What's New in Process Technology Aug 2013

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0813 WHAT'S NEW IN PROCESS TECHNOLOGY AUGUST 2013

Endress+Hauser have been world market leaders in level instrumentation for the last 20 years. The new Micropilot FMR5x family of free space radars is now even more intelligent and reliable due to its use of advanced signal analysis using a patented technique known as Multi-Echo Tracking.

This new technology not only marks and tracks level signals but also erroneous echo signals. Thanks to this new analysis, the level signal can even be acquired when partially obstructed by interference signals in the tank from heating coils, agitator blades, etc. This dynamic process is always active

CONTENTS 6

Modernise and maintain

10

Hot products online

16

New products

32

Comparing differential pressure transmitter accuracy

50

As I see it

Implementing wireless to monitor beyond the P&ID

Cybersecurity policies that threaten productivity

and guarantees safe and precise measurements at any time.

Another improvement in this new line of radar instrumentation is the HistoROM data management concept. It allows continuous backup of all relevant data enabling customers to exchange defective electronics easily without the need for recommissioning and with no additional tools required.

If required, the Micropilot FMR5x devices can be delivered with a factory 5-point calibration certificate, across a specific measuring range, based on the measuring results of a certified test bench. A comprehensive instrument and process diagnosis concept teamed with intuitive and user-friendly menu guidance complete the package.

Endress+Hauser level measurement offers safety, precision and efficiency across the entire life cycle – more than merely a measured value.

Endress+Hauser Australia Pty Ltd www.au.endress.com

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

MODERNISE AND MAINTAIN IMPLEMENTING WIRELESS TO MONITOR BEYOND THE P&ID

Many operational and maintenance problems around a plant can be solved by deploying WirelessHART transmitters beyond the P&ID together with an asset management system and other software to obtain asset health information and other additional plant data. However, plant procedures must be written so as to make full use of this new information.

Š iStockphoto.com/Huyangshu

6 WHAT'S NEW IN PROCESS TECHNOLOGY - AUGUST 2013

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P

lant-wide modernisation can be achieved through installing wireless transmitters beyond the piping and instrumentation diagram (P&ID) and feeding raw data into essential asset monitoring (EAM) software and other applications. The basic deployment phases are illustrated in Figure 1. But with the hardware, software and updated operating procedures in place, central maintenance planning, energy conservation measures, HS&E (health, safety and environment) improvement and remote operations can become a reality. That is, the new plant information must be institutionalised in daily work processes to be effective.

There will be minor differences depending on whether the project is the modernisation of an existing plant or a greenfield installation.

Justification The initial step is to get buy-in from the plant management that will approve the project. For an existing plant, there is a need to justify modernisation with wireless, and with a new plant, expanding the scope beyond P&ID to include EAM, ECM (energy conservation measures) and HS&E packages as part of the project must also be justified.

The opportunity to improve maintenance, energy consumption and HS&E by modernising should be explained to the plant management, maintenance manager, reliability engineer, HS&E officer and project/turnaround manager. Investment in wireless transmitters and centralised EAM software can be justified on the basis of reduced downtime, lower maintenance cost, lower energy consumption and improved HS&E, provided the new information is institutionalised in the daily work processes and the plant culture.

Typically, critical plant assets such as expensive compressors and large pumps are already monitored, but due to the high cost of traditional machine protection and monitoring systems, the balance of assets may not have previously been monitored. These ‘secondtier’ assets, although essential to the process, are typically only spot-checked manually on a periodic basis (see the breakout for examples). Improving the monitoring of these assets can have a direct positive impact on maintenance and energy costs.

The modernisation has to be accompanied by a culture shift, especially for EAM. Maintenance technicians will be able to tell if assets need to be maintained urgently, if

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they can wait until the next turnaround or if they need no maintenance at all. This not only enables turnarounds to be shortened, but reduces the crane and crane operator costs, and the need for hoist, scaffolding, fitters, riggers, instrument technicians, electricians, pipe fitters as well as insulation and other material. Incorporation of EAM in daily maintenance practices must be a management directive, with follow-up to ensure new work processes and EAM tools get adopted, and continue to be used to derive value from the asset health information. Deployment will have associated engineering hours and cost.

Audit existing plant For an existing plant to deploy EAM, ECM and HS&E packages as part of a brownfield modernisation project, it is necessary to audit the entire plant’s assets, processing equipment, machinery and valves to identify shortcomings in measurements beyond the P&ID which need to be filled before work practices based on asset health and automatic data collection can be adopted. The audit is an opportunity to rate the plant’s asset management readiness. The assessment should also include a look at the current work processes and procedures for operation and maintenance, as well as the maintenance regime, culture and the skills of the plant staff. That which is missing in the existing plant architecture to support essential asset monitoring, energy conservation measures and HS&E becomes the input for the frontend engineering design (FEED) stage of the project.

Define scope The asset management system for the EAM, ECM and HS&E packages can be a standalone or can be integrated with the DCS. The plant-wide asset health information will mostly be used by the maintenance department for daily maintenance scheduling and turnaround planning, but operations can also benefit from being aware of assets which have failed or are degraded, as the plant can be operated differently to work around the limitations. Conversely, the EAM diagnostic algorithms in the EAM software often use process measurements already available by connecting to the DCS. WirelessHART and OPC are the enabling technologies that permit easy deployment of automation beyond the P&ID in an existing

AUGUST 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 7

Going wireless THE PLANT MANAGEMENT IS ALSO INSTRUMENTAL IN LEADING THE CULTURAL CHANGE REQUIRED TO INSTITUTIONALISE EAM, ECM AND HS&E PACKAGES IN DAILY PLANT ACTIVITIES

plant. An OPC server should be added to the DCS in the event that OPC is not already available.

The scope has to be defined early on in the modernisation project and should involve the project/turnaround team, the DCS team, instrumentation team, modernisation solution supplier and the maintenance group. It should be documented in the form of a basis of design, a functional design specification including system architecture, network protocols to be used for DCS integration, hardware and software as well as associated services. For an existing plant, the system architecture requirements will be based on the plant audit and gap analysis.

No essential asset should be left stranded without EAM. A remote site may not have personnel with the necessary skills required for analysis of asset health information. For such locations, remote access infrastructure such as a wired or wireless backhaul network between the site and a centralised location should be considered.

Assign roles and responsibilities A number of persons are involved in the initial deployment of the EAM, ECM and HS&E package, the instrumentation and in sustaining the EAM software and associated work processes for the long term. The person that is responsible for the rollout of new practices for maintenance should be on the modernisation team and is best suited as a lead for the team. The plant management is also instrumental in leading the cultural change required to institutionalise EAM, ECM and HS&E packages in daily plant activities, so a senior member of the management should be the executive sponsor to drive the change.

This includes providing required resources for the deployment of the EAM software and the continued running of the system for the long term.

The turnaround manager or project manager also needs to be on the modernisation team to manage the work and resources required to deploy the EAM software. It is also necessary to identify the persons responsible for work processes associated with the EAM software and to establish a cross-functional modernisation team of instrumentation, control system and maintenance specialists. These will

be the experts on essential asset monitoring, energy conservation measures and HS&E to continue the modernisation for the long term.

It is a good idea to develop an organisation chart for the team with roles and responsibilities - defining who is responsible for delivering what.

graphics, asset health alarm management and reports etc.

For the IDM software, verify all versions of all device types from all manufacturers are integrated, that is, their EDDL files are loaded.

This involves the IDM supplier, plant instrument specialist and plant system engineer.

Plan deployment

Installation

The modernisation team leader should develop and document a plant-wide and site-specific modernisation plan for how the EAM software, OPC server and underlying wireless infrastructure and transmitters will be deployed at the specific site. This should include a schedule for when each phase of the modernisation project will take place and the resources required, when people will take on their new roles as well as detailed plans for the training of people in different roles.

In an existing plant, a local contractor installs the wireless transmitters as well as the wireless gateways with network infrastructure and power. In a new plant, the EPC does this work.

The modernisation package vendor can help supervise the installation of wireless transmitters and gateways.

If the correct make and model of manual valves, relief valves, safety showers and eye wash stations etc have been identified in the design phase and the correct mounting kits have been specified, the wireless transmitter installation will be smooth.

Detail design Based on the short-listed assets and the types of asset health diagnostics required for each asset, the number of WirelessHART transmitters can be determined. Next, the number of gateways and supporting networking equipment can be determined. Lastly, assets need to be ranked and their health alarms prioritised in a rationalisation process to ensure effective plant-wide alarm management.

System implementation The overall system implementation is normally done by the modernisation solution supplier.

This will involve building the EAM database, including the graphics, tags, historian, alarm management and reports based on the detail design, and also the ECM database with steam trap information.

Automatic pressure, temperature, flow, level, pH and conductivity measurements as well as safety shower and eye wash stations, valve position feedback, along with automatic vibration, temperature and leak testing data can be routed to the existing DCS or a separate HMI for HS&E purposes.

FAT The factory acceptance test (FAT) is done at the modernisation solution supplier’s staging area, witnessed by the buyer. A FAT test plan shall be agreed on and forms the basis for the FAT test procedures to verify the

8 WHAT'S NEW IN PROCESS TECHNOLOGY - AUGUST 2013

Commissioning The wireless transmitters and the software have to be commissioned. Normally a local contractor would commission the transmitters and gateways, including setting the network ID and join key, as well as the device tag and update period if this was not configured in the factory. The site instrument technicians should also take part in the commissioning so they become familiar with the WirelessHART technology.

Wireless commissioning should at least involve checking all instruments join the network and meet the requirements for number of neighbours, signal strength and reliability, and that they are transmitting correct measurement values.

The EAM system would normally be commissioned (and the baselines and weightings tuned) by the EAM system supplier.

Site integration The modernisation solution supplier works with the DCS supplier to establish communication between the two systems: for operators to receive asset health information and alarms, and for the EAM diagnostic algorithm to receive process variables already measured by wired transmitters. Site integration starts by establishing the bidirectional OPC link

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Going wireless

between the plant DCS and the EAM software.

Having a list of parameters to be linked between the systems developed in the detail design phase speeds up the integration work in the two systems.

Note that for EAM, only computed information like one overall asset health index for each asset is passed to the DCS, not all of the dozens of raw data points like vibration and temperature for every asset. This way the DCS tag count is kept low and the integration is simple.

Process variables already measured by wired transmitters connected to the DCS come from the DCS through OPC into the EAM software. At sites where the EAM software gets process variables like heat exchanger flows or variable pump speed from the DCS through OPC, the site integration and commissioning may happen in parallel.

Develop procedures Procedures and work processes should be written making use of the new plant-wide information. Development of these procedures can start early in the project and does not need to wait for the detail design to be completed.

A consultant can help in the development of the procedures and work processes for maintenance, energy conservation and HS&E. These services should be included as part of the project budget.

Training for competency Use of EAM software and other applications requires new skills, therefore training is required for all those involved to get the necessary competency in asset management.

With asset management, work is centred around computers, so computer skills are a prerequisite for maintenance work in a modern plant.

Asset management training has to be specific to the competencies required for the tasks which each role has to carry out.

Training has to be conducted not at the end of the modernisation project, but throughout the duration of the project before the next phase of the project starts. Once the plant is operational, new employee training and refresher courses should be conducted periodically.

EAM for second-tier assets Three common examples of second-tier assets that are prime candidates for wireless EAM

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Figure 1: Basic steps in site modernisation with EAM, ECM and HS&E packages. are heat exchangers, pumps and steam traps.

Heat exchangers Plants typically do not know the rate of fouling of heat exchangers, because the manual measurement of the hot fluid involved is difficult and time-consuming. Since cleaning heat exchangers usually requires a process shutdown, cleaning them too often is costly.

But if they become severely fouled, they may need to be removed completely to be cleaned - an even far more costly exercise.

Finding the optimum cleaning time for heat exchangers requires performance data at least daily to calculate the rate of fouling.

This can be achieved by measuring hot and cold fluid inlet and outlet temperatures and flow using wireless transmitters. The raw data is transmitted back to EAM software and the plant historian, to allow the automatic computation of all the factors necessary to trend the rate of transfer degradation, mak-

ing it possible to predict the optimum time for cleaning.

Pump health A pump can be affected by many different problems, with one type of problem often leading to another. Cavitation, for example, can be caused by a plugged suction strainer before the pump creating a pressure drop, or a downstream flow restriction causing internal recirculation across the impeller - leading to impeller damage and vibration. Vibration can also be caused by poor mounting or misalignment, poor lubrication or worn bearings. The list goes on ‌ Most pump problems can be detected by vibration testing, but in many cases, manual checking may not occur frequently enough to capture impending failures. Early detection of problems can be achieved by wirelessly monitoring various factors, depending on the pump, and processing the data in the EAM system. Wireless instruments that can be used to do this include vibration transmitters, DP transmitters (detecting pressure drop caused by strainers and seals), level switches (for sealing fluid), temperature transmitters (for bearings and motor windings) and hydrocarbon sensors to detect leakage. Not all pumps will need all these factors monitored, but EAM applications can be customised to suit the individual pump applications.

Steam traps Typically a steam trap has a life expectancy of four years, so if they are only inspected yearly, then on average, 25% of them may be found to have failed or be ready for replacement - and a typical plant may have thousands of them. Manually checking them is therefore difficult, because of the quantity, and the fact that many of them are difficult to access. They also require a high level of technical experience to diagnose.

Using a wireless acoustic transmitter on the outside of the steam trap inlet, with a built-in temperature transmitter, allows the detection of the ultrasonic noise and temperature change caused by steam or condensate that results from steam trap failure.

The status of all steam traps can therefore be displayed in the EAM software for easy review by technicians.

Emerson Process Management Contact info and more items like this at wf.net.au/U208

AUGUST 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 9

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10 WHAT'S NEW IN PROCESS TECHNOLOGY - AUGUST 2013

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Served up on a plate

AirLINE Quick: High quality, cost effective, fast delivery Meet AirLINE Quick. AirLINE Quick has internalised all pneumatic air channels, and integrated primary and secondary components to deliver one single complete pneumatic (or electro-pneumatic) valve bank on a stainless steel adapter plate. Unlimited modularity in valves, functions, feedbacks, I/O, and accessories, is offered, with local assembly from Bürkert’s ISO 9001 Sydney Systemhaus. The stainless steel plate mounts directly into a cabinet, effectively minimising labour for cost effectiveness and fast delivery.

Same day turn-around (on lower-quantity orders) is common.

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Ideal for end-users, OEMs, and switchboard consultants. Designed for arduous environments, for physical and chemical resistance.

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We make ideas flow

Steeling time OneSteel Whyalla is a large-scale operation built around a key South with Allen-Bradley GuardLogix systems, and the outdated power module Australian port. Its diverse operations encompass mining and export interface hardware was also upgraded, with SD3000+ interface hardware of iron ore, as well as manufacture and structural milling of steel for bringing it up to current technological standards. Each of the GuardLogix the Australian and overseas markets. cabinets was equipped with a PanelView Plus operator interface which The plant’s blast furnace is the powerhouse of its steel-manufacturing provided two fully redundant diagnostic displays. operations. The furnace operates around the clock, producing molten A risk assessment determined that critical functions including the iron for conversion to steel. Two massive skips alternately provide overspeed, overwind and emergency stops needed to meet Safety Integrity the raw materials required by the furnace: pellets, coke, lump Level 2. To achieve this, Rockwell Automation incorporated extra safety ore, limestone and dolomite. If the skip hoist shuts down, furnace functions into the design. Two overspeed and overwind devices were operations are disrupted, included in the new system, which could potentially cost one attached to each of the tens of thousands of dollars GuardLogix controllers by an per hour of lost production. absolute encoder module.

In 2008, the existing These features meant that if skip hoist process control the new online system detected system was nearing the an overspeed or overwind, it end of its operational would trigger a system shutdown. life, but opportunities to The machine operators could upgrade it were few and then investigate the problem and far between. The plant’s manually switch to the backup operations allowed for only system if required. During two 24-hour shutdowns maintenance periods, operators per year. A rare chance to would be able run test modes to overcome this hurdle was safely determine whether the to timetable installation and overspeed and overwind devices commissioning of a new were functioning correctly. system during a planned blast The new system also provided furnace repair scheduled in Raw materials for molten iron are delivered to the OneSteel Whyalla blast test modes for each of the brakes 2011, which would involve furnace alternately by each of two skip buckets. on the skip hoist’s dual motors. approximately 60 days’ break “Operators can lift one brake, in furnace operations. On average, major furnace shutdowns occur and try to drive through that brake to a certain level. If it doesn’t move it only every 15 to 20 years. passes, if it moves they know they need to do maintenance,” said Simpson.

OneSteel Whyalla contracted Rockwell Automation to locally The most critical milestone was to ensure that the new skip hoist control design, manufacture and commission an upgrade solution within this system was installed and commissioned within the 60-day shutdown tight timeframe. The company was selected because of its expert period allocated for the blast furnace repair. To achieve this, work had to knowledge and experience in maintaining and supporting the existing be scheduled around other demolition and construction tasks that took control system. place during that time, and was therefore limited to only 10 days of the The original control system consisted of a pair of Rockwell’s available time. Rockwell Automation therefore undertook considerable Automax controllers interfaced to the third-party power module. The pre-installation work and testing. A new control desk was also part of the Automax units provided control and monitoring of a pair of drive solution, so that the system could be pre-wired and factory tested before motors, either of which could be switched in to operate the skip hoist it was delivered. Commissioning of the new system ran smoothly due to drum. “Effectively there were two independent switched systems,” said painstaking preparation for this final stage. “It’s the sort of thing you don’t Andrew Simpson, Senior Design Engineer, Global Solutions Group, want to change over until you’re 100% confident,” said Simpson. “You don’t Rockwell Automation. “If a motor failed, it could be switched out and want to push to meet a deadline and then have the job carry on an extra the system would run at a reduced rate.” couple of days.”

Even though Rockwell Automation still offered after-sales support Since commissioning, the upgraded skip hoist system has been for the Automax controllers, the scarcity of spare parts and limited operating well, with only minor teething problems. Many of these issues maintenance availability were both issues affecting the viability of can be rectified by on-site maintainers, with the knowledge that Rockwell the system. For this and other operational reasons, OneSteel Whyalla Automation field engineers are available if needed. decided to upgrade the whole control system while retaining existing OneSteel Whyalla was very pleased with the achievements of the system functionality.

Rockwell Automation team, and look forward to working with Rockwell Rockwell Automation designed a control solution that interfaced to Automation on future projects. “The products are great, and the people the existing third-party power module. According to Craig Foulkes, Iron are always there to support us,” said Foulkes.

Making Electrical Engineer with OneSteel Whyalla, this was a service which was highly beneficial to OneSteel Whyalla. “The current power A longer version of this article can be read online at http://www.processonline.com.au/case_studies/61881-Steeling-time module was reliable, and we had both an online system and spare to back it up. Being able to retain this part of the system reduced project Rockwell Automation Australia costs significantly,” he said. The Automax controllers were replaced Contact info and more items like this at wf.net.au/ U493

14 WHAT'S NEW IN PROCESS TECHNOLOGY - AUGUST 2013

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NEW PRODUCTS

HIGH-PERFORMANCE COUPLING The Kop-Flex MAX-C WB hybrid coupling is a solution for managing torsional vibration in high-performance drive trains powered by synchronous motors, variable-

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to the segmented design, by which the gears are made up of multiple identical segments whose number depends on the overall diameter, even larger diameters and widths are possible. The power range reaches up to 2500 kW per pinion.

The use of special ADI cast material means that the company’s girth gears have material properties that provide minimal wear. This enables the company to offer a smaller tooth width, allowing users to save on the overall system.

Girth gears are used to drive grinding mills, kilns and rotary dryers. The solution requires a high level of consulting, which the company can provide to help users find technically and economically optimised solutions for their applications.

SEW-Eurodrive Pty Ltd Contact info and more items like this at wf.net.au/U433

high-performance gear coupling half, depending on the application. The hybrid design matches the advantages of a low-cost, lightweight flexible coupling half for the driven shaft, with the vibration damping of a MAX-C coupling half on the motor end. The maintenance-free MAX-C dampens high drive-train torque loads, while the overall hybrid design reduces weight, cost and

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MathWorks Australia Contact info and more items like this at wf.net.au/U497

16 WHAT'S NEW IN PROCESS TECHNOLOGY - AUGUST 2013

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NEW PRODUCTS

SEALED SWITCHES

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They are variously rated for temperatures between -55 and +400°C, have a low 1x10-8 atm cc/sec leak rate, up to 1M cycles, and some are rated explosion proof. They are available with leaf spring, roller or roller lever actuation, and stainless steel or ceramic mounts when required. The metal corrosion-resistant housings of some switches withstand most media and allow immersion in fluids such as synthetic hydraulic oils and jet fuels.

Motion Technologies Pty Ltd Contact info and more items like this at wf.net.au/U332

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(30W & 75W also available - call for pricing)

ing range has been optimised for packing and has the smallest footprint of all delta robots handling more than 3 kg. Advanced motion control simplifies the frame design, and the tool flange has been re-engineered to accommodate larger grippers. These larger and heavier grippers make the robot able to handle flow-wrapped products, giving the FlexPicker the ability to pick up as many as 500 products per minute directly from an indexing belt. Finally, a new mounting interface has been added to the robot’s moving plate.

• Wide power range 30W to 240W • Universal AC input voltage 90-264VAC • Voltage tolerance +/-1% • Adjustable output voltage +/-10% • High efficiency & reliability • 100% full load burn-in

• Cooling by free air convection • LED power indicator for power on • International safety approvals • Local stock • Low cost solution • 2 year warranty

* Price excludes GST and ONLY available to approved business and/or trade customers.

Bulk pricing available on request.

The upgrade improves upon the IRB 360 FlexPicker’s other existing features, such as a hygienic design for wash-down applications,

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high tracking performance and integrated control of indexing belts.

info@soanar.com AU 1300 365 551 NZ 0508 765 956

ABB Australia Pty Ltd

RANGE - RELIABILITY - STANDARD - CUSTOM

Contact info and more items like this at wf.net.au/U274

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AUGUST 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 17

NEW PRODUCTS

SECURE ROUTER/SWITCH The Moxa EDR-810 is an industrial multiport secure router with Firewall/NAT/VPN and managed L2 switching functions, which allow the EDR-810 to transmit data efficiently while protecting the network and critical devices from cyberattacks. The EDR-810’s integration of security and networking functionality into a single device saves extra deployment cost and effort, and offers eight 10/100 Mbps and two gigabit ethernet ports.

Moxa’s gigabit-performance security routers can be deployed in networks that need secure remote access or remote monitoring of field assets and provides an electronic security perimeter that protects critical assets, such as pumping/treatment systems in water stations, DCS systems in oil and gas applications, SCADA systems and PLC systems in factory automation. The EDR series secure routers support built-in PacketGuard technology, which performs deep inspection on normally unsecure Modbus TCP packets. NAT support includes N-to-1 and 1-to-1, as well as port-forwarding deployment. Up to 20 VPN connections are also available in the VPN model, for secure remote management.

Time-critical applications and data-hungry applications (such as video) have extremely low tolerance for latency. The EDR series secure router provides gigabit performance (up to 500 Mbps throughput) for fast and real-time data communications as a solution. The EDR series secure router also withstands environmental hazards such as high EMC interference or extreme temperatures from -40 to 75°C (T-models).

Madison Technologies Contact info and more items like this at wf.net.au/U302

LOW INRUSH CURRENT MOTORS ABB has identified the most common requirements for low inrush current (LIC) motors and created a set of pre-calculated motors based on enhanced designs.

The set of pre-calculated low inrush current motors are designed to meet the requirements of extruder, pump and compressor applications. The motors are said therefore combine the excellent reliability of ABB’s high-voltage modular induction motor platform (type AMI) with the best-possible performance in their given application.

LIC motors are used to minimise disturbances in weak supply networks. When a regular motor is started in a weak network, the high starting current can cause a voltage drop that may disrupt the operation of other equipment. Weak networks are often found in remote locations and are most common in sectors such as COG, marine, mining and quarrying.

SHAFT ALIGNMENT SYSTEM Available to rent, the Pruftechnik Rotalign Ultra Laser Shaft Alignment System can be used to align horizontal and vertical machines, and coupled and uncoupled shafts. It uses patented single laser technology to enable measurement and analysis of the rotating shafts. The device allows for measurement flexibility, with three different measurement modes - continuous sweep mode, multipoint mode and static mode. A built-in 5-axis receiver allows for simultaneous monitoring of vertical and horizontal machine correction.

The user-friendly interface includes a backlit colour display that is easily viewable in bright sunlight, and features an array of on-screen help, alphanumeric editing using the backlit keyboard, and USB connection to a PC or other device.

Alignment can be performed in three easy steps, and machine train align-

The company’s LIC technology is based on improved rotor designs, where the rotor bars are manufactured from carefully selected high resistivity copper alloys and the bar width and shape are varied in order to deliver the required motor performance. As a result the starting current is only 3.5-4.5 times nominal, which can be compared with figures of up to seven times nominal for regular motors.

The standard LIC range consists of 11 kV motors in 2-, 4- and 6-pole versions and frame sizes 560-900. The maximum power output is 4-11 MW, depending on the target application. The motors are supplied with non-sparking (Ex nA) or pressurised (Ex p) protection for use in explosive atmospheres.

ment is supported for up to 14 machines.

ABB Australia Pty Ltd

TechRentals

Contact info and more items like this at wf.net.au/U456

Contact info and more items like this at wf.net.au/U420

18 WHAT'S NEW IN PROCESS TECHNOLOGY - AUGUST 2013

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Integrated safety solutions at your doorstep When it comes to safety, NHP combine expert people with an extensive range of products and services from leading global suppliers to deliver integrated, valueadd solutions. It’s all a part of our customer promise to be easy to do business with.

In addition to these partnerships including Rockwell Automation and the Allen-Bradley® range, our IECEx certified Hazardous Area Workshop offers the ability to customise solutions to suit project specific application. Bringing together individual safety components, NHP has the knowledge to design integrated solutions that offer increased control across your operations.

NHP ELECTRICAL ENGINEERING PRODUCTS PTY LTD

Sales 1300 NHP NHP | nhp.com.au |

Calling upon our safety team which includes TUV certified experts, we can also offer a range of services and training opportunities to ensure you are up-to date with the ever evolving machine safety industry.

For increased convenience, this same team can also provide onsite consultation and risk assessments for site specific applications.

If you’re looking for an advantage when it comes to safety, the safe choice is NHP. For more information on our On Tour programs please visit nhp.com.au/Media/Events/On-Tour

EASY TO DO BUSINESS WITH

NEW PRODUCTS

SHIELD CLAMP

FAIL-SAFE BRAKES The SG Transmission Series 62 electromagnetic brakes are designed for fail-safe operation. When power to the unit is interrupted, the brake is energised by a permanent magnetic disk that attracts a steel armature plate and the brake is locked. When power is returned to the coil, the brake is released, allowing motion to occur.

The electromagnetic brakes are suitable for improving safety on machines using stepper and servo motors with heavy vertical loads. If the power fails, the brake locks and the load is prevented from falling.

The brakes use rare earth permanent magnets and efficient 24 VDC coils to reduce heating and power consumption. Holding torques range from 0.4 to 30 Nm with a range of sizes from 28 to 110 mm diameter. The brakes are asbestos free.

Automated Motion Systems Pty Ltd Contact info and more items like this at wf.net.au/U313

Weidmüller has released a shield clamp that allows users to shield on both sides of a cable to eliminate noise.

The KLBU RC shield clamp discharges interference currents. The built-in high pass filter in the shield clamp prevents high-frequency noise from being transferred across the cable. It effectively suppresses interfering currents to help ensure a more effective and responsive system.

Suitable for use in long or extensive systems, the KLBU RC shield clamp is particularly useful in power plants, sewage plants, wastewater and other industrial facilities where the use of numerous data cables, processors and frequency converters is growing and so too, the potential for problems.

The use of the KLBU RC shield clamp on the field side(s) reduces transfer impedance and improves system performance and stability.

According to Weidmüller, the KLBU RC shield clamp also aids functional earthing to help protect the electrical equipment. Most people are aware of protective earthing to keep life and assets safe. Functional earthing protects electrical equipment. The KLBU RC allows users to shield at both ends of long cable routes to also help ensure the performance and safety of the electrical cables.

The KLBU-RC shield clamp is also certified for resistance to vibration. It meets the requirements of wind power plants and can be used in mobile installations.

Available in three different terminal sizes from 3 to 20 mm, the shield clamps match cable diameters for secure contact.

MODBUS GATEWAY

Weidmuller Pty Ltd Contact info and more items like this at wf.net.au/U512

Turck has expanded its BL20 I/O system with a gateway for serial Modbus communication. The gateway supports both Modbus RTU as well as the ASCII protocol. The user can also choose between either RS485 or RS232 for the physical interface. Push-in terminals for connecting the fieldbus and power supply cables quickly and directly eliminate the need for any time-consuming preparation of

SF6 TRANSFER UNIT

the typical 9-pin Sub-D connectors.

The most important parameters, such as baud rate, address

WIKA’s GTU-10 is an SF6 trans-

assignment, bus termination and RS232/RS485 can be set easily

fer unit that can handle a flow

on the gateway using the DIP switches. Other functions such as

rate of 1.8 cubic metres per

ASCII mode and other baud rates can be configured using FDT/DTM

hour. The unit’s compressor

with Pactware. A mini-USB port can be used as a service interface.

runs oil free and, thus, the gas

Embedded in the Banner DX80 wireless system from the Turck

is kept safe from the possibility

range, the gateway makes it possible to implement cable-free

of contamination from lubricants.

Modbus RTU communication. With an extended temperature range

The compact instrument is simple and safe to use. Its

from -25 to 60°C, the gateway can also be used in outdoor control

concept of operation precludes the emission of gas. In addi-

cabinets. The electronics are coated with a protective lacquer to

tion, the unit is a cost-effective product - its long maintenance

provide protection from condensation. Up to 32 I/O modules can be

intervals result in very low operating costs.

connected to the compact IP20 gateways, and the BL modules can

WIKA’s SF6 product offering encompasses density monitors,

also be used for connecting RFID read/write heads. The modular

valves, filling equipment and analysis instruments. In addition,

concept enables users to deploy the same electronic modules in

the company offers practically oriented product seminars and

different fieldbus systems.

other training.

Turck Australia Pty Ltd

WIKA Australia

Contact info and more items like this at wf.net.au/U365

Contact info and more items like this at wf.net.au/U565

20 WHAT'S NEW IN PROCESS TECHNOLOGY - AUGUST 2013

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NEW PRODUCTS

UV DISINFECTION FOR WASTEWATER Xylem Inc has launched a closed-vessel, ultraviolet (UV) disinfection solution optimised for large-scale wastewater treatment plants, industrial and water re-use applications. Xylem’s WEDECO LBX 850e system is a highly energy-efficient addition to the company’s LBX Series and has been fully validated according to the US Environmental Protection Agency’s UV Disinfection Guidance Manual (USEPA’s UVDGM 2006) and

THE SWITCHMODE POWER SUPPLIES YOU WANT NOW FOR LESS AT SOANAR

the National Water Research Institute (NWRI) guidelines by independent, industry-leading Carollo Engineers.

UV treatment is an environmentally sustainable solution and a very

240W

effective alternative to chemical-based disinfection such as chlorine

100W

treatment. As a chemical-free treatment UV disinfection does not carry the risk of forming harmful by-products, such as trihalomethanes (THMs)

60W

and haloacetic acids (HAAs).

WEDECO’s low-pressure, high-output amalgam UV systems offer high performance due to the highly efficient Ecoray lamp technology. Ecoray

25W

lamps consume approximately one-third of the amount of energy that medium pressure lamp systems need to operate. Compared to other low-pressure, high-output amalgam UV lamps, they provide the benefit

IN STOCK NOW

of longer lamp life, higher sustainability, superior dimming capabilities and lower mercury content.

WEDECO’s experience with ‘sensor-based dose pacing’ offers additional energy savings. The OptiDose Control ensures the required dosage is applied while conserving power and lamp life. Additionally, the automatic wiping system maintains maximum sleeve transmittance resulting in peak efficiency. By keeping the sleeves continuously clean, the system uses less energy and lowers operational costs and maintenance effort.

Xylem Water Solutions Australia Limited Contact info and more items like this at wf.net.au/U759

AC/DC ENCLOSED SWITCHMODE POWER SUPPLIES OUTPUT OUTPUT POWER VOLTAGE (W) (V) 25W 60W 100W

GSM MODULE FOR DATA LOGGERS

240W

OUTPUT ORDER CURRENT NUMBER (A)

DIMENSIONS LIST (L x W x H) PRICE (MM)

12V

2.1A

SE-25-12

24V

1.1A

SE-25-24

12V

5A

SE-60-12

24V

2.5A

SE-60-24

12V

8.5A

SE-100-12

24V

4.5A

SE-100-24

12V

20A

SE-240-12

24V

10A

SE-240-24

98 x 97 x 35

$28.77*

159 x 97 x 38

$38.37*

199 x 98 x 38

$44.77*

215 x 115 x 50

$71.20*

The STS GSM communication module for the STS range of data loggers is a reliable and durable communication module that can be used to assist in the continuous monitoring of ground and surface waters.

The GSM module is constructed with a chromate conversion coated aluminium housing and incorporates stainless steel ports to ensure its long-term durability in the field. The module also combines a temperature compensated real-time clock to ensure accurate time and date stamping throughout the year.

• Wide power range 25W to 500W • Universal AC input voltage 85-264 VAC • Voltage tolerance +/- 1% • Adjustable output voltage +/- 10% • High efficiency & reliability • International safety approvals

• Safety standards (EN60950-1) • EMC standards (EN55022 Class B) • Low cost solution • Local stock • Local engineering and sales support • 2 year warranty

The GSM module can easily transfer data directly to an office-based computer, or if preferred, to a mobile device via SMS. The GSM module operates in the 900, 1800 and 1900

* Price excludes GST and ONLY available to approved business and/or trade customers.

Bulk pricing available on request.

MHz bands, and can read 1000 measurement values in 36 s.

Operating temperature range is -20 to 55°C

www.soanar.com

Automated Control Pty Ltd Contact info and more items like this at wf.net.au/U496

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info@soanar.com AU 1300 365 551 NZ 0508 765 956

AUGUST 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 21

NEW PRODUCTS

OPC FIREWALL MODULE Hirschmann EAGLE Tofino has introduced the OPC Enforcer, an OPC firewall module, to their distributed network protection range. Like the other modules in the range, the module is configured to pass or drop datagrams according to customisable rules. It is configured using the Tofino Central Management Platform.

Protection of traffic using OPC Classic protocol is almost impossible with traditional firewall rule sets. The OPC Enforcer takes a different approach, dynamically opening only the TCP ports required for each connection, and only between the specific OPC Server and Client forming the connection. It applies to OPC DA, HDA or A&E servers.

TUBULAR CABLE CONVEYORS

Other features include a ‘sanity check’ capability to eliminate rogue traffic, for

The Flexi-Disc line of tubular cable conveyors

multiple clients and servers, and the unique ‘learn’ mode where user rules can

is designed for the gentle transfer of friable

be tested on real data before implementation.

food and non-food products.

The EAGLE Tofino solution comprises three elements; a central management

The conveyor moves material using high-

platform that runs on a PC, distributed EAGLE Tofino appliances, and loadable

strength polymer discs affixed to a stainless

security modules (LSM) such as OPC Enforcer. These modules allow customisa-

steel or galvanised cable that slide within

tion of each appliance to manage costs, paying only for the correct solution at

smooth stainless steel tubing, moving fragile

each point in a network.

products gently, quietly and dust free, hori-

The most common application for the OPC Enforcer is to secure transfers to and

zontally, vertically or at any angle, through

from data historians, as well as protecting communications between equipment

small holes in walls or ceilings. The system

from different vendors that share no other common protocols.

can have single or multiple inlets and outlets,

The Hirschmann EAGLE Tofino is a fundamental part of a defence-in-depth cyber security strategy and is designed to be part of a centrally managed zone-based defence system, protecting against malware, equipment failures and user errors.

and convey over short distances or hundreds of metres.

Gentle handling offered by the conveyor makes it suitable for food products that are

Daanet Pty Ltd Contact info and more items like this at wf.net.au/U522

prone to breakage or degradation, including cereals, coffees, teas, dried fruits, frozen vegetables, grains, nuts, peas, pet foods, seeds, snack foods and spices. Typical non-food applications include bulk chemicals, minerals, chopped fibreglass, microspheres, regrind, pellets, tobacco and other friable materials.

Modular system components in 304 or 316

ROUND-PLUG CONNECTORS Phoenix Contact has expanded its connector range with M17, M23 and M40 round-plug connectors. This means a full range of plug connectors from M5 to M58 are now available for signal, data and power transmission.

The M17, M23 and M40 models add moulded round-plug connectors to the range. The straight and angled plug connectors are available for signal transmission with up to 17 pins. Six and eight pins are available to transfer power at up to 70 A. The moulded, angled M23 can be rotated by 240°, allowing conductors to flexibly and easily exit any device in various

stainless steel include tubing, drive wheel housings, tension wheel housings, metered and non-metered inlets, and discharges with and without valves, as well as accessories for wet or dry cleaning, including CIP sanitising.

Available in unlimited configurations, the conveyor is offered as a stand-alone system, or fully integrated with upstream and downstream equipment such as inlet hoppers, bag dump stations, bulk bag dischargers, bulk bag fillers, drum/box/container tippers, weigh batching/blending systems, screeners, filling machines and storage vessels manufactured

by Flexicon and others.

directions. Another addition to the range is the Advance product line with freely

Flexicon Corporation (Australia) Pty Ltd

configurable, EMC-protected M23 round-plug connectors for signal transmission

Contact info and more items like this at wf.net.au/U322

with up to 19 connections. All the plug connectors are also optionally available with the Speedcon quick-locking system for quick installation in half a turn.

Phoenix Contact Pty Ltd Contact info and more items like this at wf.net.au/U488

22 WHAT'S NEW IN PROCESS TECHNOLOGY - AUGUST 2013

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NEW PRODUCTS

FIBRE-OPTIC MEDIA CONVERTERS Advantech has added two media converters to its EKI-3000 family light industrial unmanaged switch range. These SC Type fibre optic media converters have the smaller compact housing that is shared with the EKI-3000 family switches. The two models include the EKI-3541M, which is a multimode version to send data up to a distance of 2 km, and the EKI-3541S, which is a singlemode version to send data up to 30 km.

The biggest advantages of optical ethernet transmission are wide bandwidth, EMI

QUADBAND 3G ROUTERS

immunity and long-distance transmissions. These compact devices, with simple

The Cybertec 2150 and 2250 3G rout-

plug-and-play installation, ensure that network administrators get up and running

ers improve on their predecessors by

quickly and easily. In the event of a fault on the device network, administrators

including a faster processor, additional

are instantly alerted through the use of Link Fault-Pass technology, which sends

memory and quad-band modules as

the error signal through whichever port is still available. The compact size also

well as additional functionality in firm-

allows the devices to be installed in a small cabinet, thereby making the most

ware. The 2150 and 2250 are direct

of the available space.

replacements for the former Cybertec

These models carry an IP40 certification for light industrial usage and work

2100 and 2220 models.

from -10 to 60°C for various industrial environments. They have an operating

The Cybertec 2150 is a 3G cellular

voltage range of between 8.2 to 52.8 VDC and provide 4000 VDC surge (EFT)

router designed to provide high reli-

protection against overvoltage.

ability and availability in industrial ap-

Advantech Australia Pty Ltd

plications. Incorporating an integrated

Contact info and more items like this at wf.net.au/U149

2-port ethernet switch and RS232 interface, it can provide secure remote

PORTABLE DEWPOINT MEASUREMENT

cellular connectivity ethernet and serial devices. Features such as smart

Michell Instruments designed the MDM300 I.S. portable hygrometer

multilevel watchdog technology ensure

for fast, easy and ergonomic operation in hazardous areas - making

long-term operational stability while

it suitable for checking the dewpoint in hydrogen-cooled electricity

comprehensive remote management

generators.

and diagnostic tools provide enhanced

Depending on plant requirements, water dewpoint in hydrogen cool-

maintainability over the cellular network.

ant can be continually monitored with online instrumentation or

The Cybertec 2250 is a high-perfor-

spot checks taken using a portable measurement device.

mance 3G cellular router which extends

An online solution has the advantage of continuous

the connectivity capabilities of the 2150

monitoring and alarm capability should the dewpoint

by incorporating an additional two serial

rise above an ambient level but a portable ‘spot

ports and four integrated digital I/O. The

check’ instrument offers a cost-effective and flex-

inclusion of multiple serial ports allows

ible solution which can be used across the site for

concurrent transmission of different

periodic checking or as backup to an online system.

serial data streams across the cellular

The MDM300 I.S. maximises operational efficiency by

network. For instance, the 2250 can

taking as many measurements as required from different appli-

provide simultaneous connections for

cations across a whole site with no waiting time in between. It gives

both polled SCADA data from the com-

fast, accurate responses and measurements are carried out at system

munications port and diagnostic data

pressure to give true representation of the risk of condensation occurring

from the configuration port of the same

in working conditions. To ensure easy quality control and compliance

device. This way remote maintenance

with the requirements of local authorities, the units are supplied with

and management of the device can be

traceable calibration certificates.

performed without a technician having

The MDM300 I.S. is an adaptable unit with a robust casing which

to visit the site. The integrated digital

can withstand the rigours of day-to-day operation at a power utility

I/O provides alarm/event triggering and

plant. Customised sampling and other accessories are available to

interlocking capabilities as well as the

ensure spot checks are as quick and easy as possible and the unit is

ability to set or reset remote devices

also suitable for other applications on site, such as the measurement

over the cellular network.

of moisture in SF6, natural gas and instrument air.

Madison Technologies

AMS Instrumentation & Calibration Pty Ltd

Contact info and more items like this at wf.net.au/U137

Contact info and more items like this at wf.net.au/U351

24 WHAT'S NEW IN PROCESS TECHNOLOGY - AUGUST 2013

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Bonfiglioli drives State of Origin fans wild Some of the best seats in the house at this year’s State of Origin rugby league matches at ANZ Stadium on 5 June and 17 July were occupied by fans who were probably unaware of the industrial gearbox engineering that brought them closer to the spectacle.

Bonfiglioli combination helical/planetary technology - of a type typically used in resources, manufacturing and materials handling - is incorporated to a drive system that rolls forward 500 tonne sections of seating to give wildly enthusiastic fans a better view of events such as the State of Origin, rugby union tests and soccer matches attracting total attendances of 80,000 and more.

The 90 x 30 m sections of grandstand on each side of the ground are rolled forward 15.575 metres before each event, taking less than half an hour to move the distance required to put about 7500 privileged fans on each section much closer to the sidelines and the action.

“The scale of the job and the technology involved was comparable with some of the biggest materials handling tasks ever undertaken in Australian manufacturing or mining, where you sometimes might have to move massive machinery of similar weight and proportion,” said Bonfiglioli Transmission (Australia) Ltd Managing Director Malcolm Lewis. The Multiplex project - which has brought spectacular action closer for millions of fans since the original installation - involved a high degree of technical innovation in the production of a series of 28 gearboxes to operate in two banks of 14 driving bogies for the mobile building structure. Instrumental in the design and installation were Eilbeck Cranes, which specified the Bonfiglioli drives involved, and Control Techniques, which worked with Bonfiglioli to resolve the technical challenges in cooperation with Structural Systems.

Each gearbox features a 1.1 kW 4-pole electric brakemotor driving an A series helical gearbox combined with a compact planetary Trasmital

26 WHAT'S NEW IN PROCESS TECHNOLOGY - AUGUST 2013

gearbox. The 105 kg combination provides high torque within a restricted space, offering a highly cost-efficient and compact installation compared with a much bulkier alternative weighing 261 kg.

“The drives operate with a number of technologically interesting features, including electronic encoders linked to PLC-controlled variable frequency drives. This arrangement functions to ensure all the motors operate in unison, so the bogies drive smoothly, without imparting any discordant stresses into the structure,” says Lewis. “The Bonfiglioli brakemotor involved was also fitted with a ventilated servo, for ongoing reliability within a restricted space, where maintenance access could be an issue. This is important in an installation that has now been proven in service for some 10 years.

“The ventilation was important to ensure reliability, because the drives, controlled by the variator, do not run at their constant design speed - a condition which, without the ventilation, can produce heat.” A final feature of the arrangement was a microswitch built into the brakemotor circuit to ensure all brakes are released before start-up.

Lewis says the project illustrated the many inputs that go to make up a large-scale industrial motors and drives project - including product range, engineering innovation and ability to deliver from quality-controlled facilities within Australia.

“In-house engineering and backup service is very important to major customers, who are going to depend on you to respond quickly to their design brief and ensure ongoing support of their installation.

“This confidence factor is vital in production circumstances, where the cost of the drives is just one component among many, but where failure could be disastrous,” said Lewis.

Bonfiglioli Transmission Pty Ltd Contact info and more items like this at wf.net.au/U355

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NEW PRODUCTS

MULTICONTACT CONNECTORS The DSN 37C multicontact connector is part of Marechal’s range of multicontact connectors designed for signal and control applications in aggressive environments and/or heavy use (up to several thousand operations).

The connectors allow for the simultaneous transmission of power, low-level signals and data. The connector has up to 37 contacts, a maximum-rated current per contact of 16 A and a maximum voltage of 480 V. It is waterproof to IP66/67 either with the plug connected or the lid closed.

The solid silver-nickel contacts ensure high conductivity, electrical performance

REMOTE ACCESS STARTER PACK

and durability. The connector comes with a GRP casing which resists the extreme

Secomea has announced that their

mechanical shock (IK08). A metal casing is also available with a locking

3G Secure Remote Access system

position connected and disconnected by a lockable shaft.

is now available in an economical

Marechal

all-inclusive starter pack. The starter

Contact info and more items like this at wf.net.au/U609

conditions often found in harsh environments and gives good resistance to

pack includes everything necessary to provide a remote connection to a PLC, HMI or any programmable device and requires no specialist IT knowledge or even involvement, and is typically operational in 15 minutes.

While many remote access solutions rely on using a computer as the site interface, the Secomea

Unbeatable Control,

Precision, and Flexibility

approach uses a SiteManager appliance which provides direct access to devices, with the remote user’s own PC hosting the application software. This provides a true end-to-end connection, performing as though the user were actually physically plugged in.

The SiteManager can be equipped with ethernet, USB and serial ports to accommodate virtually all configurable equipment. Digital I/O is provided, and commonly used for a keyed local ‘enable’ switch, and a ‘channel active’ lamp indicator. 3G models provide for situations where no LAN internet access is available.

The solution provides robust two-factor authentication, port filtering based on the actual designated model of PLC, and security based on AES/SSL encryption. A

Graphical system design combines productive software and reconfigurable I/O (RIO) hardware to help engineers lower cost, increase productivity, and shorten design times.

This customizable, off-the-shelf platform, integrates motion, vision, and I/O with a single software development environment to build complex industrial systems faster.

cloud-based authentication server provides ease of use for adding or

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

deleting authorised users, as well as eliminating the need for costly static IP addresses as found in some systems.

Daanet Pty Ltd Contact info and more items like this at wf.net.au/U367

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Australia: 1800 300 800 New Zealand: 0800 553 322 ©2013 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

AUGUST 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 27

NEW PRODUCTS

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PNEUMATIC PRESSURE CALIBRATOR Avai la b le t o re n t , t h e Dru c k DP I 6 15 - 2 0- N ATA 2 0 b a r pneumatic pressure calibrator is a self-contained battery operated instrument that contains a pressure generator, fine pressure control, and device energising and output measurement capabilities. The device is 4-20 mA configurable to allow for loop testing and data storage.

The device has been designed for simple ease of use, while still being suitable to perform a wide range of applications such as calibration, maintenance and commissioning. The built-in 10,000-value data logger enables the user to reduce calibration times and eliminate data recording errors, while maintaining a high degree of accuracy.

The supported pressure range is from 0-20 bar ±0.025% FS. Voltage input is ±50 VDC ±0.05% rdg, ±0.004% FS, while the current input is ±55 mA ±0.05% rdg, ±0.004% FS. Temperature range is -10 to 40°C ±1°C (ambient). The voltage output range is 10 VDC ±0.1% or 24 V ±5%, and the current output range is 0-24 mA ±0.05% rdg, ±0.01% FS. TechRentals

ÜÊ`ii«Ê` Þ ÕÊÜ> >Ê} ¶

Contact info and more items like this at wf.net.au/U421

ÀÃV > Ê Ê/ v Ê Ê Ì iÊv Õ `>Ì Ê vÊÞ ÕÀÊ ¼`ivi ViÊ Ê`i«Ì ½Ê iÌÜ À Ê ÃiVÕÀ ÌÞÊÃÌÀ>Ìi}Þ°

ELECTRIC ACTUATORS The Elektro range of electric drives of-

UÊÊ i ÌÀ> Ãi`Ê > >}i i Ì UÊÊ - vÌÜ>ÀiÊ `Õ iÃÊv ÀÊ ÀiÜ> É Ê `LÕÃÊ/ *ÊÉÊ"* Ê UÊÊ >ÃÞÊÌ ÊV v }ÕÀiÊÜ Ì ÊÕ µÕiÊÊ Ê ¼ i>À ½Êvi>ÌÕÀi UÊ ÊÀiV v }ÕÀ>Ì Ê vÊiÝ ÃÌ }ÊÊ Ê iµÕ « i ÌÊÀiµÕ Ài`° iÌÜ À ÊÃiVÕÀ ÌÞÊV v `i Vi V iÃÊ Ê>ÊL ÕiÊL Ý°Ê 6 à ÌÊÜiLÊv ÀÊÌ iÊÜ ÌiÊ«>«iÀ°

fered by Metal Work Pneumatic has the same overall dimensions as ISO 15552 pneumatic cylinders.

This allows replacement of a pneumatic air cylinder without the need for any mechanical alterations, and as an added bonus, all the accessories of traditional cylinders can be used.

If the application requires controlled ramping of acceleration and deceleration during the stroke of the cylinder, the ability to accurately stop at any point or points of the stroke with high repeatability, or higher forces and accuracy than normal pneumatics, then an electric cylinder undoubtedly performs this role much better than a conventional pneumatic actuator.

The Elektro family of actuators can be offered as a complete solution, allowing users to simply specify a few key requirements in regards to stroke, speed, load and orientation and a fully supported solution can be offered including

:_ijh_Xkj[Z Xo

the electric drive, servo or stepper motors and motor driver. Alternatively users can select hardware-only solutions based on size and specifications and use their own motor and drive combinations.

Metal Work Pneumatic Australia Pty Ltd

£ÎääÊ /

Contact info and more items like this at wf.net.au/U370

`>> iÌ°V °>ÕÉÌ v

28 WHAT'S NEW IN PROCESS TECHNOLOGY - AUGUST 2013

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NEW PRODUCTS

RS485 SERIAL DATA ACQUISITION DEVICES The Moxa ioLogik R1200 series is a line of smart RS485 serial

OPC UA EMBEDDED SERVER DEVELOPMENT KIT

interface remote I/O devices with features such as commu-

MatrikonOPC has announced the release of its

nication configuration by software, uploading configuration

OPC UA Embedded Server software development

or firmware by USB, dual RS485 ports and built-in repeater.

kit (SDK), which enables users to quickly and easily

The devices are designed for establishing a cost-effective,

incorporate native OPC-UA connectivity directly in

dependable and easy-to-maintain process control remote

their embedded devices.

I/O system. Serial remote I/O products offer process engineers

The SDK is purpose built for microprocessor

the benefit of simple wiring, as they only require two wires

and microcontroller environments where minimal

to communicate with the controller and other RS485 devices

memory use and highly optimised execution is es-

while adopting the EIA/TIA RS-485 communication protocol to

sential due to the limited resources available, and

transmit and receive data at high speed over long distances.

can be integrated into every class, from discrete

In addition to communication configuration by software or USB

sensors and actuators to programmable controllers.

and dual RS485 port design, the company’s smart remote I/O devices eliminate

This single product is fully configurable and

the extensive labour associated with the set-up and maintenance of data acquisi-

scalable from microcontrollers with 64 kB RAM up

tion and automation systems. The company also offers different I/O combinations,

to high-end embedded systems based on ARM9,

which provide greater flexibility and are compatible with every kind of application.

ARM Cortex-Ax and x86 based processors such as

The series offer a wide operating temperature range of -40 to 85°C, as well

the Intel Atom. The product can be optimised for

as 1 kV surge protection and 3 kV I/O isolation between I/O channels, networks

minimum RAM and flash utilisation or for large data

and power circuits.

sets and multiple concurrent client connections.

Madison Technologies

MatrikonOPC

Contact info and more items like this at wf.net.au/U359

Contact info and more items like this at wf.net.au/U368

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AUGUST 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 29

NEW PRODUCTS

TEMPERATURE BATH Available to rent, the Grant GR150-S5 temperature bath is a NATA-calibrated water/oil bath and circulator for calibration of temperature probes and analytical procedures. The GR150-S5 is suitable for applications requiring high-precision temperature control in the range of ambient to 100°C for water and up to 150°C for silicon oil.

The GR150-S5 has a stability of ±0.005°C, uniformity of ±0.02°C and display resolution of 0.1°C. Also included with this unit is a timer function that enables reaction timing, a variable high-temperature alarm setting and a user calibration facility for optimum accuracy at the required operating temperature. Stainless steel tank dimensions are 300 (w) x 150 (d) x 150 mm (h).

It also features a clear and easy-to-read digital temperature controller and display, a heater timer for early starts and late shutdowns, a dual-position bridge plate and a relay for switching external devices.

TechRentals Contact info and more items like this at wf.net.au/U156

INTELLIGENT SURGE PROTECTION Phoenix Contact’s surge protection devices, Plugtrab PT-IQ, for measurement and control and data technology provide intelligent monitoring of every voltage limiting component of a protective circuit. The push-in connection technology enables significantly faster wiring of the individual protection modules.

LOW-COST SERVOS Based on the G5 series, the Omron G5 Lite servos represents a cut-down version, with a number of advanced features removed to reduce cost.

G5 Lite servos accept a single-phase 200 V source and output between 100 to 1500 W to a servo motor. Ready-made cables with moulded plugs are available for simple plug-and-play functionality. The matching servomotors have an optional holding brake, to maintain position when power is removed.

The motor’s inbuilt encoder resolution is 20 bit, meaning 1,048,576 pulses are generated every revolution. The drive accepts a pulse train input, for direct replacement of stepper motors.

Both positioning and fixed-value speed control modes are supported, along with eight inputs and three outputs, all with configurable functionality.

Optimum motor performance is easily achieved by the real-time auto-tuning facility which can run continually. Vibration can also be significantly reduced by enabling one of several adaptive or notch filters. Damping control is also provided and is useful for keeping liquid loads level during movement to avoid spillage.

Omron Electronics Pty Ltd

Rigid conductors and flexible ones equipped with end sleeves can be inserted directly into the terminal sockets quickly and without fatigue. No special tools are needed to disconnect wires.

The integrated latch key enables disconnecting joined wires with all common screwdrivers.

A controller supplies up to 28 protection devices with voltage over mounting-rail connectors. At the same time the status of all protection devices is transferred to the controller. The wiring work is minimised, as the supply as well as remote signaling of an entire strip of protection devices is done from a central location.

The Plugtrab surge protection devices allow immediate detection of any pre-damage due to high energy surges. The function status of every surge protection device is indicated and remotely signalled on multiple levels.

Phoenix Contact Pty Ltd Contact info and more items like this at wf.net.au/U261

Contact info and more items like this at wf.net.au/U158

30 WHAT'S NEW IN PROCESS TECHNOLOGY - AUGUST 2013

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NEW PRODUCTS

RFID READER The Ha-VIS RF-R200 RFID reader has been added to HARTING’s auto-ID solution range. The RFID reader is a mid-range reader, ie, it has been optimised for read ranges up to 2 m.

Typical applications are tool identification, identification of manufactured goods on production lines, logistics, description of transponders at work or production places.

Available models include: RF-R200 with RJ45 interface and PoE; RF-R200 with USB interface for office use; RF-R200 module (only board without housing) for integration into machines or other products.

Features include: 500 mW transmitter power; supports automatic transmission of the acquired transponder information to a computer; supports an external antenna; internal antenna (read range up to approx 20 cm); IP30; minimum footprint when installed on top hat rail in switch cabinet.

HARTING Pty Ltd Contact info and more items like this at wf.net.au/U607

DOUBLE RUPTURE DISC ASSEMBLY Rupture-disc manufacturer Elfab has further developed its existing pressure-relief assembly range, adding a design specifically to prevent environmental contamination in severe process conditions.

The Double-Disc Assembly comprises primary and secondary bursting discs that are both reverse acting, both forward acting or now a combination of the two, plus a pressure gauge or switch to monitor the space between the discs. The new design opens the company’s product range up to a wider mix of users and process specifications,

Wind Energy

Photovoltaics

Communications

Process Industry

Transportation

Security Systems

particularly in the oil and gas, and chemical industries.

The product aims to help the increasing number of companies facing the pressures of zero emissions and other environmental concerns. In the event of chemical attack causing pinholing of the primary disc, the secondary disc prevents pollution of the environment, while the intermediate pressure sensor alerts process managers and maintenance teams to the need to replace the disc that has operated.

The assembly is available in a number of materials to suit user requirements, from stainless steel to Hastelloy and duplex.

Elfab Limited www.elfab.com

www.ProcessOnline.com.au

DEHN Australia EMAIL: info@dehn.com.au WEB: www.dehn.com.au TEL: +61 (03) 8414 8277 PO Box 290, South Melbourne, VIC 3205 Australia Distributors throughout Australia and New Zealand

AUGUST 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 31

COMPARING DIFFERENTIAL PRESSURE TRANSMITTER ACCURACY Ted Dimm, Honeywell Process Solutions

Accuracy statements issued by instrument manufacturers are often used as a basis for choosing devices for an application; however, these specifications are measured in laboratory conditions and may not give an accurate picture of the performance of an instrument under real process ambient conditions.

D

ifferential pressure transmitters are extremely versatile instruments fitting a broad range of applications in various process industries. Accuracy is a key performance measure for any process measuring device and is an important factor for proper device selection and maintenance.

Differential pressure devices are very versatile, but it is not always easy to understand, calculate or compare accuracies between devices. This article is intended to help the reader better understand what manufacturers’ accuracy statements mean, what specifications are important for a given application and how to properly compare various product capabilities.

Accuracy fundamentals Basic accuracy statements are published by manufacturers and are often used as a basis for comparing devices. These statements typically quote ‘reference accuracy’ (RA). When considering an actual application, reference accuracy is an important factor regarding performance, but it does not provide the entire picture.

32 WHAT'S NEW IN PROCESS TECHNOLOGY - AUGUST 2013

There are additional specifications that provide performance information for specific application conditions. Often referred to as ‘effect specifications’, these specifications apply to varying conditions such as temperature, static pressure and customeradjusted span. When selecting a device for your specific set of conditions, it is these specifications that will impact the final application performance.

Reference accuracy Reference accuracy (RA) is the device accuracy as determined through design and testing by the manufacturer. Stated as a percent of span setting, most manufacturers’ statements include the combined effects of linearity, hysteresis and repeatability with a conformance of ±3 σ. Additionally, all manufacturers specify the reference conditions under which this performance applies.

Typical/common reference conditions might be: • Temperature: 25°C • Static pressure: 0 psi • Relative humidity: 10-55%

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Instrumentation & sensors

• Turn-down effects (TDE) • Temperature effects (TE) • Static pressure effects (SPE) It is the proper combination of all these parameters in conjunction with the reference accuracy that results in defining the total probable error (TPE) of a differential pressure transmitter in a particular application.

Accuracy with turn-down effects (AC)

Error=

Effect specifications The following five elements have meaningful effect on the overall performance of a differential pressure transmitter: • Turn-down-ratio effects (resulting from customer-selected span setting) • Temperature effects on zero • Temperature effects on span • Static pressure effects on zero • Static pressure effects on span To help simplify these elements, the zero and span effects are often combined for judging temperature effects, and separately combined for static pressure effects, thus reducing the number of parameters to three:

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Where constants factor1 and factor2 are device-specific and supplied by the manufacturer, URL is the device’s upper range limit, also specified by the manufacturer, and Span is the actual customer span setting as determined by the customer-selected URV and LRV. By combining reference accuracy with the effects of actual span setting, accuracy can now be stated as the greater of either reference accuracy or accuracy with turndown effects (AC) as follows: Accuracy of span = the greater of RA or: AC =

( Span

± A+B URL

(

Due to design variations within a product family, some manufacturers may also specify specific model numbers or materials of construction depending on their potential impact on performance.

Because reference accuracy applies only to the stated conditions, it cannot be considered a measure of overall performance for industrial applications, where conditions are often elevated or varying. Reference accuracy represents transmitter performance only under laboratory conditions. To best understand actual application performance we need to examine additional ‘effect specifications’.

(

URL ± factor1 + factor2 Span

(

© iStockphoto.com/Terry J Alcorn

All differential pressure transmitters are designed to operate over a specific range and with span limits as specified by the manufacturer. This is depicted in Figure 2 by the URL and LRL limits shown. Customers have the flexibility to make adjustments within these ranges to fit their application needs as depicted by the URV and LRV. Depending on the degree of customer adjustment made within the device limits specified, additional inaccuracies may apply.

Most manufacturers will supply the necessary data and equations to allow customers to determine these additional errors.

Typically, such calculations follow a formula with a form like:

Generally, AC > RA.

Temperature effects (TE) In process applications, the process temperature as well as the ambient temperature can change dramatically. Stable or not, the process and ambient temperatures will almost certainly be different from the reference conditions under which the transmitter was manufactured and tested. This means the performance will differ from the stated reference accuracy.

Temperature changes can affect both the zero point accuracy and the span accuracy of a transmitter. It is necessary to include both components in order to understand the overall impact of temperature shifts. Although these elements are sometimes

AUGUST 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 33

Instrumentation & sensors

Figure 1: Most manufacturers' statements include the combined effects of linearity, hysteresis and repeatability with a conformance of ±3 σ.

Device Upper Range LImit (URL) Customer Upper Range Value (URV)

Customer Span(URV-LRV) Customer Lower Range Value (LRV) Device Lower Range Limit (LRL)

stated separately, many manufacturers provide a single calculation that incorporates both zero and span effects. Similar to the equation above for span effects, the following is a common example of the calculations made for temperature where the manufacturer provides C and D as well as URL, and Span is the customer-selected span or difference between URV and LRV.

(

URL ± C+D Span

(

TE =

Static pressure effects (SPE) Similar to temperature and span effects, static pressure can also have substantial influence on the accuracy of a transmitter for both its zero and its span. These effects can usually be represented by a similar equation. Again E, F and URL are all manufacturer supplied, while Span is the customer’s selected measurement span within the stated URL and LRL of the device:

(

URL ± E+F Span

(

SPE =

Total probable error (TPE) Once the RA, span settings and errors associated with temperature and static-pressure effects have all been determined, you have the necessary elements to determine the overall accuracy (total performance or total probable error). Since every product will respond differently to span settings, temperature deviations and static pressure, TPE is the only true means of comparison between products. TPE incorporates all the individual product differences with the specifics of a given application to provide the relevant error calculation. TPE can be calculated as the root sum squared of the errors: TPE = ±

AC 2+TE 2+SPE 2

What makes instruments perform differently?

Obviously, details of design, materials and workmanship all play a significant role in determining a transmitter’s overall performance. Of these, the basic design of the chosen sensor

34 WHAT'S NEW IN PROCESS TECHNOLOGY - AUGUST 2013

Figure 2: Manufacturers specify upper and lower range span values within which user ranges may introduce additional inaccuracies.

type is usually the most important determinant of the device’s ultimate capability.

At the root of all pressure-measuring product designs is the basic pressure-measuring sensor. Considering only reference conditions, many sensors will appear to provide similar performance. For industrial applications, where temperatures can be extreme and, in the case of differential pressure measurement, where static pressures can be elevated or even fluctuating, it is necessary to compensate the basic sensor to maintain accuracy.

As one example, high-performance piezoresistive sensors offer some unique compensation capabilities. These sensors can integrate static pressure and temperature measurements on the same sensor chip, thus allowing the designer to incorporate circuits that automatically correct the sensor’s performance for varying static pressure and temperature conditions. When implemented as an integrated solution, the result is better accuracy over a wider range of application conditions. Devices using sensors without such compensation usually do not perform as well under varying conditions.

Summary Differential pressure transmitters are extremely versatile devices, suitable for a wide variety of applications, such as flow, level, density and filter-quality measurement, as well as leak detection. All of these applications have differing parameters for pressure-measuring spans, static pressures and temperatures that will affect device performance. Understanding these process parameters and how they can affect differential pressure transmitter performance should influence your transmitter selection, as well as expectations regarding overall transmitter performance in your particular application. For comparison purposes, always look at total probable error to insure optimum performance.

Honeywell Limited Contact info and more items like this at wf.net.au/U549

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270x88mm HACH PACIFIC_ProcTech_bustmyths:8.25x10.75 WEAU OPT

INSTRUMENTATION-SENSORS PRODUCTS

IN-SITU OXYGEN SENSOR Mettler Toledo’s GPro 500 TDL sensor is claimed to offer exceptional measuring performance and easy installation, and to require little or no maintenance.

Being a tunable diode laser (TDL) gas analyser, no sample extraction or conditioning is necessary, it exhibits low drift, and it is immune to interference from moisture, dust or background gases.

Other 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 GPro 500 incorporates

YOUR STORIES OF FACT AND FICTION.

a probe that reflects the laser beam back to the receiver in the sensor head, therefore 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 O 2 measurement.

The company’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

didn't think there was a way to get “ We an accurate DO reading without lots of calibration. But the new LDO sensor from Hach comes calibrated from the factory— simplifying my life, and giving me more accurate readings.

”

At Hach, we are trying to re-think wastewater analysis. Help us bust common wastewater myths at: bustmyths.com

Contact info and more items like this at wf.net.au/U369

PRESSURE SWITCHES The flicker-free operation of the snap-action switch is the prominent feature of the OEM pressure switch from WIKA. The compact model PSM01 and PSM02 instruments achieve a reproducibility of ±2% full scale.

Due to their high accuracy and their robust design, the PSM01 and PSM02 pressure switches are suitable for a broad spectrum of applications, even under harsh conditions. The fitting of the PSM01 is made easier by its socketwrench mounting.

Both switches work in the ranges of 0.2-2 up to 40-400 bar, while with the PSM02 the hysteresis can also be specified. The switch parameters can be easily adjusted on site using the adjustment screw. The company also offers factory setting of the required switch point and hysteresis.

WIKA Australia Contact info and more items like this at wf.net.au/U566

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AUGUST 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 35

INSTRUMENTATION-SENSORS PRODUCTS

CAPACITANCE LEVEL SENSOR The NOHKEN CG300 series capacitance level sensors

FLOWMETER FOR PARTIALLY FILLED PIPES

are designed for liquid level detection and measurement, offering an accuracy of ±0.5% FS and an operating temperature range of -20 to 60°C (or -20 to 150°C with a heat-proof option). With a maximum operating pressure of 100 kPa and IP68 (electrode) and IP65 (housing) protection, the CG series has four models to meet individual requirements.

The zero and span points of the CG300 series level sensors are set by one push-button, making adjustment easy when the medium changes inside the tank. The sensitivity of the level sensor is 30-2000 pF, allowing the instrument to be used in a wide range of applications without considering changing the circuit board.

Using the principle of phase detection, the CG300 level instruments are not affected by noise or resistance build-up.

The change in capacitance is detected by the frequency and phase shift and is presented as a 4-20 mA signal output.

Bestech Australia Pty Ltd Contact info and more items like this at wf.net.au/U207

The Krohne Tidalflux 2300 F is an electromagnetic flowmeter designed for flow measurement in partially filled pipes. It features an integrated, non-contact capacitive level measurement and an approval for ATEX zone 1 for use in hazardous environments.

The flowmeter is designed to provide reliable flow measurement for flow streams between 10 and 100% of the pipe diameter. The accuracy in partially filled pipes is <1% of full scale, and the accuracy in full pipes is <1% of the measured value.

IMPAC INFRARED TEMPERATURE SENSORS Small, economically priced short wavelength digital infrared Thermometer with fiber optics for non-contact temperature measurement between 100 &1200 Deg. C.

■ Small housing dimensions for easy installation suitable for use in confined spaces

IGA 320/23-LO

Due to the presence of H 2S in many wastewater applications, the flowmeter features an ATEX zone 1 approval. Its electrodes are mounted at a height of 10 % from the pipe bottom, ensuring that they are always wetted to avoid corrosion and the capacitive level sensors are integrated in

■ RS485 interface for long transmission networks for connection to a PC via USB converter or machine control (PLC)

the liner and have no contact with the medium.

■ Analog output adjustable to 0 or 4 to 20 mA for connection of standard analyzing instruments

effluent brine from dredging or mining, or from

■ Internal digital signal processing for high accuracy and long temperature ranges

the measuring tube comes with a polyurethane

■ High quality optics for measurement of small objects ■ Built-in LED targeting light for easy alignment to the measuring object ■ Applications include forging, induction heating, welding and hardening

Although municipal or industrial wastewater transport is its main area of application, the flowmeter can also be used for measurement of seawater or well-water injection applications.

Ranging in diameter from DN200 to DN1600, liner which is resistant to abrasion that may be caused by particles such as sand and stones suspended in the brine. It also features a high chemical resistance and minimises the need for regular cleaning as its smooth surface prevents build-up of fat and other deposits.

Krohne Australia Contact info and more items like this at wf.net.au/U366

36 WHAT'S NEW IN PROCESS TECHNOLOGY - AUGUST 2013

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INSTRUMENTATION-SENSORS PRODUCTS

TEMPERATURE SENSORS Siemens has extended its range of temperature sensors to include the Sitrans TS product family. The resistance thermometers and thermocouples are designed for universal use, and have a modular design, with a large range of sizes, materials, sensors and transmitters.

The range not only supports the central communication standards HART, Profibus PA and Foundation fieldbus, but is also certified under ATEX and IECEx, which enables the devices to be used worldwide. Sitrans TS is therefore suitable for both basic and highly demanding applications throughout the entire process industry.

The modular product family consists of the three product lines - TS100, TS200 and TS500. They are suitable for a wide range of applications in the process industry, such as in the fields of chemicals, oil, gas and power.

The TS100 and TS200 product series are available as cable and compact thermometers. This makes them especially suitable for universal use, such as detecting the temperatures of machine bearings. The compact insertion thermometers can also be used in confined spaces, and their mineral insulated design makes them not only flexible but also resistant to vibrations and high temperatures up to +1100째C. The TS500 product line is designed for applications with low to high process stresses. A selection of protective tubes made of solid or welded pipe material is available for this purpose. The user can utilise a wide range of process connections, connection heads, sensor types, transmitters and displays to configure individual solutions for a process.

Siemens Ltd Contact info and more items like this at wf.net.au/U445

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AUGUST 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 37

INSTRUMENTATION-SENSORS PRODUCTS

DIGITAL PANEL METERS Precision Digital has released updated versions of the Trident Series digital panel meters. The model PD-765 process meter now features two relays, a 4-20 mA analog output and a 24 VDC power supply all in one meter. It is housed in a shallow, 3.6″ depth, 1/8 DIN enclosure that features a NEMA 4X front panel. Two display heights are available - 14.2 and 30.5 mm. Each display is adjustable to lighting conditions, including direct sunlight. This allows the meter to easily be read from distances up to 10 m. For hazardous area applications, the model PD8-765 integrates all the Trident meter functions into an explosion-proof, die-cast aluminium enclosure with through-glass SafeTouch buttons and worldwide agency approvals.

The Trident panel meters are designed to handle a wide range of level, flow rate, temperature and pressure applications.

They can be field programmed to accept process voltage (0-5 V, 1-5 V, etc) and current (4-20 mA) inputs, 100 Ω RTDs and the four most common thermocouples: J, K, T and E. Process inputs can be scaled for virtually any engineering units. Temperature inputs can be programmed to display in degrees Fahrenheit or Celsius; the type K thermocouple can display up to 1260°C. The Trident meters feature a variety of options: two relays, a 4-20 mA output, 24 VDC transmitter supply and serial communication with Modbus RTU protocol. The 4-20 mA output option converts the meter into a transmitter with a digital

COMPONENTS display, making it suitable for temperature applications.

Precision Digital Corporation http://www.predig.com

CONTROL COMPONENTS Control Components

DIGITAL PANEL METERS

Control Components

See… it’s that

WIRELESS GWR TRANSMITTER

Level Measurement

CONTROL COMPONENTS

The Rosemount 3308 is an IEC 62591

Control easy!

Components

(WirelessHART) guided wave radar (GWR) transmitter for continuous level and interface monitoring, and has been

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

introduced to meet the need for accurate level monitoring in remote or difficult-toreach locations where installing new cabling would

be costly or impractical.

GWR transmit-

ters are widely used for a broad

range of measurement

and control applications, including

process level measure-

ment in vessels and storage tanks in

refineries, oil fields, offshore platforms, chemical and industrial plants.

The wireless GWR transmitter features enhanced configuration and

Weka Visual leVel indicators

diagnostics. The transfer of solutions from the wired Rosemount 3300 and 5300 Series GWRs has made long battery life possible without

• Visible Level readings at 10 metres+

compromising measurement reliability. Device dashboards help to

• Locally manufactured for short lead-times

reduce errors by providing a step-by-step configuration process.

• Switches & transmitters for Ex applications • Long, maintenance free lifespan • Available in SS, CPVC, UPVC & PVDF

The transmitter is a top-mounted device for direct level and interface measurement of liquids. It is virtually unaffected by changing process conditions such as density, conductivity, temperature and pressure, and because it does not have moving parts, no calibration is required and maintenance is minimised. A wide range of process

TAKE CONTROL

CCEZY.COM.AU 02 9542 8977

38 WHAT'S NEW IN PROCESS TECHNOLOGY - AUGUST 2013

connections, probe styles and accessories ensure application flexibility.

Emerson Process Management Contact info and more items like this at wf.net.au/U444

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INSTRUMENTATION-SENSORS PRODUCTS

MECHANICAL VIBRATION SWITCH DISSOLVED OXYGEN SENSOR

IMI Sensors’ Model 685A09 linear adjust mechanical vibration switch features an improved design that

The Hach ORBISPHERE M1100 luminescent dissolved oxy-

provides a better sensitivity adjustment

gen sensor with the ORBISPHERE 410 controller offers an

than previously. It has been developed

advanced way of monitoring oxygen in beer, boiler waters

for use in various applications such as

and deaerated water.

The fast response time of the M1100 sensor comes from

cooling towers, fin fans, large exhaust and

a measurement frequency of two seconds. Using weekly

vent fans, HVAC systems, blowers and motors.

Mechanical switches do not require power and use the resistive

clean in place (CIP), measurement accuracy is maintained

force and travel of a spring as a measure of vibration amplitude. When

at this frequency over a 12-month period with no calibration

the travel of a spring exceeds the predetermined threshold, the switch

in brewing processes.

is actuated and latched by magnetic attraction. The threshold value

The M1100 sensor is designed

is adjustable by changing the proximity of the magnet to the spring

for minimal drift, which results

and hence the spring travel required for actuation. Switch reset is

in it being very stable with long

accomplished manually by disengaging the magnet from the spring.

calibration intervals. Accurate

The improved design provides much better trip sensitivity adjust-

measurement readings are es-

ment than traditional designs, which allows a user to better control

sential to control low oxygen

the trip level in the switch and improve protection of their equipment.

levels in beer production,

Some of the other benefits of the mechanical vibration switch

to decrease unnecessary line stoppages, and to increase

include low-cost protection for critical machinery, better sensitiv-

production uptime. For processes using daily CIP, the sen-

ity repeatability on reset, DPDT relay, 10 A dry contact and 120,

sor can measure accurately for over six months without the

240 VAC or 24 VDC options.

need for any calibration or intervention.

Thermo Fisher Scientific

Hach Company

Contact info and more items like this at wf.net.au/U350

Contact info and more items like this at wf.net.au/U323

Got a tough sensing environment?

The XUK-S Photoelectric Sensor looks and feels like it has been cut from a solid block of stainless steel. This tough, no-nonsense sensor is made to perform in the harshest conditions.

Standard features include: > 316L stainless steel housing > IP69K rating and ECOLAB® certification > suitable for high temperature and chemical cleaning > visible red LED beam for ease of alignment.

XUK-S side view

The XUK-S Photoelectric sensors are available in various models including: Diffuse with Background Suppression, Thru-Beam and Polarised Reflex.

The XUK-S gets the job done where others fail. If you need a sensor that steps up to the challenge in the food and beverage manufacturing process or other harsh industrial environments, then look no further.

Simply easy!™

XUK-S top view

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

Sensors

© 2013 Schneider Electric. All Rights Reserved. CLIPCOM26539

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AUGUST 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 39

INSTRUMENTATION-SENSORS PRODUCTS

FREE THERMOWELL CALCULATOR Endress+Hauser has introduced a free online thermowell calculation tool to help customers stay compliant with the new ASME PTC 19.3 TW-2010 thermowell standards.

SIL2 COMBUSTION ANALYSER

The thermowell sizing tool calculates the thermowellâ&#x20AC;&#x2122;s ability to The Ametek Thermox

withstand stresses under given process conditions, important for

WDG-V extractive com-

safety-critical or demanding applications with high flow rates or high

bustion gas analyser has

process pressures, particularly in the oil and gas and chemical industry.

been third-party certified

Because a thermowell is subjected to a variety of stresses in these

for SIL2 implementation

types of applications, typically because of inline and transverse vibra-

in safety instrumented

tions, it is necessary to run calculations on the thermowell design to

systems (SIS).

make sure these stresses do not exceed the maximum allowable limit.

It monitors hot, wet flue

Endress+Hauserâ&#x20AC;&#x2122;s

gas for excess oxygen. It

thermowell sizing calcu-

also allows operators to

lator gives users a safe

lower emissions of NOx, CO and CO2 and improve operating efficiency

alternative to not only

in power generation and petrochemical refining. Reliable detection

thermowell failure but

of excess oxygen and combustibles (CO) in a fired heater or boiler

loss of measurement,

are critical to the effectiveness of burner management systems. The

damage to expensive

device also monitors for methane for safe burner start-up.

equipment, and safety

The combustion analyser features an improved aspirator design

risks to plant personnel.

with larger orifice sizes and improved response times even with

Enrichments in the

flame arresters installed. It also has a low-flow sample alarm that

thermowell calculation

monitors combustion gas flow at the sensors and provides an

tool include a larger

indication of low sample flow.

variety of thermowell geometries, such as stepped thermowells, and

Automatic verification of cell and detector response ensures proper

the updated ASME PTC 19.3 TW-2010 standards have enhanced

accuracy and operation, and cell and detector age tracking allows

resonant frequency calculations allowing the maximum thermowell

proactive calibration or service scheduling.

length to be determined based upon the process conditions.

The device mounts directly to the process flange and is heated to

The thermowell calculation tool is available online via the

maintain all sample wetted components above the acid dewpoint. Its

Endress+Hauser Applicator tool, a program that provides step-by-step

air-operated aspirator draws a sample into the analyser and returns

assistance with product selection, sizing and configuration.

it to the process. Applications include coal- and gas-fired power

To try out the thermowell calculation tool visit: http://www.us.endress.

generation, petrochemical and chemical refining, and pulp and paper.

com/temp_manufacturing.

Analytical Control Engineering

Endress+Hauser Australia Pty Ltd

Contact info and more items like this at wf.net.au/U317

Contact info and more items like this at wf.net.au/U333

Is your

Emission Monitoring System saving you money and fully compliant with EPA requirements?

Leading technology for emission monitoring and process control Tel: 07 3255 5158

Fax: 07 3255 5159

info@groupinstrumentation.com.au

40 WHAT'S NEW IN PROCESS TECHNOLOGY - AUGUST 2013

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INSTRUMENTATION-SENSORS PRODUCTS

SENSORS WITH INTEGRATED TRANSMITTER Krohne has introduced SMARTSENS, claimed to be the first family of 2-wire, loop-powered analytical sensors with integrated transmitter technology. The sensors are said to significantly reduce the risk of failures along the chain from sensor to process control system and ease the handling of analytical sensors. The first step includes the sensors for pH, ORP and conductivity, followed by other parameters.

Considering the possible sources of error by IEC 61508/IEC 61511 in the chain from sensor to process control system, the transmitter represents the main source of error by percentage. False installation, cabling or configuration of the transmitter are frequently occurring problems. To eliminate these risks, the company miniaturised the transmitter and fitted it into the sensor

head - any SMARTSENS sensor can be connected directly to the process control system, featuring direct communication via 4-20 mA/HART. Due to influences such as medium, temperature, humidity, environmental conditions or pollution, analytical sensors lose their accuracy over time and need to be calibrated, cleaned, regenerated and ultimately replaced.

SMARTSENS sensors are digital sensors and can be calibrated offline in a laboratory under controlled conditions. The sensors will store the calibration data and can just be plugged in again on site. For offline calibration, the sensor can be connected directly to a PC running the same PACTware (FDT/DTM) as applied in the asset management system, using a USB interface cable for bidirectional HART 7 communication and a power supply.

The sensors are suitable for industries including chemical, pharmaceuticals, food and beverage as well as power, water and wastewater applications.

Krohne Australia Contact info and more items like this at wf.net.au/U358

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AUGUST 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 41

NEW PRODUCTS

CONNECTOR FOR HARSH ENVIRONMENTS The Han HMC connector series from HARTING is claimed to be the first to combine the properties of more than 10,000 mating cycles and protection against harsh environmental conditions in one connector.

The increasing modularisation in machine construction and automation is leading to a rising demand for connectors that have been developed for a large number of mating cycles. The HMC connector series is suitable for all of the applications. The connectors are also suitable for use in tool and other interchangeable systems.

The connectors are based on the Han industrial connectors,

MINI DATA LOGGER

meaning that all already existing processing tools can also be

The MSR145 compact data logger from Interworld Electronics offers five

used for the Han HMC.

internal sensors, four analog inputs and user-friendly software.

The series consists of: HMC housings; HMC connector inserts

The data logger can be factory configured to meet user specifications

with crimp connection in four different versions; HMC crimp contacts

with a range of internal sensors including 3-axis acceleration, temperature,

in two sizes; diverse Han-Modular modules together with the Han

humidity, air and fluid pressure, and also light sensors. Analog inputs allow

HMC crimp contacts; and two different docking frames.

the connection of external third-party sensors for specialised measuring tasks such as CO2, conductivity and pH.

The HMC housings are equipped with a durable locking reel in order to continue to provide the connector with IP65 protection

The analog inputs also feature an alarm output and an input for starting

against dust and water after more than 10,000 locking cycles.

and stopping data recording. If required, the external sensors can be pow-

In order to be able to offer more than 10,000 mating cycles, the

ered by the logger’s internal battery. The MSR145 is available in a standard

connector inserts contain high-performance grounding contacts.

IP60 housing or an IP67 waterproof housing. A choice of 260 or 900 mAh

The crimp contacts are equipped with a special HMC gold surface

batteries and optional memory expansion slot provide addition flexibility.

and constant spring force. These properties ensure the connector’s

The thumb-sized data logger records over two million measured values or up to a billion measured values with an optional microSD card. All measured values can be rapidly transferred to a PC or laptop via the USB interface for data analysis.

good function - also after 10,000 mating cycles.

HARTING Pty Ltd Contact info and more items like this at wf.net.au/U608

Interworld Electronics and Computer Industries Contact info and more items like this at wf.net.au/U438

PANEL PCS The DL PPC 1000 series panel PCs are sturdy IP65-compliant devices with high-resolution LED technology that support complex user interfaces.

Users can switch between single- or multi-touch displays to suit the application at hand. This also accommodates future machine operating modes such as gesture control.

The slim 60 mm panel PCs are protected by a robust die-cast aluminium housing and resist dust and water. The devices can also be used in extreme temperatures ranging from -20 up to 55°C, which also makes them suitable for refrigeration systems.

The panel PCs are highly energy efficient due to the built-in Intel Atom E series, a combination of a highly integrated chipset and a power-saving processor. This processor series’ low power consumption is also reflected in the low heat it generates, which means that the units do not require built-in ventilation. An integrated VESA 100 bracket and a rear panel service hatch furthermore provide quick installation and servicing. Users get a fullfledged, energy-efficient industrial PC equipped with a heavy-duty touch screen that can be used as an operating console for machine-related use in rough industrial environments.

Phoenix Contact Pty Ltd Contact info and more items like this at wf.net.au/U213

42 WHAT'S NEW IN PROCESS TECHNOLOGY - AUGUST 2013

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NEW PRODUCTS

STAINLESS STEEL ROLLER PINION RACKS

HAZARDOUS AREA CONTROLLER

Nexen Group has expanded its

technology similar to a mobile-phone app to help ensure

roller pinion system (RPS) by

more efficient and safer petrochemical handling operations.

Honeywell Enraf has introduced the Fusion4 MSC-A, an advanced yet easy-to-use controller that uses intuitive

adding a full line of stainless

The controller is operated using intuitive, on-screen

steel racks. The RPS is already

icons, which reduces training time and improves accuracy.

known for its high positional

The interface delivers detailed process data, resulting in

accuracy, zero backlash, high

good operational monitoring.

efficiency, high stiffness, low

The controller is claimed to offer the most advanced

noise and low maintenance. Adding the corrosion resistance of the stainless

functionality of any additive controller available. It is capable

steel product line ensures there is a solution to fit any linear motion application.

of live data transfer in hazardous areas - safe, secure

The companyâ&#x20AC;&#x2122;s precipitation hardened stainless steel is said to be the ideal

two-way data communication with the handheld Fusion4

material when strength, fatigue resistance, high stiffness and corrosion resist-

Local Access Device allows rapid transfer of transaction

ance are required. Compared to 303 stainless steel or 6061-T6 aluminium,

data, configuration files and calibration records. It also

stainless steel can offer twice the load and life capacity while maintaining similar

offers advanced process monitoring and control for up

corrosion-resistant properties.

to 12 streams simultaneously at the load rack, as well

The companyâ&#x20AC;&#x2122;s stainless steel RPS has already proved its robustness in a

as detailed transactional data, alarms, diagnostics and

variety of applications where traditional steel rack and pinion failed, including

calibration event logging for a secure audit trail for busi-

food packaging, semiconductors and clean room industries.

ness and regulatory auditing.

Norman G Clark Pty Ltd

Honeywell Limited

Contact info and more items like this at wf.net.au/U426

Contact info and more items like this at wf.net.au/U260

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AUGUST 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 43

3D magnetic field measurement Magnetic field sensors are a contact- and wear-free means of measuring the position of machine parts and products. A new generation of Hall sensors is now making the process even more precise and free of interference.

Magnetic field sensors are used to measure the position of machine parts and products with zero contact and zero wear - in a modern car, around 100 of such sensors are busy monitoring safety belt buckles and door locks, registering pedal positions, or are used for ABS, EPS and engine control. They are cost-effective and robust; however, these conventional sensors generally measure only the magnitude of the magnetic field perpendicular to the chip surface. Good enough in many ways, magnetic field measurement remains imprecise and susceptible to interference. Michael Hackner, Dr.-Ing. Hans-Peter Hohe and Dr.-Ing. Markus Stahl-Offergeld from the Fraunhofer Institute for Integrated Circuits IIS were not satisfied with these limitations. They wanted precise position measurement with the advantages of magnetic field sensors, and so they set about developing a 3D Hall effect sensor.

“First we connected up several sensors on a chip in order to improve the measuring accuracy of the individual sensors,” says Stahl-Offergeld. “Next we arranged several of these sensors to measure the three-dimensional magnetic field at one point. The result was our pixel cells.”

And so a new generation of 3D Hall sensors was born, capable of measuring all three spatial axes of a magnetic field and calculating the exact position of an object. The sensor chip contains a designated sensor for each of the three magnetic axes. These sensors are placed together in the pixel cell and attain a magnetix flux density resolution of just a few microteslas, depending on the measurement speed. Also integrated directly on the chip are the evaluation circuit and a coil, which enable self-testing and calibration.

“In spite of its complexity, the HallinOne magnetic sensor can be manufactured using standard processes of semiconductor technology - and that makes it cost-effective,” explains Hohe. For this global technological breakthrough, the three Fraunhofer IIS developers have been awarded a Joseph von Fraunhofer prize this year.

One of the first companies to exploit the potential of HallinOne was Seuffer GmbH from Calw in southern Germany. As far back as 2006, it launched a sensor that prevents washing machines from wobbling and creeping across the floor during spin cycles. A magnet is attached to the tub and the sensor to a fixed, unmoving part of the

44 WHAT'S NEW IN PROCESS TECHNOLOGY - AUGUST 2013

A 3D Hall sensor developed by Dr.-Ing. Markus Stahl-Offergeld, Dr.-Ing. Hans-Peter Hohe and Michael Hackner (from left to right) can measure position exactly. (© Dirk Mahler/Fraunhofer). washing machine. Depending on how much washing is in the drum and how it is distributed during a spin cycle, the tub moves - and therefore so does the magnet. The sensor measures this movement, evaluates the data and transmits it to the washing machine. If the drum is wobbling, it is stopped briefly and shaken around a bit in order to distribute the washing more evenly. Fraunhofer IIS and Seuffer are currently developing a wireless window sentinel, which detects whether a window is open or closed and transmits this information via a wireless sensor network combined with energy harvesting.

“Our next goal is to develop a sensor for 5-axis position measurement,” says Michael Hackner. “This will allow us to detect more mechanical degrees of freedom simultaneously, including translatory and rotary movements by the magnet in all directions. It already works in laboratory tests, but the system still needs some adjustments before it is ready for real-life applications.”

Such applications could include use in the control systems of computers, construction machines, robots and aircraft.

Fraunhofer-Gesellschafthttp://www.fraunhofer.de

www.ProcessOnline.com.au

NEW PRODUCTS

PRP COMMUNICATIONS PROCESSOR The Simatic CP 443-1 RNA communications processor utilises the Parallel Redundancy Protocol (PRP) in accordance with the IEC 62439-3 standard to facilitate high-availability network connections for the Simatic S7-400 controller. It features two RJ45 ports for connecting two parallel industrial ethernet networks. The CP 443-1 RNA doubles the frame and feeds it into the two connected networks. The network access point on the receiver side relays the first incoming frame to the addressees and discards the later frame.

Simatic CP 443-1 RNA is designed for use in process industry plants and power generation and distribution applications. The communications processor supports open communication via TCP/IP, UDP and the ISO transport protocol as well as S7,

Economical & Scalable...

PG/OP and S7 H communication for S7-400 H systems. Data can be transmitted in full- or half-duplex mode in bandwidths of 10 or 100 Mbps. The user can view diagnostics information via SNMP, STEP 7

Pilz has a wide variety of cost effective & flexible safety solutions for

or the web server of the communications processor.

your packaging machinery.

In addition, the Simatic CP 443-1 RNA has a third ethernet interface with restricted functional scope.

On the basis of the ISO transport protocol, the port supports S7 communication services only, all others are deactivated. Fewer functions mean less testing overhead and lower qualification costs. All Simatic

Looking for a reliable Partner for the automation of your packaging line?

We offer you a comprehensive portfolio of solutions ranging from the small with only a handful of sensors using our new PDP technology all the way though to the most complex of systems utilising our PSS4000 safe automation platform.

Talk to us today about your packaging safety requirements!

CP 443-1 RNA functions are configured with STEP7 engineering software, V5.5 SP2 or higher and the hardware support package included in the scope of delivery.

Siemens Ltd Contact info and more items like this at wf.net.au/U613 safety@pilz.com.au

www.ProcessOnline.com.au

www.pilz.com.au

03 9544 6300

AUGUST 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 45

NEW PRODUCTS

THERMAL IMAGING AND SECURITY CAMERAS FLIR’s range of A310 cameras can be used for both temperature monitoring and security applications.

The A310 f and A310 pt thermal imaging cameras are dual-use systems - temperature monitoring of critical installations and perimeter security. They can be installed almost anywhere to monitor critical equipment and other valuable assets.

The A310 f is a fixed mounted camera. Once installed it always looks in the same direction. It is suitable for monitoring critical installations and to protect the perimeter at the same time.

The A310 pt pan/tilt has the features and functions to build single- or multicamera solutions. It can pan ±360° continuously and tilt ±45°. It is suitable to cover large areas. Typical application examples are wood and coal pile, waste bunker and substation monitoring.

It is a multisensor and includes a lowlight 36x zoom colour CCD camera.

With a thermal A310 pt, the operator can monitor the perimeter security continuously, while equipment in the field of view can be monitored at the same time.

At selected times, it can also audit temperatures of equipment in other locations, then return to the main task of security monitoring. A fixed A310 f camera can also perform both functions simultaneously.

Other applications include: power generation and

EMBEDDED CONTROLLER The Aaeon AEC-6637 Intel Core i7/i3-based embedded controller is a high-performance, stand-alone embedded PC featuring fanless operation, compact size, robust construction and low power requirements.

The device can be supplied with an Intel i5-3610ME 2.7 GHz or an i7-3610QE 2.3 GHz multicore processor, and all AEC-6967 models are equipped with one SODIMM socket supporting up to 8 GB of DDR3 system memory, two Gigabit RJ45 ethernet connectors, two USB 3.0 and two USB 2.0 ports, one RS232/422/485 port and three standard RS232 ports for communication. A 2.5″ SATA hard drive can be internally mounted for operating system and data storage while an internal CFast slot supports the next-generation compact flash storage cards. A mini card slot is provided for additional expansion. VGA video output is provided for graphics displays.

The fanless design reduces the possibility of airborne corrosive or conductive materials entering the system to provide a long-term reliable industrial computing solution.

The device operates from a wide-range 9-30 VDC supply making it suitable for embedded vehicle systems as well as factory control applications.

distribution; critical equipment monitoring; natural gas

Interworld Electronics and Computer Industries

processing, transport and storage; fire prevention in

Contact info and more items like this at wf.net.au/U424

waste storage areas; flare detection.

Both cameras can detect temperature differences as small as 0.05°C and contain analysis and built-in alarm functions. MPEG-4 video output can be streamed over

PLANETARY RACK AND PINION SYSTEMS

ethernet to show live images on a PC. Composite video

The Atlanta HighForce ZTRS precision planetary rack and pinion drive systems are

output, PAL and NTSC is available. The cameras come

offered in three different planetary drive styles; with helical or straight (spur) rack

standard with a built-in 25° lens with both motorised

and pinion, to meet any application requirements.

focus and autofocus.

The rack and pinion drive systems are very well suited to ultra-precise applica-

Each camera comes with a single sensor copy

tions with thrust forces up to 124 kN. They are available in five sizes with backlash

of Sensors Manager. This software allows users to

levels down to one arc minute and ratios from 4:1 to 100:1, and can handle highly

manage and control a camera in a TCP/IP network.

dynamic and heavy loads. They use precision planetary reducers with an integral

The fixed camera is EtherNet/IP and Modbus TCP

output housing and outboard bearing to provide a rigid support of the output pinion.

compliant, which allows for sharing of analysis and

By adding an output bearing housing, the tilting moment capacity of the flanged

alarm results to PLCs.

planetary reducer is dramatically increased. Also, the unique design of the pinion

FLIR Systems Australia Pty Ltd

allows for smaller pitch diameters, which decreases the torque on the reducer.

Contact info and more items like this at wf.net.au/U524

Because of these design enhancements, a smaller reducer can typically be used.

Motion Technologies Pty Ltd Contact info and more items like this at wf.net.au/U506

46 WHAT'S NEW IN PROCESS TECHNOLOGY - AUGUST 2013

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NEW PRODUCTS

REDUNDANT I/O SYSTEM The ICP DAS iDCS-8830 is a modular remote re-

ETHERNET SWITCHES WITH NAT

dundant I/O system that supports Modbus/TCP and

The Allen-Bradley Stratix 5700 managed industrial ethernet switch range now includes

Modbus/UDP with eight I/O slots designed to work in

an optional integrated network address translation (NAT) feature.

duplex or simplex applications.

A challenge for machine builders and end users is that IP addresses are generally

It provides for easy installation of the I/O modules

unknown until the machine is being installed, which can add cost and time to the com-

and process cabling. The iDCS-8830 is highly modu-

missioning of the equipment, and delay moving that equipment into production. The

larised and flexible so that the I/O modules can be

hardware-based NAT feature allows for simplified integration of IP address mapping

combined to suit many applications including most

from a set of local, machine-level IP addresses to the end user’s broader plant process

types of signals, digital, analog, counter and HART.

network. This can greatly benefit manufacturers that are integrating identical machines

The station of an iDCS-8830 system consists

into a production line. The Stratix 5700 switch NAT feature allows OEMs to deliver their

of power modules, communication modules, I/O

standard machines to customers without having to program unique IP addresses into them.

modules and termination boards. The power modules

The line of switches is currently available with six, 10 and 20 fixed-port configurations.

The product includes features such as IEEE-1588 time synchronisation, QoS (prioritisation) and Resilient Ethernet Protocol (REP). Additional features also allow for increased network availability, and help improve network performance and security. Each switch includes dual-power inputs, input and output alarms, a console port, fibre-ready SFP slots, DIN rail mounting, and an operating temperature range of -40 to 60°C. Model options include NAT, two gigabit ports, SD flash card, conformal coating, and two different software configurations for a total of 20 different models to best match machine and end-user applications.

Rockwell Automation Australia Contact info and more items like this at wf.net.au/U335

provide the isolated power to the system. The communication modules are the interface to the iDCS8830 I/O modules and the iDCS-8830 I/O modules sense or control the device in the field. Termination boards are used to connect between signals to/from the field and I/O modules.

A hot-swap capability allows modules to be easily replaced, and the system supports up to four redundant pairs of I/O modules that work in duplex mode.

ICP Electronics Australia Pty Ltd Contact info and more items like this at wf.net.au/U614

Easy handling RIFLINE complete relay system You can carry out all standard relay applications using the RIFLINE complete industrial relay system.

The area of application ranges from the coupling relay and timer relay through to the small power contactor replacement.

Benefit from easy handling thanks to: • Easy wiring • Easy potential distribution • Easy expansion to the timer relay For additional information call 1300 786 411 or visit phoenixcontact.com.au

© PHOENIX CONTACT 2013

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AUGUST 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 47

NEW PRODUCTS

VIRTUALISATION PACKAGE The Experion Virtualization Solutions package is a turnkey blade solution that is optimised for virtualisation and the needs of the process control industry enabling offshore oil and gas, refining and petrochemical customers to increase operations availability and reduce the total cost of ownership of their control system, saving them millions of dollars annually.

By applying virtualisation to industrial control systems, processing plants and refineries can simplify their computing environments, streamline maintenance and reliability, and reduce the amount of hardware space needed at facilities such as floating offshore oil rigs, where space is at a premium.

Virtualisation is a major productivity and efficiency tool for commercial

HMI SOFTWARE

and industrial operations. Process controls typically require separate servers

FactoryTalk View Site Edition (SE) and Machine Edition

to support different applications - requiring additional space, hardware and

(ME) 7.0 applications, released in early 2013, offer

significant maintenance costs. Virtualisation allows a single server to simultane-

more efficient alarm management, simplified installation,

ously run multiple operating systems and applications, insulating the operating

improved user experience and integrated data sharing

systems from hardware changes, improving overall server utilisation, simplifying

in a wide range of production environments.

maintenance and reducing costs.

FactoryTalk View SE 7.0 software supports a larger

The Experion Premium Platform is based on blade server technology from

numbers of HMI clients and servers in a single system,

IBM and reduces set-up time by 90%, generates 40% more energy savings,

increasing the size of systems that can support the

has 22% greater density than alternative virtualised server platforms and allows

FactoryTalk View SE alarming subsystem, FactoryTalk

recovery from a processor failure in minutes.

Alarms and Events.

Honeywell chose the IBM BladeCenter S to power the Premium Platform

The FactoryTalk Alarms and Events alarming subsys-

because of its highly integrated design especially in the area of storage, and

tem has been enhanced to align with ISAâ&#x20AC;&#x2122;s Alarming

its focus on markets where simplicity is critical.

Standard 18.2, and will now support the shelving state.

Honeywell Limited

The subsystem now also allows users to configure

Contact info and more items like this at wf.net.au/U301

remote-alarming commands on display faceplates, saving crucial time when an operator needs to react to device alarm situations.

A network-scoped option for FactoryTalk View

EMC SHIELDED CABLES FOR MOTORS

SE Station software allows a single-computer HMI

Treoflex-EMC-UV-3 plus cables are made with a special construction

to better integrate with products such as FactoryTalk

and are used to supply power to motors from frequency converters

Historian SE and ME software. Using the networked

while maintaining full electromagnetic compatibility (EMC).

FactoryTalk View SE Station software, users will be able

These flexible cables come with multi-stranded conductors, with a

to browse to a FactoryTalk Historian SE server, select

cross-linked XLPE polyethylene insulation, double stranding element

tags and view the historical information for those tags

screen, with a UV-resistant outer sheath made of PVC. The cross-linked

directly on the operator workstation.

XLPE polyethylene insulation improves current-carrying capacity, while

Better device connectivity and diagnostics are avail-

at the same time maintaining low cable capacitance in comparison

able for Allen-Bradley PanelView Plus 6 operator terminal

with cables with PVC insulation.

applications with FactoryTalk View ME 7.0 software.

The cables are suitable for both fixed installation and movable

PanelView Plus 6 operator stations can now connect

connections in industrial equipment, process lines and machines

directly to, and display data from, non-controller devices,

operating in dry and damp rooms. The symmetric construction of

such as smart overload relays or power monitors, saving

the cable (3+3PE) ensures the symmetry of supply voltages on the

controller memory.

motor terminals.

Rockwell Automation Australia

Treotham Automation Pty Ltd

Contact info and more items like this at wf.net.au/U494

Contact info and more items like this at wf.net.au/U527

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NEW PRODUCTS

PXI POWER SUPPLIES National Instruments has announced its latest general-purpose programmable power supplies for its PXI-based automated test systems.

The NI PXIe-4112 and NI PXIe-4113 modules provide high power

PANEL PC

density, saving rack space and simplifying design by eliminating the

The Aaeon AFP-6152 all-in-one computer is

need to mix multiple instrumentation form factors. When programmed

housed in a fanless, fully sealed stainless

with NI LabVIEW software and paired with a range of PXI hardware

steel case that provides IP66 protection

instrumentation, the power supplies can help engineers create a

front, back and sides, as well as water-

complete, customised test solution.

proof I/O connectors.

The modules feature two 60 W power supply channels in a single

The computer is supplied with a

PXI Express slot. The NI PXIe-4112 power supply features 60 V at 1 A

15â&#x20AC;ł XGA 1024x768 resolution LCD and

per channel and the NI PXIe-4113 power supply offers 10 V at 6 A

a glass-film-glass touch screen making

per channel. The two channels can be combined to create a single

it suitable for operator panel and HMI control applications.

120 W channel. To easily synchronise measurements, engineers can

The panel PC features a built-in energy efficient Intel Dual Core Atom

combine the power supplies with more than 1500 PXI modular instru-

D525 1.8 GHz processor with up to 4 GB of DDR3 memory. A 2.5â&#x20AC;ł hard

ments ranging from digital multimeters to RF analysers and generators,

drive bay and an internal CompactFlash slot are provided for system and

and simply trigger the instruments across the PXI chassis backplane.

data storage. Rear waterproof I/O connections include two COM ports,

Engineers can quickly take measurements using soft front panels

one USB 2.0 port, one gigabit ethernet port and DC power. The panel PC

with an interactive user interface or build fully automated applications

can operate from a 9-30 VDC power source. VESA 75/100 rear mounting

using the LabVIEW example programs that come with the power

holes allow it to be securely wall or arm mounted.

supplies. There are example programs to perform voltage sweeps,

The panel PC is compatible with Windows XP, Windows 7 and Linux

source DC current and source DC power. With seamless LabVIEW

Fedora operating systems, allowing it to support a wide range of off-the-

integration, engineers dramatically reduce development time while

self and custom developed industrial applications.

improving system scalability for a range of applications.

Interworld Electronics and Computer Industries

National Instruments Australia

Contact info and more items like this at wf.net.au/U425

Contact info and more items like this at wf.net.au/U423

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AUGUST 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 49

AS I SEE IT A.B.N. 22 152 305 336

CYBERSECURITY POLICIES THAT THREATEN PRODUCTIVITY

T

here is a cartoon that shows an army general telling a salesman that he is busy fighting a war and has no time to see him. The gag is that his troops are seen fighting with rifles and bayonets while the salesman is offering machine guns.

Putting aside the sad undertone, I recently came across a modern parallel when asked to resolve an accumulation of performance issues with a large industrial automation LAN. The network diagram showed that the plant network was interconnected without the zone segregation I’d liked to have seen, and it was stated site policy, in all-caps in case I missed it, that internet connection was “ABSOLUTELY NOT PERMITTED UNDER ANY CIRCUMSTANCES”.

This paradox - a fear of internet-borne nasties infecting a network that by (lack of) design is prone to contagion in the event that something actually occurred - is not uncommon. It deserves discussion in the context of the prosperity of Australian manufacturing, and whether the policy ‘generals’ are keeping up to date.

The ‘No Internet’ or ‘Air Gap’ defence is widely discredited - a 2011 study by RISI (The Repository of Security Incidents) shows that 80% of network security events were unintentional - the result of errors, failures or malware introduced inadvertently, mostly through memory sticks. Direct intentional attacks by hackers account for less than 10%. The enemy is not coming through the front door, so a perimeter defence strategy is largely ineffective.

Further, restrictive policies lead employees to develop workarounds that can have undesired consequences. We saw this with safety interlocks until products like codedmagnet switches were developed, and we see it now with rogue wireless access points and broadband modems (now performed discretely by a smartphone) enabling policies to be bypassed. Policies alone - the ‘publish and pray’ approach - are not the answer.

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Embrace technology for prosperity ‘Defence in depth’ is a multilayer strategy that for both the military and networks creates a labyrinthine path that stretches the opponent, leading them to give up for easier pickings, contains them or at least provides warning as soon as an attack (or infection) has been detected. It is demonstrably more successful to put in place effective defences against the highly inevitable occurrence than to simply issue a policy.

Networks, properly designed for security and fully exploited, can add value to a business. This can take the form of secure remote access so the right person can provide support without the delays of travel, using the high bandwidth for video monitoring, publishing real-time data to head office or getting an urgent patch installed quickly. The confluence of LAN, internet, mobile telephony and the cloud, together with protections like zone-based firewalls with deep packet inspection and cloud-based authentication servers have provided the confidence to enable not cripple. The generals, however, need to be brave - they have to eschew their conservative fixations, to become informed of the possibilities and embrace them.

The survival of a battle-weary Australian manufacturing sector requires a liberal approach - exploiting the full range of technology enablers to innovate, increase uptime and reduce costs, while employing best practice in design. Few organisations have the skills in-house to address these life-cycle issues.

They need to be receptive when the experts knock on the door.

Mark Elrick, Marketing Manager at Integrated Automation, is an electrical engineer with experience in the manufacturing, i n f ra s t r u c t u r e , OEM , distribution and systems integration sectors.

He currently consults in the area of industrial automation and networks.

50 WHAT'S NEW IN PROCESS TECHNOLOGY - AUGUST 2013

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