automation - literature library

AutomationAutomationOctober 2012

TODAY ASIA PACIFICAustralia & New Zealand

When Does Migrating to a

NeW DCSMake Sense?See page 6

InsideManaging Plant-Wide Operations

Keeping Information – and Water – Flowing

Monitor Emissions with a Software Solution

Reduce Oil Extraction Costs

EDITORIAL

Scott Summerville

CONTENTSEDITORIAL

Automation Today is published byROCKWELL AUTOMATION SOUTEAST ASIA PTE LTD

2 Corporation Road, #06-01 Corporation Place, Singapore 618494Tel: (65) 6622 5188 • Fax: (65) 6622 5100

Editor: Steven Goh – [email protected]

ROCKWELL AUTOMATION AUSTRALIA LTDTel: +61 3 9757 1111 • Fax: +61 3 9729 1418

Contact: [email protected]

Copyright© 2012 Rockwell Automation Inc. All rights reserved. The contents of this publication may not be reproduced in whole or part without the consent of the copyright owner. Allen-Bradley, CENTERLINE, CompactLogix,

ControlLogix, Encompass, FactoryTalk, Installed Base Evaluation, Integrated Architecture, InteliCENTER, Kinetix, Micro800, MicroLogix, MP-Series, PanelView, PlantPAx, PLC, PowerFlex, PowerMonitor, Rockwell Automation,

RSLogix, Stratix, TL-Series and Ultra are trademarks or registered trademarks of Rockwell Automation, Inc.

Driving Plant-Wide Optimization

A s technology continues to spark innovations, companies must take steps to remain competitive.

They must maximize their operations’ productivity, speed time to market, reduce cost of implementation and minimize lifecycle costs. In addition, companies must meet regulatory compliance and support sustainability.

While such steps can seem daunting, the PlantPAx™ process automation system from Rockwell Automation®, more than a distributed control system (DCS), provides the technology to help you achieve a competitive advantage. Whether you want to migrate from an existing but no longer supported DCS, or gain the benefits of a single plant-wide platform for the first time, PlantPAx helps you achieve higher levels of business performance.

PlantPAX combines the plant-wide control technologies and scalability of the Rockwell Automation Integrated Architecture™ with the core capabilities expected in a world-class DCS. Based on open communication standards and leveraging EtherNet/IP™ as its backbone, PlantPAx makes real-time information available throughout the organization for better business decision-making.

In this issue of Automation Today Asia Pacific, you will learn when it makes sense to migrate to a new DCS. By using a metric known as the “total cost of ownership,” companies can calculate the financial justification of moving from an existing DCS to a new one.

You will also discover that Rockwell Automation has extended the reach of PlantPAx to integrate motor control centers and critical rotating assets such as compressors, pumps, turbines and fans. You can now tie intelligent motor devices into this unified control architecture, making a measurable impact on asset availability, operational efficiency and energy management. The tight integration between process automation and motor control is beneficial in resource-driven industrial applications such as metals, mining, cement, power, oil and gas, water/wastewater, and pulp and paper applications.

This issue also includes information on continuous emissions monitoring (CEM) solutions used to meet emissions monitoring requirements of regulatory agencies and trading programs. Traditional approaches to emissions management often involve hardware-based systems. Rockwell Automation offers an alternative in our Software CEM® solution, which is based on the Pavilion8® model analytic engine and the patented sensor validation system. Software CEM enables you to minimize costs in environmental compliance monitoring while helping to achieve your sustainable production objectives.

Rockwell Automation core process automation capabilities – and those of our collaborators and acquisitions – deliver an integrated control and information solution. We invite you to contact Rockwell Automation to learn more about how we can help you drive optimization throughout your plants.

Bob Ruff

Bob Ruff, PresidentRockwell Automation, Asia Pacific Region

2 October 2012 AUTOMATION TODAY ASIA PACIFIC

Features

3 News & Events Rockwell Automation® developments from around the world.

4 Country News News and events from around Australia & New Zealand.

6 Cover Story – When Does Migrating to a New DCS Make Sense? Use a metric known as the total cost of ownership (TCO) to calculate the financial justification of migrating from an existing distributed control system (DCS) to a new one.

8 Feature Story – Managing Plant-Wide Operations with a Single Platform The Rockwell Automation PlantPAx™ process automation system integrates motor control centres and critical rotating assets.

10 Application Story A scalable, integrated process automation system from Rockwell

Automation optimises operation of water desalination equipment.

12 Technology Watch Companies can minimise costs in environmental compliance

monitoring by using a software-based continuous emissions monitoring (CEM) solution.

14 Value Proposition Migrating from a decentralised control system to the Rockwell

Automation PlantPAx process automation system boosts production and optimises quality control.

15 Process Automation Canadian oil sands company relies on the Rockwell

Automation PlantPAx solution to increase the efficiency and uptime of its operations.

16 Technology Watch Scalable control solutions address many requirements – from

simple machines to complex plant designs.

18 Automation Fair®

19 Product Focus Recent additions to the Rockwell Automation product portfolio.

Rockwell Automation Acquires SoftSwitching Technologies

Rockwell Automation® Inc. has purchased the assets of SoftSwitching

Technologies, a U.S. provider of industrial power quality detection and protection systems located in Middleton, Wisconsin.

The battery-free, environmentally friendly products of SoftSwitching Technologies provide cost and performance advantages over battery-based, three-phase uninterruptible power supplies or constant voltage transformers. The global, centralised intelligent network system also provides power grid alerts so manufacturers can monitor activity and correlate power quality events with unscheduled downtime, saving hours of guesswork and mechanical diagnostics.

SoftSwitching Technologies will be aligned with the Rockwell Automation Control Products & Solutions operating segments. Terms of the deal were not disclosed.

Smart Control System wets appetites at Water Conference

A t the recent 75th Annual Water Industry

Operators Association (WIOA) conference held in Bendigo, Rockwell Automation captured imaginations and sparked interest with the latest generation of control and monitoring solutions for the Water/Wastewater industry.

Intelligent process control systems are the key to providing reliable and sustainable operations. Important information from these control systems can now be delivered to the palm of your hand via todays modern communications, anywhere at any time.

Remote stations powered by renewable energy can also now provide more than just telemetry and control. They can also offer the same level of sophistication in information enabled technology as is found in the control room.

“To achieve the benefits of the innovation now offered across a wide range of smart sensors and controllers, it has been rewarding to work with the team at Rockwell Automation and their associated partners to unleash the power of their products – designed from process control to corporate interfaces via the Virtual Control Room philosophy” stated Bruce Anderson, Water Infrastructure Group, Operations Systems Manager.

NEWS & EVENTS

BRIEFS

Promoting Ethical Business Standards The Ethisphere Institute has recognised Rockwell Automation® as one of the world’s most ethical companies. The Ethisphere Institute is a leading international think-tank dedicated to the creation, advancement and sharing of best practices in business ethics, corporate social responsibility, anti-corruption and sustainability. Through in-depth research and a multi-step analysis, it reviewed nominations from companies in more than 100 countries and 36 industries. Rockwell Automation Chairman and CEO Keith Nosbusch says, “Our global commitment to responsible business practices is absolute. For us, honesty, fairness, quality and responsiveness are guiding principles, and integrity is an underlying value in every business transaction.” The Ethisphere Institute has recognised Rockwell Automation on three previous occasions.

A Best Corporate Citizen Corporate Responsibility Magazine has named Rockwell Automation® to its 2012 list of 100 Best Corporate Citizens. The magazine compiles the list based on publicly available information through which companies disclose key data about climate change policy and performance, diversity practices, governance, charitable giving and other key indicators. “Making the list of 100 Best Corporate Citizens puts us in good company with many of the world’s leading organisations,” says Doug Hagerman, senior vice president, general counsel and secretary. “It confirms that our mission, vision and values are shared by all employees as we work in more than 80 countries to help make the world more productive and sustainable.”

A Leader in Automation Automation World magazine has named Rockwell Automation® to its “First Team” in multiple categories for the magazine’s latest Leadership in Automation Program. Chosen by customers, Rockwell Automation was awarded a place in 13 categories, including batch control, motion control drives, programmable logic controllers and variable frequency drives.

AUTOMATION TODAY ASIA PACIFIC October 2012 3


Rockwell Automation partners with FIRST to bring technology to the engineers of the future

NEWSCOUNTRY

Rockwell Automation is proud to announce that the company’s longstanding global association with FIRST (For Inspiration and Recognition of Science and Technology) will now be extended to Australia and New Zealand. Both FIRST and Rockwell Automation are committed to inspiring young people’s interest and participation in science and technology—developing the next generation of engineers for tomorrow. While Rockwell Automation and FIRST share an association that has evolved over more than ten years in the US, this will be the first year that the South Pacific region participates in local sponsorship of the organisation. According to Matthew Treeby, Commercial Marketing Manager, Rockwell Automation South Pacific, “We are happy to be supporting FIRST locally—the organisation addresses the need for strong preparation in science, technology, engineering and maths to improve our communities, create jobs and educate tomorrow’s workforce and customer base.” FIRST provides the opportunity for students from different age groups to participate in three exciting programmes: The FIRST Lego League, the FIRST Tech Challenge and the FIRST Robotic Challenge. In Australia, FIRST is co-ordinated by Professor Michael Heimlich, of Macquarie University’s Faculty of Science. “This year there are approximately 300 teams which equates to about 2500 students that we are reaching all over Australia,” said Professor Heimlich.. “Having only been in Australia for six years, the growing number of students participating in the FIRST Lego League has been encouraging.” The FIRST Lego League uses robotics to teach the principles of real-world science and technology to children aged between 9 and14 years.The next programme—the FIRST Tech Challenge—is aimed at students in the lower years of high school.

Utilising metal components to design, build and program actual robots, this competition requires students to apply real-world mathematics and science concepts to develop problem-solving and team-building skills. The final program, the FIRST Robotics Challenge, provides the ultimate challenge to students in the upper years of high school. Under strict rules, with minimal resources and time limits students are challenged to build and program a robot to perform prescribed tasks in an environment that mimics real world engineering. While Rockwell Automation sponsors the FIRST Lego League and the FIRST Tech Challenge, the company is also the premier sponsor for the FIRST Robotics Challenge which recently held its first annual event, the Duel Down Under, at Barker College in Hornsby, NSW. As with all FIRST programmes, the challenge changes each year. In 2012, students in upper high school grades competed in the Rebound Rumble— a game of extreme basketball. At the Rockwell Automation on the Move, held earlier this year in Sydney, FIRST displayed one of their robots,

giving visitors the opportunity to meet some of the team members, while gaining a first-hand understanding of what these incredibly talented students are capable of. “We are enjoying getting involved with FIRST and assisting them with direct sponsorship as well as competition events and family fun days,” said Treeby. “Our involvement with FIRST really demonstrates our own company culture of innovation and is part of our Engineering our Future program to promote science, engineering and technology to the next generation.” “Rockwell Automation are more than sponsors—they are allies. In addition to contributing valuable funding they are providing mentors which are a big part of the FIRST program—connecting students to engineers in the community provides them with important insight to real life engineering,” said Professor Heimlich. “Rockwell Automation is a well-respected company around the world and we look forward to working with them to inspire young people’s interest and participation in science and technology.” AT

AUSTRALIA & NEW ZEALAND


Rockwell Automation in the South Pacific region provides a dedicated team for the Mining Industry Australia’s expanding multi-billion dollar mining technology and services industry is leading the drive for innovations to boost productivity and efficiency. As Australian mining exports increase, mining companies are investing significant resources into the development and implementation of remote automation and unmanned machinery to meet this demand. From an automation industry point of view, the key elements of success are the ability to provide a system which encompasses key issues including safety, asset management, process control and the ability to perform remote operations in a secure manner. In keeping with its commitment to Australian and New Zealand industry, Rockwell Automation has formed a new Mining Industry Solutions team. This team will consist of domain experts to cover the major mining companies, the major EPC’s involved in the mining industry and the packaged power solutions Rockwell Automation offers. The Rockwell Automation Mining Team will play a central role in coordinating the combined global resources of

Rockwell Automation engineering, support and product groups to ensure the most effective and efficient outcome for our mining customer base. Heading up the team is Geoff Irvine as Mining Industry Manager, Rockwell Automation. “The amount of technology that is available to make mining processes more efficient has come a long way; we’re not talking about futuristic technology, it’s all here and now,” said Irvine. ‘This technology is being applied today into sites world-wide including applications such as autonomous machines, remote operations diagnostics and decision support, increasing the supply chain efficiency from “pit to port” Principle members of this team will also include: Greg Schultz - with 19 years tenure at Rockwell Automation, Greg carries significant expertise in management and customer relationships and solutions Scott Southby – holds 18 years of electrical and automation industry experience, since 2008 Scott been involved solely in the mining industry both within Australia and overseas

and recently rejoined Rockwell Automation Cheng Wen - extensive global automation industry experience, Wen joined Rockwell Automation China in 2006 and since re-located to Australia Simon Cox - possessing a Chemical engineering background and involved with the automation industry for over 15 years, Simon will focus on the EPC and consultant specialists This team demonstrates Rockwell Automation’s increasing commitment to the mining industry in the South Pacific region and globally. We are in this for the ‘long haul’ and want to bring to the market high value solutions such as the PlantPAx Mining Solution (a solution that came with the acquisition of Hiprom) bundled power solutions (including low voltage and medium voltage drives, and the new 2500 MCC), integrated Condition Base Monitoring and Information Solutions that can provide decision support in Remote Operations. We will also focus on new service offerings in the areas of remote network diagnostics and support, safety systems audits and consulting, and embedded project services. AT

2012 ECANZ Challenge For the 11th year running, Rockwell Automation was proud to sponsor the 2012 ECANZ (Electrical Contractors Association of New Zealand) Challenge Event alongside distributor partner NHP. With this year the finals being held in Tauranga last August. Challenge 2012 is a competition-based event to find the best electrical apprentice in either domestic/commercial or industrial work. It is comprised of a series of Preliminary Rounds held nationwide where competitors have to build a working simulation. The apprentices with the top six scores from each stream qualifying to compete in the three day New Zealand Final. Rockwell Automation has been

involved since the beginning of the challenge in 2002 and recognise the importance these apprentices have towards our future in the electrical industry and congratulate all the finalists. Commercial/Domestic, 1st Alex Tyson, 2nd Vaughan Marshall & 3rd Joshua Lewis. Industrial, 1st Rowan Cann, 2nd William Ballantyne & 3rd Jonathan McFall. ECANZ Challenge National Coordinator Colin Tilley says “Rockwell Automation has benefited the apprentices by creating greater awareness of the technologies available and its’ application in industry today. The organisation

appreciates and thanks Rockwell Automation for their tremendous support and assistance over the years.” AT


A distributed control system (DCS) represents a major financial investment for companies. It

typically controls and monitors various process plant operations on a daily basis without overly excessive downtime or frequent safety-related incidents.

Depending on years of service and vendor support, the DCS may be very expensive to own and operate. As a DCS reaches the end of its useful life, internal plant personnel often must provide to their corporate offices a financial justification comparing the cost of continued operation versus migrating to a new DCS.

A metric called the total cost of ownership (TCO) can help plant personnel perform their analyses. The TCO takes into account various ownership factors so that personnel can accurately assess the costs and benefits of each factor as it relates to existing or new automation equipment, explains Michael Vernak, process technical consultant, Rockwell Automation®.

Comparing ComponentsSeveral components comprise the

TCO including purchase price, cost to integrate into balance of plant, training, required maintenance, spare parts acquisition, downtime and changeover time. Off-spec product due to quality issues, energy to run the system, less-than-optimal throughput, cyber security compliance, integration to other plant automation/information

systems and long-term support round out the TCO components.

While purchase price, cost to integrate into balance of plant and training are not relevant to an analysis of an existing system, the other components are.

Required maintenance and acquiring spare parts are significant factors in any migration decision and typically can be quantified. An existing DCS, for example, can become very expensive to maintain as electronic components reach the end of their useful life, replacement parts become expensive, excessive spare parts inventory may need to be maintained, and personnel qualified to troubleshoot and repair these older systems are difficult to find.

Excessive failure rates, difficulty in procuring spare parts and lack of qualified maintenance personnel can result in relatively high levels of downtime, particularly for process plants. Unlike discrete part manufacturing facilities, plants running continuous processes frequently take hours or even days to restart after a process upset.

Downtime is also caused by product changeovers. Many older plants were originally built to produce just a few products, with infrequent required changeovers. The DCS was often specified accordingly, with little built-in flexibility to accommodate changeovers.

Today, product changeovers tend to be much more frequent, and the automation system must be designed

to react accordingly. If product changeovers require excessive manual operation, then downtime is often excessive, greatly increasing production costs.

Excessive maintenance and support costs along with relatively high levels of downtime are perhaps the most visible reasons to migrate from a DCS to a new automation system. They are also the easiest to quantify. Much harder to analyse, but often more important, are the costs associated with poor process control, says Vernak.

Poor Process ControlPoor process control results in excess

costs because of poor quality, excessive energy use and reduced throughput. When processes are controlled near setpoints, quality is maximised. Deviations from setpoints, particularly for long periods of time, can directly impact quality in a negative fashion.

Also, the closer control is to setpoint, the less energy is consumed. Heating a product to 0.1 degrees over setpoint consumes less energy than heating it to 2 degrees over setpoint.

In addition, throughput can be affected by poor process control. In general, the more automated a process, the greater the throughput and the less variation. Newer automation systems often allow more processes to be automated – and may allow tighter control of existing processes.

Once it is determined that existing DCS TCO is currently

Use a metric known as the total cost of ownership (TCO) to calculate the financial justification of migrating from an existing distributed control system (DCS) to a new one.

When Does Migrating to a

New

DCS Make Sense?Im

age

cour

tesy

of E

vans

Con

soles

.

Deciding whether or not to migrate from a distributed control system (DCS) to a new automation system

involves careful financial analysis. Using a metric known as the total cost of ownership (TCO) is more accurate than the metric companies often use, payback period, which does not take into account savings realised from the new automation system after the payback period.

As part of the TCO, net present value (NPV) enables plant personnel to estimate the value of continuing with the existing DCS as opposed to the new automation system, and it incorporates the interest rate (also referred to as the corporate discount rate).

The table above provides a comparison example. The existing DCS has an annual TCO of $100,000 that’s increasing at a

rate of 10% the first year, rising by 5% per year to 25% in the fifth year as the DCS becomes increasingly unsupportable. A new automation system would require an investment of US$1 million but would save $150,000 per year in TCO as compared to the DCS. These savings would reduce the first year cost to

$850,000 and would accrue annually. The interest or discount rate is assumed to be 6%.

The bottom line is that the NPV of the DCS would be negative US$560,843 while that of the new automation system would be a negative US$311,542, making the new automation system a good investment.

Net Present Value Existing DCS New Automation System

Interest or Discount Rate – 6%

Net Present Value $560,483 $311,542

Year 1 TCO, investment plus savings minus costs $100,000 $850,000

Year 2 TCO, savings minus costs $110,000 $150,000





excessive or quickly increasing to an unacceptable level, the next step is to examine costs and benefits of a new automation system.

Quantifying Costs for a New Automation System

New automation system costs can be broken down into three main categories: installed cost of the new system, cost to train employees and downtime incurred while installing the new system. Installed cost includes all cost to purchase, test, install and start up the new automation system.

Installed cost of the new system and cost to train employees are generally straightforward to quantify. The cost of downtime incurred while installing the new system is harder to quantify, but it can be minimised by following certain migration methods.

According to Vernak, the most common migration method is to replace the entire DCS at once, including the human-machine interfaces (HMIs), the controllers and the input/output (I/O). This method is simple to execute and often results in lowest overall purchase and installation costs; however, downtime can be excessive, with all of it coming in one period.

Breaking the total required downtime up into multiple periods is often advantageous and can be accomplished with a three-phase migration strategy. This strategy also spreads migration costs out over a longer period.

With the three-phase migration, the

most obsolete components, the HMIs, are converted first. Next are the controllers. In the third phase, the I/O is replaced. The migration process includes various practices to minimise costs.

Benefits of New Automation System

Once the new automation system is installed and operating, and plant personnel are trained in its operation, maintenance should be minimal. Most new systems include tools that can proactively identify problems with field devices before they occur, further reducing maintenance costs.

Costs for performing maintenance proactively as opposed to reactively can be quantified by first estimating maintenance costs for the existing DCS. Maintenance costs for the new automation system can then be quantified, with some savings added for avoiding downtime due to proactive maintenance.

Estimates for maintenance and spare part stocking costs for a new automation system can typically be provided by the machine supplier. Alternately, these costs can be identified with greater certainty by entering into a maintenance agreement with the supplier.

Quicker product changeovers can generally be expected, and time saved can be quantified by comparing change over time with the existing DCS to that anticipated with the new automation system. Most plants have a cost number

for each hour of downtime, and that number can be used to complete the calculation.

With a new automation system, there may be existing manual operations that can be automated. This should result in direct labor costs savings that can be quantified, as well as estimated cost savings for greater accuracy and repeatability of automatic as opposed to manual operations.

Vernak notes that many process plants today are faced with costs to comply with cyber security mandates. Most new automation systems will have built-in cyber security tools, reducing compliance costs, with added savings from increasing overall automation system security.

Perhaps hardest to quantify are savings due to improved process control. The new system can be expected to provide tighter process control, thus helping a plant reduce energy use, increase throughput and improve quality. These improvements are often realised through implementation of advanced process control technologies such as model-based control.

Vernak summarises that there are many options for quantifying the value of migrating from an existing DCS to a new automation system. To attain accuracy, the TCO for each option must be considered. TCO takes into account all factors related to each option and includes cost savings as well as benefits from investment in a new automation system. AT

CrunChing the numbers

R ecent updates to the Rockwell Automation PlantPAx™ process automation system extend

the reach of the system to integrate motor control centres and critical rotating assets such as compressors, pumps, turbines and fans. The system combines Rockwell Automation® core process automation capabilities and technologies with those of collaborators and acquisitions to

deliver an integrated control and information solution.

Users can now tie intelligent motor devices into this unified control architecture, making an immediate and measurable impact on asset availability, operational efficiency and energy management. The tight integration between process automation and motor control is especially beneficial in resource-

driven industrial applications with considerable mechanical investments such as metals, mining, cement, power, oil and gas, water/wastewater, and pulp and paper applications.

PlantPAx system users will have access to diagnostic information on many types of devices including motor control centres, drives, compressors, pumps, fans and instrumentation. By leveraging the EtherNet/IP™ network,


Managing Plant-WiDe O P e r at i O n S W i t h a

SINgle P l a t f O r M

The Rockwell Automation PlantPAx process automation system integrates motor control centres and critical rotating assets.


engineers can monitor process conditions such as electric motor current, vibration signatures of key rotating assets and torque signatures of variable speed drives.

“To improve plant performance, our customers prevent unplanned shutdowns while protecting expensive machinery,” says John Genovesi, vice president and general manager, Information Software and Process Business, Rockwell Automation. “Leveraging a single network architecture to bring operational information from motor control devices into the control system helps engineers extend the life of their mechanical assets and improve their overall configuration, operation and maintenance experience.”

Unlike distributed control systems (DCS) that require users to manually map data from motor control devices to the control system, the PlantPAx system mirrors the device memory, making data automatically available within the control system. Users can also set up applications in the PlantPAx system to collect and archive performance data from motor control

devices into databases for analysis.This data acquisition provides cost

savings throughout the life cycle of the equipment. For example, bringing intelligent motor control devices into the PlantPAx system is useful in managing the performance of energy-intensive assets. Furthermore, since EtherNet/IP is the delivery mechanism for the PlantPAx system, users can avoid electrical hazards by accessing information remotely, helping personnel to safely monitor, troubleshoot and diagnose motor control centres and other equipment. This saves time associated with suiting up with personal protective equipment and helps protect personnel from exposure to hazardous conditions.

With regard to operation and maintenance, the intelligent motor control integration in PlantPAx also enables automatic device replacement. For example, if a PowerFlex® 755 should fail and be replaced with the same new system, the PlantPAx system will recognise this activity and flash the drive’s firmware, as required. Then, the system will automatically download the drive’s configuration without manual

intervention. This compares with the conventional practice of engineers manually keying in the existing drive and configuration data into the new drive along with the configuration in the process automation system in the device replacement.

In addition to integrating motor control devices into the control system, the PlantPAx system features EtherNet/IP network support for redundant systems and Device Level Ring network topology that provides a highly available EtherNet/IP network without any additional infrastructure costs. For design productivity, a PlantPAx system provides accelerated design engineering, with initial sizing and architecture design, the creation of reusable engineering and template objects, and engineering and deployment tools for objects and diagnostics that minimise human error prior to checkout and testing. AT

on the web

For more information, visit: www.rockwellautomation.com/solutions/process/systems

The new 955 eBrik linear displacement transducer.

Price and performance so well balanced,

it just might displace potentiometers.

At last, there’s a purely electronic solution to position sensors.Our new 955 eBrik uses magnetostrictive technology sothere’s no contact, no moving parts, nothing to wear out. Noerratic position signals. Available in 25 mm to 1,825 mmstroke lengths, it’s economical and versatile enough for manyapplications, field-programmable, and the perfect replace-ment for old-style potentiometers. Learn more at our websiteor send e-mail to [email protected].

ametekapt.comwww.ametekapt.com.cn

©2012 AMETEK Inc. All rights reserved.

AMETEKAPT10017-eBrick-7'5x5_Rockwell_APT10017 05/18/12 3:15 PM Page 1


Water Treatment Supplier Keeps Information – and Water – FlowingA scalable, integrated process automation system from Rockwell Automation optimises operation of water desalination equipment.

J apanese company Toray Industries Inc. (Toray), established in 1926, manufactures, processes

and sells a range of products including fibres and textiles, plastics and chemicals, carbon fibre composite materials, IT and life science products, and environmental and engineering products. Within its environmental and engineering business is a range

of products used in water treatment applications. These products include reverse osmosis (RO) and nanofiltration (NF) membranes, which have been produced since 1967. Toray also offers ultrafiltration (UF) and microfiltration (MF) membranes in addition to membrane bioreactors (MBRs).

Toray is engaged with water treatment system supply that effectively utilises

membrane technology accumulated through the membrane business. This water system expert is piloting the latest state-of-the-art machine capable of a new type of filtering system for desalinating sea water to produce drinking water.

In particular, RO membrane elements are designed for seawater desalination, brackish water desalination and waste water reclamation. This filtration method removes large molecules and ions from solutions by applying pressure to highly concentrated solute solutions, causing the solvent to pass through a membrane to the lower concentrated solution. This process results in a higher concentration of solute on one side and only solvent on the other side.

Membrane quality, longevity and maintenance are competitive differentiators for Toray in the production of RO membrane elements. They are also attributes that are important to Toray’s customers. That is why Toray collaborated with Rockwell Automation® to optimise its operations.

Improving MaintenanceWhen it comes to water desalination,

membrane maintenance is a constant struggle for water treatment companies. Knowing when to change membranes and having adequate spares on hand has been a challenge for Toray, especially in dealing with spotty local providers.

A facility with a mission of treating water for human consumption must operate with as little downtime as possible. As such, one of Toray’s goals for remote maintenance was to implement automatic notification. This capability would automatically provide notification that a membrane should be exchanged so that the end user could proactively order and change the membrane, resulting in

STORYAPPLiCAtiOn

Japanese company Toray Industries Inc. manufactures a range of products used in water treatment applications, including reverse osmosis membranes.

The Rockwell Automation PowerFlex 40 drive and relays in the control panel are part of the scalable, integrated process automation solution Toray Industries Inc. uses in its water treatment system supply operations.


reducing downtime and improving maintenance planning.

In addition, Toray required connectivity to other systems for communication between the water treatment facility and the server in Toray’s main office to reduce the maintenance burden on the end user.

Another goal was to discover operational problems and provide solutions by troubleshooting remotely, as well as to minimise troubleshooting time using data from the machine. Previously, it was challenging for Toray to get remote data from the machine and convert that binary data into “friendly” data for engineering to use.

To address these needs, Toray sought a new automation collaborator so it could broaden its offerings and build a remote maintenance function into its system. “We needed a partner that could manufacture a control panel to our specifications in Japan and also support that control panel wherever our end users operate, which is often in remote areas,” says Kazunori Tomioka, senior engineer, Water Treatment System Department, Toray.

A Scalable SolutionAfter careful evaluation, Toray

purchased a scalable, integrated process automation solution from Rockwell Automation Global Solutions – Japan. It included CompactLogix™ automation controllers with RSLogix™ 5000 programming software, FactoryTalk® View Site Edition (SE), PowerFlex® 40 drives and PanelView™ Plus human-machine interfaces (HMIs). Also part of the solution were EtherNet/IP™ network media, Stratix™ switches and relays.

The CompactLogix process automation controllers manage the water treatment system. PowerFlex 40 drives control the water pressure of the pump and several industrial components with an EtherNet/IP connection. When Toray wants to know the operational status of the water treatment system and detail any error without traveling to an end-user’s site, the machine can provide data remotely via FactoryTalk View SE.

Toray now can optimise the capacity of remote log data through a radio modem for remote data transmission from ProSoft Technology, a Rockwell Automation Encompass™ Partner.

Smoother OperationsUtilising comprehensive remote

support offerings is expected to accomplish several goals for Toray: help to improve uptime, fill knowledge gaps, reduce maintenance costs, protect against costly downtime, optimise operations for maximum throughput and simplify the maintenance process.

Because the products and solution are scalable, Toray can add HMI graphics as needed. EtherNet/IP minimises wiring and makes it easier to access information. Using a drive to control the frequency of the pump reduces the power consumption from valve on/off solutions. Also, the smaller footprint of the automation solution leaves extra space in the container and I/O for future expansion.

In addition, with RSLogix 5000, users can copy and paste the existing program with a local tag, allowing them to expand their program. This use of software development tools for standardisation and deployment s i g n i f i c a n t l y r e d u c e s engineering time.

With improved infrastructure and capabilities, Toray is now getting data from the plant in one-minute intervals, so problems are caught quickly. The machine operation is more stable. Because the s y s t e m automatical ly provides the r e m a i n i n g available hours of the current RO, upon Toray’s advice, the end user can schedule the exchange of RO membranes to minimise u n p l a n n e d downtime.

If a problem does occur, one remote

Toray engineer can find the cause of the trouble. This can help prevent serious problems and damages to the RO unit in the long term. Furthermore, Toray can use data from the system to continue to improve membrane quality and the water treatment equipment process to become even more competitive in the water treatment industry.

The strength of Rockwell Automation locally is important to Toray and the end user. Tomioka concludes, “Rockwell Automation will continue to sell, repair and provide migration paths for products. This, along with advanced technology and global support, is an important factor for any long-term relationship and something we value with Rockwell Automation. During the development of this machine, whenever we faced a problem, it was addressed quickly and completely. This is how you build a relationship of trust.” AT

Strain gage input for Point I/O™

Helm Instrument Company, Inc.361 West Dussel DriveMaumee, OH 43537P: 419.893.4356 F: 419.893.1371E: [email protected] www.helminstrument.com

Two channels per module.

24-bit analog-to-digital conversion.

Resolution of 1 count per 100,000 counts.

Built-in averaging.

Compatible with all industry load cells and weigh scales.


WATCHteChnOLOgY

Monitor Emissions with a Software SolutionCompanies can minimise costs in environmental compliance monitoring by using a software-based continuous emissions monitoring (CEM) solution.

Companies are required to meet the continuous emissions monitoring (CEM) requirements of

various regulatory agencies and trading programs. These requirements include periodic accuracy verification as well as near 100 percent uptime.

As regulations continually become more stringent, many industries and processes that were once exempt now find themselves required to account for their impact on the environment. Implementing a monitoring system must meet these regulatory demands while also being cost-effective to operate and maintain.

Traditional approaches to emissions management involve complicated data collection systems and reporting workflows, many of which are hardware-based, manpower-intensive and rely heavily on multiple spreadsheets and log forms. These approaches lack the accuracy,

timeliness, consistency and security demanded by today’s regulations.

An alternative to traditional hardware-based systems is software-based CEM solutions. These provide real-time emissions monitoring through correlations with existing process and ambient sensors, resulting in accurate, virtually real-time emission information. The outputs can be interfaced with control applications to help reduce emissions and improve operations.

Access to detailed, up-to-the-minute, plant-wide emissions information provides a means to the control of emissions, which can be factored into plant automation strategies on a continuous basis.

In OperationRockwell Automation® offers its

Software CEM® solution, which is based on the Pavilion8® model analytic engine and the patented sensor validation

system. Its built-in sensor validation system detects failed or drifting sensors and automatically reconstructs an appropriate value used in place of the failed sensor to determine accurate emissions levels. The model then predicts emissions, regardless of sensor failures and interruptions.

For example, in a boiler, the fuel flow, air flow and steam flow are highly interdependent. Similarly, modern plants typically have redundant temperature, flow and pressure measurements. Thus, it is possible to estimate any one of these readings as a function of the other sensors.

In a similar fashion, sensor values can be validated by comparing raw values to predicted values as a function of the “peer” sensor data. A raw sensor value that is suspect in relation to its peer readings can be identified.

Software CEM uses the sensor validation model as a qualifier to detect sensor failures and to set appropriate alarms. The patented reconstruction routine – which adheres to the U.S. Environmental Protection Agency Process Specification 16 – facilitates continued accurate prediction of sensor values while the failed sensor is repaired or replaced.

Getting StartedA kick-off meeting to discuss the

scope of the Software CEM project is held prior to initiating any onsite activities. At this meeting, the functional design of the Software CEM is established and the necessary process sensors identified.

If no existing process is in place – hardware CEMs or other monitoring system – process data is obtained from the process data historian or the Rockwell Automation Pavilion8 Data Logger. If no emissions data is available from existing hardware CEMs, stack emissions data is collected

A software-based continuous emissions monitoring (CEM) system enables companies to lower installation and maintenance costs while providing higher reliability.


concurrently by an environmental testing firm.

The emission unit is put through its applicable range of operation over a two- to seven-day period (depending on the complexity of the unit) while data is collected. The process and stack data is then used to construct an accurate emissions model.

Sensor Validation and Emissions Prediction

The Software CEM is used to construct a sensor validation system for the process sensors, taking into consideration variable inputs (such as air flow and process O

2) and emissions

output (NOx, CO, O2 and CO

2 ). The

system’s models can detect failed instruments and will automatically reconstruct an appropriate value to determine accurate emissions.

If an input sensor fails during normal operations, the system has the capability to use information from the remaining sensors to reconstruct the value of the failed sensor. In addition to continuing to predict emissions, the Software CEM will also issue an alarm alerting the operator of a failed sensor.

A key regulatory requirement for most predictive emissions monitoring systems (PEMS) is 95 percent uptime. The Software CEM typically achieves greater than 99 percent uptime through the use of the Rockwell Software® Sensor Validation System.

The Software CEM system is initiated online by interfacing to the process distributed control system or data historian. It acquires current process data, passes the data to the model for execution and returns the emission prediction back in the form of a tag value.

This approach allows existing operator console interfaces to be used to present information from the models to operations or engineering staff. The Software CEM can then be integrated with commercially available reporting packages.

The Software AdvantageTaking a software-based approach

to PEMS provides a range of benefits. Chief among them is cost-effective monitoring and regulatory compliance. For example, the Software CEM solution lowers installation and maintenance costs while providing higher reliability. There are no labor and material costs associated with operations and maintenance, and there are lower safety risks. In addition, there is quicker deployment, compliance and return on investment.

A second benefit revolves around accurate emissions monitoring and reporting. Through Software CEM, quality assurance of input data reduces compliance monitoring and reporting

errors. Companies experience accurate fault-finding and reduce their meantime to repair (MTTR). What’s more, they maximise monitor uptime, which minimises downtime penalties.

Finally, Software CEM is a proven solution, introduced in 1993. With more than 300 installations, it holds a 100 percent certification record in global applications across major industries. Companies implementing Software CEM report that the solution has reduced project risk and minimised compliance monitoring, record-keeping and reporting costs. AT

More than 300 applications of Rockwell Automation Software CEM® are in use

in countries including China, New Zealand, Norway, the Netherlands, Bahrain, Saudi Arabia, UAE and the United States. Sources• Boilers• Turbines• Duct Burners• Dryers • Thermal Oxidisers• Reciprocating Engines• Regenerative Thermal Oxidisers• Process Heaters• Olefin Furnaces• Crude Heaters

Fuel Types• Natural Gas • No. 2 Fuel Oil • Other Fuel Oils• Refinery Gas• Process Gas• Combined Fuels

sOftwAre Cem APPLiCAtiOns T he following sensor inputs

have been used to develop Software CEMs for natural

gas, oil and wood-fired combustors. Boiler Sensors • Feedwater Flow Rate• Grate Temperature (if applicable)• Steam Flow Rate• Air Flow Rate• Air Inlet Temperature• Economiser Outlet Flue Gas

Temperature• Economiser Inlet Flue Gas

Temperature• Economiser Outlet Water Gas

Temperature• Economiser Inlet Water Gas

Temperature Fuel Conditions

• Natural Gas Flow Rate• No. 2 Oil Flow Rate• Wood Feeder Master Rate

Ambient Conditions

• Relative Humidity• Barometric Pressure• Temperature (air preheat

temperature or after flue gas recirculation)

PrOCess sensOr exAmPLes

Petrochemicals Company Overhauls Operations to Expand its CapacityMigrating from a decentralised control system to the Rockwell Automation PlantPAx process automation system boosts production and optimises quality control.


Petrocoque S.A. Indústria e Comércio, based in São Paulo, Brazil, manufacturers, refines

and markets calcined coke, coal and charcoal products. Calcined green petroleum coke is used to make anodes for the aluminum, steel and titanium smelting industries.

As part of its process, Petrocoque’s operations include calcination furnaces, rotating coolers, boilers and solids transport systems. There is also equipment to combat air pollution and handle liquid waste treatment. Approximately 400 kg of coke is necessary to produce one tonne of aluminum.

The company’s existing discrete and decentralised control system had been in use for decades. Process control was based on single-loop controllers that were more than 20 years old. In addition, the company had one of three production units deactivated; the other two were using much older control solutions.

Manuel Lind Gomes, the company’s industrial manager, explains, “We needed to unify the process control

system of the three green petroleum coke calcination units into a single site and to modernise unit number one, which is the oldest.”

The old system was not interconnected with the network. It did not provide predictive diagnostics, historic data collection or process tracking. There were also quality control problems. In addition, there was no integration with the electrical components, resulting in maintenance and prevention issues.

In order to adapt to market demands and increase production capacity, the company decided to update its control system with a solution based on the Rockwell Automation PlantPAx™ process automation system. Petrocoque’s PlantPAx system included several CENTERLINE® 2500 Motor Control Centers (MCCs) with IntelliCENTER® technology, featuring a built-in, preconfigured and tested network as well as integrated hardware and software. The technology helps reduce installation time with its plug-and-play setup and can help minimise facility downtime by providing intelligent diagnostic and predictive failure information. For I/O, the company chose 4-20 mA+HART Analog I/O devices.

To address data management needs, the company configured its PlantPAx system with FactoryTalk® Historian software. This solution collects time-series data that can be used as a basis for calculations, estimations, statistical processes and quality controls. For asset management requirements, Petrocoque installed FactoryTalk AssetCentre, which enables users to secure access to control systems, track users’ actions, manage asset configuration files, configure process instruments and provide backup

and recovery of operating asset configurations. It also configured its system with FactoryTalk ViewPoint, a Web-enabled, human-machine interface that enables users to monitor plant floor operations from any location to improve real-time decision making.

The PlantPAx solution also included remote access display; training for operation, maintenance and configuration teams; hot-loop migration of operating units; and system configuration, commissioning and startup.

Modernising the plant was carried out with the migration of the single-loop controls and interlocking with PLC-5® for the distributed control system (DCS) PlantPAx, where discrete and regulatory controls were implemented. The PLC-5 I/Os were retained, protecting the investment Petrocoque made years ago.

The high availability of the PlantPAx system and ease of operation and maintenance help minimise downtime and process interruptions caused by modifications to the control system. Edinaldo Pereira, Petrocoque process engineer, says, “What we currently have, in addition to centralised control in a single room, is the ease and simplicity of obtaining online information about the process (historic) variables and the ability to obtain faster diagnostics.”

As a result of the system overhaul, production capacity reached 100 tonnes of green petroleum coke per hour. In addition, the system is prepared to support the advanced process control system, Pavilion8® software, as well as integrate with the ERP system for production control tracking. AT

PROPOSITIONVALUE

The need to modernise its operations to increase production capacity led Petrocoque S.A. Indústria e Comércio to install a solution based on the Rockwell Automation PlantPAx process automation system.

Canada has the third largest oil reserves in the world, estimated at 180 billion barrels. About half

of it comes from “oil sands,” which contain naturally occurring mixtures of sand, clay, water and a dense form of petroleum known as bitumen. Bitumen is a thick, sticky form of crude oil that will not flow unless heated or diluted with lighter hydrocarbons.

Grizzly Oil Sands, an independent oil sands company based in Alberta, Canada, holds over 700,000 net acres of oil sands leases and permits. The company employs technology known as steam-assisted gravity drainage (SAGD) in its in-situ oil recovery process. With SAGD, two horizontal wells are drilled into the oil sands, with one located at the bottom of the formation. Heat melts the bitumen,

which allows it to flow into the lower well, where it is then pumped to the surface.

The company has devised a unique facilities model, known as Advanced Relocatable Modular Standard development, to reduce costs, risks and the environmental footprint associated with its in-situ thermal technologies. For this unique facility model, it required an advanced,

integrated process and motor control system that would monitor multiple SAGD sites from one central location.

After evaluating conventional solutions from distributed control system (DCS) and electrical house vendors, Grizzly awarded a contract valued at more than US$4 million to Rockwell Automation®. Based on the PlantPAx™ process automation system, the solution includes project management, engineering services, low- and medium-voltage motor control centres, a PowerFlex® 7000 medium-voltage variable frequency drive and a third-party power generator.

A shadow control room, built on a virtualised computing environment, will be developed at Grizzly’s Calgary headquarters to monitor and control current and future oil sites across

Northern Alberta, explains Brian Harrison, Grizzly Oil Sands vice president of engineering. “The unique, open architecture is an important reason Rockwell Automation won the order,” he says. The Rockwell Automation Integrated Architecture™ leverages open industry standards where traditional DCS vendors use proprietary systems not suitable for this type of application.

Byron Black, Rockwell Automation

manager, territory and channel sales, Calgary, says, “This company was very reluctant to locate a remote operator station several hundred kilometres from its proprietary control system. Since Grizzly’s sites are spread across Northern Alberta, connecting individual operating plants to a master control room in Calgary enables the ‘super operator’ to monitor and compare activity at multiple sites.”

Rockwell Automation in-house engineering expertise was one of the key differentiators in Grizzly’s decision to select the solution. For example, the “Premier Integration” feature of the Rockwell Automation Intelligent Motor Control solutions helped to simplify drive configuration and maintenance. This approach provides an array of programming tools to better integrate Allen-Bradley® drives with other Allen-Bradley products.

Terry Gebert, vice president and general manager, Rockwell Automation Global Solutions, says, “Our experience, oil and gas domain expertise, and global resources will help Grizzly Oil Sands run a profitable and sustainable operation. This combination of systems and products, together with experience and knowledge, will help Grizzly reduce integration costs throughout engineering, commissioning and startup.”

First steam at a Grizzly site is scheduled in early 2013. Grizzly’s goal is to produce more than 5,000 barrels of oil per day at the first phase of its Algar Lake Project. AT

Canadian oil sands company relies on the Rockwell Automation PlantPAx solution to increase the efficiency and uptime of its operations.

AUTOMATIONPROCESS


The Rockwell Automation Integrated Architecture leverages open industry standards where traditional DCS vendors use proprietary systems not suitable for this type of application.

Integrated Process Control System Reduces Oil Extraction Costs


WATCHteChnOLOgY

Scalable control solutions address many requirements – from simple machines to complex plant designsRockwell Automation delivers a full scope of intelligent, scalable automation solutions that cover basic, limited-I/O machine control applications all the way up to fully integrated plant-wide control solutions.

As a worldwide supplier to a wide variety of industries, Rockwell Automation has a self-imposed

responsibility to deliver scalable automation solution to all facets of the engineering industry. From the simplest, stand-alone machine, all the way up to plant-wide, multi-site control and information capabilities, Rockwell Automation can offer a solution..

What is more, as well as delivering these multi-level solutions, Rockwell Automation has standardised on an infrastructure for its mid- and high-range solutions that permits the reuse of code, programming time and engineering effort. This scalable solution – Integrated Architecture – allows users to develop and tailor assets to suit their current needs, while being mindful of the fact that should they need to expand and adapt, they can simply scale up or down to meet their requirements while still using the same single and scalable development environment.

The Rockwell Automation Integrated Architecture approach supports multiple disciplines in a scalable and information-enabled architecture that leverages an EtherNet/IP network and provides premier integration to a broad portfolio of world-class products and services. The use of EtherNet/IP allows the convergence of process, batch, discrete, drive, safety and motion into one automation discipline. As EtherNet/IP is also based on standard unmodified Ethernet, data exchange and information flow between production and the management is seamless.

The benefits go beyond connectivity

as users have access to a common platform for a machine’s configuration, programming, commissioning, diagnostics and maintenance. This provides tighter integration while giving equipment suppliers the simplified architecture they need to streamline design and development. Reducing the number of networks also helps to ease machine maintenance, as EtherNet/IP aids the simplified movement of information, giving powerful diagnostics and troubleshooting capabilities. Ultimately, this helps machine builders sharpen their competitive edge with

higher-performance, more flexible machines.

Scalability between ranges caters for expansion on a larger scale, but Rockwell Automation has not lost sight of the fact that many machine builders simply do not need to call upon the capabilities of powerful automation solutions. Many equipment suppliers produce smaller-footprint, lower cost machines that although not requiring advanced control solutions, still need to be able to offer a wide range of capabilities. It is in these applications that users can turn to Rockwell

The beauty of the Rockwell Automation approach is that any investments you make will also allow for significant scalability to match yours and your customers’ future needs.


Automation’s Connected Components Solutions.

Connected Components provides “just enough” control to meet machine and end-user requirements, while still helping to improve operating efficiencies. Engineering and application tool sets allow easy design and installation with preferred interoperability of a broad range of component class products.

Built around a core of Micro800 programmable controllers, PowerFlex drives and PanelView Component HMIs, users benefit from convenience, ease of use and simplicity of machine design with Connected Components products and pre-developed Building Blocks tools. Combining this simple, yet powerful control core with a full suite of associated components and a dedicated set of class-leading application development tools, Connected Components gives machine builders what they need to address their control requirements in the shortest possible time. They can also take advantage of the Connected

Components Building Blocks (CCBB) – essential tools that make it quicker and easier to implement common control tasks as part of the machine design.

Whatever your automation needs, it is highly likely that Rockwell Automation can deliver an effective and widely deployed solution that can match

your exact requirements. The beauty of the Rockwell Automation approach is that any investments you make will also allow for significant scalability to match yours and your customers’ future needs. And this is all without significant engineering effort and expenditure on additional infrastructure. AT

Personal contact is more than phone calls and e-mail. It’s people working together to develop unique solutions.

Take the guesswork and risk out of choosing your extended automation

team. Selecting a qualifi ed Rockwell Automation Authorised Distributor

brings you resources closely matched to your industy or application need.

Go to http://www.rockwellautomation.com/distributor/

RA-Partner-Advert_Half-page_wnipt.indd 1 3/02/2011 11:55:05 AM

Automation Today is an Asia Pacific focussed magazine featuring local and international articles. Automation Today has a reputation for intellectual topics, featured application stories, technology

trends, local and international news and more. Published quarterly, this magazine is a worthwhile read!

Articles of interest from recent issues:• Integrated Solutions & Services Help

to Maximise Automation Investment• Delivering New Dimensions of

Scalability• Design a Component Infrastructure

that Complements the Automation Architecture

• Making Process Upgrades with Minimal Disruptions

What have you missed!!

Subscription is FREE so register for your copy Now!

Australia - www.rockwellautomation.com.auNew Zealand - www.rockwellautomation.co.nz


2012 marks the 21st annual Automation Fair® event, hosted by Rockwell Automation and

is to be held in Philadelphia in the week of November 4th. Regarded by manufacturers, media and analysts as the premier automation industry event, the Automation Fair® event is uniquely designed to help manufacturers and OEMs leverage their automation investments to achieve their business goals. Rockwell Automation and our partners will share insights on smart, safe, sustainable solutions that can help customers optimise their plants, improve performance of their machines, and manufacture products in a more

sustainable manner.The Industry Forums at Automation

Fair present examples and concepts which different manufacturers have used to increase their productivity and improve the efficiency of their business. They strive to reduce product development cycles to maximise sales opportunities. They also look for ways to reduce production costs and meet ever-changing global regulatory requirements while producing a wide variety of consistently high-quality products. They must adopt new strategies in order to survive.

At Automation Fair 2012, representatives and experts from the

several industries will present their experiences and application of the latest automation technologies.

Visitors will also have the opportunity to meet one-on-one with Rockwell Automation subject-matter experts throughout the week to hear and discuss the latest trends and control, power and information technologies. The event also includes free workshops, technical sessions, industry forums, hands-on labs and a large exhibition zone.

For more information, or to register please visit: http://www.rockwellautomation.com/events/automationfair

The Industry’s Premier event - Automation Fair

FOCUSPRODUCT


Designed to meet your switching capability needs

The Allen-Bradley Stratix 5700™ is a compact and scalable Layer 2 managed switch with Cisco technology embedded. Automation professionals can apply this switch to applications from small isolated to complex networks, monitor and control distributed devices and to integrate the plant floor to the enterprise systems. By choosing a switch that is co-developed by Rockwell Automation and Cisco, your operations and IT professionals leverage technology that is familiar to them and better enables collaboration to meet their business goals.

Key benefits of these modules include:• Management and diagnostics from within both IT and controls

environment • Simple device replacement via SD card that holds the configuration

for easy swap out• Default configurations for industrial automation and EtherNet/IP

devices (Global and Smartports)• Security features help ensure that only authorized devices, users

and traffic can access and traverse the network• “Right-size” network infrastructure with scalable hardware and

software configurations

For more information, visit:http://ab.rockwellautomation.com/networks-and-communications/stratix-5700-ethernet-switches Capture, analyse, store and

share critical energy information

FactoryTalk® EnergyMetrix is a web-enabled, energy management software package that gives you access to critical energy information from virtually any location. The software combines data communication, client-server applications and Microsoft’s advanced .NET™ Web technology to provide you with a complete energy-management decision support tool.

With FactoryTalk EnergyMetrix, you can capture, analyze, store and share energy data with key stakeholders using a standard web browser. This makes it simple to distribute the knowledge necessary to optimize energy consumption, manage power quality, correlate energy usage, determine cost to production, negotiate energy rates and improve efficiency.

Offering insight across processes, across facilities or across countries, FactoryTalk EnergyMetrix is an enterprise-wide solution that can help you drive intelligent energy management decisions.

For more information, visit:http://www.rockwellautomation.com/rockwellsoftware/assetmgmt/energymetrix/

Kinetix 6000M Integrated Drive-Motor System

The Allen-Bradley® Kinetix 6000M integrated drive-motor system combines the high-performance MP-Series™ food-grade servo motor and Kinetix 6000 servo drive technologies into a single, compact package that provides significant space savings and machine control system simplification. The Kinetix 6000M integrated drive-motor is available in three different torque ratings with optional holding brakes.

This on-machine solution integrates seamlessly with our Kinetix 6000 and Kinetix 6200 multi-axis servo drive systems and is designed to help reduce wiring time and simplify cabling. The Kinetix 6000M integrated drive-motor units feature mounting flanges and shaft dimensions that are identical to MP-Series food-grade motors of the same frame size, making it easy to upgrade to integrated drive-motor technology.

A Single hybrid power cable and single sercos motion network cable connect the Kinetix 6000M power interface module to as many as 16 Kinetix 6000M integrated drive-motor units.

For more information, visit:http://ab.rockwellautomation.com/motion-control/kinetix-6000m-servo-drive-motor

ArmorStart LT Distributed Motor Controller

Bulletin 290E/291E/294E ArmorStart® LT is an integrated, pre-engineered distributed motor control solution. It provides excellent performance at a great value to meet today’s needs in size, simplicity, and performance. It also provides material handling equipment suppliers with a compact footprint which is essential when space is at a premium, without sacrificing performance or functionality.

The user will experience premier integration with ArmorStart LT and the Rockwell Automation family of Logix PLCs. The embedded Ethernet/IP and Premier Integration enable seamless data and information flow from the factory floor to the enterprise level using Integrated Architecture. You can use RSLogix 5000 for programming, setup, and commissioning.

Advantages of On-Machine Architecture does include increase of productivity which helps to build more machines faster, and the improvement of overall equipment effectiveness through excellent diagnostics.

For more information, visit:http://ab.rockwellautomation.com/motor-control/armorstart-lt-distributed-motor-controller

FOCUSPRODUCT


PowerMonitor W250 for Flexible Energy Monitoring

The Allen-Bradley® wireless PowerMonitor™ W250 measures energy consumption and delivers the data over a self-generating wireless network.

Using innovative communication technology, the PowerMonitor W250 wirelessly transmits data derived from power meters with built-in Current Transformers. The self-generating wireless network simplifies installation. The PC Receiver recognises and connects to the PowerMonitor W250 meters without additional configuration.

The latest metering device enables users to monitor multiple points to help pinpoint key energy users and to identify failing equipment before shutdown. Users can also view and assess energy usage remotely.

With the PowerMonitor W250, there are fewer components to install, and the compact size saves time and space. What’s more, timely energy information can help lower operating costs.

For more information, visit:http://ab.rockwellautomation.com/ energy-monitoring/ 1425-powermonitor-w250

Anti-Surge Control in a Cost-Effective Package

The Rockwell Automation® Single Stage Compressor Controller is a compressor anti-surge controller providing advanced control algorithms, allowing for energy-efficient operations across the compressor’s operating range.

Algorithms compensate for variations in gas composition, temperatures and pressures while patented incipient surge detection helps protect the compressor by predicting the onset of surge before it occurs. The Single Stage Compressor Controller has standard compressor capacity and load control capabilities, accommodating variable speed, inlet guide vanes or gas throttling.

It uses the Allen-Bradley® CompactLogix™ control platform, supporting an open architecture with a multitasking, multiprocessing operating system. The pre-assembled, ready-to-install cabinet includes power supplies and terminations and offers standard Ethernet and serial Modbus communications. An Allen-Bradley PanelView™ Plus human-machine interface simplifies and enhances operator interface and provides insight and control.

For more information, visit:http://www.rockwellautomation.com/ solutions/global/packagedsolutions/ singlestagecompressorcontroller.html

Profibus Linking DevicesThe EN2PA-R and CN2PA-R provide a fast and integrated

solution for adding Profibus PA field devices to any Logix platform. These linking devices provide a direct link between Profibus PA and EtherNet/IP™ or ControlNet™ (Redundant), with no intermediate Profibus-DP layer required.

The device features:• Direct Logix to Profibus PA• No Profibus DP required• Dual Port Ethernet Embedded Switch• Ethernet Device Level Ring (DLR)• Redundant PA Media (Dual Trunk/Ring)• Auto default configuration• Support FDT/DTM technology• Advanced diagnostics (oscilloscope)• Web interface

For more information, visit:www.hiprom.com/Pages/Products/ 1788_Range/1788HP-EN2PA-R/ web/1788hp-en2pa-r.htm

www.hiprom.com/Pages/Products/ 1788_Range/1788HP-CN2PA-R/web/ 1788hp-cn2pa-r.htm

Foundation Fieldbus Linking Devices

The EN2FFR and CN2FFR provide a fast and integrated solution for adding Foundation Fieldbus devices to any Logix platform. These linking devices provide a direct link to a single Foundation Fieldbus H1 Segment via EtherNet/IP™ or ControlNet™ (Redundant).

Features include:• Support for up to 16 field devices• Single Segment• Built-in Power Conditioner• Premier Integration• Dual Port Ethernet Embedded Switch• Ethernet Device Level Ring (DLR)• Redundant H1 Media (Dual Trunk/Ring)• Auto default configuration• Supports FDT/DTM technology• Advanced diagnostics (oscilloscope)• Web interface

For more information, visit:www.hiprom.com/Pages/Products/ 1788_Range/1788-EN2FFR/web/ 1788-EN2FFR.htm

www.hiprom.com/Pages/Products/ 1788_Range/1788-CN2FFR/web/ 1788-CN2FFR.htm

FOCUSPRODUCT


I/O Modules Provide High Performance for Demanding Applications

With the inclusion of Peer-to-Peer I/O Control, the latest additions to the ControlLogix® family of I/O deliver significant performance improvements, increasing production capacity and minimising system response time.

Peer-to-Peer devices (modules with Peer-to-Peer capabilities) establish in-chassis connections that allow them to communicate directly with each other. Outputs are then energised based on data received from the input peer, independent of the controller. When this method of control is employed, screw-to-screw throughput speeds are reduced, resulting in higher machine speeds.

Modules with Peer-to-Peer capabilities include: 1756-IB16IF Fast 24vdc Isolated Input module, which detects fast signals from proximity switches and other high-speed switching devices; 1756-OB16IF Fast 24vdc Isolated Output module, which provides symmetrical on/off control in response to either a ControlLogix system or any peer input device for high-speed control applications; and 1756-LSC8XIB8I 24vdc Low Speed Counter module, which provides eight 40KHz counters for applications requiring multiple counters.

For more information, visit:http://ab.rockwellautomation.com/io/chassis-based/1756-controllogix-io

Manage Multiple Controller SystemsRSLogix™ Architect software gives users a single place to manage multiple Logix systems.The software enables users to simplify deployment and management of control systems,

decrease design time, minimise errors and synchronise configuration with the EPLAN® Electric P8 to match electrical drawings to their control system. In addition, users can store Add-On Instructions and User-Defined Data Types in libraries.

Version 20 enhancements include support for RSLogix 5000 version 20; hardware support for the latest ControlLogix® 5570 and CompactLogix™ 5370 controllers; hardware support for Ethernet switches, including Stratix™; EtherNet/IP™ network design and configuration enhancements; support for Device Level Ring configurations; and import and export enhancements for Integrated Architecture Builder and EPLAN XML.

For more information, visit:www.rockwellautomation.com/rockwellsoftware/ design/rslogixarchitect/

Plug-In Modules Customise Micro830 Controllers

New Digital I/O plug-in modules enable users to cost-effectively customise Micro830™ controllers for applications that are input/output-intensive, with the flexibility to add up to 20 individually isolated relay outputs.

Total amount of I/O can be expanded up to 88 digital I/O points with five plug-in slots on the 48pt Micro 830 controllers without increasing the panel size. When used in combination with the analog, TC/RTD and serial port plug-ins, Micro830 controllers can be customised to meet your needs.

For more information, visit:http://www.ab.com/en/epub/catalogs/12762/2181376/2416247/ 10769738/10769740/ Digital-I-O-Modules.html

Operators Input Data via Touch Screen

The Allen-Bradley® PanelView™ Component C400 graphic terminals have a 4.3-in. TFT color flat-panel display and support 64k colors at a high resolution of 480 x 272 pixels.

The graphic terminals have a built-in Ethernet port along with communication support via RS232/485 and are certified for Class 1 Division 2 applications. PanelView Component C400 (27111C-T4T) terminals are optimised for compatibility with MicroLogix™ and Micro800™ controllers.

For more information, visit:http://ab.rockwellautomation.com/ Graphic-Terminals/ 2711c-PanelView- Component- C400-Terminals

FOCUSPRODUCT

Electric Cylinders Provide Precise, Dynamic Response

The MP-Series™ and TL-Series ™ Electric Cylinders contribute to reductions in mechanical design engineering, assembly, wiring and commission time.

With the ability to synchronise and coordinate with multi-axis machine motions, the MP-Series and TL-Series cylinders can be used in a range of linear motion applications. When integrated into the Rockwell Automation Integrated Architecture™, these cylinders use RSLogix™ 5000 software to extend and retract with precise positioning, velocity or force.

Cylinders feature peak feed force of up to 14679 N (3,300 lbs); speeds up to 1 m/sec; linear stroke lengths to 800 mm; and positioning repeatability of plus/minus 0.02 mm.

The MP-Series is used with either 230V AC or 480V AC Kinetix® 6x000 servo drives as well as Ultra™ 3000, Kinetix 300 and Kinetix 350 drives. The TL-Series is used with 230V AC Kinetix 3 drives.

For more information, visit:http://ab.rockwellautomation.com/motion-control/actuator/ mp-series-and-tl-series-electric-cylinders

Lifecycle Extension and Migrations Services

Lifecycle automation challenges have evolved due to advancements in technology. The Rockwell Automation® Lifecycle Extension & Migrations help to identify, mitigate and eliminate automation obsolescence risk.

Services consist of three offerings – reserve repair, remote technical support and on-site services. Lifecycle Migrations Agreements are best developed using the output of an Installed Base Evaluation™ (IBE). In the identification phase, the IBE has been enhanced to include a Lifecycle Analysis, which helps customers to pinpoint their automation obsolescence risks by site, area, line, machine and panel. Once the risks have been identified, options can be provided for immediate product migration to newer technology; or, a “service bridge” can be developed via a Lifecycle Extension Agreement.

For more information, visit:http://www.rockwellautomation.com/services/lifecyclemanagement/

Copyright © 2012 Rockwell Automation, Inc. All Rights Reserved. IASIMP-AD002A-EN-E

Understand key technical details about Rockwell Automation programmable automation

controllers with one quick glance at the Popular Configuration drawings. The drawings

provide important performance, capacity and configuration details in a simple,

easy-to-understand format. Match sample

configurations to your application and discover the value of

CompactLogix programmable automation controllers,

Condition Monitoring, Motor Control Centers and more.

Available at www.ab.com/go/iatools

Integrated Architecture Tools: Popular Configuration Drawings

Want to use IEC 61850 communications to monitor and control your IED devices?

Make the SMART choice.• Application-specificAdd-On

InstructionsandUserDefinedDatatypesautomaticallygenerated

• Usersnotrequiredtodevelopcommunicationlogicortagstructures

• ConfigurationfilestoredinaremovableindustrialSDcardwhichenablesrapiddisasterrecovery

• ExtensivediagnosticsforbothEtherNet/IPandIEC61850networks

• AllIEDdataattributesavailabletotheprogrammableautomationcontroller

IEC- 61850

Ethernet Switch

PAC

ETHERNET

RESET

ERR

FLT PWR

MS NS

CFG

LINK/ACT

100 Mbit

EIP-61850

E1

Ethe

rNet

/IP

n

IEDs

1

2

3

4

5

IEC-

6185

0

EtherNet/IP

ProSoft Technology’s EtherNet/IP to 61850 Gateway.

Where Automation Connects™ www.prosoft-technology.com/61850

(APRep)Office–MalaysiaTel:+603.7724.2080

Email:[email protected]

A S I A P A C I F I C | A F R I C A | E U R O P E | M I D D L E E A S T | L A T I N A M E R I C A | N O R T H A M E R I C A

automation - literature library

Documents