What’s New in Process Technology May 2012

0512

ON THE COVER

WHAT'S NEW IN PROCESS TECHNOLOGY MAY 2012

CONTENTS

After more than 30 years and with over 14 million units sold worldwide, Mitsubishi Electric is one of the largest manufacturers of variable speed drives in the world and is continually contributing innovations to

4

The true cost of bearing lubrication Over half of all bearing failures are lubrication related

The Freqrol 700 series covers a broad

8

New products

output range from 0.1 kW all the way up

14

Hot products online

series for simple applications, to the

22

Matching valve type to function tutorial in valve selection A

42

To err is human

the FR-F740 series that is optimised for

Using technology to try to solve this problem is equally human

the special requirements of pump and fan

50

As I see it

variable speed drive technology.

to 630 kW. From the smallest FR-D700

A brief look at systems - more ways to save energy and costs?

medium-range FR-E700 series and up to the high-performance FR-A700 series.

The product range is complemented by

applications in the HVAC sector.

Energy savings of up to 60% can be made by using Mitsubishi frequency inverters, thereby helping to reduce CO2 emissions and protect the environment.

Mitsubishi Electric always has the right drive system for straightforward and complex applications alike. With so many sizes, outputs and features, the right frequency inverter solution is available for every conceivable drive requirement.

Mitsubishi Electric’s frequency inverters meet all the standards and specifications laid down in the UE Low Voltage Directive and the Machine Directive. Needless to say, all the units carry the CE mark and are certified as conforming to UL, cUL and GOST. Mitsubishi Electric Australia www.mitsubishi-electric.com.au

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

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

THE TRUE COST OF BEARING LUBRICATION

© iStockphoto.com/Leon Rafael

Matt Mowry, Product Manager, igus Inc.

4 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2012

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Today, machine and equipment manufacturers are feeling more pressure than ever to reduce costs without sacrificing machine performance and this balancing act can be difficult to achieve. Original equipment manufacturers (OEMs) often overlook a simple solution that can have a positive, long-term impact on profitability for themselves and their customers: the elimination of bearing lubricant.

B

y eliminating lubrication systems where possible, OEMs can reduce production costs, while at the same time making their equipment more marketable and less expensive to operate for the end users.

What are the issues with bearing lubricant? According to a major ball bearing company, 54% of bearing failures are lubrication related (see Figure 1). In a study by the Massachusetts Institute of Technology (MIT), it was estimated approximately US$240 billion is lost annually (across US industries) due to downtime and repairs to manufacturing equipment damaged by poor lubrication.1 Improper bearing lubrication or re-lubrication accounts for up to 40 to 50% of machine failures. By eliminating lubrication from machinery, OEMs can minimise the costs and risks associated with maintenance for the end user. At the same time, costs related to the proper disposal of oil can be eliminated and the initial expenditure for ancillary components and processes (grease lines, grease nipples, manifolds, etc) can also be decreased.

There is a lower cost, easier-to-maintain machine component that eliminates the total cost of bearing lubricants: highperformance, dry-running plastic bearings.

Hidden costs of lubrication Proper lubrication delivery is critical for the operation of ball bearings, and most require continued maintenance for re-lubrication. The re-lubrication process typically requires scheduled machine downtime, which increases maintenance costs and causes a loss of production time. In addition, re-lubrication maintenance practices often fall short. While some processes are automated, the majority of re-lubrication is performed manually using a grease gun. This seemingly simple task actually involves a number of critical steps to ensure proper lubrication delivery, including correct amount of lube, the right grease gun, proper cleaning, and careful storage and handling conditions, just to name a few. In addition, it is critical to use the

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same grease for the entire lifespan of a bearing. The Technical Training Division of Life Cycle Engineering conducted a study that found 80% percent of maintenance workers surveyed scored less than 50% when it came to the basic technical skills needed to perform their job; 2 and bearing lubrication was noted first on their list of tasks.

The main reasons re-lubrication maintenance practices fall short are: • Lubrication not being properly or consistently administered • Lubrication points not being easily accessible • Maintenance personnel not being properly trained • Incorrect or improper quantity of lubricant being used

Ancillary components for OEMs Using lubricated bearings can increase manufacturing complexity and expenses.

They often need to be fitted with grease nipples and manifolds, oil lines, and sometimes oil reservoirs and pumps.

Not only are there extra costs associated with purchasing these components, there are also manufacturing costs associated with the machining and assembly of the mating parts.

Ancillary components for lubricated bearings include: • Grease fittings, grease nipples, oil lines and pumps • Wipers, scrapers, felt wicks and seals • Grease guns • Grease, oil and other lubricants There are also additional parts required to protect them from contaminants. According to McNally Institute, the leading cause of bearing failure is due to contamination of the lubrication by moisture and solid particles. If as little as 0.002% water gets mixed into the lubrication system, it increases the probability of failure by 48%. Just 6% water can reduce the lifetime by 83%.3 Ball bearings require seals to keep oil in and unwanted water and liquids out, as well as wipers or scrapers to keep dust and debris out. Seals only last so

MAY 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 5

Asset management

Figure 1: Types of lubrication-related bearing failures. Source: SKF, USA Inc.

Figure 2: Comparison chart comparing ball bearings to self-lubricating plastic plain bearings.

long and do not perform well in dirty and dusty environments and can also increase friction in the application. In applications where dust and debris are prevalent during operation, seals and wipers may require frequent replacement.

The extra costs associated with lubricated bearings can include: • Gravity-fed oil reservoirs and lines: $50 to $300 • Grease nipples: $2 to $40 (for four bearings and machining) • Seals, wipers and felt wicks: $4 to $12 (per bearing) • Automated oil reservoirs and lines: $1500 or more • Lubricant disposal These are all things that are generally not required with self-lubricating plastic bearings.

Disposal costs According to Valin, 6 proper disposal of lubricants by a process management company can amount to approximately 20% of the cost of annual lubricant expenditures. This means if a plant spends $50,000 per year on lubricants, they will spend approximately $10,000 in disposal costs. In addition, the cost of the lubrication itself can impact overall expenditures, as it is normally petroleum based and directly linked to the price of oil.

Other costs not required for self-lubricating bearings Labour A major oil company studied the time required to manually lubricate a single grease point. The results showed manual lubrication takes an average of three minutes per point. The average machine has 20 grease points to maintain. This correlates to a total labour cost of $7300 annually for maintaining 20 grease points on one machine, every day, seven days per week.4 Another source claims that the average plant employs 2196 bearings and spends $60,000 in re-lubrication costs per year; of that $60,000, $57,000 is used for labour alone.

Downtime Improper bearing lubrication or re-lubrication accounts for up to 40 to 50% of machine failures. When a bearing fails prematurely, a number of actions may need to be taken. Replacement of the bearings, shafts, and even motors and other parts can be very costly. If the machine needs to be taken offline, expenses can potentially skyrocket. In a six-sigma lean manufacturing guide, 5 it is estimated that the average cost for downtime is $500 per hour, and in some automotive and other high-volume production factories, downtime costs are considerably higher.

In addition, unplanned downtime can cause a ripple effect that impacts a plant’s production schedule.

6 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2012

Self-lubricating plastic bearings Self-lubricating plastic bearings are made of high-performance polymers and, unlike rolling-element bearings, slide instead of roll. They consist of a base polymer, which is optimised with fibre reinforcement and solid lubricants. The fibre reinforcements increase load-carrying capabilities and wear resistance, and the solid lubricants are transferred from the bearing to the microfinish of the shaft in order to reduce friction. No external oil or grease is needed for their operation; self-lubricating bearings operate completely dry. They are an ideal solution for applications in labs and food processing machinery that require clean, oil-free operation. Plastic bearings also perform well in dirty and dusty environments since there is no oil to attract dust and dirt. They can be used on softer shafting, even anodised aluminium, which has excellent corrosion resistance and is usually less expensive and easier to machine than case-hardened material or stainless steel.

Eliminate maintenance costs Using high-performance, self-lubricating plastic bearings can significantly reduce maintenance costs, as well as reduce unplanned downtime due to bearing failure. OEMs that use self-lubricating plastic bearings are able to deliver a maintenance-free system that increases their end customer’s production throughput and the overall marketability of their product. In the event that a self-lubricated bearing does need replacement, the replacement part (a small, inexpensive plastic sleeve) can be purchased for a fraction of the cost of an entire recirculating ball bearing.

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Asset management

USING HIGH-PERFORMANCE, SELF-LUBRICATING PLASTIC BEARINGS CAN SIGNIFICANTLY REDUCE MAINTENANCE COSTS, AS WELL AS REDUCE UNPLANNED DOWNTIME DUE TO BEARING FAILURE.

Figure 3: Self-lubricating plastic bearings are made from high-performance polymers, which are corrosion-resistant and maintenance-free.

Lower production costs Plastic bearings do not require the machining and other processes required to install ball bearings. They are less expensive and do not require grease fittings, lines or pumps. Plastic bearings also can be used on less expensive shafting, such as aluminium or cold-rolled steel. Some companies offer online calculators to predict bearing lifetime to ensure it is ideal for the application; this eliminates the need for testing and saves time and errors in material choice.

Applications not appropriate for self-lubricating plastic bearings Of course not all applications are suitable for the use of plastic bearings. Examples of situations in which they are not appropriate are: • Applications with high loads and high speeds: These lead to excessive frictional heat build-up and wear.

• Highly cantilevered loads: Since self-lubricating plastic bearings slide (unlike ball bearings that roll), linear applications with higher coefficients of friction may result in uneven movements for highly cantilevered loads or drive forces.

• Extremely precise applications: Plastic bearings have a higher running clearance than ball bearings, sometimes 0.025 mm to 0.055 mm, and therefore are not ideal for applications needing extreme precision.

• Extreme temperatures: Plastic bearings are not recommended for applications with long-term temperatures exceeding 250°C.

Other benefits of plastic bearings Apart from lower maintenance and production costs, plastic bearings also offer: • Corrosion resistance • Lower cost than ball bearings • Good handling of contamination, often not requiring seals or scrapers • Suitability for very short-stroke applications, unlike linear ball bearings

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Figure 4: Total cost of replacement parts over five years – plastic liners vs. recirculating ball bearings. Based on ¾” closed linear bearing and assuming replacement is required once per year.

Self-lubricating bearings are ideal for: • Harsh, extreme environments - dirt, dust, agriculture, outdoor equipment • Sensitive, clean environments - biotech, lab machines, medical equipment • Washdown applications - packaging, food processing • Weight-sensitive applications (aimed at reducing fuel consumption or lowering the inertia of moving parts)

Example of an application of plastic bearings An example of the use of plastic bearings to replace traditional metal bearings is that of a packaging machine manufacturer that specialises in vertical, form, fill and seal (v/f/f/s) packaging equipment for handling a wide range of products: from green beans to candy to detergent. The machines are capable of reaching up to 160 cycles per minute and withstanding loads up to 65 N, while operating at speeds of 230 metres per minute.

The manufacturer had been using metal linear ball bearings.

After the metal bearings scored the shafts and leaked grease on some of the machines, the company decided to replace them with self-lubricating igus DryLin R linear plain bearings.

To date, the linear bushings have surpassed the 10 million cycle mark on some of the company’s packaging machines with little to no noticeable wear.

References 1. http://www.azom.com/news.asp?newsID=11342 2. http://www.lce.com/pdf/trainingneeds.pdf 3. http://www.mcnallyinstitute.com/02-html/2-10.html 4. http://www.lubricationautomation.com/ez.php?Page=2087 5. http://www.plant-maintenance.com/articles/lean_maintenance_for_lean_manufacturing.pdf 6. http://www.valin.com/index.php/blog/15-filtration/117-cutlubricant-costs-up-to-50 Treotham Automation Pty Ltd Contact info and more items like this at wf.net.au/N528

MAY 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 7

NEW

STANDARDISED AUTOMATION FRAMEWORK

PRODUCTS

Process control engineering firm MIPAC has developed a standardised Rockwell Automation ControlLogix and Wonderware ArchestrA framework that is claimed to make it possible to save many hours and money on the average automation project.

Designed for the benefit of MIPAC's key clients, the framework's library of objects enables a project's rapid configuration.

It supports the following features: objects to support alarming and setpoints managed within the PLC; ease of configuration with functionality similar to a DCS; standard window layouts and navigation standards; multiple monitor support; windows for alarm summary, alarm history, event history, help files and reports; ControlLogix function block library; built-in I/O simulation capability; analog signals with standard HH, H, L, LL, out-of-range and deviation alarms with time delays and deadbands.

The framework enables express deployment of projects while providing DCS-style functionality. Rather than repeat configuration steps for each project, MIPAC's framework reduces engineering time on the average project by about two months, increasing clients' profits and productivity and improving production quality even sooner.

The framework is currently being applied in the mining industry and would also benefit manufacturing, and food and beverage settings.

MIPAC Engineering Pty Ltd Contact info and more items like this at wf.net.au/P306

STRAIN GAUGE METER Red Lion Controls has announced its PAX2S strain gauge meter.

The PAX2S provides advanced control and communication for weight measurement applications in environments that include food processing, truck scales, material storage and other weighing scenarios.

It allows plant engineers and maintenance staff to enhance overall efficiency and lower cost by increasing accuracy in weighing processes. With the meter, users can display net weight and gross weight simultaneously, as well as communicate real-time weight information to a database or management system for monitoring,

HOSE PUMPS Bredel APEX pumps are designed to suit dosing, metering and transfer applications from

storage and reporting. In addition,

2.8 to 1,200 L/h across a broad range of applications. With a cast aluminium housing,

the meter uses a colour-changing

providing good heat dissipation, robust, direct-coupled technology and precision machined

LCD system to alert operators to

hose elements, APEX pumps are designed to provide decreased cost of ownership, reduced

show when weight limits are being

operating costs and low inventory stocking.

approached or exceeded.

Should process requirements change, easy upgrades are achievable without having to

Control Logic Pty Ltd

buy a new pump. This is because APEX models are three pumps in one, with a single

Contact info and more items like this at wf.net.au/N530

pump body adjustable for three hose sizes (10, 15 and 20 mm) for when production volumes change. APEX pumps are suited to applications ranging from lime dosing and slurry transfer through to handling food and beverage products.

Hose pumps have no expensive wearing components such as seals, valves, membranes, stators, rotors or glands. Subsequently, they are suitable for handling difficult fluids - such as abrasive, corrosive, viscous, shear-sensitive or crystallising fluids or fluids presenting a combination of these properties.

Watson-Marlow (Pty) Ltd Contact info and more items like this at wf.net.au/N460

8 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2012

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NEW PRODUCTS

RUGGED MONITORS The 15″ FPM industrial monitors are designed for harsh environments and are certified for use in the oil and gas industries. The FPM-8151H series is class 1, division 2 certified, meaning that it won’t cause explosions if gases, vapours and liquids are present.

With its NEMA4/IP65 protection and the 2.8 mm thick resistive glass panel, the front panel prevents dust, water and oil from entering the monitor when it’s being used in temperatures ranging from -20 to 60°C. A 316 L stainless steel front panel is included, making it suitable for food, beverage, chemical and pharmaceutical environments.

To increase flexibility the series has dual function support, meaning that users can choose to control the system using either a USB or RS232 connected controller; power it using either a Phoenix or a DC jack; and the display can be connected via either VGA or DVI-D ports.

For added reliability and lower power consumption, the monitor

EMBEDDED DEVICES FOR CUSTOM DEVELOPMENT

uses 5-wire and an LED backlit screen that reduces power consump-

National Instruments has announced four NI

tion by 22% while increasing brightness by 12%.

Single-Board RIO board-level embedded devices

Advantech Australia Pty Ltd

featuring a real-time processor, Spartan-6 field-

Contact info and more items like this at wf.net.au/N434

programmable gate array (FPGA), analog and digital I/O and more built-in peripherals for custom embedded control and monitoring applications.

The devices provide engineers with off-the-shelf FPGA and real-time processor technology through NI LabVIEW while maintaining the custom I/O often required for high-volume deployments through the option of a RIO Mezzanine Card connector. The connector provides direct access to FPGA digital I/O lines and certain processor-specific functions for mating custom daughter cards.

The devices also feature built-in analog I/O so engineers can take advantage of analog technology in addition to their application-specific circuitry.

The devices’ low-cost, small form factor, built-in I/O, real-time processor and FPGA provide a suitable platform for embedded monitoring and

M12 CONNECTORS Belden’s Lumberg Automation product range now includes M12 receptacle connectors that can be used to connect control units to ProfiNet/Profibus networks via bus modules as well as to transmit analog data at field level. Integrated shielding between devices delivers a high level of functional reliability.

The receptacle connectors are available with assembled control cables or with printed contacts for PCB mounting. In the printed contact versions, the integrated shielding ensures flexibility for shield continuity. With the assembled connectors, and depending on the port assignment of the control units, a diagnostics interface can be implemented outside the switch cabinet using an ethernet connection. This practically eliminates the disruptions resulting from repair or maintenance work.

These receptacle connectors are simple to install due to standardised M12 connection technology and colour-coded bus connections. Additional features include industrial protection class IP67, high shock and vibration resistance, and a wide temperature range of -30 to +80°C. Versions with assembled control cables are intended for rear mounting.

Belden Australia Pty Ltd Contact info and more items like this at wf.net.au/M490

10 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2012

control applications in industries such as medical and energy.

The NI sbRIO-9623 features 256 MB of memory, 128 MB RAM, 16 channels of 12-bit analog input, 4 channels of 12-bit analog output, four DIO and 96 RMC DIO. The NI sbRIO-9626 comes with 512 MB of memory, 256 MB RAM, 16 channels of 16bit analog input, four channels of 16-bit analog output, four DIO and 96 RMC DIO. The NI sbRIO-963 contains 256 MB of memory, 128 MB RAM, 16 channels of 12-bit analog input, four channels of 12-bit analog output and 28 DIO, while the NI sbRIO-9636 features 512 MB of memory, 256 MB RAM, 16 channels of 16-bit analog input, four channels of 16-bit analog output and 28 DIO. National Instruments Australia Contact info and more items like this at wf.net.au/N225

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Six of 500+ panels we built in 2011

Competence, capability, quality This picture shows six of the 500+ panels Bürkert Australia built in 2011.

Our Sydney Systemhaus is ISO 9001 certified for the ‘development, assembly and distribution of customised system solutions,’ making Bürkert the ideal partner for large and small scope projects. In addition to standard panels, we engineer custom panels with pneumatics, I/O, transmitters and programming designed to meet your wider control system needs.

Call on Bürkert to build your 2012 panels.

www.burkert.com.au | 1300 888 868 www.burkert.co.nz | 0800 BURKERT (0800 287 537)

We make ideas flow

NEW PRODUCTS

NEW White Papers

now available online!

ACTUATOR DRIVE/CONTROLLER WITH ETHERNET The addition of ethernet connectivity to Tolomatic's ACS stepper drive/ controller brings greater flexibility and economy to electric actuator applications. The ACS with ethernet supports both EtherNet/IP and

Control systems and operational security - are you properly covered?

Security has always been a relevant concern during the design and deployment of automated control systems. But recent worldwide events, combined with technological and industry trends of the last decade, have significantly raised the visibility and public awareness of this issue.

Modbus TCP, allowing easy connectivity to Allen Bradley PLCs and many other PLCs and HMIs. With built-in configurations for all of Tolomatic's electric actuators, the ACS with ethernet makes creating linear motion simple.

The combination of the ACS and Tolomatic's ERD low-cost, rod-style electric actuators cre-

Oxygen measurement on air separation plants

ates very economical solutions

Industry consumes vast quantities of oxygen and nitrogen annually, all of which is obtained from the air around us. There are two main techniques used to separate these two primary gases from air. These processes are cryogenic separation and pressure swing adsorption (PSA).

for automation applications such as product changeovers, diverting, sorting, pick-and-place or pressing.

The ACS with ethernet is capable of commanding motion with immediate move command or preconfigured moves for infinite position capability. Each move has configurable motion profile

50+ FDA acronyms that matter most to your business If you work in the pharmaceutical, biotech or medical device industries, you know the importance of complying with Food and Drug Administration regulations. Read this paper to gain an understanding of the FDA acronyms that matter most to your business.

parameters (position, velocity, acceleration/deceleration, force) that are independent for each move. The ethernet connectivity also provides additional status and diagnostic information to the control system for better monitoring and fault recovery.

The ACS with ethernet comes complete with a starter kit that includes the configuration software and two set-up manuals.

Pneumatic Products

Portable gas detection for safety in confined spaces In today’s working environment, confined spaces are ongoing areas of review. Nearly all workers can expect to come into contact with a gas detector during their working career but few have the opportunity to understand the basics. Are you safe?

Contact info and more items like this at wf.net.au/P308

P&ID ISO 15926 SUPPORT Intergraph has released its SmartPlant P&ID ISO 15926 Export Utility, a commercially available solution to support interfaces based on the ISO-based data exchange.

SmartPlant P&ID ISO 15926 Export Utility offers data exchange benefits between the process design schematics and the 3D physical design for engineering companies and facility owners.

This allows piping and instrumentation diagrams (P&IDs) to be exported in the ISO 15926 format, which means data, as well as graphical content, can be exchanged with other ISO-compliant plant design and information management solutions.

SmartPlant P&ID is an asset-centric, rule-driven P&ID solution that is designed to help users to develop and manage their facilities using SP P&IDs with a focus on the plant asset rather than the documentation representation. This accurately reflects the as-

For these and more White Paper downloads, visit www.processonline.com.au/white_papers

built plant for enhanced safety, quality, efficiency and productivity.

Intergraph Corporation Pty Ltd Contact info and more items like this at wf.net.au/N469

12 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2012

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NEW PRODUCTS

WIRELESS DEVICE SERVER The Quatech AirborneAP APXG-Q5420 enables M2M equipment to become the centre of a self-sufficient Wi-Fi network. The server allows easy access to serial data and network resources from Wi-Fi enabled devices, including laptops, tablets and handhelds powered by Android, iOS, or Windows.

The server includes a 10/100 ethernet interface and two serial ports. The ethernet interface can be placed in bridge mode allowing wireless devices to connect to an existing wired network. Alternatively, the ethernet interface can be set to wireless router mode, enabling direct connection to wide area networks including the internet using a cellular modem. In router mode the access point provides secure authentication using WPA2 (AES-CCMP) and a fully functional DHCP server to provide unique addresses for each authenticated client. In addition the built-in serial device server allows the wireless clients to utilise the serial interfaces to remotely access serial data. The serial interfaces provide compatibility with RS232/422/485 devices and allow simultaneous use of both ports in any serial data configuration.

The server can be powered by a wide range 5-36 VDC power source and provides both terminal block and barrel-jack power connections. It can be configured using a remote web browser or by using the Airborne Management Centre softwarebased administration utility.

Interworld Electronics & Computer Industries Contact info and more items like this at wf.net.au/P046

CAPACITIVE POINT LEVEL DETECTOR FOR BULK SOLIDS The FTI77 is a compact capacitive point level transmitter that can be used for point level detection at high temperatures in bulk solids and can be operated in minimum or maximum failsafe mode.

The FTI77 has a robust design for harsh process conditions. It is suitable for the level detection of abrasive media, withstands lateral loads of up to 800 Nm and has the option of active build-up compensation where bulk solids have a caking tendency.

It is easy and fast to commission and calibrate with push-button operation. Two-stage over-voltage protection helps protect against static discharge, which is often present in silo and electrostatic precipitators. Shortening the length of the probe is easy and quick, reducing the need to keep a number of length variations as spares.

With a SIL2/SIL3 rating when used in combination with the FEI55 electronic insert, it is suitable for use in safety systems, and it has increased safety due to permanent automatic monitoring of the electronics.

Endress+Hauser Australia Pty Ltd Contact info and more items like this at wf.net.au/N268

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MAY 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 13

HOT PRODUCTS

ON WWW.PROCESSONLINE.COM.AU THIS MONTH

HANDHELD DIGITAL PRESSURE INDICATOR Designed specifically for pressure measurement and calibration tasks in harsh

>

HART CONCENTRATOR SYSTEM The HCS HART Concentrator System from Moore Industries converts HART digital signals to the serial (RS485 or RS232) Modbus RTU communications protocol.

Moore Industries Pacific Inc

has a measuring range of up to 1000 bar.

WF.NET.AU/N426

>

environments, the WIKA model CPH6300 WIKA Australia

WF.NET.AU/N605

OXYGEN ANALYSER The XTP601 thermo-paramagnetic oxygen analyser provides fast, accurate measurements of oxygen levels in various background gases.

AMS Instrumentation & Calibration Pty Ltd

WF.NET.AU/N359

> >

>

DC-DC CONVERTERS supplies equipped with selective

ELECTRONIC PRESSURE GAUGE

fuse breaking (SFB) technology

The Mercoid Series EDA electronic pres-

now have approvals for use in

sure control gauge can replace a separate

hazardous zones.

gauge, two switches and a transmitter.

Phoenix Contact Pty Ltd

Dwyer Instruments (Aust) Pty Ltd

WF.NET.AU/N524

WF.NET.AU/N279

Quint DC/DC converter power

14 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2012

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Level switches keep electrostatic precipitators online A Midwest US power plant has eliminated spillover of fly ash from its hoppers, by enlisting Endress+Hauser to assist in the upgrade of its level switch technology.

Fly ash is composed primarily of inorganic, non-combustible minerals such as alumina, silica and iron and is one of the non-combustible materials that remain after burning coal to produce electricity. Along with the other by-products, which include bottom ash, and flue gas desulphurisation gypsum, fly ash requires disposal but has proved to be an economical, high-quality raw material feedstock for several other industries. For example, the materials can be used in structural fill and in land development, buildings, metals recovery and highways, and to manufacture agricultural fertilisers, carpeting and plastics filler.

Although most modern power plants collect their coal combustion products to meet environmental regulations, coal-fired power plants have discovered they can be profitably recycled. Many plants now sell combustion products to add to their bottom line.

The US power plant in question was built around four decades ago and is boiler rated for just less than 500 MW. Over the last decade, it has invested hundreds of millions of dollars into environmental equipment designed to reduce SO2 emissions by over 95%. It is now a leader in its re-use program for fly ash, bottom ash and FGD scrubber material. For example, 100% of the gypsum produced from the plant scrubbers is used to manufacture wallboard.

One remaining issue, however, was that spillover from fly ash hoppers was creating issues with Environmental Protection Agency/Occupational Safety and Health Administration reporting as well as causing a major hazardous cleanup procedure.

The old capacitance probes that were being used to measure the level of fly ash collected in the hoppers of the electrostatic precipitator (ESP) were so unreliable that plant operators did not trust the control information the devices were supposed to be providing.

Failures were frequent, and when they happened, the precipitator would often clog up, resulting in downtime and repair costs. On one occasion the failure of an older-design point level device resulted in damage to a precipitator that cost $100,000 to repair. This did not include the lost electricity production, which was worth several times the cost of repairs.

T h e l ow re l i a b i l i t y o f t h e s e o l d e r technology devices was most likely a result of high temperatures, insufficient surface area on the probe for the low dielectric constant, inability of the devices to withstand the physical rigours of the application or a combination of these reasons.

The key element of the upgrade project was Endress+Hauser’s site visit to review the point of installation to ensure the instrument was properly configured and set up. Thereafter it was important to ensure probes were delivered on time as the power plant had a window of time for which it had scheduled maintenance.

For applications such as this, a level switch that is designed for point level detection at high temperatures in bulk solids is the best choice. The switch must also be able to withstand the harsh conditions of abrasive fly ash. After considering its control device options, the utility installed the Endress+Hauser Solicap S-FTI77 level switch on the precipitator to replace the failed capacitance sensor.

There were a number of reasons that made the FTI77 a suitable choice. The switch features active build-up compensation for when fly ash accumulates around the probe, facilitating safe switching. It can also

16 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2012

withstand a maximum load or lateral stress of up to 800 Nm, making it suitable for fly ash hopper applications.

In addition, the FTI77 has a sword probe instead of a round probe to increase the surface area of capacitance, which improves performance in low dielectric applications such as fly ash level measurement. The design of the switch prohibits fly ash from entering the electronics housing should probe damage occur, eliminating the possibility of any static electricity discharges.

Space was also a consideration in this project. The precipitator hoppers were grouped tightly together with limited clearance. The FTI77 requires probes to be only a minimum of 508 mm apart, with the threaded coupling as short as possible as condensation or product build-up can adversely affect operation in long-threaded couplings.

The installation of the FTI77 switch was so successful in enabling the plant to eliminate the spillover of fly ash from its hoppers, it is now planning to install two FTI77 switches on all of its precipitators.

Endress+Hauser Australia Pty Ltd Contact info and more items like this at wf.net.au/N521

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NEW

OIL-FREE COMPRESSOR

PRODUCTS

CompAir has announced the expansion of the Quantima range of oil-free centrifugal compressors with the introduction of the Q-70L model, suitable for lower pressure applications. Now available with a minimum

MANAGED ETHERNET SWITCHES ICP Electronics Australia Announces the release of the RGS7168GCP series managed redundant ring ethernet switches by ORing.

RGS-7168GCP series are managed redundant ring ethernet switches with 16 gigabit combo ports and eight 100/1000Base-X SFP ports. With support for Ethernet Redundancy protocol, O-Ring (recovery time < 20ms over 250 units of connection) and MSTP/RSTP/STP (IEEE 802.1s/w/D) it is designed to protect mission-critical applications from network interruptions or temporary malfunctions.

working pressure of 3 bar(g), the Quantima Q70-L oil-free centrifugal compressor model is suitable for those applications which require lower pressure oil free compressed air.

The Q70-L includes a direct-drive compression and motor assembly that uses magnetic bearings to provide stable control of the rotor shaft. The shaft is supported in a magnetic field, spinning at up to 60,000 rpm. With only one moving part, there is no contact and no wear for long life and reliable operation.

ORing’s Thunder switch series provides advanced IP-based bandwidth management that can be used to limit the maximum bandwidth for each IP device. The user can configure an IP camera and NVR with more bandwidth and limit the other device’s bandwidth. ORing’s thunder switch series also supports application-based QoS, which can set priorities for data stream according to TCP/UDP port number.

A special IP police function will only permit an IP address with a MAC address to access the network. This prevents anyone hacking into the system, as users need permission to gain access. The Thunder series switch also provides advanced DOS/ DDOS auto prevention. All functions of the RGS-7168GCP series can also be managed and centralised with Open-Vision 3.0, except for web-based interface, Telnet and console (CLI) configuration.

ICP Electronics Australia Pty Ltd Contact info and more items like this at wf.net.au/N168

Operating at high speeds, the Q-drive motor incorporates an asynchronous induction design. As a result, a conventional gearbox is not required. This

PANEL METER Futek Advanced Sensor Technology has introduced the IPM650 intelligent panel meter. The IPM650 is intended to gradually replace the IPM5490/ IPM500 family and is claimed to have significant improvements in performance and quality over the previous models.

These improvements include 24 bits internal resolution (20 bits noise free), compatibility with the entire Futek transducer range, provision of various outputs including 0-5 VDC, ±5 VDC, 0-20 mA, 4-20 mA, 0-25 mA and 5-25 mA. The IPM650 also provides alarm relay output, TEDS and USB output, ASCII stream and data logging (21 kpoints), and is CE approved. The LCD is capable of displaying multiple lines plus units of measurement.

Accessories included in the IPM650 package include a power supply adapter, 2 m USB cable, 8-pin connector plug, 6-pin connector plug and two 4-pin connector plugs.

Metromatics Pty Ltd Contact info and more items like this at wf.net.au/N598

eliminates costly gearbox losses and means that the compressor does not require any oil.

The Quantima oil-free centrifugal compressor range offers zero risk of oil contamination, making Quantima suitable for applications which require absolutely oilfree compressed air, such as in the food and beverage, pharmaceutical, healthcare, glass and chemical industries.

Variable speed technology matches output to exact requirements minimising off-load running. In addition, off-load power consumption can be achieved at 2.5% of full load power. Energy savings of up to 25% and more are achievable.

The Q70-L has a small physical footprint (295 x 200 x 195 cm) and weighs 3800 kg. It is quiet in operation with noise levels as low as 69 dB(A) making it suitable for point-of-use applications. The motor rating is 300 kW, minimum working pressure 3 bar(g) and free air delivery 70.9 m3/min.

CompAir (Australasia) Limited Contact info and more items like this at wf.net.au/M575

Check out this magazine’s sister website.

18 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2012

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| EK11-05E |

EtherCAT Terminals.

The ultra fast “all-in-one” system for automation.

The Beckhoff I/O system integrates terminals for: All standard digital/analog signal types Drive Technology such as for stepper motors, AC/DC motors Gateways for legacy fieldbus systems High-precision instrumentation, Condition Monitoring Safety PLC and safety I/Os High-speed automation (XFC)

www.beckhoff.com.au/EtherCAT-Terminal Real-time Ethernet down to the I/O level Low system costs Flexible topology Maximum performance Easy configuration Simple integration of fieldbus systems and safety devices

IPC I/O Motion Automation

Ethernet directly in the terminal: with full duplex Ethernet ring topology and a telegram for several devices. Connects directly with a standard Ethernet port.

NEW PRODUCTS

PLANT DESIGN SOFTWARE Intergraph has released the latest versions of its plant, offshore and

PANEL PCS IEI has released the AFL2-12A-D525 flat-bezel panel PC with Intel second-generation Core i7/i5/i3 processors and the AFL2-12A-HM65 industrial panel which supports a projected capacitive touch screen or a 5-wire resistive-type touch screen.

The panel features a 12.1″ 600 nits 1024 x 768 flatbezel LCD with LED backlight. It has an IP64-compliant front panel with two built-in 1.5 W speakers and a microphone.

The D525 Intel Atom Dual Core CPU can support applications with demanding graphics requirements. Interfaces include a RS232 (DB-9 connector), RS232 (RJ45 connector), RS422/485, four USB 2.0, mini-USB 2.0 and VGA ports. For data storage there is a 2.5″ SATA drive bay, a SATA SSD slot as well as a CompactFlash II socket available.

Networking capabilities include a dual Gb ethernet LAN for high-speed network applications and an EM or Mifare RFID reader.

A 204-pin DDR3 SO-DIMM slot is provided for memory with a maximum 4 GB. Wi-Fi 802.11b/g/n wireless is supported. It can be deployed in various self-service and interactive applications with a wide-range operating temperature of -20 to 60°C. The projected capacitive screen supports multitouch and features good sunlight readability and a true flat panel surface with no bezel. It also has a protective antiscratch glass surface so the AFL2-12A-D525 functions even if the screen is damaged or broken.

ICP Electronics Australia Pty Ltd

materials handling design solutions, SmartPlant 3D, SmartMarine 3D and SmartPlant 3D Materials Handling Edition. Collectively known as Smart 3D, all three Smart 3D 2011 Service Pack 1 (SP1) solutions are now available. They offer nearly 1200 enhancements and continuous testing over the past 20 months. Several significant Smart 3D customers have been involved in testing and piloting the Smart 3D 2011 SP1 solutions for production.

The Smart 3D releases offer enhancements to Intergraph's Reference 3D capability, which enables users to reference data from Intergraph plant design system (PDS), Aveva PDMS and other formats - allowing companies to share piping, structural and equipment portions of Smart 3D models with multiple subcontractors without exposing other ultrasensitive parts of the model. The capability offers opportunities for productivity gains on mega projects while also protecting intellectual property.

The latest versions of Smart 3D also offer improved design re-use and new modelling capabilities, such as functionality for circular and arced pipe modelling vital to the oil and gas, power and process industries. Enhancements have also been made to the electrical and duct modelling environments. Users can benefit from easier creation of project deliverables, improved management of change tools, enhanced 3D data viewing and manipulation and expanded sample catalogue data. In SmartMarine 3D, new offshore and shipbuilding structural functions have been added for detailed design and fabrication of knuckled structures and rolled members. A full library of connections has been added to allow a rule-based selection of the appropriate end-cut features. SmartMarine 3D also has a new service to find and manage common parts, significantly enhanced the functionality to define and control marking on manufactured parts, as well as numerous other productivity and usability enhancements.

Intergraph Corporation Pty Ltd Contact info and more items like this at wf.net.au/P045

Contact info and more items like this at wf.net.au/M489

20 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2012

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NEW PRODUCTS

SOLENOID AND MANIFOLD SOLUTIONS The Bifold Group range of direct-mount solenoid valves, manifold and accessories for general valve actuator applications is available in 3/2, 5/2 or 5/3 port configurations.

Compact in its design, the solenoid valve features a NAMUR mounting pattern according to VDI/VDE 3845 designed to mount to any NAMUR valve actuator thus reducing actuator response times, space requirements and also negating the need for a back plate. Installation costs are lower as the need for tubing, fittings, brackets and assembly labour are greatly reduced. All mounting screws and seals are included with the valve. The Bifold design includes a mounting/spacer block that is free to rotate through 360°.

This feature avoids the solenoid housing from coming into contact with the switch box and ensures the filter regulator remains upright at all times.

This range also includes a manifold option that incorporates the NAMUR interface kit based on the Axis system, allowing the direct mounting of filter regulators, check valves, flow control valves, pressure relief valves and manual valves. The valves are manufactured from 316L stainless steel with an operating temperature range of -60 to +180°C and worldwide approvals Ex d, Ex ia, Ex emb and explosion proof. This product range is available with a wide range of override options including auto reset, spring return manual override, stayput manual override, manual reset, tamperproof manual latch and latch energised.

All FP Solenoid valve assemblies have SIL 3 third-party certification to IEC 61508.

Rotork Australia Contact info and more items like this at wf.net.au/M807

You’ll love what we’ve done with your calibrator.

The new Fluke 754 lets you do the work of several tools. Calibrate temperature, pressure, voltage, current, resistance and frequency. Easily troubleshoot HART instrumentation. All this plus a brighter screen, newer software, improved battery life, USB port, and improved accuracy.

Contact Fluke Australia today, for your 754 demonstration: w: www.fluke.com.au e: sales@fluke.com.au p: +61 2 8850 3333

©2012 Fluke Corporation.

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MAY 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 21

MATCHING VALVE TYPE TO FUNCTION

A TUTORIAL IN VALVE SELECTION

Michael D Adkins, Product Manager, General Industrial Valves, Swagelok Company

In selecting valves for instrumentation, the choices are many and varied.

The choice depends mostly on the application the valve is to be used for.

W

hen selecting a valve for an instrumentation system, your choices may seem overwhelming. Just to name a few, there are ball valves, diaphragm and bellows valves, as well as check valves, excess flow valves, fine metering, gate, multiport, needle, plug, relief, rising plug and safety valves. Further, each of these valves comes in many sizes, configurations, materials of construction and actuation modes.

To make the best choice, it is always good practice to ask the first question in valve selection: what do I want the valve to do?

Most valves fulfil one of five primary functions - on-off, flow control, directional flow, over-pressure protection, and excess-flow protection. Matching valve type to function is the first and most important step in the valve selection process. It is not unusual in the field to see the misapplication of valves, such as a ball valve used for throttling flow. In some cases, the

22 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2012

mismatch can be catastrophic, say, if a ball valve were used in a high-pressure oxygen system. With a source of ignition, the sudden burst of oxygen - enabled by the fast opening of the valve - could lead to an oxygen fire.

On-off valves On-off control is the most basic valve function. Valves in this category stop and restart system fluid flow. Primary on-off valves are ball, gate, diaphragm and bellows valves.

Perhaps the most common of all valve types, ball valves (see Figure 1) are designed for on-off control. Quarter-turn actuation starts or stops flow by positioning a metallic ball in a straightthrough flow path. The ball has a large hole through the centre of it, and when the hole is lined up with the flow path, it enables flow. When it is turned 90째 from the flow path, it stops flow.

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© iStockphoto.com/ Scott Cressman

Fluid power

If you are seeking an on-off valve with quick shutoff and high flow capacity, then a ball valve is a good choice. The position of the handle provides a quick indication of whether the valve is open or closed, and, for safety purposes, ball valves are easy to lock out and tag. They are most practical and economical at sizes between 6 and 50 mm.

Typically used for process control rather than instrumentation applications, gate valves are commonly chosen for on-off control, particularly for lines above 50 mm. They are also frequently used as the first valve off the process line for process instrumentation, often in a double block and bleed configuration. Among the oldest types of on-off valves, they are typically specified in general industrial applications, such as large process or transmission lines. Some can even be larger than 2500 mm. Multiple rotations of the handle raise and lower a sealing mechanism in and out of a straight flow path. Shut-off is gradual.

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Often packing is used to surround the stem, preventing system media from escaping to atmosphere where the stem meets the valve body. Valves that seal to atmosphere with metal-to-metal seals are referred to as ‘packless’ because they do not contain the soft packing material, such as gaskets and O-rings, normally found around the stem in other valves. The valve stem is the cylindrical part that connects the handle (or actuation) with the inner mechanism for shut-off, flow control and directional control. Usually, the stem turns and/or moves up and down.

All stem seals or packing are subject to wear, and wear can lead to leakage. Valves with packing must be serviced or replaced at regular intervals, although some types of packing create more effective seals and last longer than others, such as the two-piece chevron design.

Contrary to packed valves, diaphragm valves (see Figure 2) are packless and provide rapid shut-off and precise actuation speeds. In some cases, they may also deliver consistent quantities of process fluid. Typically, diaphragm valves are employed in high-purity applications in the biopharmaceutical and semiconductor industries. Among all valve types, they provide the highest cycle life, a product of the valve’s highly engineered anatomy. Each valve contains a thin metal or plastic diaphragm, which flexes up and down, creating a leak-tight seal over the inlet. This robust valve is usually small, with the largest orifice - or internal pathway - typically less than 50 mm.

Like the diaphragm valve, bellows valves are packless, making them a good choice when the seal to atmosphere is critical and access for maintenance is limited. Frequently, they are specified for the containment area in nuclear power plants.

A welded seal divides the lower half of the valve, where the system media resides, from the upper parts of the valve, where actuation is initiated. The stem, which is entirely encased in a metal bellows, moves up and down (without rotating), sealing over the inlet.

Bellows valves and diaphragm valves are said to have a globe-like flow path. In globe valves, fluid does not flow straight through on a level plane as it does in a ball valve. The flow path enters the valve under the seat and exits above the seat.

Globe valves will have lower flow rates than valves with a straight-through flow path of the same orifice size.

Flow-control valves Flow-control valves enable the operator to increase or decrease flow by rotating the handle. The operator can adjust the valve to a desired flow rate and the valve will hold that flow rate reliably. Some flow-control valves also provide very reliable shut-off, but many turns of the handle are necessary to move from the fully open to the fully closed position.

The most common flow-control valves are needle, fine metering, quarter-turn plug and rising plug. Needle valves (see Figure 3) provide excellent flow control and, depending

MAY 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 23

Fluid power

MOST VALVES FULFIL ONE OF FIVE PRIMARY FUNCTIONS - ON-OFF, FLOW CONTROL, DIRECTIONAL FLOW, OVERPRESSURE PROTECTION AND EXCESS-FLOW PROTECTION.

Figure 2: Diaphragm valves provide rapid shut-off and precise actuation speeds. Among all valve types, they provide the highest cycle life, a product of the valveâ&#x20AC;&#x2122;s highly engineered anatomy.

MATCHING VALVE TYPE TO FUNCTION IS THE FIRST AND MOST IMPORTANT STEP IN THE VALVE SELECTION PROCESS.

Figure 1: Ball valves are ideal for on-off control. Quarter-turn actuation starts or stops flow by positioning a metallic ball in a straight-through flow path.

on design, leak-tight shut-off. They consist of a long stem with a highly engineered stem-tip geometry (vee- or needle-shaped) that fits precisely into a seat over the inlet. The stem is finely threaded, enabling precise flow control. Stem packing provides the seal to atmosphere.

Some designs contain a metal-to-metal seat seal; consequently, needle valves are a good choice for high-temperature applications.

As discussed earlier, flow is limited because of the globe-style flow path. Needle valves are a good choice with lighter, less viscous fluids. For the most precise flow control, consider fine metering valves, typically found in laboratory settings. Fine metering valves are a type of needle valve, with a long, fine stem that lowers through a long, narrow channel. This anatomy makes for a pronounced globe pattern, ideal for marking fine gradations of flow. Some fine metering valves are not designed to shut off.

Quarter-turn plug valves are utility valves, economically priced.

Quarter-turn actuation rotates a cylindrical plug in a straightthrough flow path. The plug contains an orifice to permit flow.

Plug valves are commonly used for low-pressure throttling applications, in addition to shut-off.

Another type of plug valve is the rising plug valve. Like a needle valve, a tapered plug lowers into an orifice to reduce flow.

It differs from a needle valve in its flow path, which is straight through rather than globe patterned. Because of the straight path, the valve is not as effective at providing fine gradations of flow.

The rising plug is roddable, which is a good choice if the valve becomes clogged with system media.

24 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2012

Figure 3: Needle valves provide excellent flow control. The stem is finely threaded, enabling precise flow control.

Directional flow valves A third type of valve directs fluid flow.

Check valves (see Figure 4) ensure flow in one direction only. In most designs, the upstream fluid force pushes a springloaded poppet open, allowing flow. In the case of an increase in downstream or back-pressure force, the poppet is forced back into the seat, stopping reverse flow. Check valves are available with fixed or adjustable cracking pressures. Some ball valves and diaphragm valves are designed with multiple ports. In most multiport valves, fluid enters through a single inlet but may exit through one of many outlets, depending on the position of the actuator. Multiport valves may or may not have a shut-off position (see Figure 5).

Overpressure protection valves Valves in this category prevent the build-up of system pressure beyond a certain pressure setting. They are available in two types: relief valves and rupture discs. One type of relief valve is a proportional relief valve (see Figure 6). It contains a vent to atmosphere that opens when pressure in a system exceeds a certain point set by the operator. A spring-loaded poppet enables the measured release of fluid. The vent closes when pressure returns to a point below where it was set.

A safety relief valve is designed to open very quickly, releasing a large amount of system media. Because of their critical safety function, safety relief valves are required by code in certain ap-

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Fluid power

Figure 4: Check valves ensure flow in one direction only. Check valves are available with fixed or adjustable cracking pressures.

Figure 5: Some ball valves and diaphragm valves are designed with multiple ports.

Figure 6: A proportional relief valve is a type of overpressure protection valve.

It contains a vent to atmosphere that opens when pressure in a system exceeds a certain point set by the operator.

plications. Safety relief and proportional relief valves are not to be used interchangeably with check valves, since the three have different functions.

Rupture discs are used mainly on sample cylinders to protect against over-pressurisation, which may occur, for example, when temperatures rise during transport. Similar to relief valves, rupture discs vent to atmosphere. A metal diaphragm bursts when pressure reaches a set point. This value is preset by the manufacturer. Once activated, the rupture disc must be replaced. Transportation codes require that compressed gas cylinders be equipped with a pressure relief device. A rupture disc is an economical choice for this application.

following, if you have not had occasion to so far in the process: • Installation issues, maintenance schedules and access.

• Safety and code requirements.

• System parameters, such as pressure, temperature, flow rates, and system media.

Ultimately, you will need to determine: • Valve size and actuation types.

• Materials of construction (including O-rings and seals), which must be compatible with the chemical composition of the system media, pressures, and temperatures.

The manufacturer’s representative will be your guide in this process. Product catalogues and product test reports are also valuable resources in refining your valve choice.

Excess flow valves

Swagelok Corporation www.swagelok.com

Excess flow valves stop uncontrolled release of system media if a downstream line ruptures. Under normal conditions, a spring holds a poppet in the open position. In an excess flow condition downstream, the poppet moves to a tripped position stopping almost all the fluid flow. When the system is corrected, the valve returns to its open position. These valves are available with fixed tripping values.

Conclusion Once you have matched valve type to function, you are well on your way in the valve selection process. Many details remain, though. You will need to give detailed attention to each of the

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Michael D Adkins is Product Manager, General Industrial Valves, Swagelok Company, and joined Swagelok in 1994.

In his current role he assesses market needs and develops product strategy, positioning and pricing. He also works internally with engineering and production teams to develop new products and product enhancements, as well as reduce costs. Prior to this role he served as supervisor of new product development, quality control supervisor, project manager and manufacturing engineer. He holds a Bachelor of Mechanical Engineering Technology degree from the University of Dayton and an MBA from John Carroll University.

MAY 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 25

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NEW PRODUCTS

HANDHELD VIBRATION METER Fluke Corporation will soon introduce to Australia the Fluke 805 vibration meter, a portable multifunction vibration screening tool that provides quantifiable information on the bearing and overall health of motors and other rotating equipment. The Fluke 805 is suitable for frontline mechanical troubleshooting teams that need reliable and repeatable measurements of rotating equipment to make imperative go/no-go maintenance decisions.

The vibration meter measures overall vibration from 10 to 1,000 Hz and provides a four-level severity assessment for overall vibration and bearing condition. It also provides indication of bearing condition (CF+, or Crest Factor Plus) by detecting peaks in the vibration signal readings of roller bearings from 4000 to 20,000 Hz, and uses a proprietary algorithm to interpret severity to determine if the bearing is going bad. Surface temperature is also measured using an infrared sensor to automatically measure contact temperature and display it along with the vibration reading for a broader understanding of machine health.

The handheld vibration meter has a sensor tip design that minimises measurement variations caused by device angle or contact pressure. This reduces operator error and improves the accuracy and repeatability of quick vibration screening. The meter also provides a severity scale for both overall vibration and bearing condition readings, delivering more information than comparable vibration pens. Logged data can be easily uploaded into Excel to create trending reports.

Fluke Australia Pty Ltd Contact info and more items like this at wf.net.au/N599

MODULAR WIDE BELT CONVEYOR The FlexLink modular plastic wide belt conveyor has a flat, smooth belt surface, that minimises the risk of scratches, and sturdy guide rails, to prevent items falling off. The components of the conveyor system are standardised for easy engineering and maintenance and troublefree operation. The modular design makes assembly and modifications easy, and the system can be adapted to any requirements.

The conveyor is available as components, modules or a complete system. The three widths, 322, 424 and 626 mm make it suitable for handling cartons, bundles, bags and other large individual items that require the stable support of a wide chain. It also allows large flows of smaller products.

Vertical bends and a length of up to 15 m allow efficient and simple layouts in three dimensions, without additional elevators in constant flow, and with a maximum conveyor speed of 40 m/min.

FlexLink Systems Contact info and more items like this at wf.net.au/N464

FANLESS PANEL PC Backplane Systems Technology has available the Aplex APC-3081 8″ Intel Atom Z510 rugged aluminium fanless panel PC. The PC has an aluminium die-cast casing and comes with a 75 x 75 VESA mount. This model has an IP67 rating and is available with an Intel Atom Z510 1.1 G processor or a Z530 1.6 GHz. This rugged PC has a system memory of 1 GB DDR2 SDRAM on board and a DC 9 to 32 V power input. The external I/O layout offers the user two USB ports, a DC in, one gigabit LAN and a COM port. The cables are 2 m long and have one waterproof side.

Featuring an 8″ LED backlit TFT-LCD display with a high resolution of 800 x 600, the PC comes with an optional 5-wire resistive type touch screen and a backlight lifetime of 40,000 h. Other features include a standard operating temperature of 0 to +50°C and an extended operating temperature of -20 to +70°C. The APC-3081 supports Windows CE 6.0 R3, XP, XP Embedded and Windows 7 and has an optional wireless LAN, Bluetooth or GPS module. With its compact size (251 x 201 x 64 mm) and durable construction, the APC-3081 panel PC is suitable for industrial applications requiring good performance and ruggedness in limited spaces.

Designed for applications with high ambient light, the APC-3081 is available with a standard brightness of 350 nits or a high-brightness LCD option of 800 nits.

Backplane Systems Technology Pty Ltd Contact info and more items like this at wf.net.au/M996

28 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2012

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MAY 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 29

NEW PRODUCTS

CLOUD-BASED REMOTE MANAGEMENT The cloud-based Netbiter remote management solution from Swedish company

ENCODER SIGNAL EXPANDERS M o t r o n a â&#x20AC;&#x2122; s e n c o de r

HMS Industrial Networks allows users to monitor and control field equipment

signal expanders are

such as power generators, wind turbines, tanks and other field applications via

rail-mounted modules

an office computer, laptop or smartphone. The company now offers the online

designed to take the

data centre, Netbiter Argos (www.netbiter.net), as a free service.

signals from one incre-

By connecting a Netbiter communication gateway to the desired field equipment,

mental square wave

it is possible to immediately log into Netbiter Argos, visualise all parameters of

output encoder and ex-

the field installation, and control it remotely. Netbiter Argos is available in nine

pand it to two or more

languages: English, Swedish, German, Italian, French, Spanish, Portuguese,

encoders.

Chinese and Japanese.

The latest addition Netbiter is a complete pack-

to the Motrona range

age for remote management

of encoder signal ex-

consisting of three main ele-

panders expands the

ments. The first is the physi-

signals from one encoder

cal layer - a Netbiter gateway

and provides up to eight individual galvanic isolated output

attached to the remote equip-

groups. All input and output signals are terminated using

ment which sends and receives

plug-in screw terminal strips, one for each device. There is

data. The second is the Netbiter

an additional loop facility to cascade as many expanders

Argos data centre that collects

required for the installation.

and stores the data from the

The series is available with either four or eight output groups,

field equipment. This data

each with the true and complementary encoder signals, even

centre offers secure storage of

if the input encoder has only true signals available. The

information and enables users

operating voltage of each group can be individually set for

to get statistics and reports on the performance of their devices. The third is

any voltage between 5 and 30 VDC. The modules also act

secure access to data via an office computer, laptop or smartphone where

as a line conditioner for encoders, ensuring good rise and

users see the status of their devices and can monitor and control equipment

fall times for the equipment to which they are connected.

in a graphical dashboard.

A demo of the Netbiter Argos web interface can be tested at www.netbiter.com.

Plant Control & Automation Contact info and more items like this at wf.net.au/N270

Global Automation Asia-Pacific Contact info and more items like this at wf.net.au/N247

Is your

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

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

Fax: 07 3255 5159

info@groupinstrumentation.com.au

30 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2012

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NEW PRODUCTS

CLASS 0 COMPLIANT COMPRESSORS The Class 0 certifications of Ingersoll Rand’s compressors have been upgraded to comply with the ISO 8573-1 Class 0 2010 standard.

The certifications were granted to the entire range of Ingersoll Rand air-cooled and water-cooled oil-free rotary screw compressors (37 to 350 kW) and water-cooled, oil-free centrifugal compressors (160 to 5000 kW) by TÜV Rheinland. Air purity is essential to many critical processes in industries such as pharmaceutical, food and beverage, electronics, and textile. Class 0 - created in 2001 in response to industry demands - is the most stringent air quality class and certifies that a compressor discharges air free of added oil aerosols, liquids and particulates. Oil-free compressors provide purer air, save users time and money while improving their productivity, and reduce maintenance costs by minimising the need for lubricating oil, inline filters and oil/ air separator components. By providing pure air, free from additional contaminants, oil-free compressors minimise downtime associated with cleaning filters and other air system components. Reduced levels of contaminants also help air system components last longer and ensure higher overall product quality.

CAPS Australia Pty Ltd Contact info and more items like this at wf.net.au/N459

What are the crucial

considerations to

determine the correct level detection sensor?

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©2012 TURCK

FANLESS EMBEDDED PC The Kontron embedded Box-PC Microspace MPC-pOne is an application-ready platform for cost-sensitive applications that require a robust design and high availability. The compact, fanless Box-PC is based on the Intel Atom Z5xx processors and the Intel USW15W controller hub.

With the completely sealed aluminium housing, operation can be carried out maintenance free for more than 11 years in 24/7 operation (MTBF \>100,000 hours).

The fanless Kontron embedded PC is scalable from the Intel Atom Z510 processor with 1.1 GHz up to the Z530 with 1.6 GHz and provides up to 2 GB system memory. It comes in a small footprint of 122 x 99 mm which is smaller than a CD cover and can be deployed in a range of space-constrained applications. The optional mounting kit enables tophat rail mounting. Even with its low-profile construction height of 53 mm, it offers all the standard PC interfaces: video signals with a resolution of up to 1920 x 1080 are transmitted via the integrated DVI connector. For data transfer, a gigabit ethernet (RJ45) is available. External peripherals can be connected via the two USB 2.0 ports on the front and at the back. A TPM takes care of data security. The robust fanless aluminium housing also has enough space to integrate an optional 500 GB 2.5″ hard disk or 40 GB SSD for maintenance-free designs. Alternatively, the system can be booted via the integrated MicroSD slot, so system designs without moving parts can be created that are shock- and vibration-proof.

Kontron Australia Pty Ltd Contact info and more items like this at wf.net.au/P171

32 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2012

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NEW PRODUCTS

THERMAL MASS FLOW METER RANGE ST100 Series thermal mass flow meters from Fluid Components International (FCI) are available with FCI’s VeriCal in-situ calibration verification system. They are suitable for flare gas applications aboard offshore platforms, land-based oil/gas facilities and chemical plants.

Three types of flow meter are available: the FPC style for compressed air and clean gas applications, the S style for wet or dirty gases and erratic flows, and the general-purpose FP style.

The calibration system enables users to verify flow meter calibration in minutes without removing the meter from the pipe or process.

The system is compatible with 4-20 mA analog, frequency/ pulse, alarm relays or digital bus communications such as HART, Fieldbus, Profibus or Modbus. It can be adapted with a plug-in card replacement.

The flow meters have an LCD display/readout that provides continuous display of all process measurements and alarm status with the ability to interrogate for service diagnostics.

The system stores up to five calibration groups and obtains up to 1000:1 turndown.

The ST100 Series comprises two core model families. ST meters measure mass flow and temperature; STP meters also measure pressure.

The basic insertion-style air/gas meter features a thermal flow sensing element that measures flow from 0.07 to 305 NMPS with accuracy of ±0.75% of reading, ±0.5% of full scale.

Designed for rugged industrial processes and plants, the meters include service up to 454ºC and are available with both integral and remote (up to 300 m) electronics versions.

The ST100 is approved for hazardous environments.

AMS Instrumentation & Calibration Pty Ltd Contact info and more items like this at wf.net.au/N058

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MAY 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 33

NEW PRODUCTS

THERMAL IMAGERS Fluke Corporation has introduced five new thermal imagers, of which the Ti110 and Ti125 are designed for industrial applications.

The imagers feature automatic focus with a manual focus option for close-ups, IR Optiflex, which is claimed to make it fast and easy to take sharply focused, accurate images. IR-Fusion technology can be used to blend digital and infrared images into a single image to precisely document problem areas. Up to three digital photos per thermal image file can also be captured to help keep an exact record of equipment models, nameplates and other useful information.

With a weight of 739 g, these thermal imagers are light enough to aim either vertically or horizontally and to use for long stretches without tiring out the user’s hand, and they are designed to survive drops up to 2 m.

Focus-free video in visible light and infrared with full IR-Fusion capabilities is also possible, so it processes can be monitored over time, to troubleshoot frame by frame and create infrared video reports.

SmartView, a suite of analysis and reporting tools for viewing, annotating and editing infrared images, is included, with unlimited licences and free lifetime upgrades.

The Fluke Ti110 and Ti125 thermal imagers come with an AC power adapter, two lithium-ion smart batteries, a USB cable for direct to PC image download, SD memory card, hard carrying case, soft transport bag, adjustable hand strap (left- or right-handed use), and manual (both printed and electronic). Ti125 and TiR125 models also include a two-bay charging base, a multifunction USB memory card reader and a separate, longer USB cable for streaming video use.

Fluke Australia Pty Ltd Contact info and more items like this at wf.net.au/N089

Global Support. Local Address.

Peace of Mind. And We Mean It. By leveraging our global infrastructure of support centres and subject matter experts, we’re here to help you protect your automation investment.

Beyond providing you peace of mind, as we help you keep your plant running, we’ll assess your entire operation and recommend the right mix of services to help maximise productivity, optimise plant assets and improve your overall financial performance.

Visit: www.RockwellAutomation.com.au

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34 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2012

10-Apr-12 11:08:49 AM

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NEW PRODUCTS

INFRARED THERMOMETERS The Ircon Modline 7 Series infrared thermometer is a rugged, IP65 (NEMA 4) sealed sensor system for continuous temperature monitoring and control requirements.

The thermometer is used in a wide range of industrial applications, including semiconductor manufacturing, metals processing, furnace refractory, primary and secondary glass, as well as plastics thermoforming.

The Modline 7 offers extended temperature ranges (-40 to 3000ºC), high-resolution optics and fast response times. The thermometer’s sensing head can operate as a standalone sensor, providing simultaneous analog and digital outputs of process temperatures. Motorised focus control and both through-the-lens and laser sighting are standard on all units.

The thermometer’s sensor design - with integral watercooling in a stainless steel enclosure or high-temperature water jacket - reduces installation and set-up time. The water jacket is intended for use in ambient temperatures up to 315ºC with an integrated air purge capability. An optional air purge collar accessory enables the lens to be cooled and kept free of debris in hot dusty environments.

The sensor system also features preset alarms for early warning detection, system on/off control or quality record keeping. A programmable relay output can be triggered by product temperature (process alarm), sensor internal temperature (sensor alarm) or manually.

The Modline 7 Series thermometer uses high-speed digital signal processors with an RS485 serial data communications networking capability that supports up to 32 sensors.

AMS Instrumentation & Calibration Pty Ltd Contact info and more items like this at wf.net.au/N095

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MAY 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 35

NEW PRODUCTS

DESIGN SOFTWARE AND CLOUD SERVICES FOR MANUFACTURERS Autodesk Product Design Suite and Autodesk Factory Design Suite provide a broad range of cloud services to help manufacturers more efficiently design, build and deliver better products, faster, and at reduced costs.

Autodesk suites provide comprehensive workflows to connect desktops to mobile devices and to the cloud.

These workflows enable manufacturing customers to: develop complete definitions of product designs; integrate electrical and mechanical design (to increase productivity); predict product performance; and visualise designs or complete factory layouts in 3D. Autodesk’s 2013 design suites integrate with Autodesk 360 cloud offerings to better enable collaboration.

Cloud-based assets promote design sharing and reuse. The suites also offer interoperability with the new 2013 version of Autodesk Vault product data management software and the company’s next generation, cloud-based alternative, Autodesk PLM 360. Autodesk Vault software enables workgroups to organise, manage and track their engineering CAD data, manufacturing bills-of-material and change processes from a centralised location.

Autodesk Product Design Suite 2013 adds one-click workflows to help users seamlessly move through the engineering design process, advanced cloud-based services for simulation and the inclusion of additional software allowing customers to realise their end-to-end design process.

Autodesk Factory Design Suite brings digital prototyping to the factory floor and enhances AutoCAD and Autodesk Inventor software with exclusive access to interoperable, layout-specific workflows, new cloud-based factory asset resources and powerful visualisation and analysis tools that help increase design accuracy, efficiency and communication.

Autodesk Australia Contact info and more items like this at wf.net.au/N465

FLOW SWITCH/MONITOR FOR PROCESS SAMPLING SYSTEMS The Model FS10A flow switch/monitor from Fluid Components International (FCI) has

IS 8 SERIES

received ATEX and IECEx approvals, mak-

PORTABLE DIGITAL PYROMETERS FOR ROUGH INDUSTRIAL APPLICATIONS BETWEEN 250-2500°C

ing it suitable for continuous flow verification applications supporting process analyser sampling systems operating in hazardous plant areas.

■ Focusable precision optics with small measurement spots for operation at a safe working distance.

The FS10A’s ATEX and IECEx approvals are as follows: II 3 G Ex nA IIC T4 Gc, II 3 D Ex tc IIIC T T81°C Dc, IP64; Ex nA

■ View finder and 2x external temp displays.

and Ex t, Ex nA IIC T4 Gc, II 3 D Ex tc

■ Multifunctional numeric or graphical display.

IEC, agency approvals also include FM and FMc:

■ Integral data logger with variable storage interval date stamping of readings with USB interface.

Groups E, F, G; Class III T4@Ta=71°C Type 4X. It also features the CE Mark.

■ Robust die-cast aluminium housing.

Carry case, software, USB cable, traceable calibration certificate included, together with 2 year warranty, surprisingly affordable pricing and quick delivery

IIIC T81°C Dc. In addition to ATEX and Nonincendive, Class I, Division 2 Groups A, B, C, D; Class II, Division 2 Small and lightweight, the instrument features a relay alarm trip point, an analog output and an RS232 interface. It is suitable for continuous monitoring of analyser sample flows to provide process analysis without interruption. The instrument’s wetted parts are corrosion-resistant 316L stainless steel with Hastelloy-C22 sensor tips.

Depending on the tube size, the analyser flow switch operates over a wide flow range in air or gas; from 10 cc/min to 100,000 cc/ min, and in water and liquids from 0.70 cc/min to 750.00 cc/min.

It accommodates wide turndowns with a ratio up to 100:1.

The electronics can be integral mounted with the sensor element in a uni-body configuration or remotely mounted for easy front panel display viewing. The instrument features a top-mounted, ten LED array and two pressure-sensitive button touch controls.

AMS Instrumentation & Calibration Pty Ltd Contact info and more items like this at wf.net.au/M990

36 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2012

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NEW PRODUCTS

EMBEDDED BOX PC A palm-size fanless embedded box computer featuring a compact, low-power design is claimed to provide power efficient performance. Using HDD, CompactFlash or SSD storage, the ARK-1120 is suitable for a wide range of embedded uses.

It includes an array of interfaces including serial, USB and gigabit ethernet plus VGA and audio line-in/line-out for space- and power-conscious multimedia.

A mini-PCIe socket also allows for add-on expansion such as wireless LAN. Being Intel based, it supports all the Microsoft Embedded and desktop operat-

WIRELESS INSTRUMENTATION RANGE

ing systems plus support for Linux and QNX. The companyâ&#x20AC;&#x2122;s SUSIAccess provides remote management including monitoring system status, remote control and remote recovery.

The Accutech range of wireless in-

Advantech Australia Pty Ltd

strumentation products is designed

Contact info and more items like this at wf.net.au/N435

to provide cost-effective and easyto-install alternatives to traditional, hard-wired sensors. The products come with push-button configuration, power, radio and sensor in one unit and are suited to harsh environments.

The products have a secure and high-performance, licencefree radio, with a range of up to 1000 m, and built-in batteries that last up to 10 years. The rugged units are designed for the majority of industrial applications, with installations ranging from the plant floor, to remote installations with extreme temperature and humidity ranges. Up to 256 Accutech base radios can coexist and each base radio can support 100 field instruments with up to 1 s sampling on all instruments. The products come with NEMA4 and explosion-proof packaging options and are certified CSA Class 1, Div 1 and ATEX/IECex (-ai and -d). For environments where there are considerable obstructions and ultralong reach is required, high-gain antennas are available.

Typical applications include wellhead monitoring, gas pipeline leak

RYCO hydraulic hose and fittings are designed and manufactured to meet and exceed relevant industry standards. RYCO manufactures hydraulic hose that is dimensionally consistent and matched with RYCO fittings, resulting in increased safety and performance.

A requirement of MDG 41 states that a Hose Assembly (hose with couplings attached) must be fit for purpose and that hose and couplings must be MATCHED. A hose assembly that is made of hose and couplings from different manufacturers is NOT MATCHED unless it has been fully tested and certified. RYCO offers a MATCHED system, with all products clearly branded with a unique RYCO part number and batch code, where practical.

detection with acoustic monitors, tank level measurement, environ-

Individual part number Batch numbered RYCO branded Matched to hose Series code grooves

mental monitoring, pressure measurement, securing remote sites with discreet input switches and delivering 4-20 mA signals from third-party instruments.

Schneider Electric (Australia) Pty Ltd Contact info and more items like this at wf.net.au/N356

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MELBOURNE

+61 3 9680 8000

ADELAIDE

+61 8 8237 0547

SINGLETON

+61 2 6572 3967

SYDNEY

+61 2 9765 2500

NEWCASTLE

+61 2 4014 7000

PORT HEDLAND

+61 8 9140 0000

BRISBANE

+61 7 3866 8888

MACKAY

+61 7 4968 2300

GUNNEDAH

+61 2 6742 0089

PERTH

+61 8 9360 3800

KALGOORLIE

+61 8 9093 9800

NEW ZEALAND

+64 9 573 2680

MAY 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 37

Driving desalination in WA It is a fact that we need fresh water to survive, but two-thirds of our planet is covered with salt water so an obvious solution seems to be to remove the salt from the water that is readily available to make drinking water. Most states in Australia have recognised the importance of purifying seawater using reverse osmosis technology and have desalination plants either operating or under construction in an effort to drought-proof our nation.

The first stage of WA’s latest desalination plant was officially opened in September 2011, three months ahead of schedule and within the $955 million budget, ensuring an ongoing climate independent water source for West Australians. This new plant, the second for the west coast, is located between Binningup and Myalup south of Perth and the desalinated water will be fed into the existing Integrated Water Supply Scheme (IWSS). The IWSS pumps fresh water into Perth’s metropolitan dams that supply residents with high-quality drinking water, converting 50 billion litres of water annually.

T h i s , co m b i n e d w i t h t h e ex i s t i n g desalination plant based in Kwinana, ensures that more than 30% of Western Australia’s water supply will come from climate independent sources.

To achieve the optimum operating efficiencies, the Southern Seawater Alliance (SSWA) awarded ABB the contract to supply nine identical 800 kW 3.3 kV drives to power and control the main reverse osmosis (RO) and seawater intake pumps for the desalination plant following a competitive tender process.

SSWA was mindful of the ongoing environmental impact of a desalination plant on the local area and hence, all aspects of engineering design on the project required the highest possible energy-efficiency performance. This exacting standard also ensures the site will continue to have the lowest possible environmental impact into the future.

In order to prove the high levels of energy efficiency offered by ABB, the motors and ACS 1000i variable speed drives were thoroughly tested and achieved results which not only met but exceeded the customer’s rigorous energy-efficiency expectations.

John Kutniewski, medium voltage drives specialist for ABB in Australia, said, “In our initial tender, we quoted an efficiency of 96.1% at maximum operating speed and the results of the testing carried out at our drives factory in Turgi, Switzerland, revealed the efficiency was 96.4%.

“The ACS 1000i model is a fully integrated standard drive which includes an 11 kV input transformer and this combination is an unbeatable solution for pumping stations in the water industry. By employing our drives on the pumps instead of throttling, SSWA’s energy bill can be reduced by as much as 60% for the RO and seawater intake pumping applications.”

John continued, “In addition to being efficient, the drives include key interlocking to prevent opening of the inverter power

38 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2012

sections while the drive is energised.

ARC-Guard and output isolators were also included to address site operation and maintenance requirements without increasing floor space.”

The desalination plant has also ordered five ABB 750 kW motors to operate in conjunction with the ACS 1000i drives and the pumps manufactured by FlowServe which will be operating on site. ABB has been working with FlowServe to test its drives and motors to ensure they will achieve maximum efficiency with the customer’s chosen pump supplier.

Additional to the drive systems provided on this project, ABB has also supplied low-voltage switchboards, motor control centres, power factor correction equipment and transformers. Al l products have been designed with the aim of delivering reliability, lower operating costs and minimising life cycle costs.

ABB Australia Pty Ltd Contact info and more items like this at wf.net.au/N458

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NEW PRODUCTS

EXPLOSION-PROOF LINEAR POSITION TRANSDUCER Balluff’s Micropulse TA12 explosion-proof linear position transducer now has IECEx hazardous area approval rating, in addition to existing ATEX and North American approvals, expanding the acceptability for the Balluff TA12 transducer for worldwide use in applications where hazardous gases and/or dusts are present.

The Micropulse TA12 is a non-contact magnetostrictive linear position sensor with a compact, explosion-proof housing. It is specifically designed for continuous feedback on hydraulically and pneumatically actuated valves for oil and gas refining, storage, transport and handling.

Non-contact, wear-free magnetostrictive technology ensures long life and MTBF for maximum production uptime. If the unit does require service, the TA12 incorporates its electronics and sensing hardware in a Rapid Replacement Module (RRM) that allows fast field repairs by the customer. With the RRM, there is no need to break the hydraulic seal. This eliminates fluid spillage and the need to bleed air from the hydraulic system after repair. The Balluff Rapid Replacement Module allows a user to get production up and running quickly in the event that repair is necessary.

The Micropulse TA12 offers a wide array of control signal interface options, including analog voltage and current, start/ stop pulse digital, synchronous serial digital, digital quadrature, and digital fieldbuses such as Profibus and CANbus.

Balluff-Leuze Pty Ltd Contact info and more items like this at wf.net.au/N165

Compact HMI panels with revolutionary Ø22mm mounting system Magelis STU mounts in seconds and provides crystal clear, high resolution visibility Thanks to a revolutionary Ø22mm pushbutton

style mounting system, Magelis STU 3.5” and 5.7” touch screens are easy to install and packed with innovative features such as:

Discover more

>

a removable, high resolution, TFT 65K colour screen backlit by LED

>

versatile communications via integrated serial and Ethernet ports

>

application downloads using a simple USB memory stick.

Ø22mm mounting system

Magelis compact touch panels

View the Magelis STU online video and download a copy of the selection guide today!

Simply visit www.SEReply.com and enter key code 52511K www.schneider-electric.com.au | Call 1300 369 233 © 2012 Schneider Electric. All Rights Reserved. CLIPCOM24493

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MAY 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 39

NEW PRODUCTS

DEVICENET ANALYSER Balluff’s DeviceNet Analyzer is designed for analysing, commissioning, monitoring and maintaining DeviceNet and CANbus installations. Maintenance technicians, integrators, technical experts or anyone who requires reliable information on the functional status of their DeviceNet system can use the DeviceNet Analyzer to increase the overall efficiency of their facility.

Balluff’s DeviceNet Analyzer can analyse signal square wave quality, monitor overall network health by node, detect the location of cable breaks and short circuits, and locate weak points such as incorrect cable types and lengths and faulty plug connections. Assisting with making sure the network is healthy during start-up and set-up, it also allows for the health of the network to be documented when the equipment is turned over to the end customer.

The DeviceNet Analyzer can also help with the day-to-day maintenance of DeviceNet installations in multiple ways. It can help identify trouble nodes on the network and, used over time, it can see trends in network health. The device can also be used to check the quality of cables (or field wireable connections), and during downtime troubleshooting, the analyser can help root out the zone where the trouble is occurring.

Balluff-Leuze Pty Ltd Contact info and more items like this at wf.net.au/N163

STAINLESS STEEL PANEL PC The IPPC-8151S is a fanless industrial panel PC with a 15″ XGA TFT LCD, an Intel Celeron-M 1 GHz CPU and a chemicalresistant touch screen using a special tapered and food-safe rubber seal between the bezel and the touch screen, and can come with an optional fully sealed 316L stainless steel enclosure, allowing it to satisfy the stringent standards required in food processing, clinical, chemical or pharmaceutical applications.

When modified with the fully sealed enclosure, it is completely protected against water damage, achieving a NEMA4 (IP66) grade of protection.

Stainless steel chassis are a great fit for many industrial applications due to their ability to minimise contamination and maintain strict hygienic requirements. 316L stainless steel is more resistant to corrosion than 304 and IP66 protection provides waterproof protection, making it easy to clean or disinfect even with high-pressure water. Moreover, the dust­proof capabilities make it suitable for applications in hazardous environments.

The IPPC-8151S is equipped with a bright, sharp LCD. The embedded Intel Celeron M 1 GHz CPU with 1 MB L2 cache and 1G B DDR2 memory satisfy most application computing needs. The fanless design extends operation life, with enhanced antishock and antivibration properties suitable for harsh environments. With a CompactFlash slot, one PCI expansion and one SATA HDD, the IPPC-8151S provides flexibility and meets high-capacity demands.

Advantech Australia Pty Ltd Contact info and more items like this at wf.net.au/N333

40 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2012

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NEW PRODUCTS

MODULAR INDUSTRIAL PATCH PANEL The Belden MIPP is a modular industrial patch panel that is able to combine copper and fibre management in one solution.

Using patchcords to connect to active equipment, cables can be terminated outside the cabinet in an organised and structured manner to ensure the highest level of reliability. With a lightweight aluminium structure, the MIPP can easily be mounted on a DIN rail, or fixed at the sides of the cabinets using a wall-mount plate. Due to its small housing, high port density and modularity, cabinet space is kept to a minimum.

The MIPP is suitable for use in a wide range of industrial applications requiring maximum system reliability and flexibility. The industrial design makes it suitable for use in machine building, transportation, alternative power generation, power transportation and distribution, and oil and gas markets, as well as more general use in enterprise, buildings and other applications.

Up to six modules can be combined in any permutation to create a large single patch panel, to which both fibre and copper cables can be connected at the same time. When required, each module can be easily removed or replaced.

The MIPP is available as both single and double modules. Single modules provide either six SC duplex adapters (up to 12 fibre connections), six LC duplex adapters (up to 12 fibre connections) or four RJ45 keystone jacks. Double modules provide either 12 SC duplex adapters (up to 24 fibre connections) or 12 LC duplex adapters (up to 24 fibre connections).

Belden Australia Pty Ltd Contact info and more items like this at wf.net.au/P307

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MAY 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 41

TO ERR IS HUMAN USING TECHNOLOGY TO TRY TO SOLVE THIS PROBLEM IS EQUALLY HUMAN Humans are wonderful, complex beings. That our very name, homo sapiens, can be translated to wise man, is an indication of our intelligence. We have the ability and capacity to do so much and, along with our advanced language capability, we can reason, problem-solve, introspect and quickly adapt to current conditions around us. But we are not infallible.

S

cientists and engineers have, for decades, been trying to mimic the capability of a human being, developing machines, robots and computers that can take on tasks to make our lives better. Huge advances have been made in areas of computer science such as artificial intelligence but we still need people to operate and oversee the systems that run production processes in all market areas.

As humans, however, we are not infallible. We are prone to making mistakes. Phrases such as “to err is human” and “nobody’s perfect” are commonplace in our lives. The likelihood of us making the wrong choice, however, varies depending on the conditions around us. Fatigue, illness, environment and even our diet can vary our performance levels. However, the biggest influencers are possibly extreme stress or pressure. These have been proven to be a major factor and will dramatically increase the chances of us making a mistake. Now here lies the problem: we rely on system operators to oversee process systems and we particularly

42 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2012

need them when something goes wrong. We need them to make the right choices quickly to minimise the impact of a looming situation. It is, however, exactly at this time that they are under the greatest stress. If a control system starts to throw out hundreds of alarms and warnings in quick succession, this can overwhelm or even panic an operator. Hesitation and self-doubt can take hold and it is at these very times we need the operator to make the right decision quickly.

In 2003, ConocoPhillips Marine conducted a study of the initial behaviours that are the root causes of incidents or accidents.

It showed that for every 300,000 ‘at-risk’ behaviours there are 3000 near misses, 300 recordable injuries, 30 lost workdays and, ultimately, one fatality. In a control room scenario, if we can maximise the ability of the operator to make the correct decision when called upon, we can maximise human reliability with the aim of reducing the number of at-risk behaviours and ultimately the number of major incidents or fatalities.

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© iStockphoto.com/ Павел Игнатов

Alarm management

and clearer, critical information to hand, the operator stands a much better chance of making the right decision.

Reducing alarm noise by aggregating alarms - whether it is the chatter of alarms switching on and off as the process is near to a threshold or stale alarms that are continually present - reduces the alarm volume and helps the operator a great deal. The information presented to the operator is, however, also important. Imagine the difference between receiving the following: • a high pressure alarm in a vessel.

• information about what has caused the high pressure, what the consequences of this pressure are, the impact of the operator’s reaction time on the severity of the situation and what is needed to be done to respond.

In the second scenario, the operator not only receives much more information regarding what is wrong but detail about what they need to do. This is not to say that the operator wouldn’t know what to do but it does reduce the pressure on them and increase human reliability. In many large industrial accidents the operator has known what to do but was not sure whether action should be taken.

A passive endorsement ensures the operator has tacit approval to take action ie, “You need to shut the unit down”.

Alarms should occur when an operator needs to take action. PAS, a company that provides services and software to improve human reliability, when reviewing alarm strategies in plant systems has typically seen as few as 10 ‘chattering’ points in the system causing 60% of the alarms. Working with key plant personnel, it is therefore necessary to review and consolidate alarms with the aim of reducing the chances of human error which could contribute to reduced productivity, equipment damage or a major incident.

Controlling changes

Alarms - can you see the forest for the trees?

Alarms are a key feature of a modern plant control system. They can be generated at multiple levels from multiple pieces of instrumentation and even across multiple systems. Unlike the hardwired gauges and alarms of yesteryear, today’s technologies make it easy to create alarms and, often, many are set that are not really needed. Take an example of an alarm configured to trigger when a pump is off. If this pump is a spare pump, this alarm just becomes an extra ‘noise’ to the operator, reducing their ability to observe the important details.

When an operator is sitting in front of a HMI and a plant upset occurs, there is often a flood of alarms in quick succession. This overwhelms the operator’s capability to respond and they may well start to just acknowledge alarms and, with the volume of data presented, miss the critical information they need to make the right decision.

It is not a big step, therefore, to realise that reducing the number of alarms reduces the stress on an operator and the unnecessary distraction of data that does not require action. With reduced stress

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A plant will typically have multiple automation systems. The installation of these may have been over a period of time as the plant grew and developed. Interactions between alarms and various equipment are not always obvious, and a change to an alarm, on face value, may seem a straightforward decision. But unseen consequences of this change may not be realised until it is too late.

Here, technology can really help. Intelligent software that consolidates and supervises all of the alarm systems in a process plant, such as Plant State Suite from PAS, can read in alarm settings and check for any changes - whether in threshold value or operator’s inhibiting alarms. Such software can audit against the values that should be present and produce a report showing differences from the documented settings. All operators and managers can then quickly and easily see the current state of the system, and reports showing the current status are part of a formal handover between shifts. Such software helps to highlight changes where alarms may have been inhibited for maintenance and not returned to their correct state; which would otherwise effectively remove a layer of protection for the plant. It can also enforce an alarm strategy by writing the master settings back into the system and provide a documented sign-off process for any changes.

MAY 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 43

Alarm management

WE RELY ON SYSTEM OPERATORS TO OVERSEE PROCESS SYSTEMS AND WE PARTICULARLY NEED THEM WHEN SOMETHING GOES WRONG. WE NEED THEM TO MAKE THE RIGHT CHOICES QUICKLY TO MINIMISE THE IMPACT OF A LOOMING SITUATION. IT IS, HOWEVER, EXACTLY AT THIS TIME THAT THEY ARE UNDER

© iStockphoto.com/ DenGuy

THE GREATEST STRESS.

Figure 1: Example of an alarm boundary heirarchy.

Being careful not to peel off layers of protection Just like the broader safety assessment, the alarm strategy employs layers of protection. You may, for example, have a high-temperature warning alarm indicating a process has moved away from its optimal conditions; a further alarm indicating the temperature has moved outside the normal operating limits; an alarm above this to indicate the temperature is moving outside of the safe operating limits, after which the safety instrumented system (SIS) would typically trip, and a final alarm should the plant not trip, to indicate temperature is above the design limits of the system. These ‘onion’ type layers are designed to protect equipment and personnel. In many applications, these levels, or boundaries, may change. For example, reaction vessels with catalysts that activate under certain conditions can make the response dynamic and the alarm limits or trip settings will then need to be adjusted accordingly. In areas such as offshore oil platforms, trip settings will vary dependent on the production rate.

Whether a process is static or dynamic in its alarm requirements, comprehensive boundary information for all of the different pieces of equipment may not be readily available to operators through the alarm system in front of them. Also, the impact of a change to boundary settings may not always be clear, with multiple pieces of equipment affected.

Technology can again provide a framework to consolidate multiple sources of information and provide additional checks to ensure process boundaries are where they need to be.

Ideally, alarm management software should aggregate all of the alarm settings and other operational boundary information and present it to the operator in the context of a boundary hierarchy - exposing vulnerable areas and providing the operator with the information they need to prevent the system tripping and to keep productivity optimal. By supervising alarms across the plant, it should be possible to automatically detect and report any deviations to this boundary hierarchy, such as an alarm setting that is set higher than a safety trip point. This provides additional assurance to keep

44 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2012

configuration parameters such as alarm limits and instrument ranges within the safe operating boundaries of the plant.

Action can only be taken if the operator knows it is needed How information is presented also has a big impact on human reliability. A high-performance HMI (HPHMI) uses the best practice in design for a control interface. Poorly designed HMI graphics have been shown to degrade safety, quality and process efficiency. A HPHMI gives an operator a much higher chance of dealing with a process that is moving outside of its optimal limits with clear and direct display of critical information. Research conducted for the ASM Consortium’s Nova Study in the early 1990s showed that it can give an operator a fivefold increase in the ability to deal with an abnormal situation before an alarm occurs. Furthermore, it can lead to over 35% increase in making the right choice in handling an abnormal situation and over 40% reduction in the time taken to complete the necessary tasks.

Avoid the incident Safety and productivity are vital factors in business. Plant control systems today have often evolved over time with multiple vendors’ systems installed at different stages of the plant life cycle. Most of the time the expertise of operators keeps processes running smoothly. When there is the possibility of a major incident, however, they are under the most pressure and mistakes are more prevalent.

Using technology in the form of software solutions that give better alarm and boundary information, and better data presentation, will greatly increase the chances of timely action to prevent safety trips, avert major incidents and keep productivity high. To err is human but it is also human to try to solve this problem. The goal is just that: to improve human reliability and improve safety, compliance and profitability.

PAS, Inc. www.pas.com

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NEW PRODUCTS

OPTICAL TACHOMETER RheinTacho has released the EchoTach handheld, non-contact optical tachometer for checking rotational speeds quickly and accurately.

It features a measuring range of 1-60,000 rpm, is lightweight and pocketsized. The red LED light beam is reflected by a reflection mark fixed on the equipment to be measured. The result can be read from up to 450 mm distance and at a very wide angle. The device is resistant to extraneous light due to the use of a bright LED and matching optical system.

The large LCD makes the measurement easy to read. The last measurement is stored for 30 seconds, giving plenty of time

INDUCTIVE PROXIMITY SENSORS

to note the rpm results. The EchoTach then shuts down, conserving batteries. The EchoTech is durable, features a two year warranty, has a total weight of 147 g (including batteries)

Balluff has expanded its Factor

and is comfortable to carry in hand or pocket.

1 series of inductive proxim-

SI Instruments

ity sensors to now include a weld-immune Factor 1+ version

Contact info and more items like this at wf.net.au/N463

with longer sensing distances.

Factor 1+ sensors incorporate a multicoil design that enables them to sense all metals - both ferrous and nonferrous - at the same distance without the need to de-rate the sensing distance based on target material. These sensors are suitable for use in applications where sensors encounter high levels of magnetic interference from sources such as transformers, motors, drives or welders.

Factor 1+ sensors offer greater switching distances for increased performance, and greater reliability with vibrating objects. The housing and sensor identification are optimised to meet the requirements of the automobile industry and are designed with welding applications specifically in mind.

The PTFE coating helps protect the sensor from weld slag and weld flash generated during the welding process. Beyond their enhanced application flexibility, Balluff Factor 1+ sensors also provide the opportunity to standardise on a smaller number of sensor designs, which can lower supply chain and tool crib stocking costs, especially for welding operations.

Balluff-Leuze Pty Ltd Contact info and more items like this at wf.net.au/N166

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MAY 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 45

NEW PRODUCTS

MARKLESS SENSOR The ML20 markless sensor from Sick is designed to be used like a print mark sensor but does not require any optical marking on the package, instead detecting a taught-in design pattern.

It therefore features more flexibility and more design freedom when planning packaging and needs less set-up time when it comes to changing labels and formats, avoiding unnecessary use of materials.

The ML20, which can be used for controlling cutting edges, for example, employs a method for contrast pattern detection that involves teaching in a pattern sequence to the sensor. The pattern

SCADA CONTROLLERS

is detected during processing, at a

Schneider Electric SCADAPack controllers combine the

scanning speed of up to 7 m/s, result-

monitoring and communications capabilities of RTUs with

ing in a switching signal. Even in the

the processing and data-logging capabilities of PLCs,

case of complex designs, tolerances

providing automatic supervision and autonomous control

in the track course of the continuous

wherever needed.

material and high machine speeds,

SCADAPack controllers are designed for installations

the ML20 delivers reproducibility of

ranging from the plant floor, to remote environments with

up to 0.6 mm and precise and stable

extreme temperatures and humidity. The controllers integrate

detection of nearly any pattern.

with most third-party field and networking equipment, and

When changing label or film rolls,

operate under low or restricted power conditions.

the sensor avoids unnecessary cutting

Particularly relevant for the oil and gas sector, SCADA-

loss and waste, since pattern detection is

Pack provides a digital oil field solution with electronic flow

active immediately - the material can be used very soon

measurement that is able to be integrated with Smart RTU

after the beginning of the roll. Moreover, in the case of various

multivariable sensor and gas flow computer algorithms

packaging procedures, such as when labelling bottles, it is

and configuration GUIs for Class 1, Division 1 hazardous

possible to save additional material that used to be dedicated

areas. With the Realflo gas flow measurement software,

exclusively to the mark.

SCADAPack Smart RTUs can become a fully functional

Sick Pty Ltd

gas flow computer with up to 10 gas flow runs available

Contact info and more items like this at wf.net.au/M858

on selected models. EFM functionality works concurrently with the Smart RTUâ&#x20AC;&#x2122;s logic code for maximum flexibility.

SCADAPack Smart RTUs also have integrated tools to ensure that remote communication links are not compromised by malicious intent or interference from other communication networks.

Key characteristics of SCADAPack 100, 300, 32 and 4203 series controllers include enhanced security through IEEE1711 (AGA12) encryption and IEC62351 (DNP3) to help mitigate the effects of interference with data monitoring and control commands; optional DFI support; programming and configuration by TelePACE Studio; and pre-built oil and gas focused applications such as Realflo and Production Plus Well Optimisation.

Schneider Electric (Australia) Pty Ltd Contact info and more items like this at wf.net.au/N357

46 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2012

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NEW PRODUCTS

LIQUID COOLING PACKAGE Water cooling, which is already established in IT applications, is increasingly seen as important by mechanical engineers and plant engineers. Rittal’s LCP (Liquid Cooling Package) technology already established in server enclosures is now also available with an output of 10 kW - optionally scalable up to 20 kW - for industrial applications in mechanical and plant engineering. There is complete separation of the water circuit and electronic components in the enclosure.

In contrast to the IT variant, in which the 19″ level is cooled laterally at a constant 22°C, air routing in the industrial LCP is adapted to the requirements of enclosure climate control. Since the cold air has to be routed to the bottom of the enclosure, right in front of the mounting plate, the warm air is taken in from the top and blown out cold at the bottom. In the enclosure, a typical control temperature of 35°C must be maintained. Two high-power blowers provide for good air circulation. Both air intake as well as cold air exit is possible on both sides.

The bayable air/water heat exchanger can be flexibly mounted in the middle between two enclosures or at the outer end of an enclosure suite. The option of mounting the water connection above or below and the variable air routing provide room for individual adaptations. Making the essential components easily accessible facilitates replacement when service is needed.

Rittal Pty Ltd Contact info and more items like this at wf.net.au/N358

Allen-Bradley High-Power PowerFlex 755 AC Drives Provide Expanded Application Flexibility The PowerFlex 755 AC Drives now offer an extended power range (0.75kW...900kW at 400/480 VAC and 200kW...530kW at 600/690VAC) providing increased flexibility, ease of use, and high performance in a single product family.

Visit: www.RockwellAutomation.com.au

PF755_WNIPT-Half-Page_April-2012.indd 1

www.ProcessOnline.com.au

10-Apr-12 2:57:38 PM

MAY 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 47

NEW

PROFIBUS DRIVE MODULE

PRODUCTS

The PowerFlex 750-Series Profibus DPV1 module enables users to integrate the Allen-Bradley PowerFlex 750-Series AC drives with Profibus networks through a standard D89 connector. The optional module mounts inside the PowerFlex 753 and 755 AC drives to save panel space and offers V1 services beyond the standard V0 services. Various tools can be used to flash upgrade and configure the module and connected drive(s) including the Enhanced PowerFlex 7-Class HIM or drive configuration software such as DriveExplorer and DriveExecutive.

The module supports I/O Messaging, which is

BULK BAG CONDITIONER The Block-Buster bulk bag conditioner, with two hydraulic rams and specially contoured end plates, presses opposing sides of bulk bags, loosening material that has solidified during storage and shipment, enabling bulk bag unloaders to discharge it through bag spouts.

A cantilevered I-beam with motorised hoist and trolley allows loading

used to transfer time-critical information, including data that controls the drive. The module can send and receive logic command/reference, logic status/ feedback and datalinks and read and write up to 32 parameters simultaneously. It also supports Explicit Messaging for non-time-critical information that is typically triggered by the application (such as a ladder program in the controller). The module supports reading/writing of drive parameters, reading the drive fault queue and reading/writing of option or other peripheral parameters.

and unloading of bulk bags without the use of a forklift. The bag can also be raised and lowered using the hoist and rotated manually, for conditioning at any height on all sides.

The system controller and hydraulic pump can be mounted on the exterior of the safety cage or remotely. The conditioner is fully enclosed on all four sides for operator safety and includes full-height doors that are interlocked to disallow operation of the system when the doors are open.

The conditioner is recommended for bulk bags containing hygroscopic chemicals, certain spice blends, heat-sensitive products and other materials prone to solidifying to the point at which pneumatically actuated flow-promotion accessories integral to bulk bag dischargers are inefficient or completely ineffective.

An optional hydraulically actuated, variable-height turntable allows automated in-frame bag rotation and conditioning of bulk bags at varying heights. The number and pressure of hydraulic ram actuations, the height of the turntable, and the number of 90째 rotations are user-programmable.

The module has a binary-coded decimal switch for setting the node address (01-126). Alternatively, the switch can be disabled (00 - all off), allowing the node address to be set using a configuration parameter. There is a dedicated switch setting that allows for byte swapping on the network, depending on the controller selected to communicate with the module. A Network Operating Mode jumper allows users to set the operating mode of the module

Flexicon Corporation (Australia) Pty Limited

from either standard Profibus or ProfiDrive, providing

Contact info and more items like this at wf.net.au/M495

network flexibility and convenience.

Rockwell Automation Australia Contact info and more items like this at wf.net.au/N466

48 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2012

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

A BRIEF LOOK AT SYSTEMS - MORE WAYS TO SAVE ENERGY AND COSTS?

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 wnipt@westwick-farrow.com.au Chief Editor

W

ith the introduction of the carbon tax and rising electricity prices, it is important for Australian industry to reduce energy consumption wherever possible. Electric motor driven equipment accounts for almost 65% of electricity consumed in the manufacturing sector, meaning improving the efficiency of motor and drive systems is a major consideration for cost cutting.

The use of energy-efficient motors plays a central role in increasing the efficiency of automation systems and has thus developed into an elementary component in re-engineering processes for existing systems, as well as for completely new designs. Political activity is also leading in this direction, in particular with the new international efficiency standards IEC60034-30 now available. This standard gives the use of energy-efficient motors (IE1: Standard Efficiency, IE2: High Efficiency, IE3: Premium Efficiency, IE4: Super Premium Efficiency) a binding character.

Replacing old motors with High Efficiency motors (IE2) improves energy efficiency in a plant by about 5%, but will depend on the motor duty and application.

While Australian companies can certainly save energy and money by replacing a motor with a premium efficiency model, more savings are available by looking at the entire drive system from motor control and integration, right through to the physical drive mechanism and driven load.

For example, in systems comprising geared motors, worm gear reducers are one common option seen on many systems. The worm gear reducers typically have an efficiency range of 50% to 90%, depending on configuration, gear ratio and lubrication type. Coupling a premium efficient motor to such a gear unit will give a marginal efficiency increase - but does it really make sense to look only at the motor and not at what it is driving?

In contrast, helical-bevel gear reducers have a typical efficiency of 95%. Replacing not only the motor, but also the low-efficiency worm gear unit with a significantly higher efficiency gear unit and motor combination will potentially provide efficiency gains an order of magnitude larger than just slapping a high-efficiency motor onto a low-efficiency gear unit. And there can

Janette Woodhouse

be further efficiency gains by optimising the actual driven load.

The way energy-efficient motors and gear systems reduce energy consumption is by reducing losses. In many applications it is possible to reduce power losses still further by using a system of distributed mechatronic drive systems that combine a premium efficiency motor, gear unit and electronics into one optimised unit.

With optimised interfaces between the components that minimise mechanical and electrical losses, energy efficiency can be increased by a further 10-25% over conventional drive systems.

This type of system, while suitable for many industries, is perfect for a horizontal materials handling application such as conveyor lines, in which multiple drive systems distributed along the conveyor work together in a networked system. With the use of such mechatronic drive systems, the built-in inverter has an overload capacity that can handle start-up torque of 3-4 times the continuous torque requirement, meaning that the entire motor/drive combined system can be downsized and specified for the continuous requirement, operating the motors closer to their optimal point and reducing the power required to drive the system.

Depending on the application using one or a combination of the above steps, and taking a systems efficiency approach, will help to reduce a companyâ&#x20AC;&#x2122;s plant energy consumption, resulting in significant savings to their business.

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

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

Sept 2011 total CAB audited circulation (Aust + NZ) 7,451 readers (92% personally requested)

For over 20 years, Frank Cerra, Engineering Manager at SEW-Eurodrive Australia, has been working with motor and drive technology.

His expertise and knowledge in his field, particularly in the area of energy efficiency, is now more integral than ever. Cerra has a Masters in Electrical Engineering, and is Chair of the AI Group Rotating Machines Forum.

50 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2012

Contact the editor

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

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

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

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