JULY 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 1
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ON THE COVER
WHAT'S NEW IN PROCESS TECHNOLOGY JULY 2013
Global electrical connectivity manufacturer Weidm端ller has released its new range of
Electric control valve actuators
SIL 3 safety relays.
Eliminating the problems of compressed air as a power medium
Created specifically for use in the emergency
the process and pharmaceutical industries,
Hot products online
availability and safety.
As I see it Enabling flexible operational teams
shutdown of plants and plant components in the safety relays considerably increase plant The devices meet the requirements of EN61508 as well as the demands of ISA S71.04-1985, Class G3. Designed to deliver reliability and peace of mind, the Weidm端ller SIL 3 safety relays ensure safe electrical isolation of the safety PLC from the field and initiate protective measures in the face of danger or immediately cut the energy supply. The M and MG3 types feature a monitoring circuit for receiving signals from the field, while the MG3 also has a special coating over the electronics to protect against harsh industrial conditions. Additionally, the monitoring circuit ensures that feedback voltages from 24 V to 240 VAC/DC are recognised by the controlling system. Other smart features include special input protection to secure the circuit against test pulses generated by the DCS system, as well as a replaceable fuse on the front panel for easy maintenance should a short circuit of the output occur. Rugged and robust, the devices deliver peace of mind. Weidmuller Pty Ltd www.Weidmuller.com.au
NOW in DIGITAL! Your copy of What's New in Process Technology is now available as an online eMag.
ELECTRIC CONTROL VALVE ACTUATORS ELIMINATING THE PROBLEMS OF COMPRESSED AIR AS A POWER MEDIUM Chris Warnett, Sales Director, Rotork Process Controls
4 WHAT'S NEW IN PROCESS TECHNOLOGY - JULY 2013
Electric actuation can help control valve users avoid many of the problems and inefficiencies associated with using compressed air as a power medium.
totally electric solution for control valve actuation is appropriate and cost-effective for a wide variety of control valve applications, including those found in such sectors as power generation, chemical, petrochemical and most other process industries. While the new generation of electric control valve actuators may not be suitable for all process applications, it is ideal for many situations, especially where users have experienced problems with frozen air hoses, lack of process precision, stick slip and so on. Therefore, it is prudent for today’s process control engineers to take a serious look at how the design features of totally electric control valve actuators can benefit them. In many situations, this equipment can substantially increase the output and efficiency of their process as well as help reduce maintenance and operating costs.
Control valve actuation: a brief history Before discussing electric valve actuation technology, it’s beneficial to understand how the control valve actuator has evolved. Decades ago, the main medium for controlling process control valves was by varying the pressure of the air supply to the valve’s actuator. Typically, this air pressure varied between 3 and 15 psi. A closed valve position would relate to 3 psi and the open valve position to 15 psi. This was an international standard for positioning linear control valves (and also later rotary valves) by balancing this air pressure against an opposing spring. The higher the pressure, the more compression was exerted on the spring and the greater the movement of the control valve. As the pressure backed off down to 3 psi, the spring pushed the valve stem back to the original position. This simple means of position control was used in a wide variety of process control plants. It was the mainstream
solution offered by control valve actuator manufacturers as well as control systems suppliers. In the simplest form, compressed air was both the power medium and the control medium. Desired positions were achieved by varying this applied pressure and entire plants were controlled by compressed air channelled through small-bore copper tubing. The backs of control panels were a mass of tubes skilfully arranged by control systems craftsmen into symmetrical layers of carefully laid pipe. However, with the advent of computers and PLCs the days of the 3-15 psi control signals were numbered. Soon they were replaced by electronic signals carried on much lighter duty copper wire with control at the speed of the electrons rather than pressure waves. This was a revolution in control technology, bringing with it tremendous cost savings in installations as well as vastly improved control capabilities. The other great benefit of this change in technology was the elimination of the labour-intensive maintenance of the pneumatic control system. Filters, regulators, lubricators and a multitude of small pilot control valves were eliminated and replaced with PLCs and their final element controllers. In place of the 3-15 psi pressure signal, a 4-20 mA current control signal was adopted as a global standard. Although the control air signal has been superseded by a control current signal in most process plants, the power to move many of these process control valves has remained as compressed air. Having used instrument air as the control medium in the past, it was perceived by many that there were some benefits in retaining instrument air as a power medium. The air can be used to transport energy from one place to another to operate remotely positioned control valves, dampers and other equipment. In the evolution of pneumatic process control, the instrument air was upgraded from the 3-15 psi supply to a nominal 80 psi. This
JULY 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 5
GENERALLY SPEAKING, TAKING ELECTRICAL ENERGY, CONVERTING IT TO COMPRESSED AIR THEN TRANSPORTING IT VIA A FILTER REGULATOR AND LENGTHS OF TUBING WITH FITTINGS, BEFORE DIRECTING IT INTO A CHAMBER FOR EXPANSION IS AN INCREDIBLY INEFFICIENT METHOD OF MOVING POWER FROM ONE POINT TO ANOTHER.
allows greater forces to be generated by smaller pistons or diaphragms. The result is that pneumatic spring diaphragm and piston type actuators have been the default standard for positioning control valves for many years. The simple pneumatic positioner has evolved, from the basic functionality of controlling applied high-pressure air using a low-pressure signal, to the smart positioner of today that not only directs high-pressure air to the valve actuator, but also is able to gather information at the various pressure positions within the actuator assembly to provide diagnostic information, which can be transmitted back over the 4-20 mA signal using a communications protocol such as HART. This method is currently the de facto standard for the majority of linear and rotary process control valves in almost every industry, from oil and gas production through power generation to the chemical, petrochemical and many other process industries.
Why electric-powered actuation may be better However, the de facto standard of coupling instrument air with a smart positioner may not be the best solution for every application. Just as electronics have taken over control signal technology, electrically powered actuators now offer a viable alternative to those using the pneumatic spring diaphragm and piston design.
Specifically, there are many drawbacks to using compressed air as a power medium. For years, process engineers have had to engage in complex workarounds to overcome them. The drawbacks vary in degrees depending on particular applications. Generally speaking, taking electrical energy, converting it to compressed air then transporting it via a filter regulator and lengths of tubing with fittings, before directing it into a chamber for expansion is an incredibly inefficient method of moving power from one point to another. The inefficiencies of compression and the friction losses in transmission can easily account for a net loss of 50% of the applied energy. This can be directly compared to the much more energy-efficient method of transmitting the power via electricity and translating that electrical energy to kinetic energy in a motor located directly at the process control valve. In effect, the electric motor drive has been transferred from the compressor to the actuator, eliminating all the intermediate conversions and transmissions, together with their attendant losses. When considering the large number of process control valves in a plant and compounding this with the constant movement of process control valves, the elimination of compressed air in a plant can be significant and can result in a much more productive and cost-effective operation. In addition, plant reliability and the associated availability are significant factors to be
6 WHAT'S NEW IN PROCESS TECHNOLOGY - JULY 2013
considered. Air supplies require proactive maintenance to ensure that moisture, dirt and other contaminants to do not accumulate in the air lines and cause the small orifices in smart controllers to plug up. This proactive maintenance has a significant cost, which should be included in every objective analysis. Although many processes are enclosed in buildings that protect the valves and instruments controlling the process, this is not always the case. There are several examples where valves are located in open areas and are vulnerable to temperature swings that can drop below the freezing point of water. This affects not just European and North American plants, but also Asian plants such as the many new process plants being built in China, Japan, Korea and other areas. A drop in the temperature below freezing point can cause airlines to freeze and incapacitate the pneumatic control valve actuator or controller.
Examples of why electric control valve actuators are often the best solution In Halifax, Nova Scotia, a refinery technician recounted that every year he needed to replace frozen airlines because they had ruptured. After the hoses ruptured, certain modulating control valves could only be operated by hand. This, of course, defeats the basic reason for investing in automatic process control.
Figure 1: An example of an electric control valve actuator.
Figure 2: Typical stick slip action in a control valve.
Another example is from a power plant in New Hampshire which recently replaced all of its spring diaphragm control valve actuators on fuel control due to the effects of reduced temperatures. Low temperatures not only had an adverse effect on the actuators, but also on the viscosity of the medium being controlled and the friction effect on the valve seats. That is, the valve became very difficult to control due to the stick slip effect, causing â€˜overshootâ€™ of the desired set point of the valve. In high-altitude mining applications, such as those found in Chile and Peru, reduced temperatures and high altitude combined to make power air supplies extremely costly. Maintenance and running costs were problematically high. In such an environment, freezing airlines were also an ongoing problem which caused valve actuator failures with attendant loss of production capability. There are some instances where an air supply is not required for anything other than controlling a single process control valve actuator. In these circumstances a small air compressor complete with air set needs to be provided, taking up space, weight and cost. There are many small package boilers, for example, that require a steam control valve. Quite often this requirement also includes the need for a fail-to-position capability. The traditional method of doing this would be to use a spring diaphragm actuator where a loss of air or a shutdown
Figure 3: Graphic description of stick slip action.
signal would vent the air to allow the spring to close or open the valve, depending on the requirements of the process. Electric actuators are capable of storing electric energy such that a loss of electric power can trigger a fail-to-position, which has been pre-programmed into the actuator. Furthermore, because of the greater degree of control available with an electric actuator, a preset position - either fully open or fully closed or anywhere in between - can be programmed easily into the actuator should the power or the control signal be lost. A different failure position could be programmed dependent on either loss of power or loss of control signal. Finally, compressed air is by definition a resilient medium. In fact, some cars even use it as a method of suspension. Because compressed air acts like a spring, then pneumatic control valve actuators do not often have the stiffness required for precise process control. For example, consider a globe valve with a high degree of friction in its stem packing or a ball valve with a high degree of friction on its seat. In either case, the static friction is quite high, requiring an excessive amount of air pressure in order to initiate movement in the valve. Once the valve moves, static friction is replaced by dynamic friction, which is invariably lower. This causes the resistance to the excessive air pressure to drop. The result is the valve runs away with itself and often overshoots
the desired set point, causing a correction to be made resulting in oscillation around the set point. This problem is eliminated with an electric control valve actuator due to the higher stiffness and controllability of todayâ€™s electric drive trains and the advent of sophisticated dual sensor technology in the actuator.
Electric control valve actuators: a summary of features and benefits Electric control valve actuators can provide superior control performance, are easy to set up and they eliminate the need for troublesome power air supplies and all their problems. They are available in linear and quarterturn actions and are suitable for a wide range of control valve applications throughout a wide range of process industry applications including power generation, pipeline and gas installations, petrochemical and refinery facilities, mining and many other process applications. The new actuators eliminate the need for costly air supplies and are easily integrated into most process control environments, including those that use HART and FOUNDATION Fieldbus protocols. Rotork Australia Contact info and more items like this at wf.net.au/U222
JULY 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 7
PORTABLE LOAD CELL DISPLAY The Instrotech Calog LC Display is a small, rugged, portable handheld battery or auxiliary-powered load cell display with data-logging functions. The load cell indicator powers one 350 Ω or three 1000 Ω load cells with a fixed 5 VDC excitation. The display may be set to show mass, force, strain or torque from load cells. The load cell sensitivity, range, decimal points and engineering units are all user programmable. Both automatic and manual trims are provided to offset zero
CALIBRATION INTEGRATION SOLUTION
dead weight and set span, with or without known weights. User
Beamex has introduced the Business Bridge - a standardised, but
options such as tare, peak hold and auto zero maintenance are
configurable software solution for connecting a Beamex CMX calibra-
included in the load cell display menus.
tion management system to an ERP/CMMS system.
Data logging to the internal SD card may be set at fixed
Many of the common system integration risks relate to the fact that
real-time automatic logging intervals or instantly at any time by
system integration typically requires software development, customi-
pressing the enter key. Data may be retrieved from the remov-
sation or configuration on both ends of the integrated system, the
able card or via the USB interface in CSV format.
calibration software and the ERP/CMMS system. Beamex is aiming to
The built-in rechargeable lithium ion battery pack provides up
minimise these system integration risks by offering a solution where
to six hours of use for load cell display and data logging. The
the integration part related to the calibration software is based on a
Calog LC Display may also be used with either of the supplied
standardised, but still configurable solution.
mains AC or vehicle outlet DC battery chargers. The load cell
The main purpose of the Business Bridge software solution is to
display kit comprises a carry case with battery chargers, SD
provide a transfer channel for sharing instrument, work order and
card, operating manual, factory calibration certificate and M12
basic calibration data between the calibration management and ERP/
load cell cable connector.
CMMS systems. Productivity may be increased significantly due to
Instrotech Australia Pty Ltd
system integration, as data needs to be entered and kept up to date
Contact info and more items like this at wf.net.au/U072
in one place only, instead of manually re-keying the data into two or more separate systems. Additionally, because data needs to be entered only once, human typing errors and delays related to manual re-keying of data are minimised. The Business Bridge solution is available for integrating Beamex CMX calibration software with several of the leading ERP/CMMS systems used in the processing industry. AMS Instrumentation & Calibration Pty Ltd Contact info and more items like this at wf.net.au/U229
PORTABLE PH AND TEMPERATURE METER FOR MEAT PROCESSING The Hanna Instruments HI 99163 is a portable pH and temperature meter for meat processing applications. The meter utilises a specialised pH electrode designed specifically for meat applications. The FC232D pre-amplified pH electrode and removable stainless steel blade enables users to perform measurements quickly and easily. The free diffusion junction helps to avoid a clogged reference and the external body material is non-toxic and food compatible. The meter has automatic one- or two-point calibration, automatic temperature compensation and BEPS (battery error prevention system), which alerts the user in the event that low battery power could adversely affect readings. Battery power percentage is also shown at start-up. With a multilevel LCD and on-screen tutorial messages for calibration and set-up, this compact unit is waterproof and easy to clean. Hanna Instruments Pty Ltd Contact info and more items like this at wf.net.au/U256
8 WHAT'S NEW IN PROCESS TECHNOLOGY - JULY 2013
CORIOLIS METERS TRICOR Coriolis mass flow meters from KEM/AW are now available with IECEx hazardous area approval. The TRICOR range is capable of simultaneous monitoring of mass flow, volumetric flow, media temperature and density. Free from moving parts, these instruments provide accurate measurement of even aggressive and contaminated media. Compact installations benefit from no straight piping requirements before or after the meter. Available in a wide range of flow capacities, the TRICOR family offers a broad choice of industry-standard flanged, threaded and food industry process connections. With a choice of wetted materials, challenging media viscosity, temperature and pressure can be accommodated, as can gases. In-situ push-button calibration makes set-up easy, while the dead spotfree construction ensures the meter can be easily flushed or sterilised between the changing of process media. Local or remote mounted electronics are available with real-time displays enhancing standard I/Os, including two independent analog signals (for any parameter), frequency output and control I/O signals (eg, batching). RS485, HART and FOUNDATION Fieldbus are also available. Control Components Pty Ltd Contact info and more items like this at wf.net.au/T836
DC-UPS AND BUFFER Weidmüller’s DC-UPS and buffer modules provide industry with solutions to overcome electricity supply interruptions from 200 ms to 40 A for 30 min enabling a high-reliability 24 VDC system to hold up control,
CABLE CERTIFICATION TESTER Versiv cable certification testers from Fluke are designed to help data communications installers more quickly, accurately and profitably achieve system acceptance for copper and fibre jobs. Versiv offers interchangeable modules for copper, fibre and optical time domain reflectometer (OTDR) testing, as well as software innovations that speed test time and accuracy, and simplify testing set-up, planning and reporting. Key to simplifying the complexity is the ProjX management system. In addition to letting team leaders set up test parameters to work across multiple jobs and media, the system accelerates planning and set up of projects by letting technicians capture consistent test parameters across an entire job, or switch from job to job by simply clicking between projects stored in the tester. The system also enables up-to-the-minute project analysis and oversight to help speed certification and reporting. If problems are encountered during the testing process, technicians can create a ‘fix later’ troubleshooting to-do list for later evaluation by more experienced installers. Versiv also features an intuitive and instructive touch-screen interface that elevates the capabilities of the less experienced installers
safety and communications systems for a length of time. As most power dips are less than 200 ms, the maintenance-free buffer module is suitable for momentary interruptions using capacitive-based storage, when placed in series with a 24 VDC supply to provide short-term energy support. Outputs are provided for ready and fault with LED indication for operational status. For more controlled override solutions when total power loss occurs, the DC-UPS controller together with a battery module provides backup power safely and reliably. The DC-UPS module provides power up to 40 A for 30 min or 1 A for 30 h, depending on the application. Five battery modules between 1.3 and 17 Ah are selectable to ensure a tailor-made solution. All batteries are highquality AGM VRLA batteries with integrated temperature sensor in the battery module that ensures extended life. Operational status via digital outputs, with LED indicators, ensures positive feedback, with both buffer and DC-UPS units operational from -25 to +70°C. Being 66 mm in width, either can be mounted beside a PRO-M power supply with no space required between them, ensuring a seamless cabinet design. Weidmuller Pty Ltd Contact info and more items like this at wf.net.au/T815
and increases the speed of testing and global ISO Level V testing compliance. Fluke Australia Pty Ltd Contact info and more items like this at wf.net.au/U275
10 WHAT'S NEW IN PROCESS TECHNOLOGY - JULY 2013
THE SWITCHMODE POWER SUPPLIES YOU WANT NOW FOR LESS AT SOANAR 45W
LEVEL SWITCH The Series PLS2 is an electromechanical level switch designed for level monitoring of bulk materials. The rotating measuring vane is driven by a brushless synchronous motor at one revolution per minute. As product builds up, the paddle rotation is impeded and the resulting motor torque activates the output switch and stops the motor. A spring mechanism reactivates the motor and returns the switch to normal state when the material no longer impedes the paddle rotation. A torque adjusting mechanism eliminates the need for different-sized paddles. The PLS2 is designed with the industry standard 1¼″ male NPT connection and unit can be side or top mounted. The Series PLS2 also features three sensitivity settings and a screw cover for easy access without the risk of los-
IN STOCK NOW
NEW DIN RAIL SERIES
ing bolts or screws. Dwyer Instruments (Aust) Pty Ltd Contact info and more items like this at wf.net.au/U071
OPC SERVER FOR ALLEN-BRADLEY MatrikonOPC has released its updated OPC server for Allen-
AC/DC DIN RAIL SWITCHMODE POWER SUPPLIES OUTPUT OUTPUT OUTPUT ORDER POWER VOLTAGE CURRENT NUMBER (W) (V) (A) 45W
Bradley, which expands the range of supported Allen-Bradley devices, improves performance and simplifies configuration. Additional devices supported include ControlLogix, MicroLogix, and PLC5s - providing users with comprehensive, open access connectivity for their Allen-Bradley PLCs. The Allen-Bradley OPC server includes built-in security that protects data from unauthorised user access by allowing administrators to define exactly what data is visible to which users, based on each user’s Windows login credentials. This means the Allen-Bradley OPC server plays an active role in maintaining data integrity. Key features include: comprehensive connectivity support for PLC5s, SLC500s, Micrologix (1100 A, 1400, 1200 etc) and ControlLogix; automatic discovery of Allen-Bradley PLCs, making integration seamless; and a high-performance OPC
60W 120W 240W
DIMENSIONS (W x H x D) (MM)
78 × 93 × 56
78 × 93 × 56
65.5 × 125.2 × 100
125.5 × 125.2 × 100 $109.60*
(30W & 75W also available - call for pricing)
• 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.
server suited for sequential, process, drive and motion control. MatrikonOPC
Contact info and more items like this at wf.net.au/T685 RANGE - RELIABILITY - STANDARD - CUSTOM
firstname.lastname@example.org AU 1300 365 551 NZ 0508 765 956
JULY 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 11
ON WWW.PROCESSONLINE.COM.AU THIS MONTH
CAPACITANCE LEVEL SENSOR VIRTUALISATION PACKAGE
The NOHKEN CG300 series capacitance level sensors are designed for liquid level
The Experion Virtualization Solutions Pack-
age is a turnkey blade solution that is optimised for virtualisation control systems.
accuracy of ±0.5% FS. Bestech Australia Pty Ltd
detection and measurement, offering an
ABB has increased the IRB 360 FlexPicker’s top payload to 100 cycles/min. ABB Australia Pty Ltd
INTELLIGENT SURGE PROTECTION
from 3 to 8 kg, handling up
The Plugtrab PT-IQ surge protection devices
provide intelligent monitoring and push-in connection technology. Phoenix Contact Pty Ltd
DISSOLVED OXYGEN SENSOR The ORBISPHERE M1100 luminescent dissolved
oxygen sensor offers an advanced way of monitoring oxygen in beer, boiler waters and deaerated water. Hach Company
12 WHAT'S NEW IN PROCESS TECHNOLOGY - JULY 2013
EMI SOFTWARE UPDATED Invensys has enhanced its Wonderware Intelligence software with concurrent licensing, enabling multiple-user access to plant dashboards and interactive reports. The updated software reduces the administration usually required for multiplant, multi-instance Intel-
MICRO SERVO CONTROLLER
ligence software deployments and for groups of concurrent users who share or need access to the same information in rotating shifts or during 24/7 manufacturing operations. For shop floor operators,
Built on the CP1L plat-
it provides cost-effective enterprise manufacturing intelligence while
form, the Omron CP1L-E
facilitating multiplant and enterprise-wide collaboration.
micro servo controller
Wonderware Intelligence connects, collects, aggregates and
now offers an ethernet
contextualises operational metrics into a single and open informa-
port, two analog inputs
tion model and database in near real time. An EMI application,
and pulse I/O as standard
Intelligence crosses multiple industrial data sources, such as historians, MES and batch management systems, as well ERP or quality systems data. Operators can easily access this highvalue information themselves and are provided with easy-to-use tools for self-service analytics, interactive reports and dashboards, helping to improve daily decision making and enabling continuous process improvement. For example, plant or production line/ unit performance can be compared with unified operational KPIs within business units to apply best practices from the companyâ€™s most productive plants.
features. A maximum of six 100 kHz counter inputs (two with quadrature input) and two 100 kHz pulse outputs can now be configured on all CPUs. The programming software incorporates a library of function blocks to handle servo control functionality. A range of functions are supported, including simple absolute or relative moves and interrupt feeds. Simple position control using a VSD is also possible, where the control loop is closed through the controller, which uses its built-in high-speed I/O.
Intelligence supports connectivity to many Wonderware and
CP1L-E CPUs are available in a choice of 20, 30 or 40
non-Wonderware data sources, including Wonderware Historian,
I/O and support all the logic functions expected in a modern
OSI PI Historian, transactional data sources (databases), file-based
PLC. Programming is via IEC 61131 3-compliant software
data and other operational databases. Out-of-the-box data models
and supports online editing. Expandability is possible by the
and dashboards provide instant reporting results for Wonderware
addition of extra modules or boards that plug into the CPU.
MES Software, Wonderware InBatch, ArchestrA System Platform
External RS232 and RS485 communication modules can be
and SimSci-Esscor ROMeo software solutions; and integration to
inserted for Modbus RTU or other connections.
ArchestrA System Platform provides a standardised configuration
Omron Electronics Pty Ltd
environment, real-time data connectivity and data preprocessing.
Contact info and more items like this at wf.net.au/U152
Invensys Process Systems (Australia) Pty Ltd Contact info and more items like this at wf.net.au/U055
JULY 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 13
Fieldbus device couplers simplify chemical plant upgrade Ashland Inc is a global leader in providing specialty chemical solutions to customers in a wide range of consumer and industrial markets. In August 2011, Ashland purchased International Specialty Products Inc (ISP), which had acquired BP’s 1,4-butanediol (BDO) production operation in Lima, Ohio six years earlier. The plant has an annual capacity of 65,000 metric tons of BDO, an intermediate ingredient in common industrial and commercial products. BDO is reacted to make items such as engineering plastics, polyurethane systems (eg, golf balls, skateboard wheels, car bumpers) and as carrier solvents in printing inks and cleaning agents. The Lima plant’s integrated butane-to-butanediol production process combines catalytic oxidation of butane in air with fixedbed fatty acid hydrogenation technology. The facility processes butane and air to maleic acid in a fluidised bed reactor, and maleic acid to BDO in a high-pressure, H2-rich, fixed-bed hydrogenation reactor. It also utilises an off-gas boiler for steam and environmental compliance. The Lima plant uses an Emerson DeltaV distributed control system (DCS) using the Foundation fieldbus protocol. As part of the Foundation-based automation architecture, proportional-integralderivative (PID) control algorithms are located in a majority of the digital valve controllers. In addition, all dual-element transmitters are equipped with onboard signal-select blocks. A total of 80 fieldbus H1 (31.25 kbps) segments connect approximately 600 fieldbus instruments and valves, handling 150 control loops. The facility’s original 400 discrete I/O devices (mostly on-off valves) were wired directly to process controllers, which have since been supplemented with dozens of fieldbus-capable on-off valves. The system also includes approximately 400 emergency shutdown I/O and 200 resistance temperature detectors and motor statuses integrated through Modbus multiplexers. In October 2012, Ashland embarked on an upgrade of the Foundation fieldbus system. The scope of work, completed during a three-week planned outage, involved enhancements to the existing DeltaV system, as well as replacement of legacy terminal blocks, instrument wiring, power supplies and other fieldbus physical layer components on 60 device segments throughout the facility. At the time of the plant’s construction in 1999, device coupler technology did not exist. Control system designers had to rely on terminal wiring blocks, which didn’t offer short-circuit protection or current limiting on spurs. Although this approach was convenient for field wiring, it caused concerns about maintenance activities inadvertently shorting out the segment. When terminal wiring blocks are used in a plant, personnel also cannot perform live work on instruments located in Division 2 classified areas. An initial solution to this problem was the use of quick-disconnect connectors, which allowed technicians to disconnect devices without unnecessary risk of shorting conductors and shutting down segments. However, electrical code restriction authorities also called
14 WHAT'S NEW IN PROCESS TECHNOLOGY - JULY 2013
for the installation of disconnect switches to comply with hazardous area requirements. Over the years, many of the disconnect switches became corrupted by corrosion and water, posing an operational liability. This prompted plant engineers to seek a way of replacing legacy hardware on control loops throughout the facility while still maintaining existing area classifications. John Rezabek, process control specialist at the site, noted that the choice of a device coupler technology was particularly important on the Lima upgrade project since “device couplers touch every valve in the plant.” He and other team members determined that a coupler design incorporating short-circuit protection and providing non-incendive spurs was necessary if the disconnect switches were removed. Project engineers evaluated a number of alternative fieldbus physical layer technologies based on price, performance and reliability. They ultimately chose to install MooreHawke’s Trunkguard Series 200 (TG200) device couplers. Starting with early models intended for use with parallel bus wiring, device couplers have advanced from fuses to safeguard fieldbus installations from failure, to current-limiting technology to better protect the device network. However, current limiting places additional load on the bus that can affect other devices. Moore Industries’ fourthgeneration device coupler solves the common issue of segment termination and short-circuit protection by providing end-ofline-sensing auto termination and ‘fold-back’ short-circuit protection. Rezabek admitted some trepidation in installing the latest coupler technology, due to its perceived complexity and advanced functionality. “On the surface, these device couplers have more features than competitive solutions,” he said. “We wondered whether functions like fold-back short-circuit protection and auto termination would create compatibility issues with power supplies, device couplers and other equipment installed on our existing segments. “To date, everything has worked as we anticipated. It’s there when you need it, and the rest of the time it goes unnoticed. We’ve been able to mix and match different suppliers’ couplers on our segments without any difficulties whatsoever.” “Thanks to an increased power budget, you can hook up test equipment without having to account for a short circuit,” said Rezabek. “If I’m building a segment with other types of coupler technology, I have to add another 50 mA of spare power capacity - which is equivalent to two devices worth of current - to account for a potential short-circuit load.” “The parts of our plant where we performed upgrades were mature, so the auto-terminator capability allowed us to extend segments on the fly as needed,” Rezabek said. “We weren’t worried about adding devices because we knew the segment could be extended while running without disrupting communications.” A longer version of this article can be read online at http://www.processonline.com.au/case_studies/61351-Fieldbus-device-couplers-simplifychemical-plant-upgrade Moore Industries Pacific Inc Contact info and more items like this at wf.net.au/U211
GAS METERING MANAGEMENT SYSTEM Honeywell has launched its RMG Gas Metering Management software and service solution, which enables natural gas and measuring station
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operators to monitor operations on site or remotely, provide data analysis and facilitate remote maintenance. The solution is designed to reduce operational costs and improve the accuracy and reliability of measurements.
The RMG Gas Metering Management system supports both RMG by
Honeywell and third-party measurement devices, allowing users to accurately determine the technical condition of all gas measurement devices
in a metering station using a single software package. In addition, the ability to remotely access measuring devices simplifies planning and organisation, and reduces costs as it keeps station visits to a minimum.
The system employs a framework of gas metering management, analysis and terminal modules that can be installed without the need for customised code changes and are easily configured. Dynamic system
IN STOCK NOW
displays allow for detailed schematic diagrams of the monitored station, and enable technical and accounting personnel to access and act upon current flow, pressure and temperature data and alarms in real time. Honeywell Limited Contact info and more items like this at wf.net.au/U259
AC/DC ENCLOSED SWITCHMODE POWER SUPPLIES UPGRADED ROBOT ABB has upgraded the IRB 1600 robot’s top payload from 8 to 10 kg. The increased payload expands the already-large range of general industry applications the IRB 1600 can serve. The improved payload is available for both the 1.2 and 1.45 m robot variant.
OUTPUT OUTPUT POWER VOLTAGE (W) (V) 25W 60W
The IRB 1600 is already known for its combination of accelerations and accuracy. Second-generation
OUTPUT ORDER CURRENT NUMBER (A)
DIMENSIONS LIST (L x W x H) PRICE (MM)
98 x 97 x 35
159 x 97 x 38
199 x 98 x 38
215 x 115 x 50
QuickMove motion control and the low friction spur gears help cut cycle times by up to 50%. Meanwhile, ABB’s TrueMove technology and a stiff design enable path accuracy even at high speeds. The upgrade improves
• 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
on the IRB 1600’s other existing advantages, such as solid protection for use in harsh environments (IP67 compliance of the entire robot as part of the Foundry Plus 2 option) and total mounting
* Price excludes GST and ONLY available to approved business and/or trade customers. Bulk pricing available on request.
flexibility. The 1.2 m reach variant also makes the robot more dexterous in confined spaces for improved reach and flexibility.
ABB Australia Pty Ltd
email@example.com AU 1300 365 551 NZ 0508 765 956
Contact info and more items like this at wf.net.au/U150
RANGE - RELIABILITY - STANDARD - CUSTOM
JULY 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 15
SERVER CHASSIS Advantech has launched a pair of server chassis, the 4U HPC-7442 and 2U HPC-7242, which provide users with highperformance operating platforms that can serve as NVR and
PIPELINE PROTECTION FILTERS
DVR servers for video surveillance applications, as SCADA
The wide range of filtration products available from SPX’s Airpel Series
servers, and for applications in factory automation.
suit many applications within a power-generation facility. The filters offer a
HPC-7442 and HPC-7242 support versatile EATX and ATX
cost-effective method of providing protection of more expensive equipment
motherboards, with an efficient switching power supply and
in the pipeline, such as pumps, valves and heat exchangers. Suitable for
easy-to-maintain cooling fans. They provide at least four SAS/
areas such as steam lines and raw water intake, the filters come in single,
SATA HDD trays, which offer flexible options for data storage.
dual and multi-basket configurations and operate at pressures up to 50 bar.
Other data storage choices include one slim-type drive bay
Single filters are said to offer an extremely cost-effective protection
for an optical disk drive and one or two drive bays for internal
system and can be used where flow can be shut off for short cleaning
hard drives. The unique alarm module monitors system status
periods. They have quality 316 grade stainless steel baskets with large
such as power, HDD, temperature, fan and LAN, to maximise
filtration areas to minimise pressure drop and can be fitted with differential
system uptime. Fan speed is controlled according to chassis
pressure indicators and transmitters to reduce maintenance, by ensuring
internal temperature, optimising system power consumption and
cleaning is only carried out when required.
minimising noise. A wide range of standard computing periph-
Dual and dual multi-basket models offer the capability to clean filters
erals can be integrated with these chassis to accommodate
during continuous flow. Where there is continuous operation and lower
robust, 24/7 applications in rugged environments.
maintenance is preferred, manual and automatic self-cleaning filters and
HPC-7442 and HPC-7242 are designed for SCADA applica-
back-flushing strainers are also available. All Airpel filters come in a range
tions. When combined with ASMB-782G2 and AIMB-701G2
of standard housings, including cast steel, cast iron, stainless steel and
industrial motherboards, the systems provide secure, reliable
gunmetal to best suit any given application. Quick-release covers on
SCADA server solutions to vertical applications in factory au-
the filters ensure rapid and easy maintenance to minimise any process
tomation, environmental monitoring, transportation and BEMS
(building energy management systems), offering robust con-
Options such as remote signalling are available to suit many applica-
nectivity, remote manageability, flexible display support and
tions and a wide range of sizes and materials are available from standard
leading-edge computing technology.
stock to meet budget and delivery requirements.
Advantech Australia Pty Ltd
SPX Flow Technology Australia Pty Ltd
Contact info and more items like this at wf.net.au/U148
Contact info and more items like this at wf.net.au/U273
PHOTOVOLTAIC SURGE PROTECTION The Weidmuller VPU DC surge protection series has been specially designed for photovoltaic systems. Independently tested by CTI in Austria, the series complies fully with both the latest international and local (AS/NZS 5033:2012) requirements. The range includes 600, 1000, 1200 and 1500 VDC models in Type I and Type II options. Type I provides surge protection for use with external lightning protection systems while Type II delivers surge protection to installations that have no external lightning protection. The VPU series combines varistor and gas discharge technology to provide sustainable protection. This, together with the thermal fuse system offers maximum reliability in lightning and surge voltage protection. A mounting rail clip enables simple and fast assembly and removal, without the need for tools. The devices can also be rotated 180° in the cabinet to ensure the highest degree of flexibility during installation and without impacting on overall visibility. The large, central status display window allows users to see at a glance the status of the protective function. If the flag in the status window changes from green to red it is no longer providing protection and needs to be replaced. The choice of an alarm function that notifies users via relay is available on all models. All the modules are self monitoring. Once the life of the module has been extinguished the alarm function indicates the need for replacing. The units also feature ‘Y’ type models to ensure that fault currents do not affect the surge protection device from overvoltage. Weidmuller Pty Ltd Contact info and more items like this at wf.net.au/U226
16 WHAT'S NEW IN PROCESS TECHNOLOGY - JULY 2013
SAFETY DESIGN TOOLS The Rockwell Automation Safety Automation Builder (SAB) configuration software and Safety Functions pre-engineered design documents help users navigate the safety-system design process and apply best practices. The SAB tool is available as a free download from the Rockwell Automation website. It guides manufacturers through the safety
HMI SYSTEM Opto 22’s groov is claimed to be a new way to build, deploy and view simple, effective, scalable operator interfaces to monitor control systems and equipment using computers and mobile devices. Using only a web browser, groov lets users quickly and securely build and deploy browser-based interfaces for automation, monitoring and control applications. These operator interfaces can then be viewed on almost any computer or mobile device regardless of its manufacturer or operating system, including PCs, tablets, smartphones and even smart high-definition televisions. Opto 22 is calling this interface a HDI (human device interface) instead of HMI because it takes the regular HMI in a different direction: towards the tablets, smartphones and other mobile devices. Opto 22 developed groov with proven HMI best practices in mind, providing the tools necessary to build high-performance, intelligible information and control screens. It is not intended to directly replace HMIs, but to augment traditional HMIs by making important information available at any time and in any location. Systems 22 Pty Ltd Contact info and more items like this at wf.net.au/T998
system design process by providing options for layout, safety performance level (PL) analysis based on ISO 13849-1 using IFA’s SISTEMA (Safety Integrity Software Tool for Evaluation of Machine Applications), and product selection using Allen-Bradley safety automation products. The SAB software automates the safety selection process to help speed system design and minimise human error. With the SAB tool, users import an image of machinery and answer questions using a drop-down menu and help screens to identify and select the necessary safeguards. The software then compiles all product selections, generates a bill of materials, and compiles necessary data to populate SISTEMA. SISTEMA indicates the attained PL of the safety system using ISO 13849-1 through an automatic calculation. As part of the process, users also receive a SISTEMA project file. The SAB software can be downloaded on the Rockwell Automation website, and also requires that users download and run SISTEMA. To support the SAB tool, Rockwell Automation has also released new safety functions, which are pre-engineered design documents containing detailed information for each safeguarding method, including specific functionality, PL and required input, logic and output components. These documents also include parts lists, electrical drawings, a SISTEMA project file and verification and validation plans. Rockwell Automation Australia Contact info and more items like this at wf.net.au/T707
JULY 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 17
ULTRASONIC FLOW METER FOR LNG The Daniel 3818 is a liquid ultrasonic flow meter for liquefied natural gas applications. Specifically designed for reducing flow measurement uncertainty throughout the LNG value chain, this meter is suitable for many marine and offshore applications, including custody transfer, fiscal metering, line balancing, check metering, allocation measurement and tanker loading and unloading. With a completely redundant 4-path, multiplane configuration that is the equivalent of two 4-path meters in a single body, the Daniel 3818 ultrasonic meter utilises two independent transmitters - one for each set of four chordal paths. This ensures complete measurement redundancy and the ability to poll each 4-path meter separately. Acoustic processing is performed by specialised electronics designed to achieve high sampling rates, provide stable ultrasonic signals and optimal low flow response, delivering accurate, stable and reliable measurement. The 3818 provides a linearity within ±0.15% and a meter factor uncertainty of ±0.027%. Each Daniel 3818 ultrasonic meter is calibrated at Daniel’s ISO/IEC 17025 certified flow calibration facility using a static zero flow test on liquid nitrogen and a full dynamic test on water. The 3818 is designed to withstand product temperatures ranging from -196 to +60°C, making it suitable for a wide variety of cryogenic LNG applications. The 3818 meters are full-bore meters with no internal moving parts to wear or drift, providing for low pressure drop and minimising the risk of LNG flashing. Also available in large sizes, ultrasonic meters are suitable for highvolume LNG transfers, which equates to faster tanker loading and offloading. Emerson Process Management Contact info and more items like this at wf.net.au/U125
OVERMOULDED VALVE PLUG CORDSETS Turck has introduced overmoulded valve plug cordsets. The overmoulded face eliminates the need for an additional sealing gasket, ensuring optimal performance in harsh environments. Featuring a translucent moulding material with embedded, bright LEDs, these cordsets provide good visibility for power indication from any angle with black, grey, yellow and clear colouring options to accommodate diverse applications. Turck’s overmoulded design offers a full cordset alternative to
BAG DUMPING SYSTEM
traditional field-wireable connectors, which require assembling and
The Flexicon Bag Dumping System with glove box, bag compactor and
hand wiring before they can be used. Field-wireable configurations
flexible screw conveyor, isolates bulk material from the operator and plant
increase the chances of mis-wiring, and also incur high labour
environment throughout opening, dumping and compaction of bags, and
costs. Overmoulded valve cordsets provide a completely assembled
the conveying of material downstream. Bags are staged on a stainless
solution that is 100% factory tested and ready to use for fast,
steel tabletop and then transferred through a plastic strip curtain into a
easy implementation. Overmoulded valve
dumping enclosure comprised of a glove box, empty-bag chute and dust collector atop a receiving hopper.
plug cordsets conform
The dust collector maintains negative pressure within the enclosure,
to the EN 17 5301-803
preventing the escape of dust through the curtain, while containing dust
generated during bag opening and dumping activities. A bag infeed
DIN 43650) for electri-
chute through the sidewall of the enclosure allows the operator to pass
cal connectors, which
empty bags directly into the bag compactor, causing dust generated from
service hydraulic and
compaction as well as dumping activities to be drawn onto the system’s
two filter cartridges.
valves as well as pres-
An automatic reverse-pulse, filter-cleaning system releases short blasts
sure sensors. Solenoid
of compressed air inside the filters at timed intervals causing dust build-up
valves control the flow
on the outer surfaces to fall into the hopper, conserving useable product.
of gas or liquid in cylin-
The compactor employs a large pneumatic air cylinder to compress bags
ders, fluid power motors or larger industrial valves. Applications
into a removable bin that accommodates 50 to 80 bags. The waste access
include food and beverage, oil and gas refineries, water treatment
main door, and a flapper door within the bag infeed chute, are equipped
facilities, chemical and petrochemical and pharmaceutical. These
with safety interlocks that prevent operation of the compactor unless both
cordsets also meet NEMA 1, 3, 4, 6P and IEC IP67 standards.
doors are closed.
Turck Australia Pty Ltd Contact info and more items like this at wf.net.au/U191
The hopper discharges into an enclosed Flexicon flexible screw conveyor for dust-free transfer of a broad variety of products. Flexicon Corporation (Australia) Pty Limited Contact info and more items like this at wf.net.au/T942
18 WHAT'S NEW IN PROCESS TECHNOLOGY - JULY 2013
Oil and Gas Let Fetch Automation reenergise your oil and gas communication software from KepwareTechnologies Kepware's flagship solution, KEPServerEX, is an interoperable software solution that connects disparate devices and applications to deliver reliable information thoughout your organization. The Oil and Gas Suite for KEPServerEX provides industry professionals with the software needed to monitor and control petroleum, natural gas, and pipeline process installations. Whether you are monitoring a process locally or a remote site hundreds of miles away, KEPServerEX can help lower operational costs and improve project efficiency.
Upstream: Improve project success backed by faster, better decisions Midstream: Monitor environmental impact, oil and gas flow, and ensure proper reporting of custody transfer data. Downstream: Gain visibility and control to improve business decisions and operation excellence.
Fetch Automation Pty Ltd Level 1/63 Railway Street Mudgeeraba Qld 4213
Email: firstname.lastname@example.org Web: www.fetchautomation.com.au
New! ... ViewMarq™ Industrial LED Message Displays ViewMarq LED message boards can display preformatted and real-time factory floor data messages sent by a PLC, PC, or other master device. The text message display can be controlled by any of the following: •ASCII input strings through the RS-232 or RS-485 port •Modbus RTU messages through the RS-232 or RS-485 port •Modbus TCP messages through the Ethernet port (Ethernet cable included) ViewMarq electronic message boards are ideal for use to display process and equipment status such as tank level, pressure level, oven temperature, pump or motor status (ON/ OFF), equipment failures, conveyor line error conditions, production output levels, and more. 6 Models: 1, 2 and 4-line text message displays, 12 and 24 characters Quality tri-color Green, Amber, and Red LEDs in all models Supports Scrolling Lines (up, down, left, right) and Blinking options FREE Configuration Software for ViewMarq industrial LED message boards Rugged Extruded Aluminum Housing for use in harsh environments NEMA 4 (wash down) and NEMA 12 (dust, oil, water, and dirt) Industrial LED Messaging Made Easy ... ViewMarq is a series of LED message displays that uses the latest LED and communications technologies for industrial applications. These industrial text message displays utilize both serial and Ethernet communications. The display can be connected to a PLC (programmable logic controller), PC, or any device capable of serial ASCII, Modbus RTU, or Modbus TCP communications. • Free, easy-to-use ViewMarq™ Configuration Software PRICE CHECK: MD4-0112T- ViewMarq industrial LED message display, 1 line by 12 characters, tri-color, 2 inch maximum character size. $499 Download the Software- Free The ViewMarq Configuration Software can be downloaded at no charge from the AutomationDirect Web site, Help files are included in the software.
www.automationdirect.com.au Australia Wide: 1-800-633040 E: email@example.com New Zealand:
Aust: 1-800-633 040 N.Z: 0-800-6330405
ETHERNET SWITCHES AND GATEWAYS Moxa has announced a selection of automationcertified profiles for its family of industrial ethernet switches and industrial ethernet gateways that can be easily integrated into ProfiNet, Ethernet/IP and Modbus TCP networks. The company’s industrial ethernet switches and gateways can easily provide reliable connections between SCADA and network controllers, and are enabled with industrial protocol stacks such as Modbus TCP, ProfiNet I/O and Common Industrial Protocol (CIP) for device monitoring on SCADA systems. Moxa’s plug-and-play ProfiNet, EtherNet/IP and Modbus TCP switches feature fast booting in less than 10 s, network redundancy recovery in under 20 ms, full status parameters for SCADA/PLC communications, and over 200 industrial-grade models for application flexibility to ensure an optimised network performance, efficiency and reliability. The company’s industrial fieldbus-to-ethernet gateways, including ProfiNet, EtherNet/IP and Modbus gateways, are easy to use and maintain, with auto-detection technologies and user-friendly MGate Manager Utility. The robust housing and wide-temperature operation enable MGate gateways to provide maximum reliability for field-layer applications of PLC/SCADA systems. Madison Technologies Contact info and more items like this at wf.net.au/U162
STRAIN METER DATA LOGGER SYSTEM TML has introduced the TC-32K digital strain meter and data logger, and the CSW-5A 5-channel automatic switching box. In addition to strain, DC voltage, thermocouple and Pt RTD measurements, the TC-32K can be used as a digital multimeter for measurement of resistance and insulation resistance. The liquid crystal display (LCD) backlit screen shows not only the value measured, but auxiliary information associated with programming of the instrument, such as sensor mode and scaling parameters. Data measured and stored by the digital strain meter can be transferred to a PC using a flash memory card (FAT16). A maximum of 80,000 measured data can easily be processed and analysed by software such as MS-Excel. An interval timer is also available so that users don’t have to be on site to record data. The input terminals feature a finger-touch design that allows quick and easy connection to leads of different sensors with no screws or solder needed. Alkaline or rechargeable Ni-Cd AA batteries power the unit, and a built-in battery prevents data loss. The CSW-5A is a 5-channel automatic switching box using the TC-32K interval timer to allow multiple channel inputs. Each channel can be programmed with its own scaling parameter and sensor mode through the keypad of TC-32K, up to a total of 50 channels. These switching boxes, specially designed for TC-32K, can be used for strain gauge, strain gauge type transducer, TEDS compatible load cell, DC voltage, thermocouple and platinum resistance-temperature devices. USB and RS232C interfaces are available for online measurement and control purposes. Bestech Australia Pty Ltd Contact info and more items like this at wf.net.au/U241
20 WHAT'S NEW IN PROCESS TECHNOLOGY - JULY 2013
WIRELESS OIL AND GAS TERMINAL SOLUTION Honeywell has announced its OneWireless Terminal Solution, which brings together a portfolio of wireless-enabled products, services and productivity tools tailored for terminal operators. It is designed to enable operators of oil and gas terminals to increase their productivity while also complying with stringent health, safety and environment (HSE) regulations, all at significantly lower cost than wired technology. The OneWireless Terminal Solution includes the ISA100-compatible Honeywell Enraf SmartRadar FlexLine wireless radar gauge. Requiring no external wireless module, the FlexLine’s integrated radio sends tanklevel measurements securely and wirelessly to the central control room. The Flexline is also used as a data concentrator, collecting data from local tank instruments and sending the data wirelessly through the same ISA100 network. The solution includes additional applications such as Honeywell’s mobile productivity tools (Field Advisor, Mobile Station and Experion Mobile Access), helping with the adoption of operator-driven reliability (ODR) programs and enabling operators to complete activities more efficiently and safely. Other applications include wireless fixed and portable gas detectors and wireless video, including Honeywell’s Digital Video Manager to enhance plant security and process monitoring. Honeywell’s OneWireless Network enables all of these applications, which can be tailored to offer either ISA100-only coverage or ISA100 and Wi-Fi coverage. The OneWireless Network can implement Wi-Fi and ISA100 instrumentation coverage in a single network, realising an additional 25% cost savings in material, installation and maintenance costs over other wireless solutions. Honeywell Limited Contact info and more items like this at wf.net.au/U258
BLUETOOTH WIRELESS MODULE The FL BT EPA MP wireless module adds a Bluetooth access point to Phoenix Contact’s range of industrial wireless devices. The compact and rugged module transfers ethernet data over a distance of up to 250 m at a rate of up to 3 Mbps. Features like QoS and LLDP make it compatible with ethernetbased automation protocols such as ProfiNet and ProfiSafe, Ethernet/IP and Modbus TCP. The device conforms to protection category IP65 and can handle up to seven Bluetooth connections in parallel. With features such as an external antenna port, an included omnidirectional antenna, and a low power consumption of approx 1.1 W, the device is particularly suitable for use in battery-powered systems. The wireless module supports any Bluetooth-compliant unit with a PAN profile, eg, the FL BT EPA module from Phoenix Contact with a built-in antenna. Phoenix Contact Pty Ltd Contact info and more items like this at wf.net.au/T937
JULY 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 21
FLAT PANELS AND THIN CLIENTS Siemens has now added efficient industrial monitors and thin clients to its range of HMI devices in widescreen format. Available as terminals or operating and monitoring devices with touch screen or key-operated fronts, Simatic IFP (industrial flat panels) combined with Simatic ITC (industrial thin clients) are designed to provide robust long-term availability. The devices are used for machine-level operator control and monitoring, as well as for linking to remote control or SCADA systems. Simatic flat panel monitors, with display sizes from 12 to 22â€ł, are suitable for connection to industrial PCs at distances of up to 30 m, while Simatic thin clients can be used for distributed solutions involving long distances
THERMAL IMAGING CAMERAS
and multiple stations. Equipped with die-cast aluminium fronts, they are designed for maintenance-free, 24-hour continuous operation and also meet high-temperature, vibration, shock and EMC requirements. The energy-saving LED background lighting can be continuously dimmed by up to 100% and is especially long lasting and suitable for use in brightly lit working environments. The thin clients are equipped with a 1.2 GHz Intel Celeron processor. A large number of functions and interfaces are integrated: a gigabit LAN interface for fast communication with the server, two USB interfaces for saving data on a USB stick or external hard disk, as well as for connecting mouse and keyboard; a web browser and multiple protocols for flexible connection to other systems, such as RDP, SmartAccess for Simatic WinCC Sm@rtServer, VNC and Sinumerik. Siemens Ltd Contact info and more items like this at wf.net.au/T868
FLIR Axx-Series thermal imaging cameras are suitable for applications that require thermal imaging but do not need exact temperature measurement, such as automation and process control applications. The FLIR Axx-Series visualises temperatures between -40 and +550Â°C. Temperature differences as small as 50 mK become visible on a crisp thermal image. Since the FLIR Axx-Series comes with power over ethernet, communication and power are supplied with only one cable. The FLIR A65 produces crisp thermal images of 640 x 512 pixels. Users that do not need this high image quality for their application can choose the FLIR A35, which produces thermal images of 320 x 256 pixels. Also available is the FLIR A15, producing thermal images of 160 x 128 pixels or the FLIR A5, which produces thermal images of 80 x 64 pixels. The cameras come standard with GigE Vision compatibility. GigE Vision is a camera interface standard developed using the gigabit ethernet communication protocol. GenIcam support is also provided. The goal of GenICam is to provide a generic programming interface for all types of cameras. Regardless of interface technology (GigE Vision, Camera Link, 1394 DCAM, etc) or features implemented, the Application Programming Interface (API) will always be the same. It is also possible to configure one camera to be master and others to be slaves for applications that call for more than one camera to cover the object or for stereoscopic applications. The cameras work seamlessly with FLIR Tools. This software allows for viewing and analysing thermal images and includes functions such as time versus temperature plots. For users needing to record images, FLIR Tools+ is also available. FLIR Systems Australia Pty Ltd Contact info and more items like this at wf.net.au/T599
22 WHAT'S NEW IN PROCESS TECHNOLOGY - JULY 2013
THICKNESS GAUGE The Olympus 45MG is an ultrasonic thickness gauge and is compatible with the complete range of Olympus dual-element and single-element thickness gauge transducers. The basic configuration of the 45MG is a simple and straightforward gauge that requires minimal operator training to tackle most common thickness-gauging applications such as wall and coating thickness, mineral deposition and corrosion. Additional software options and transducers allow it to be used for more advanced applications such as fibreglass (to 100 mm), rubber, very thin materials (<200 µm), and high-precision quality control (to 1 µm resolution). All the options are built into the unit at manufacture and accessed by purchasing ‘unlock codes’. Each function is controlled by a separate software module, and additional features are available by upgrading the software, so that users can have as few or many options as required. The 45MG is built for operation in difficult environments, for example those encountered in the marine, aviation, refinery and pipeline industries. It has a rugged, sealed construction meeting the IP67 standard, and has also been shock and vibration tested using MIL-STD-810G. The gauge has been designed for easy operation with a simple keypad that can be used by both right- or left-handed technicians. The display is a colour transflective QVGA monitor that is bright both indoors and in direct sunlight. With the data storage option, up to 475,000 thickness readings can be copied to a spreadsheet via microSD card or USB connection. Olympus Australia Pty Ltd Contact info and more items like this at wf.net.au/U075
JULY 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 23
INDUCTIVE SENSORS Steute Xtreme has introduced a line of ATEX and IECEx certified inductive sensors designed for use in Zone 0 and 20 explosive atmospheres and extreme environments. Units are available in M8, M12, M18 and M30 sizes with a cable or plug-in connector. Models are also available with IP68K or IP69K ratings and for temperatures of -40 to +120°C. Operating voltage range is 10-30 VDC and switching current is 200 mA. Switch outputs include one NO contact, PNP and a 3-wire switch output, and repeatability is less than 3%. These sensors include inductive interference protection, polarity reversal protection, and short circuit and overload protection. Typical applications include construction equipment, conveyors, food processing, chemical processing, valve position monitoring, materials handling, and grain storage and processing.
VISION SENSOR SYSTEM Omron’s FQ2 vision sensor makes it possible to automate reliably and simply. The vision sensor is claimed to provide the best in image quality and clarity base, using 16.7 million colours. Power LEDs, high dynamic range (HDR) and polarisation enable stable inspections on difficult surfaces. The sensor can be used for pattern recognition, batch code and expire date confirmation, size measurement, counting, colour confirmation, barcode reading (1D, 2D and pharmacode) and OCR. The vision sensor includes communication interfaces (digital I/O, Fins/TCP or EIP) for compatibility with a wide range of host devices. This helps integrate the vision sensor with the rest of the automation system. Logging historical results is very useful for testing a new production line. Samples are fed down the line and inspection results are logged. The logged data can be checked against a timescale in graph form
NHP Electrical Engineering Products Pty Ltd
and used to adjust judging conditions. File logging
Contact info and more items like this at wf.net.au/U263
is also convenient during operation - large inspection histories can be saved in SD cards and referred to later for traceability.
RETROREFLECTIVE LIGHT ARRAY The Banner Engineering PVL Parts Verification Array is designed with retroreflective technology and provides quality visibility, quick response time and wide, reliable coverage to help streamline pick-to-light and conveying processes for factory and warehouse applications. The fast two-millisecond response time and wide coverage area also make the PVL a suitable solution for other applications, such as detecting medium- to large-sized objects moving at high rates of speed, such as boxes on a conveyor. The PVL light array features opto-mechanical alignment with bright red emitter beams spaced 70 mm apart for easy set-up and installation. To ensure effective light-guided assembly in diverse applications, the PVL is available in two lengths - 225 or 500 mm - and can be mounted either vertically or horizontally to racking systems. Upon applying the supplied retroreflective tape to an adjacent PVL or accessory bracket, the PVL’s emitted light beams are directed to the tape strip and a highly visible indicator arrow lights up to notify users which bin to pick from. As the operator reaches into the bin, the light beam is interrupted, triggering an output to the control system indicating the correct parts have been selected. Picking from the incorrect bin causes the arrow to turn red and also sends an output signalling a mis-pick error. Micromax Pty Ltd
When multiple sensors are connected to the touch finder (touch screen), the display automatically switches to the image of the sensor which has produced an NG result. This allows dynamic visualisation of rejected conditions. The vision sensor allows fast and easy real-time parameter adjustment, eliminating the need to stop the machine for finetuning and optimisation of settings, resulting in zero machine downtime. The camera has an IP67 rating and can therefore be used in harsh environments. Omron Electronics Pty Ltd Contact info and more items like this at wf.net.au/T708
Contact info and more items like this at wf.net.au/U262
24 WHAT'S NEW IN PROCESS TECHNOLOGY - JULY 2013
INFRARED TEMPERATURE SENSORS The Williamson Pro 100 and Pro 200 Series multi-wavelength infrared temperature sensors are suitable for industrial applications where devices such as thermocouples and RTDs would be inaccurate, too slow, or difficult to use - such as dirty windows, smoke, steam, plasma coatings, dust, water spray, partially obstructed fields of view, or small or wandering targets. Example applications include metal forging, casting, milling, finishing and heat treating; thermal reactors; flares; boilers; incinerators; kilns; and glass forming. Pro 100 and Pro 200 multi-wavelength sensors use ESP algorithms to provide ‘aim-and-read’ capabilities for non-greybody materials (annealed, galvannealed and stainless steel; aluminium; brass; copper; zinc; etc) that are not accurately measured by single- or dual-wavelength sensors because their change in emissivity varies by wavelength. The sensors measure temperatures between 95 and 2500°C. Accuracy is within 2°C or 0.25% of the reading (whichever is greater). Pro 100 sensors use visual or integrated laser aiming alignment. Pro 200 sensors use fibreoptic alignment, with an integrated aim light available as an option. Every Pro 100 and Pro 200 sensor can be used as a stand-alone transmitter with a choice of inputs, outputs and alarms. For more advanced capabilities, remote interface modules, PID controllers and PC software are available. When in the stand-alone mode, the sensor’s local interface is used to display the temperature and adjust sensor settings from a text-based menu. Units are compatible with RS232 and RS485 as well as 4-20 mA and voltage-sensor outputs, which offer a choice of up to five different measured parameters. Williamson Corporation http://www.williamsonir.com/
PROXIMITY SWITCH Turck has extended its uprox+ sensor range with a robust washdown variant in a Q80 housing. The non-flush inductive proximity switch detects all metals with the same switching distance of 75 mm. The sensor can even be mounted partially embedded or fully flush - its switching sensitivity adjusts itself to the mounting conditions accordingly. The Q80WD is therefore suitable for use in a wide range of applications, enabling users to effectively reduce the range of variants required. The sensor is available with a four-pin M12 connector and an antivalent PNP switch output. The application fields of the Q80WD are varied, ranging from gap detection in filling beverage cans to switching tasks on materials handling systems in washdown environments, in addition to outdoor applications on railway tracks. The Q80 washdown is the only 80-mm rectangular sensor that comes with protection to IP68/ IP69K, and is therefore also suitable for applications in the food and beverage industry. All housing materials are FDA-compliant and are able to withstand typically used high-pressure cleaners and aggressive cleaning agents. The robust design is a benefit of the Q80 washdown sensor which is also useful for outdoor applications. The fully encapsulated proximity switch cannot be damaged by dew or condensation. Turck Australia Pty Ltd Contact info and more items like this at wf.net.au/T843
TAPE EXTENSION SENSOR The ASM WB61 tape extension sensor provides up to 4 m measuring length in a compact, industrial housing. ASM tape extension sensors have been designed to operate in harsh conditions, making them a suitable choice for installation on cranes, excavators, forklifts and access platforms. Due to the design of the sensor and the inherent strength of the stainless steel tape, the WB61 range of sensors can be found in environments and on applications where other traditional pull-wire sensors struggle to survive. The durability of the extension tape allows for the reliable use of directional changing pulleys and also within applications where icing may occur. These features make the sensor also suitable for safety critical control functions within the mobile equipment market. The sensor housing is manufactured from composite and stainless steel components, and the sensors’ sealing meets the sealing level of IP67/69K. Linearity is ±0.10% and there is a choice of three analog and three digital outputs (SSI, CANopen or CAN J1939). Automated Control Pty Ltd Contact info and more items like this at wf.net.au/U140
JULY 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 25
TEMPERATURE TRANSMITTER RANGE
PH AND ORP TRANSMITTER Sensorex’s TX-3000 pH/mV transmitter monitors changes in process fluids, displaying pH or oxidation reduction potential (ORP, measured in mV) and temperature for more accurate control in water, chemical, electronics, food production, environmental and wastewater applications. The line-powered device can be user programmed on-site to measure either pH or ORP. Its dual output design, with an isolated (0)4-20 mA output for pH or ORP readings and one for temperature measurement, eliminates the need for a separate
ifm efector’s TAD series of temperature transmitters, with integrated drift monitoring, diagnostic function and backup function, monitors temperatures with 0.2 K accuracy. By monitoring each other, the two integrated sensor elements ensure increased process safety. Occurring drift between the calibration intervals is immediately detected, diagnosed and signalled. If a sensor element fails, the process can be continued with a second measuring element (backup function). Due to the self-monitoring, the calibration intervals can be in-
temperature transmitter. A large backlit LCD screen displays both
creased and maintenance costs reduced. Each TAD temperature
parameters simultaneously and two adjustable hi/lo relay contacts
transmitter is supplied with a 5-point calibration certificate.
deliver results to automated process control systems.
The TAD series transmitters have probe lengths from 33 to 87.5 mm. An additional 50 mm intermediate length probe has been added to the series with the TAD091 and TAD081 transmitters. The transmitters are all equipped with IO-Link 1.1.
With an extended pH measurement range of -2 to 16, the device is suitable for a range of applications. The NEMA 4x, IP65 enclosure can be wall, panel or pipe mounted for easy integration in most installations. The device can be easily programmed
ifm efector pty ltd
on site with its push-button interface. The unit can be password
Contact info and more items like this at wf.net.au/T598
protected for secure installations. Envirosensors Pty Ltd Contact info and more items like this at wf.net.au/T596
BURST DETECTION SYSTEM Rupture disc manufacturer Elfab has been awarded IECEx approval for its burst detection system, Flo-Tel+. Flo-Tel+ is a non-invasive, fail-safe burst detection system and can be either hardwired or used in conjunction with Elfab’s fail-safe wireless detection system, Radio-Tel. Modern industrial automation has increased the need for electrical equipment in hazardous areas, where flammable liquids, vapours, gases or combustible dusts could present a fire or explosion hazard. The use of equipment, especially electrical, in these areas is highly regulated. IECEx approval ensures that equipment and systems are manufactured and operated according to the highest international safety standards. At a time when stringent safety standards are of utmost importance, Flo-Tel+ offers many advantages, from triggering alarms to shutting down a process. IECEx approval certifies the Flo-Tel+ system for use internationally in hazardous processes and environments. Elfab Limited www.elfab.com
26 WHAT'S NEW IN PROCESS TECHNOLOGY - JULY 2013
Korean brewery sees the light
As part of its environmentally conscious approach to brewing, Korea’s Hite Brewery Company recently installed 25 Hanovia UV water disinfection systems at its Massan and Gangwan plants. The UV systems ensure water used in the production processes remains free from microbial contamination, ensuring a high-quality final product. Seven units are installed at Massan and 18 at Gangwan. In Massan, the UV is used to treat clean-in-place (CIP) water, cooling water injected after the CIP and activated carbon-filtered water. At the Gangwan plant, three UV units are used to treat water after deaeration and the remaining 15 units treat activated carbon-filtered water. CIP is used for cleaning the interior surfaces of pipework, vessels, filters and other process equipment. CIP water must be completely free from microbial contamination, otherwise it could infect the whole system. As CIP uses very hot water, pipework and vessels need to be cooled down afterwards and before beer production can recommence. Cooling water also helps flushes out the remaining CIP water, which contains acid and caustic soda. The purity of the cooling water is therefore extremely important to prevent any residual contamination. Activated carbon is commonly used in water treatment for decolouring and deodorisation, due to its strong adsorption properties. This adsorption can also remove residual chlorine from the water, leaving the post-filter
water vulnerable to microbial contamination. UV therefore plays a vital role in ensuring the post-filter water is adequately disinfected. Deaeration removes dissolved oxygen from water prior to the addition of yeast, a key part of the brewing process. Any contamination of the deaeration water could kill the yeast, meaning the whole batch would have to be destroyed. UV is ideal for this step as it is quick acting and effective without producing any unwanted disinfection by-products which could affect the yeast. “When Hite was considering UV for the first time it looked at a number of UV system suppliers,” said Ying Xu, Hanovia’s Asia-Pacific Sales Manager. “Hanovia was selected as our UV systems not only produced the highest microbial reduction rates, but we also offer a comprehensive and cost-effective spare parts and maintenance service. Hite now uses over 45 Hanovia UV systems in its breweries across Korea, including the latest project at Massan and Gangwan.” “According to the company it also needs to do CIP less frequently, it uses less preservative in the finished product, and the final water has no unwanted residuals, so the taste and colour is not altered in any way. This all adds up to a cleaner, greener process and product,” she added. For manufacturers seeking to improve the quality of the end product, Hanovia says UV is an economic, realistic option. It is an established method of disinfecting drinking water throughout the world, and is also widely used for high-purity applications such as pharmaceutical processing and microchip manufacturing, where water of the highest quality is essential. There are no microorganisms known to be resistant to UV this includes pathogenic bacteria such as Listeria, Legionella and Cryptosporidium (and its spores, which are resistant to chlorination). UV disinfection systems are also easy to install, Hanovia says, with minimum disruption to the plant. They need very little maintenance, the only requirement being replacement of the UV lamps every 9-12 months, depending on use. This is a simple operation that takes only a few minutes and can be carried out by general maintenance staff. Fluidquip Australia Contact info and more items like this at wf.net.au/U198
JULY 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 27
SAFETY INSTRUMENTED SYSTEM CONTROLLER The Triconex Trident Safety Instrumented System package is a SIL3-certified fail-safe, fault-tolerant controller, designed to deliver high reliability and availability for distributed use in refineries, petrochemical, oil and gas plants and other highly hazardous facilities. Now featuring embedded OPC Universal Architecture com-
MATHEMATICAL MODELLING SOFTWARE
munication integration, the system offers greater connectivity
Maplesoft has announced a major release of its flagship
with third-party systems. It complies
product, Maple, the technical computing software for
with IEC 61508:2010 international
engineers, mathematicians, and scientists. With Maple
standards and fulfils the require-
17, the company introduces more computation tools
ments for emergency shutdown,
and a large collection of enhancements dedicated to
fire and gas, burner management,
supporting the creation of applications.
turbomachinery control, high integrity
New functionality includes solving a whole new class
pressure protection systems (HIPPS)
of differential equations, major advancements in solving
and oil-well RTU system applications
systems of equations, new signal processing tools, and
that need to be distributed in remote
expanded support for physics, statistics and dynamic
instrumented buildings or located
remotely in the production fields. It
Performance has also been enhanced with improve-
is suitable for use in environments
ments to frequently called routines and algorithms as well
with operating temperature ranges
as in the low-level infrastructure of memory management.
from -20 to +70°C.
One example is a new memory manager, which takes
Implementing OPC UA maximises
advantages of multiple processors to allow computations
interoperability between systems
to run 10% faster on average, with memory-intensive
and streamlines connectivity through
computations running up to 50% faster.
open-platform architecture and futureproof design. The new
While the computation engine forms the heart of Ma-
communications interface module also contains an embedded
ple’s technology, the company has always considered
OPC UA server to provide a cohesive, secure and reliable cross-
the entire user experience to be important, from the first
platform framework for real-time data, alarms and events. The
explorations by a new user to the development of power-
new communications interface module also provides enhanced
ful applications by experienced customers. This version
security features by implementing X.509 certificates for additional
introduces further productivity advancements, with special
emphasis on application development. Highlights include:
The Trident safety system is scalable from small stand-alone
a new advanced code editor to make algorithm devel-
applications (32 I/O points) to large site-wide systems (in ex-
opment even easier for more complex applications; an
cess of 40,000 I/O points), and provides application program
embedded video component, for adding rich multimedia
execution at millisecond speed for critical control applications.
content to applications; improved command completion
Invensys Process Systems (Australia) Pty Ltd Contact info and more items like this at wf.net.au/T894
while using math notation; improvements to 2-D and 3-D visualisations; new programming constructs to make it easier to write multithreaded code for parallel execution. ASES - Australian Scientific & Engineering Solutions www.ases.com.au
28 WHAT'S NEW IN PROCESS TECHNOLOGY - JULY 2013
FIBRE CONVERTER SWITCHES Turck has extended its in-cabinet ethernet switch range with a multimode fibre-optic port unit for reliable, fast performance in process and factory automation environments requiring conversion from fibre to copper media. The complete product line, consisting of unmanaged and managed models, has also been approved for use in hazardous locations per UL and ATEX ratings. These IP20-rated ethernet switches conform to all necessary IEEE standards and support a wide range of ethernet protocols including EtherNet/IP, Modbus TCP and Profinet. In-cabinet ethernet switches are available in small expansion 5- to 8-port unmanaged configurations and 8-port managed options. All models contain RJ45 sockets for fieldbus connection and removable terminals for power. Operators can also employ the fibre-copper converter to efficiently convey data from standard devices over great distances not possible with copper. The rugged switches are capable of information transfer and real-time I/O control in a wide variety of industrial locations, including UL/ATEX hazardous areas. Providing simple installation, switches are easily set up by applying power and connecting devices to the ports. Turck Australia Pty Ltd Contact info and more items like this at wf.net.au/T940
DISTRIBUTED FREQUENCY INVERTERS SK 200E distributed frequency inverters from NORD Drivesystems feature several safety functions which, depending on the switching device, enable safe shutdown procedures in high-risk applications that comply with Category 4 or Performance Level e according to EN 13849-1. Conventional frequency inverters in this performance class prevent motors from restarting by disconnecting the voltage supply or the 24 V control supply. By contrast, SK 21xE and SK 23xE models feature a certified safe pulse blocking device as well as digital inputs for the ‘disable voltage’ and ‘quick stop’ functions. These enable Stop Category 1 (controlled motor braking in line with SIL1), followed by Safe Torque Off (SIL3-compliant) or Stop Category 0 (SIL3-compliant) according to EN 60204-1. Since the voltage supply is blocked without switching off the control or power electronics, the units remain on standby and are ready to be switched on without reinitialisation after the safety circuit is closed. In addition to high availability, the inverters’ safety technology provides more economic benefits: contactor components are not required and, since the safety functions are activated electronically, there is no need for regular maintenance or exchange of electromechanical contacts. NORD Drivesystems (Aust) Pty Ltd Contact info and more items like this at wf.net.au/U196
JULY 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 29
POWER SUPPLIES FOR COMPACT CABINETS The high power density Uno Power supply units from Phoenix Contact are designed to reliably supply loads of up to 100 W at 24 or 12 VDC in compact control cabinets. Low stand-by losses and highly efficient operation guarantee a high level of energy efficiency. The product range comprises five modules. The three housings dimensioned 22.5/35/55 (w) x 90 (h) x 84 mm (d) take up very little space in the control cabinet. Power supply units providing 24 VDC output voltage are available in 30, 60 and 100 W versions; units for 12 V DC consumers are available in 30 and 55 W. With low no-load losses of less than 0.3 W and an efficiency rating optimised for the entire operating range, the power supplies are very economical. With an efficiency of up to 90% at nominal load, only a small fraction of the electrical energy is converted into unwanted heat. The range is UL certified and features a wide-range input. Uno Power can handle input voltages from 85 to 264 VAC, resulting in reliable operation even in the event of mains grid voltage fluctuations. With an extended mains buffering time of up to 140 ms under full load and MTBFs exceeding 500,000 hours, these power supplies are said to be exceptionally reliable in operation. Outdoor use is also possible due to a broad operating temperature range of -25 to +70°C. Phoenix Contact Pty Ltd Contact info and more items like this at wf.net.au/U267
CERTIFIED OIL-FREE COMPRESSORS Following independent testing, the Class 0 certifications of oil-free centrifugal and rotary air compressor technologies by Ingersoll Rand (IR) have recently been updated to
comply with the ISO 8573-1 Class 0 2010 standard. Class
The ICPDAS I-87024UW/I-
0 is the most stringent class of air quality and certifies that
87028UW is a source-type
the air discharged by the compressor is free of added oil
analog output module that in-
aerosols, vapours and liquids.
cludes 4/8 single-ended analog
The updated certifications were granted to the entire
output channels, and provides
range of Ingersoll Rand air-cooled and water-cooled oil-
options for setting power on
free rotary screw compressors (37 to 350 kW) and water-
and safe values. It also provides a
cooled, oil-free centrifugal compressors (160 to 5000 kW)
programmable analog output range
by TÜV Rheinland.
(0-5 V, ±5 V, 0-10 V, ±10 V, 4-20 mA or
Oil-free compressors not only provide purer air, but save
0-20 mA), and each analog output can be configured
users time and money while improving their productivity.
for an individual range.
They reduce maintenance costs by minimising the need for
The output value for each channel can be set to be stored
lubricating oil, inline filters and oil/air separator components.
before the module is powered down, so the last output value can
Contaminated air can spoil and ruin products, creating
be restored when the module is restarted. The options for voltage
significant losses of revenue and customer trust. IR oil-free
or current output of the I-87028UW are selectable via jumpers. The
technology can help reduce these risks by providing pure
module also features per-channel open wire detection for the 4-20
air, free from additional contaminants. Oil-free compressors
mA output. Together with 4 kV ESD protection as well as 2500
also minimise downtime associated with cleaning filters
VDC intra-module isolation, it also provides an RF immunity level
and other air-system components.
matching that defined by the IEC 61000-4-3 standard. The current output module is suitable for use in industries such
Reduced levels of contaminants also help air-system components last longer and ensure higher overall product
as building automation, factory automation, machine automation,
remote maintenance, remote diagnostics and for testing equipment.
CAPS Australia Pty Ltd
ICP Electronics Australia Pty Ltd
Contact info and more items like this at wf.net.au/U073
Contact info and more items like this at wf.net.au/T641
30 WHAT'S NEW IN PROCESS TECHNOLOGY - JULY 2013
LINEAR SERVOS The R88D-L series of linear servos encompasses a large range of linear products with multiple options and will extend the range of the G5 series servos to include linear applications. The R88D-L servos come in two formats - iron core and ironless - which output 760 or 348 N nominal force respectively. Both systems utilise moving coil technology, which allows easy lengthening of the magnetic track. Iron core systems use a compact, flat design and have a good force-to-weight ratio. Theyâ€™re also available with a 400 V source voltage to double the running speed. A wide range of externally mounted linear encoders can be used. These can be absolute or incremental types and provide movement accuracies down to 50 nm. Temperature and Hall effect sensor connections are available and systems can be purchased either as individual components or a complete axis assembly. The R88D-L drives are almost identical to the G5 rotary units and offer outputs up to 3 kW. They are part of Omronâ€™s Sysmac product family and can thus be controlled by EtherCAT, and are supported by both the Sysmac Studio and CX Drive software. Omron Electronics Pty Ltd Contact info and more items like this at wf.net.au/U138
JULY 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 31
EMBEDDED CONTROL SYSTEM The high-performance multicore NI cRIO-9082 system provides advanced Intel Core i7 dual-core processing at 1.33 GHz, built-in VGA display output for an integrated user interface, and the option to use a Windows Embedded Standard 7 (WES7) or LabVIEW Real-Time OS. The cRIO-9082 also provides 32 GB of non-volatile storage and 2 GB of 800 MHz DDR3 RAM. The increased processing power of the system makes it well suited to perform the advanced processing tasks required by complex applications such as machine vision and rapid control prototyping.
VALVES AND FITTINGS
The high-performance multicore system also offers the
The Swagelok IPT series includes precision
widest array of connectivity and expansion options available
valves, fittings and fluid control devices suitable
in the CompactRIO platform, including the high-bandwidth
for surface and subsea installation, instrumenta-
and low-latency MXI-Express bus for expansion using the
tion, injection and sampling systems. Products
14-slot MXI-Express RIO chassis. An 8-slot Spartan-6 LX150
in the IPT series are made standard from cold-
FPGA chassis is built in. Other ports are two serial expansion ports, two Gigabit Ethernet ports and four USB ports. The operating temperature range is 0-55°C. The NI CompactRIO product family includes a wide variety of controllers, reconfigurable chassis and hot-swappable C Series I/O modules. Currently, there are more than 50 C Series I/O modules for different measurement types including voltage, current, resistance and digital signals.
worked, 316 stainless steel. Annealed 316 stainless steel and other corrosion-resistant special alloys are available to meet NACE MR0175/ISO 15156 requirements. The IPT series medium- and high-pressure product line features check valves, ball valves, relief valves and needle valves, as well as a range of tubing, nipples, fittings and tools. IPT series check valves are available in ball seat poppet, soft seat poppet and dual-seal ball styles to meet most applications, and are available with maximum working pressures up
National Instruments Australia
to 60,000 psig (4136 bar). The IPT trunnion ball
Contact info and more items like this at wf.net.au/T813
valves accommodate applications up to 20,000 psig (1378 bar) and are available in sizes up to 21″. These valves are available with electric or pneumatic actuators and accessories for
ENGINEERING DESIGN SOFTWARE
remote operation. IPT series relief valves also have a maximum working pressure up to 20,000
Intergraph has released SmartPlant Enterprise Control Panel, the first step of a multi-
psig (1378 bar) and are available in 3/8 to 3/4″
release strategy to centralise the administration and deployment of all tools within
the integrated suite of SmartPlant Enterprise solutions. SmartPlant Enterprise Control
Available in six body styles for a wide range
Panel 2013 provides a simplified and consistent user experience and harmonises
of applications, IPT series needle valves are
the administration processes of all SmartPlant Enterprise applications.
designed to prevent galling and scoring with a
The first release delivers streamlined and simplified enterprise data flow adminis-
two-piece, non-rotating stem tip and acciden-
tration for SmartPlant Enterprise integration projects, allowing users to enable and
tal disassembly with a packing gland locking
disable which properties are published and retrieved through the SmartPlant Enterprise adapters. It also takes advantage of reporting capabilities to review enterprise data flows in current projects. Intergraph’s SmartPlant Enterprise offers powerful design and data management solutions, enabling companies in the process, power and marine industries to capture integrated engineering knowledge at the enterprise level. SmartPlant Enterprise’s integrated suite of solutions is claimed to enable productivity gains, improving engineering efficiency by up to 30%. Intergraph Corporation Pty Ltd Contact info and more items like this at wf.net.au/U272
32 WHAT'S NEW IN PROCESS TECHNOLOGY - JULY 2013
mechanism. Needle valves are available with maximum working pressures up to 60,000 psi (4136 bar). The IPT series also includes a wide range of medium- and high-pressure tubing and nipples, as well as coned and threaded connections and preparation kits. Swagelok Corporation Contact info and more items like this at wf.net. au/T939
wmb-602 quarter page artwork_Layout 1 10/01/2013 13:20 Page 1
ROLLER ENERGY CHAIN igus has introduced a roller energy chain and a modular plastic guiding profile designed for long travel lengths. The 3500R energy chain, which can be opened from the external radius, is variable due to its modular interior separation. Easy to install, it is suitable for horizontal applications and the modular design of the roller chain link allows the use of all widths of the standard series 3500 energy chain. The roller system not only safely drives energy, it is also energy efficient compared to other sliding solutions. The company says travels up to 150 m at speeds of up to 4 m/s can be achieved more economically. All energy chains of the series 3500R are part of a comprehensive modular system, meaning they are ready to install. The chain series 3500R can be safely guided in the guidelite system, a modular plastic guiding profile. While the lower run of the energy chain is guided in two L-shaped and glass-fibre-reinforced guiding troughs, the upper run partially passes through guide brackets that
Join the no-valve metering revolution • No valves, no ancillaries, no vapour lock
are mounted in distances of 1 m. This system is useful in harsh conditions with its weather resistance, insensitivity against dirt and high-impact strength at low temperature.
• Accurate, linear and repeatable flows • Up to 5000:1 flow control to 500ml/min at 7 bar • ReNu pumphead technology: fully sealed for safe, tool-free maintenance
Because the upper run of the energy chain is only partly guided, it is designed for slow applications with low cycle numbers. Due to its open design it is insensitive to dirt so, for example, can be used
in greenhouses to guide water hoses. The corrosion-resistant, lightweight guidelite can be used as a
Tel: 1300 WMBPUMPS
cost-effective supporting trough for free-supporting applications and is suitable for different e-chains of the series E2/000 and E4.1. Treotham Automation Pty Ltd Contact info and more items like this at wf.net.au/U254
SAFETY MODULES ReeR Mosaic modules allow the connection of remote I/O system expansions via an MSC bus. This range is suitable for the interconnection of the safety functions of multiple machines on a single production line. The units can be connected in series or in a tree network, with the maximum number of expansion units being five. All modules are also designed for use within a range of industrial IP protocols including ethernet, DeviceNet, ProfiNet and Profibus. The following modules are available: MCT1, with one connection interface, for installation at the end or at the beginning of the network; and MCT2, with two connection interfaces (one input and one output), used for passthrough or as a tree network connection. The MCTs are interconnected using RS485 type shielded cable (four wires plus shield), allowing up to 100 m per connection. Treotham Automation Pty Ltd Contact info and more items like this at wf.net.au/U197
JULY 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 33
AS I SEE IT A.B.N. 22 152 305 336
ENABLING FLEXIBLE OPERATIONAL TEAMS
Head Office Cnr. Fox Valley Road & Kiogle Street, (Locked Bag 1289) Wahroonga NSW 2076 AUSTRALIA ph: +61 2 9487 2700 fx: +61 2 9489 1265 www.westwick-farrow.com.au ph: +61 3 9381 2952 Editor Glenn Johnson
hat would happen if we went 25 years back in time and used the systems of today, or what would happen if we used these same systems for the next 25 years? For those living in the past it would feel alien and for those living in the future, the systems would be ready for the museum. So what exactly do we need? The pace of change is increasing with a previously unseen level of complexity, so companies will need to have programs in place to protect their assets and increase operational effectiveness – through aligning the human assets, and empowering them. This means that companies should be forward thinking and start implementing a platform that can help them to embrace the coming changes. In today’s organisations, the ability to change and evolve must be a natural part of the company’s environment, culture and systems – and the only asset with the necessary reasoning capacity for making complex decisions is the human one. As I speak with executives in the leading process companies – in oil and gas, power, mining, utilities (water) and general manufacturing – the question of the empowerment of operations personnel is the difficult but critical key to success in the operational excellence journey. At this time a significant cultural transition of the workforce is going on. By 2020, 60% of today’s leaders will retire and with this a lot of experience is leaving. Generation Y will make up 42% of the workforce and the average tenure will be less than 2.5 years. Don’t forget that they are ‘digital natives’ who expect instant access to knowledge. If companies want to be competitive, decisions must be in real time, where operational agility requires collaboration no matter the location. Taking all these factors into consideration, we will require a rethink of the today’s operational experiences, across the existing automation systems, and aligned with the existing business system, but empowering a flexible operational team. A team made up of different roles, and with varying expertise – where people on-site work with an operational center and a virtual team of experts – all on-hand accessing the same trusted information. Targets and KPIs
are aligned to roles in their context, but with governance, so that decisions stay aligned with the company’s high-level strategy. Addressing that significant change will require a combination of techniques: • A new generation operational interface – offering embedded knowledge, experience, actionable procedures and natural intelligence. • A new operational experience design – in which the availability of information content is device independent. • New alignment across disparate systems – applications and sites aligned to operational contexts and actions. • Collaboration and team sharing – a common information and supervisory control model that naturally enables sharing, collaboration and notification across team members in real-time across multiple interfaces and over multiple devices. • Consistency – interface experience, notifications, and operational actions and processes across teams and sites should be consistent to reliably support rotating roles and people. • A new operational culture – sharing and asking needs to be natural within the organisation. • Time to experience – self-service learning and intuitive systems, enabling decisions based upon the past, the current and the future. Yesterday an enterprise was managed as a group of independent companies, tomorrow the successful enterprises will be operated as one integrated company where knowledge will be available in real time and at the fingertips of all.
Tim Sowell has more than 30 years’ experience designing automation products in Europe and then in the USA, combining the development and design of systems with application experience on large process a n d s t e e l p r oj e c t s throughout the world. Tim was part of the core architecture team behind the ArchestrA technology foundational to the Invensys range of software and automation products.
34 WHAT'S NEW IN PROCESS TECHNOLOGY - JULY 2013
March 2013 total CAB audited circulation (Aust + NZ) 6,984 readers (79% personally requested)
Contact the editor
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CLICK Series Programmable Logic Controllers (PLCs)
The Almost Free PLC ... Only $99.00
Download the FREE CLICK PLC Programming Software www.automationdirect.com.au
CLICK™ Series Programmable Logic Controllers (PLCs) Why buy a smart relay when you can have a real PLC for less? The almost free micro PLC starting at only $99.00
The CLICK PLC offers a scalable solution. The stand-alone CPUs can compete on size, price and ease of use with hardware designed for microprojects, even programmable relays. But they’re also expandable and have features you'd expect in a practical PLC, a great fit for small projects... and nice to have when feature creep turns your micro project into a small project! Try the full-feature FREE Programming Software. Easy Installation •The CLICK PLC control system does not require a mounting base, which saves on space. •The CLICK CPU and I/O modules are connected together via an expansion port on the sides of the modules. Expandable I/O •A powered CLICK CPU module can be used as a complete standalone PLC control system with eight input points and six output points built-in, •Or, the PLC controller can be expanded with the addition of up to eight I/O modules. •A variety of I/O modules are available for flexible and optimal PLC system configuration. The I/O numbering system is decimal. Built-in Communications •CLICK Basic CPUs have two built-in RS-232 communications ports that can be configured for either MODBUS RTU or ASCII networks. •CLICK Standard and Analog CPUs have an additional built-in RS-485 communications port Analog Input/ Analog Output •Analog CPU modules have built-in analog I/O (2-channel analog inputs and 2-channel analog outputs). •Each channel can be separately set for voltage (0 to 5 VDC) or current (4 to 20 mA). Calendar / Clock & Battery Backup •Standard and Analog CPU modules include the real time clock and battery backup for the internal SRAM. •Battery allows data to be stored for 5 years. FREE PLC Programming Software •The CLICK PLC supports a very simple, but useful set of 21 easy to use instructions. •The 21 instructions cover most applications that are suitable for this class of programmable logic controller. •Download FREE CLICK PLC Programming Software Now! Analog I/O Modules ... New! •4-channel analog current & voltage input modules •4-channel RTD & thermocouple input modules •4-channel analog current and voltage output modules •4-channel analog current input / 2-channel analog current output module •4-channel analog voltage input / 2-channel analog voltage output module
TECHNOLOGY THAT MAKES YOUR JOB EASIER
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Published on Jul 7, 2013
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