration in a variety of packaging machine IT environments and extensive analysis and diagnostic possibilities. The Lector620 eco offers basic functions for reading and assessing codes. The Standard version meets the reading and automation requirements of the most varied of applications in packaging machines.

The readers record codes at a frequency of 60 Hz and use all images for evaluation. For continuous packaging processes, the readers can also autonomously adjust reading parameters such as brightness or contrast settings. The device automatically adapts to varying code qualities so that there are no non-identifiable packaging units.

Laser points in the centre of the image support alignment of the code readers on the area of the packaging in which the codes are located. A variety of modes, from Standard to Expert, then offer an appropriate amount of configuration possibilities. Parameterisation by means of software is possible and is supported by the live picture displayed in the user interface and by dialogue-guided enquiries.

AutoSetup - the automatic teach-in process - can be started by pressing a single button. LEDs on the device provide information on the focal distance and reading quality of the taught-in codes.

Up to 100,000 pictures on the code reader’s microSD card and stored evaluations of code quality allow users to understand and solve problems on packaging equipment.

Sick Pty Ltd Contact info and more items like this at wf.net.au/S848

CAPS

PLUGS

COVERS

MASKING

CONFIGURABLE IPC The Valueline P7000 is a powerful, maintenancefriendly configurable industrial PC solution. The IPC can be configured as a box PC with various mounting options or as a classic panel PC, and can be used in ambient temperatures up to 45°C. The TFT touchscreen monitors, available in sizes between 12 and 24″, allow complex processes to be visualised.

Equipped with Intel Core-i7 processors, the industrial PCs offer high processor and graphic performance. With the integrated turbo boost technology, more performance is there when needed. The hyperthreading technology increases processor performance to allow threads (tasks) to be more efficiently processed. This is complemented by fast DDR3 memory with ECC support and solid state drive (SSD) storage with fast single-level cell (SLC) memory technology. The hardware is

Nobody has a greater range of Flexible Vinyl Caps and Plugs than STOCKCAP. And they’re in stock now for immediate delivery.

Ideal to protect, mask or insulate components from shipping, storage or processing damage, STOCKCAP Flexible Vinyl Caps and Plugs fit snug to seal out moisture, oil and dirt. Choose from thousands of sizes, shapes and colours all at the industry’s most competitive prices.

So if you need Caps or Plugs in stock, get ours ex-stock.

supported by Windows XP or Windows 7 operating system in the various embedded versions.

The IPCs have an intelligent fan concept, based on an external convection blower. Contrary to integrated fans, this concept prevents dust from being whirled up on the mainboard. Further, the integrated power management of the processor reduces energy consumption.

Important components such as the replaceable hard disk or the CMOS

Sinclair & Rush Pty Limited 51 Wellington Street Riverstone NSW 2765 info@sinclair-rush.com.au Fax: (02) 9627 5156 Tel: (02) 9627 3211

FOR FREE SAMPLES AND A CATALOGUE CALL

battery can be easily and quickly accessed due to the maintenance-

1800 003 211

friendly design. As a result of the modular production technique, this

www.stockcap.com

industrial PC has fast delivery times, even for customised configurations.

Phoenix Contact Pty Ltd Contact info and more items like this at wf.net.au/T059

26 WHAT'S NEW IN PROCESS TECHNOLOGY - APRIL 2013

www.ProcessOnline.com.au

www.ProcessOnline.com.au

APRIL 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 27

NEW PRODUCTS

ETHERNET SERIAL DEVICE SERVER The IED-4020 is an industrial ethernet serial device server that can be used to remotely configure, monitor and manage the operation of PLCs, process controls, power monitoring equipment, barcode scanners and other factory floor serial devices.

The serial interface is selectable between RS232, RS422 and RS485, and the ethernet interface supports TCP, UDP, ICMP, IGMP, HTTP, and ARP networking protocols.

Designed for easy installation, the device comes with Windows-based driver software, which allows existing software applications to be connected as if they were attached locally. It can also be set up remotely over the local network or internet using telnet, SNMP or a web browser. A 64 KB port memory buffer prevents data loss in case the network goes down.

All of the LevelOne Infinity range of industrial ethernet products have been tested to safeguard against dust, vibration, extreme heat and cold, humidity and shock. The IED-4020 features a DIN-rail mounting with aluminium housing, as well as redundant power inputs with a terminal block and a DC jack. It is tested for functional operation at -20 to 70°C. LevelOne Australia au.level1.com

DATA COLLECTION SYSTEM Sensor Fusion is a 3U data acquisition device from Aerotech that provides precise time alignment of motion and data acquisition functions. Integrating data acquisition into the motion control platform is a cost-effective data acquisition solution. It provides quick and easy configuration and set-up for shorter development time.

The Sensor Fusion is applicable in any test, measurement or inspection situation where sensor data must be precisely aligned with position. Major application areas include semiconductor, display, automotive and medical device manufacturing. It is available in desktop, rack-mount and panel-mount configurations.

Coupled with Aerotech’s Automation 3200 (A3200) motion control software, the device accepts input from up to four different cards. Collection is synchronised in real time so there is no need for an additional alignment process. Cards are available for digital input and output, analog input and output, encoder input and PSO output.

Set-up, data recording and data playback can be done through .NET, C, LabVIEW, MATLAB or Aerotech’s own AeroBasic programming language. All inputs and outputs can be managed graphically through the I/O Manager utility that is part of the Motion Composer in the A3200 software suite. By managing data acquisition directly from the same library or interface used to program motion control, less time is spent managing separate environments.

Coupling data playback with Aerotech’s PSO functionality allows precision control of multiple devices - up to 96 digital outputs or 48 analog outputs - from one positioning system.

Lastek Pty Ltd Contact info and more items like this at wf.net.au/T003

28 WHAT'S NEW IN PROCESS TECHNOLOGY - APRIL 2013

www.ProcessOnline.com.au

www.ProcessOnline.com.au

APRIL 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 29

NEW PRODUCTS

TILT-DOWN FLEXIBLE SCREW CONVEYOR The Sanitary Tilt-Down Flexible Screw Conveyor from Flexicon has a castor-mounted frame that can be manoeuvred through narrow aisles and around corners. With the hopper, support boom and conveyor assembly tilted down, the unit fits through standard doorways and orients the conveyor tube horizontally, allowing the flexible screw to be removed easily for thorough cleaning and inspection.

The conveyor’s surge hopper, which is configured for dust-tight connection to the outlet of upstream equipment, includes an air displacement vent with cartridge filter that is equipped with a reverse pulse cleaning system that dislodges accumulated dust with short bursts of compressed air, returning the dust to the hopper on a timed cycle, maintaining operating efficiency.

Material flows through the hopper into an adapter that charges the conveyor. The flexible screw is driven only at the discharge end and does not require any bearings or seals within the product contact area.

The conveyor transports bulk ingredients ranging from submicron powders to large pellets, while the gentle rolling action of material being conveyed prevents the separation of blends. The enclosed tube prevents product and plant contamination and permits thorough washdown.

The inner screw is the only moving part contacting material, and a broad range of specialised screws is available to handle free-flowing and non-free-flowing bulk materials, including products that pack, cake, smear, seize, plug or fluidise.

The mobile conveyor frame is constructed of stainless steel or in carbon steel with durable industrial coatings and can be finished to sanitary or industrial standards.

Flexicon Corporation (Australia) Pty Limited Contact info and more items like this at wf.net.au/S978

30 WHAT'S NEW IN PROCESS TECHNOLOGY - APRIL 2013

www.ProcessOnline.com.au

Process Technology Roadshows

2013 SERIES

PROCESS CONTROL | AUTOMATION | INSTRUMENTATION | SAFETY

NOW IN ITS 9TH YEAR Coming soon ... to a city near you!

If you work in mining, minerals, metals processing, utilities, food and chemical manufacturing and processing then the Regional Roadshows are designed for you.

Don’t miss out ...

NEW TRAINING SESSIONS FOR 2013

• Engineering quiz on process instrumentation

with prizes

Substation automation • • Perform basic troubleshooting of a typical industrial ethernet system • Simulate and troubleshoot a Modbus/TCP master communicating with a Modbus/TCP slave over IEEE 802.11 (Wi-Fi)

Design and construct your own closed circuit TV • (CCTV) system for a mine site and analyse the network traffic • Troubleshoot a tuning problem with your Flow Loop • Use Tunnelling to connect a local OPC* client to a remote OPC server via the internet

Brisbane • June 17 Gladstone • June 18 Mackay • June 19 Townsville • June 20

Previous Exhibitors include:

Includes FREE: Supported by:

Training by:

• Access to exhibition • Training sessions - NEW • Lunch and networking drinks • Product demonstrations • Prize draws

To register or for more info visit: www.regionalroadshows.com.au

NEW

SURGE PROTECTION DEVICES

PRODUCTS

Weidmüller has released a range of surge protection devices that meet the new global IEC standards while exceeding Australian standards.

The lightning and surge protection VPU series meets the current

IS MULTIFUNCTION CALIBRATOR

IEC 61643-11 and EN 61643-11 standards. While Australia’s prevailing

An intrinsically safe calibrator is designed to be incapable of

standards may not be updated for another two years, users will now be

causing ignition in the surrounding environment, which may have

able to ensure they meet any future engineering design requirements,

flammable materials, such as gases, vapours or combustible dust,

saving both time and money.

in it. Intrinsically safe calibrators are de-

The VPU range includes models for Category C3 to A for energy

signed for use in potentially explosive

networks with about 200 variants available to ensure optimal choice for

environments, such as oil refineries,

users. The range also includes products for photovoltaic facilities

oil rigs and processing plants, gas

and wind power installations.

pipelines and distribution centres, petrochemical and chemical plants, as well as in pharmaceutical plants.

The ATEX and IECEx certified second generation of the Beamex MC2-IS intrinsically safe multifunction calibrator is a practical tool designed for field calibration and testing in explosive environments. Compared to the first generation there is a new

The range combines varistor

display with an LED backlight for

and gas discharge technology to provide

improved display visibility in various environments. It also has a more powerful processor and an improved battery shelf life. The appearance of the second generation MC2-IS has a stronger IS unit identification.

As with the previous generation, the MC2-IS has calibration capabilities for pressure, temperature and electrical signals, and it connects to almost 20 available Beamex intrinsically safe external pressure modules. It is a compact-sized, lightweight portable calibrator with a multilingual interface and a complete numerical keyboard.

AMS Instrumentation & Calibration Pty Ltd Contact info and more items like this at wf.net.au/S936

sustainable protection. This, together with the newly designed thermal fuse system, offers maximum reliability in lightning and surge voltage protection.

Each VPU module is easily and quickly pluggable. A mounting rail clip enables simple and fast assembly and removal, and without the need for tools. The devices can also be rotated 180º in the electrical/control cabinet to ensure flexibility during installation.

The units also feature a large, central status display window. If the flag in the status window changes from green to red it is no longer providing protection. The device can be replaced quickly because of the plug-in connectors and without the need to disconnect any wiring.

All modules are self-monitoring and an alarm function notifies users via a mechanical relay that the unit needs replacing.

Weidmuller Pty Ltd Contact info and more items like this at wf.net.au/T175

32 WHAT'S NEW IN PROCESS TECHNOLOGY - APRIL 2013

www.ProcessOnline.com.au

LASER GAS ANALYSER Tunable diode laser (TDL) gas analysers are a significant improvement over extractive analysis systems. Firstly,

The new Push-in Experience !

no sample extraction or conditioning is necessary. Secondly, they are immune to interference from moisture, dust or background gases. And thirdly, they exhibit very low drift.

The GPro 500 oxygen sensor has combined TDL technology with expertise in industrial application analytical instrument design to create a probe that delivers the convenience of an inline sensor and the level of measurement confidence of a top-line analyser.

Many TDL gas solutions are of a cross-stack design, meaning that the receiver must be positioned directly opposite the laser source. This causes installation difficulties and requires regular, troublesome realignment. The oxygen sensor incorporates a probe that reflects the laser beam back to the receiver in the sensor head so that alignment is never required. And because the laser beam travels twice through the gas stream, the optical path length is doubled, resulting in more accurate O2 measurements.

Mettler Toledo’s Intelligent Sensor Management (ISM) technology adds to the features of the sensor by incorporating predictive diagnostics that continually assess the optical path quality and indicate when cleaning is required, before measurements are affected. Other than yearly verification and occasional cleaning of the optics, no other maintenance is required.

Mettler Toledo

50 % less insertion force, 100 % contact quality

Contact info and more items like this at wf.net.au/T323

With Push-in modular terminal blocks you can connect all wires of up to

RUPTURE DISCS

0.34 mm2 in diameter easily and

Elfab has further improved its Opti-Gard range so that it can now

depending on the burst pressure required. Simple enhancements made

without the use of any tools. An integrated button enables easy release of the connected wire with any tool –

to that version have enabled Elfab to produce a single-disc design

without touching any conductive parts.

offer the rupture disc as a single-disc solution.

Opti-Gard was previously available in either the OPR or OPK design,

covering the full range of sizes and burst pressures, offering users

Call us today: 1300 786 411 or visit phoenixcontact.com.au

potential stock reductions of more than 65%.

The Opti-Gard rupture disc is covered by a three-year warranty, demonstrating the ongoing reliability of a range initially launched in 2003. The disc is still supplied with Flo-Tel, Elfab’s non-invasive IECEx-approved burst detection, as standard. With tolerance of 3% across a wide range of burst pressures and a 95% operating ratio, Opti-Gard continues to offer high-performance characteristics in liquid, gas or vapour applications.

© PHOENIX CONTACT 2013

Elfab Limited www.elfab.com

www.ProcessOnline.com.au

APRIL 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 33

NEW PRODUCTS

SHAFT ENCODER TESTER The Encoder Laboratory is designed to test and simulate all ment which produces a square wave output signal, such as

PIPING ISOMETRICS SOFTWARE

linear encoders and flow meters.

Intergraph has released CloudWorx

aspects of an incremental shaft encoder, or any other instru-

The large four-line LCD allows the user to see in one view

for SmartPlant Isometrics 2012 R1,

all the test results on one screen; in addition there is now

an add-on to its SmartPlant Iso-

available application software which will repeat and analyse the

metrics solution that allows users

information shown on the LCD and produce an oscilloscope

to quickly create accurate, as-built

view of the input wave form, an individual test report sheet

piping isometrics directly from a

and adds all the information to a production log file for future

laser scan point cloud. CloudWorx

analysis. This instrument combines into the one housing and

for SmartPlant Isometrics 2012

updates two separate encoder instruments PCA has produced

R1 leverages Leica Geosystems’

for more than 10 years.

Cyclone software technology to ef-

Plant Control & Automation

ficiently display the laser scan point

Contact info and more items like this at wf.net.au/S885

cloud and navigate through it in a window with measured piping data overlaid graphically, a revolutionary method of creating as-built piping asset documentation. Intergraph and Leica Geosystems are parts of Hexagon.

Unbeatable Control,

Precision, and Flexibility

CloudWorx for SmartPlant Isometrics supports the rapid creation of piping isometric documents using Intergraph ISOGEN. The easily understood sketching functionality and automated drawing creation means CAD or 3D skills are not required, but also allows experienced piping designers to be highly productive in creating as-built piping data.

The software is complementary to 3D model-based solutions based on Smart 3D, PDS or CADWorx, since the same ISOGEN software is used to produce the deliverable. Results are consistent and underlying data - regardless of its source - can be used to create documentation for inspection of piping systems, including the automated, rule-based placement

Graphical system design combines productive software and reconfigurable I/O (RIO)

of inspection location points.

When used in conjunction with

hardware to help engineers lower cost, increase productivity, and shorten design times.

SmartPlant Enterprise for Owner

This customizable, off-the-shelf platform, integrates motion, vision, and I/O with a single

Operators (SPO), the comprehen-

software development environment to build complex industrial systems faster.

sive as-built documentation can be

>> Accelerate your productivity at ni.com/industrial-control-platform

managed to ensure the integrity of the piping asset. SPO adds change management and audit capability when the piping documents are

Australia: 1800 300 800 New Zealand: 0800 553 322 Š2013 National Instruments. All rights reserved. LabVIEW, National Instruments, NI, and ni.com are trademarks of National Instruments. Other product and company names listed are trademarks or trade names of their respective companies. 10367

published to the plant engineering data store and maintained through time.

Intergraph Corporation Pty Ltd Contact info and more items like this at wf.net.au/T060

34 WHAT'S NEW IN PROCESS TECHNOLOGY - APRIL 2013

www.ProcessOnline.com.au

NMW RETURNS TO MELBOURNE

N

ational Manufacturing Week (NMW 2013) is returning to With manufacturing more competitive than ever, manufacturers the Melbourne Convention and Exhibition Centre (MCEC) are constantly seeking process improvements to enhance efficiency between 7 and 10 May, focusing on helping industry and boost profitability. NMW allows you to source the latest products leverage what the Prime Minister’s Taskforce calls and services across all industry sectors, in one place at one time. “critical challenges” and “rich opportunities” ahead. In particular, • See products and services from over 200 quality suppliers that NMW 2013 will present solutions that help manufacturers target will keep you at the forefront of the industry new, higher value sectors as well as boosting productivity in their • Manage expenditure and increase profitability that will improve day-to-day operations. your competitive edge Co-located with Austech, NMW 2013 will feature - for the first • Discover how to increase efficiency and deliver greater productime in Victoria - two new product zones: Sustainable Manufacturtivity ing and Metals & Composites. The Sustainable Manufacturing Zone • Develop a low-cost optimisation strategy to get the most out will focus on opportunities for reducing industry’s environmental of your operations footprint, while Metals & Composites presents new developments • Procure services and products in an effective and efficient way in industry’s quest to develop reliable, lightweight, easily moulded • Network with peers, exchange ideas and expand your knowlmanufacturing materials. edgebase With the two new zones, NMW 2013 will present a total of 12 product zones - a clearer segmentation aimed at helping buyers Date: 7-10 May 2013 and sellers easily find each other.

Venue: Melbourne Convention and Exhibition Centre When last held in Melbourne in 2011, NMW attracted over 11,500 Organiser: Reed Exhibitions Australia trade visitors, with nine out of 10 visitors saying they were ‘satissourcing all your manufacturing Website: needswww.nationalmanufacturingweek.com.au at one time? fied’Imagine or ‘very satisfied’ with the event.

Making Manufacturing

• Discover the latest in manufacturing innovation • Enhance efficiency and boost productivity • Exchange ideas on critical industry issues • Network and do business face-to-face with over 300 suppliers

Looking for an emergency stop pull rope 12switch dedicated Product including... thatZones goes the extra distance?

OsiSense XY2... the simple,

Auser-friendly definitive showcase for sourcing analysers & analytical safety solution. equipment, process & control systems, sensors & instrumentation equipment, test & measurement tools, temperature & pressure The OsiSense XY2 Pull Rope Switch is the equipment, flow measurement… and much more perfect point-to-point safety solution.

With a pull rope distance of up to 30 metres and a variety of optional accessories, safety between people and moving equipment doesn’t get simpler.

Standard features include:

7–10 MAY 2013

MELBOURNE CONVENTION & EXHIBITION CENTRE

> > > > >

metal housing with a stainless steel face 3 contacts (2N/C, 1N/O) integrated turnbuckle for easy cable tensioning viewing window for ease of tension adjustment IP65 degree of protection.

Easy to install and set up. They are ideal for woodworking machines, conveyor systems, roller mills and printing presses.

Simply easy!™

Discover more www.tesensors.com/au | Call 1300 369 233

Sensors

© 2013 Schneider Electric. All Rights Reserved. CLIPCOM25789

www.ProcessOnline.com.au

APRIL 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 35

PAT GAINS TRACTION IFPAC, United States

At IFPAC 2012, industry experts from the pharmaceutical and biopharmaceutical industries met with suppliers and partners to discuss the latest trends and development in PAT. During talks, it became evident that PAT implementation is gaining traction in the biopharmaceutical industry.

A

lthough process analytical technology (PAT) has been implemented by other industries, biopharmaceutical companies have been slow to adopt it on an enterprisewide scale. Historically, one of the limiting barriers to PAT implementation has been the FDA’s prescriptive regulations. But, during the past decade, the FDA has promulgated three separate guidelines - cGMPs for the 21st Century (2002), PAT (2004) and Process Validation (2011) - creating a regulatory environment that not only allows PAT implementation but strongly encourages it.

Under the framework of PAT, the use of real-time process analysers can be integrated into a control system, allowing manufacturers to understand their processes and, through this understanding, control them. Inextricably linked with PAT is the concept of built-in quality, or quality by design (QbD), which is the use of model-predictive methodologies to relate material properties and process parameters for finished product performance. The same analysis that allows manufacturers to apply QbD also tells them what they need to measure and what they need to control.

36 WHAT'S NEW IN PROCESS TECHNOLOGY - APRIL 2013

PAT Guidance has set off a few important trends in biopharmaceutical manufacturing: the gradual shift from scientists to process engineers driving manufacturing processes; the incorporation of information loops into the design of manufacturing processes; and the implementation of continuous manufacturing, first on a project-by-project basis for the most part, now moving towards enterprise-wide programs.

“The industry is striving to achieve ‘real-time release’ of finished products,” said Glenn Restivo, Industry Manager Pharma US, Siemens Industry. “And continuous manufacturing (with PAT as its heart) is the approach rapidly gaining acceptance to achieve this vision.”

The voices of process engineers become louder One of the barriers to PAT adoption by the biopharmaceutical industry has been that the manufacturing process was heavily driven by the scientists who were responsible for product quality, rather than the process engineers responsible for the manufacturing process itself, according to Dr Sam Watts, Busi-

www.ProcessOnline.com.au

© iStockphoto.com/Catalin Stefan

Process Analytical Technology

perhaps more so than chemical. The small molecule process is less uncertain and higher yield. Biologicals are a very low-yield process, so we need to make every percentage point count.”

Using information loops in biopharmaceutical manufacturing

ness Development & Commercial Officer, Stratophase, a company that provides biopharma with inline monitoring of glucose status.

“Over the last couple of years, the voice of the process engineers has become louder. They’re moving away from saying they must take absolute measurements,” Watts said. “There’s been a shift towards process engineers, who say, ‘If we can engineer a quality process, then we will have a quality product.’”

As the chemical industry, outside of pharmaceutical work, has been implementing PAT for some time now, there is transferable technology available. However, there isn’t a precedent for controlling biological processes, and in many cases, manufacturers are starting at square one with them - not in terms of available technology - but in terms of what they believe they can implement and the best way to do so.

“Given that biological processes are reactive, they do migrate.

It’s important not only to do the upfront analyses, then lock the process down, but also to continue to verify the process through the course of its lifetime - and that’s where we get into process engineering. That’s where the industry hasn’t gotten that far,” said George Barringer, Consultant, Stratophase. “Biologicals need it

www.ProcessOnline.com.au

Ten years ago, biopharmaceutical manufacturers typically learned which manufacturing process designs worked well and which didn’t through one-at-a-time experiments, after which designs would be deemed successful or not. Failure was the driving force behind design changes, rather than the desire to acquire information about the process in order to optimise it.

“The biggest change in the pharma domain is that we are creating many situations where we’re using an information recycle loop. That was not the case 10 years ago,” said Fernando Muzzio, PhD, Director, Engineering Research Center for Structured Organic Particulate Systems, Rutgers University.

Information loops are intrinsic to QbD within a PAT framework.

Muzzio described two situations where information recycle loops are in use: the control loop and the design loop. The control loop is in place when manufacturers implement a control process because they are measuring, analysing and then acting on the information. The design loop is in place when manufacturers do sequential design of experiments (DoE), meaning they do a DoE, take note of something and plan the next DoE accordingly. The design loop is also present when manufacturers are optimising their system.

“You develop a model, make predictions about what the process is going to do, implement those predictions and measure your outcomes. Your outcomes are never exactly like your predictions, so you refine your model, you make new predictions, and that’s the learning process,” Muzzio said.

Continuous manufacturing: moving from pilot projects to a strategic approach It is widely anticipated that the use of QbD will become an expectation by the FDA - at least in the generic domain - sooner rather than later, perhaps in just a few years. It is also believed that the next iteration of PAT will be driven by different manufacturing methods and different product concepts. Muzzio said, “What’s coming next is that increasingly we’re going to deploy other ways to make products; for example, continuous manufacturing is a different way to make products.”

Muzzio recently started working with Janssen and Siemens on a continuous manufacturing project at Rutgers.

“Continuous manufacturing requires real-time control so that the process is running at a set point where you want it to run - and you can determine that it’s running that way. Without PAT, continuous manufacturing doesn’t work,” Muzzio said. “What you’re doing in continuous manufacturing is making predictive models as agile as possible so you can use it in real time and

APRIL 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 37

Process Analytical Technology

ONE OF THE BARRIERS TO PAT ADOPTION BY THE BIOPHARMACEUTICAL INDUSTRY HAS BEEN THAT THE MANUFACTURING PROCESS WAS HEAVILY DRIVEN BY THE SCIENTISTS WHO WERE RESPONSIBLE FOR PRODUCT QUALITY, RATHER THAN THE PROCESS ENGINEERS RESPONSIBLE FOR THE MANUFACTURING PROCESS ITSELF

then import it into your system and control your process. Continuous manufacturing is where you bring everything together.”

The need for top-down support of PAT implementation cannot be overstated for successful enterprise-wide adoption. Otherwise, companies risk getting stuck in the pilot stage. There is an enormous difference between a company implementing PAT for a project here and a project there, and a company that takes a strategic approach to PAT implementation.

An important part of the Rutgers-Janssen continuous manufacturing project is Sipat, a standardised, modular PAT data management application/software solution developed by Siemens. Through Sipat, it is possible to control CPP (critical process parameters) and CQA (critical quality attributes) that are intermachine-related.

Eventually, one of the key elements of the project will be Siemens’ ability to offer Janssen the capability of using information on materials, process and finished product in an integrated way so that the company can ensure the product is under control all the time, ensuring final product quality.

Hot-melt extrusion: an upcoming technology for the continuous approach One part of the process chain for a continuous line in manufacturing is hot-melt extrusion. Other industries, such as plastics and food and beverage, have been implementing hot-melt extrusion for some time, but it is a new concept for biopharma. Through a cooperation agreement, the Research Center for Pharmaceutical Engineering (RCPE) in Graz, Austria, and Siemens AG teamed up to learn which parameters are of interest to biopharma and how to control them during hot-melt extrusion for biopharmaceutical manufacture.

“One of the trends we see is that the industry is moving towards a continuous manufacturing approach, and when you use a continuous approach, there are different analysers, new steps and new processes. An upcoming technology for pharma is hot-melt extrusion, which gives a continuous run of blending, mixing and conveying. For our project with RCPE, we are looking at many different variables and possibilities in continuous manufacturing data,” said Barbara Kavsek, Team Lead Process Analytics, Life Science Systems, Siemens AG. Added Daniel Markl, Junior Researcher, RCPE, “It’s very important to monitor all these parameters. For this, we are using Sipat.

We have a Sipat installation at RCPE configured for an extruder, a feeder and a spectrometer. We built a chemometric model, set up the analysers and used Sipat to monitor, measure and finally predict the API concentration. We also established a feedback loop, which allows us to control the process.”

38 WHAT'S NEW IN PROCESS TECHNOLOGY - APRIL 2013

The project is in the pilot stage for proof of functionality, proof of feasibility and, to a certain extent, proof of concept.

“Hot-melt extrusion is a new topic, and pharma companies want to know the feasibility of these probable changes to the whole manufacturing system,” Kavsek said.

Personalised medicine In addition to continuous manufacturing, Rutgers’ Muzzio believes that there will be other new processes that will be just as transformative to biopharmaceutical manufacturing, if not more so.

“For personalised medicine, we’re eventually going to have to learn how to manufacture for the individual,” he said. “Personalised medicine manufacture is surely going to lead to very small systems, micro-manufacturing that makes micro-batches. In each of those systems, we’re going to make a small number of units, and we are going to have to assay them non-destructively. We will not be able to take 20 out of 20 units, for example, and send them to the lab. We’re going to need to be able to predict what we’re doing and what we’re supposed to do. We’re going to have to learn assay product properties without destroying product units.

We’re definitely going to use PAT for personalised medicine.”

On the horizon: OPC UA ADI Facilitating a standard data collection and communication between PAT analysers and automation or data mining infrastructure is the next generation of communication protocol for PAT data management, according to Johan Vanhoutte, Project Manager, Industry Sector, Siemens. OPC UA (OLE for Process ControlUnified Architecture) is a platform-independent standard through which various kinds of systems and devices can communicate by sending messages between clients and servers. Siemens has implemented the OPC UA ADI (OPC UA for Analyzer Devices) standard into Sipat.

“Making a good (specialised) instrument is the focus of small vendors; they have less interest in having IT people develop a lot of software for their instruments. So, they try to find standards in the market, and that’s where Siemens wants to help them overcome that hurdle.”

Though PAT adoption by biopharmaceutical companies has not yet hit the inflection point, it is clear from the companies themselves and the vendors who provide services to them that this point is coming soon. Companies that are prepared for PAT adoption to become an expectation on the part of FDA and a requirement for competitive advantage will be well positioned for the future.

Siemens Ltd Contact info and more items like this at wf.net.au/S726

www.ProcessOnline.com.au

NEW PRODUCTS

POWER SUPPLY The PULS CPS20-series DIN rail power supply requires only 65 mm of space on the DIN rail and delivers 24 V, 20 A or 48 V, 10 A. The power is available over a wide temperature range from -25 to +60°C. A 20% power reserve may be used continuously at temperatures up to +45°C. For short-term peak loads with a maximum length of 15 ms, the units can deliver four times the nominal output current.

This also helps to trip fuses on faulty output branches.

All units of the CPS20-series are equipped with the HiccupPlus overload behaviour, a balanced power management, which in normal

STAINLESS STEEL I/O UNITS

operation mode

Turck’s I/O solution, BL Compact, is now available in a stainless steel

provides generous

model. Stainless steel replaces the exposed metal on BL Compact

power reserves but ef-

components, including the receptacle housing, ground plate and window

fectively protects con-

screw. Providing greater resistance to corrosion and other environmental

nected equipment and

contaminants than standard nickel-brass variations, stainless steel en-

cables against damage

hances operation and extends product longevity.

in the event of failure.

The BL Compact system collects a variety of signals in a single,

Other features of these

rugged node on a network. Rather than routing all signals through a

units include 94% full-load efficiency,

control cabinet, this device makes it possible to obtain analog, digital,

good partial-load efficiencies and low no-load losses, ac-

thermocouple, RTD, serial, RFID or a mixture of signal types in a com-

tive PFC, high immunity to transients and power surges,

pact, on-the-machine device over Ethernet/IP, DeviceNet, CANopen and

low electromagnetic emission and electronic inrush cur-

Profibus-DP.

rent limitation.

Up to two signal types can be combined in any combination in the

There is a DC-OK signal for remote monitoring and a

BL Compact system, including RFID and analog, digital and serial. To

provision for equal current sharing when units are used

extend application flexibility, up to 16 devices may be added to an ex-

in parallel. The robust mechanical design also allows use

isting network and signals may be gathered on the machine without an

in harsh environments, where the unit is exposed to high

enclosure. This reduces the time it takes to run wires for each device

shock and vibration loads. An optimised thermal design

back to the control cabinet and the potential for wiring errors.

achieves a lifetime expectancy of over 60,000 h (calculated at full load and 40°C ambient temperature).

Control Logic Pty Ltd Contact info and more items like this at wf.net.au/T007

The IP67- and 69K-rated system is currently available with four, eight or 16 ports. M8 or M12 connectors for bus communication and auxiliary power facilitate easy installation into any application, existing or new.

Turck Australia Pty Ltd Contact info and more items like this at wf.net.au/T322

SERIAL-TO-ETHERNET DEVICE SERVER The Lantronix xDirect device server is a compact serial-to-ethernet device server that provides quick and easy connectivity to virtually any device or machine with a serial interface. With plug-and-play simplicity and a small form factor, the server is suitable for a variety of markets from security to industrial automation.

With an integrated 10/100 ethernet port and serial cable, and multiple power options, the device also features a built-in web server that enables users to access and configure the unit using a standard web browser on a PC, smartphone or tablet. It measures less than 240 cm in length, and weighs less than 700 g, and includes PoE and USB power options, as well as LED serial activity indicators. The operating temperature range is -40 to 85°C. Soanar Limited Contact info and more items like this at wf.net.au/T237

40 WHAT'S NEW IN PROCESS TECHNOLOGY - APRIL 2013

www.ProcessOnline.com.au

Making Manufacturing

Imagine sourcing all your manufacturing needs at one time?

• Discover the latest in manufacturing innovation • Enhance efficiency and boost productivity • Exchange ideas on critical industry issues • Network and do business face-to-face with over 300 suppliers 12 dedicated Product Zones including...

A definitive showcase for sourcing analysers & analytical equipment, process & control systems, sensors & instrumentation equipment, test & measurement tools, temperature & pressure equipment, flow measurement… and much more

7–10 MAY 2013

MELBOURNE CONVENTION & EXHIBITION CENTRE

www.ProcessOnline.com.au

APRIL 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 41

AS I SEE IT A.B.N. 22 152 305 336 Head Office Cnr. Fox Valley Road & Kiogle Street, (Locked Bag 1289) Wahroonga NSW 2076 AUSTRALIA

THE IMPORTANCE OF STANDARDISATION

C

an you imagine a world where telephone systems only worked within a city but not outside it? Or where emails could only be sent within a company’s intranet but not externally? Can you imagine the resultant inefficiency and lack of productivity? Had it not been for the implementation of standards, these sorts of incompatibilities would be the norm for most technologies.

During the development phases of a new technology, standards rarely exist, so products can’t comply with them. Standards only become viable when multiple vendors are active for some time, and it becomes clear that certain methods or features are universally accepted as desirable. However, standards are only as good as the closeness with which vendors adhere to them.

Industrial communication protocols are a classic example. Users have been demanding intercommunication between devices sourced from different vendors for many years. It’s only when the underlying technology has matured that open protocols can be considered and that vendors can utilise them for their products.

We’ve seen this repeatedly with protocols like DeviceNet, EtherNet/IP, EtherCAT and many more.

Other examples abound in the process and automation industries. ANSI/ISA-S88 is now seen as ‘the approach’ to batching systems. The IEC61131 suite has become the yardstick for programmable controllers, with 61131-3 establishing programming methodology. Similarly, PLCOpen’s safety and motion control offerings will almost certainly become the programming standards for industry. In these cases, not only have the particular standards become entrenched, they’re often seen as the sole approach. Alternatives, if they exist at all, are discarded.

Standards provide a commonality of performance and a consistency of expectations. Once established, they allow end users to make real and valid comparisons between vendors’ products. The sensitive issue of electronic safety systems is a prime example. It’s been handled very effectively by robust safety standards, such as EN ISO 13849-1 for Performance Level

ph: +61 2 9487 2700 fx: +61 2 9489 1265 www.westwick-farrow.com.au ph: +61 3 9381 2952 Editor Glenn Johnson wnipt@westwick-farrow.com.au Chief Editor

requirements (PLr) and IEC 61508 for Safety Integrity Levels (SILs). These standards have been universally accepted by vendors, giving users great confidence to benchmark products and even interchange them.

More recently, OMAC (Organisation for Machine Automation and Control) established two working groups, for the packaging industry and machine tools. PackML (Packaging Machine Language) lays the ground rules for devices from different vendors to communicate with each other. It does not define a control language, only a method of passing status information between devices.

There have traditionally been two arguments against standards. Firstly, there are too many of them, nullifying the whole point of having standards! This is still somewhat true in areas like the plethora of industrial ethernet protocols. However, various vendor-neutral organisations, like the ODVA and EtherCAT Technology Group, promote technologies to users, educating them and finally allowing them to make better choices.

Standards also tend to freeze technology.

The time lag for a standard to be developed, subjected to review and compromise, promulgated and actually used could mean better methods are available. One solution is for vendors to comply with the standard as a minimum, but then add incremental features that exceed it. Standards are often regularly updated to account for product improvements.

Janette Woodhouse Publisher Geoff Hird Art Director/Production Manager Julie Wright Art/Production Tanya Scarselletti, Colleen Sam, Jeanette Teuma Circulation Manager Sue Lavery circulation@westwick-farrow.com.au Copy Control Mitchie Mullins Advertising Sales NSW/QLD - Nicola Fender-Fox ph: 0414 703 780 nfender-fox@westwick-farrow.com.au VIC/SA/WA - Lachlan Rainey ph: 0402 157 167 lrainey@westwick-farrow.com.au NZ - Gemma Burr ph: 0800 44 2529 gburr@westwick-farrow.com.au USA - Huson International Media East Coast ph: +1 212 268 3344 West Coast ph: +1 408 879 6666 ralph.lockwood@husonmedia.com UK - Huson International Media ph: +44 1932 56 4999 gerryb@husonmedia.com Asia - Lachlan Rainey ph: +61 (0) 402 157 167 lrainey@westwick-farrow.com.au Subscriptions For unregistered readers price on application.

If you have any queries regarding our privacy policy please email privacy@westwick-farrow.com.au

September 2012 total CAB audited circulation (Aust + NZ) 7,419 readers (83% personally requested)

Harry Mulder has been involved in the industrial control industry for around 25 years, with the last 22 years at Omron Electronics. With a degree in computer science, his experience includes sales, engineering and product management. He currently manages an engineering team across four states but still likes to get involved with day-to-day problem solving.

42 WHAT'S NEW IN PROCESS TECHNOLOGY - APRIL 2013

Contact the editor

Printed and bound by Webstar +61 2 9748 0020 Print Post Approved PP255003/00198 ISSN No. 0819-5447 All material published in this magazine is published in good faith and every care is taken to accurately relay information provided to us. Readers are advised by the publishers to ensure that all necessary safety devices and precautions are installed and safe working procedures adopted before the use of any equipment found or purchased through the information we provide. Further, all performance criteria was provided by the representative company concerned and any dispute should be referred to them.

Information indicating that products are made in Australia or New Zealand is supplied by the source company.

Westwick Farrow P/L does not quantify the amount of local content or the accuracy of the statement made by the source.

www.ProcessOnline.com.au

List (A) Job Function 1 Management - Corporate/General 2 Management - Manufacturing/ Engineering/Specialist 3 Engineer - Electrical 4 Engineer - Electronics 5 Engineer - Process 6 Engineer - Project 7 Purchasing/Procurement 8 Technician - Maintenance/Service 9 Technician - IT 10 Technical Officer 11 Scientific Officer - R&D 12 Scientific Officer - QA 13 Consultant 14 Contractor/Tradesperson 15 OHS/EHS 16 Education/Training 17 Student-Undergraduate/Apprentice 18 Analyst 19 Sales/Marketing

List (B) Industry 1 Agriculture/Rural 2 Building/Construction 3 Chemicals/Allied Products 4 Communications Systems 5 Defence/Military 6 Education 7 Emergency Services/Law Enforcement/Security 8 Engineering Services 9 Environmental Services 10 Finance/Banking/Insurance/Legal 11 Food Industry - Bakery 12 Food Industry - Beverages 13 Food Industry - Confectionery 14 Food Industry - Dairy 15 Food Industry - Fruit & Vegetables 16 Food Industry - Meat 17 Government - Federal 18 Government - State 19 Government - Local 20 Health/Hospital 21 Instrumentalities (eg CSIRO) 22 IT - Networking 23 IT - Security 24 IT - Storage 25 IT - Wireless 26 Laboratory - Analytical 27 Laboratory - Clinical/Medical 28 Laboratory - Life Sciences 29 Logistics/Transport/Warehouse 30 Manufacturing 31 Mining 32 Oil/Gas/Coal 33 Packaging 34 Processing 35 Retail/Wholesale/Hire 36 Service/Maintenance 37 Telecommunication 38 Testing/Certification (eg NATA) 39 Utilities

One Stop Safety Solutions

You‘re in safe hands with Pilz.

Melbourne • Sydney • Brisbane • Auckland

Ph: 03 9544 6300 Fax: 03 9544 6311 www.pilz.com.au safety@pilz.com.au

the spirit of safety