what’s new in process technology feb 2012

http://www.au.endress.com

http://www.miinet.com/au

ON THE COVER 0212CONTENTS

WHAT'S NEW IN PROCESS TECHNOLOGYFEBRUARY 2012

4 Securingthebenefitsofintegratednetworks

Convergingplantandenterprisenetworksintroducenewrisks

8 Newproducts

16 Hotproductsonline

20 Corrosionmonitoring Breakingdownthemisconceptions

32 Backgroundsuppressionphotoelectricsensors Tenkeystepsinselectingandusingthem

42 AsIseeitInformaltrainingisthemostpowerfulformofengineeringeducation

Endress+Hauser’s Levelflex family provides

precise measurement of levels and inventories

in process applications using guided radar

technology.

The innovatively engineered Levelflex FMP54

is specially designed for the most demand-

ing level measuring tasks in the oil and gas,

chemical, and power industries. Typically,

these measurements require solutions for

high temperatures and high pressures and

the FMP54 is a good match with its ability

to operate in process temperatures up to

450±C and pressures up to 400 bar.

The design of the process connection with its

ceramic-graphite seal safeguards processes

both in high temperatures and pressures such

as those that occur, for example, in steam

boilers and toxic media applications. The

second gas-tight feed-through provides ad-

ditional safety at the process connection point.

In high-pressure applications the density

of the gas phase is drastically increased,

causing changes in microwave run time.

These changes cause conventional guided

radar instruments to perform unreliably and

present risks to process safety.

The gas phase compensation offered in the

Levelflex uses a special reference reflector

to dynamically correct for this condition to

provide reliability and precision of measur-

ing results.

The Levelflex range, in particular the FMP54,

is also popular as a ‘displacer replacer’ for

legacy mechanical methods used in bypass

chambers or bridles, as it eliminates the high

maintenance and measurement drift that these

mechanical systems are prone to.

Levelflex offers more than merely a meas-

ured value.

Endress+Hauser Australia Pty Ltd

www.au.endress.com

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

NOW in DIGITAL!http://www.processonline.com.au/latest_issues

www.ProcessOnline.com.au4WHAT'SNEWINPROCESSTECHNOLOGY-FEBRUARY 2012

SECURINGTHEBENEFITSOFINTEGRATEDNETWORKS

Gordon Bartlett, Rockwell Automation

FEBRUARY 2012-WHAT'SNEWINPROCESSTECHNOLOGY 5www.ProcessOnline.com.au

© iS

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yosh

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Converging plant and enterprise networks into an integratedarchitecture is rapidly gaining ground in industry as a means toproviding a method of uniting multiple control disciplines into asingle cohesive plant-wide system. However, the use of ethernetto facilitate integration may expose the company to an increasedlevel of risk. Gordon Bartlett, Architecture & Software BusinessManager South Pacific for Rockwell Automation, discusses thecurrent approach to integrated architecture security.

arapidratedue,inpart,tothefamiliarityandusageattheenterpriselevel.Manycompaniesareusingstandardisedunmodifiedethernetasthe basis for this architecture, and the useofopenprotocolsmakescomplexautomationcontrolintegrationeasierasitrequiresfewersteps to accomplish connectivity of deviceandapplication.

It is recognised that enterprise networksprovide a door to the outside world via theinternetand,assuch,exposethecompanytoagreaterriskofintrusionsfromvirusesandmalware.Connectingtheplantfloorthroughthesamenetworkcannowpotentiallymaketheentirecompanyvulnerabletothesamethreats.

Theapplicationofsecurityprocedures isdesigned to minimise the risk of maliciousexternal attack, but unintentional securityissues fromwithinthecompanyshouldalsobeaddressedwhenconsideringsecurity.Thepotentialforbreachesaretypicallytheresultof a lack of attention to standard operatingprocedures and poor training or accidents,and account for the majority of problemsencountered.

Locking the door to the server room isnot sufficient if network access is availablefrom any computer via a default password.Equally,changingtherecipeforthecompany’sbestsellingproductshouldnotbepossibleviathe computer at reception. Solutions suchas locking doors on network infrastructurecabinets, maintaining software updates andbackups,andrestrictingaccess,bothphysicallyandelectronically, aresimplemeasures thatshould be addressed by standard operatingprocedures.

Industryisrapidlyseeingthebenefitsofintegratingthemanyfacetsofprocessand enterprise functions into a unifiedsystem.Inthepast,individualprocesses

across the plant floor used proprietary orseparatenetworks,isolatedfromenterprisebusinessapplications,whichoftenledtothedoublingupofinformationandresources.Theaimofan integratedsystemistomergethemultipledisciplinesofprocessandautomation(continuous process, batch, discrete, drives,safetyandmotion)intoasingle,streamlinednetworkthatcanbecentrallyadministeredinconjunction with the business network. Theadvantage of an integrated architecture formanycompaniesisshownthroughincreasedproductivityasassetsarebetterutilisedandinformation is accessible in real time.

Transparencythroughstandardised infor-mation presentation also allows monitoringof resource usage to help provide energyconsumption and emissions consistent withbusiness KPIs and commitments to sustain-ability.

Theuniformityintroducedbyanintegratedarchitectureallowsadditionalprocessingde-vicestobeaddedwithrelativeease.Scalabilityofthesystemisnowmanageableanddevel-opmenttimefornewhardwareorprocessesis reduced, so that businesses now have adegree of flexibility not previously availablewithdisparate systemconfigurations.

Networks and securityThe key to successfully integrating the ar-chitecture is in theunderlyingnetwork.Thedeployment of ethernet is being takenup at

6WHAT'SNEWINPROCESSTECHNOLOGY-FEBRUARY 2012 www.ProcessOnline.com.au

Networksecurity

In recent years, there have been severalhigh-profile incidents, such as the securitybreachrecentlyexperiencedbySonyinregardtocreditcardprivacyviathePlayStationplat-form.Thecompanyhascertainlysufferedasaresultofthebreach.Additionally,therecentdiscoveryofmalwarethatspecificallytargetsindustrialcontrolsystemshasbroughtindus-trialsecuritytotheforefrontinmanufacturing.As a result, there is growing recognition ofnew risks and real-world threats that arecapableofdisruptingcontrolsystemoperationandadverselyaffectsafety,productivityandtheabilitytoadequatelyhelpprotectassets,machineryand informationalike.

The potential for disastrous outcomesfrom malicious attacks has prompted somegovernmentagencies in theUSA, forexam-ple, to take a more proactive approach tosecurity and managing risk, and to identifycritical infrastructure industries in the USAthat pose a heightened risk to the public ifunderattack.Theemergingindustrialsecuritystandards from the International Society ofAutomation(ISA-99),theNationalInstituteofStandardsandTechnology(NIST800-82)andthe Department of Homeland Security (INL/EXT-06-11478) all recommend two principlestrategiestocoverthemanyfacetsofsecurityforplantandenterprise:defence-in-depthandDMZ deployment(structuringthenetworkintomanageable levels andzones).

Defence-in-depthOftendescribedasthe ‘onionmodel’duetoitsschematicrepresentation,defence-in-depth

strategies break down the various aspectsof security into five core layers.

Theouterskinrepresentsphysical securityand deals with tangible aspects such aslimitingentrytoserverroomstoauthorisedpersonnel,lockingcontrolpanelsandcabling,and the tracking and escorting ofvisitors.

Firewalls, secure switches and routersform the backbone of the second layer -network security. It is here the underlyinginfrastructure framework is protected withintrusiondetectionandpreventiontechniques.

Manysecuritymeasuresfailduetomis-managementofsoftwareupdates, includingantivirusapplications,particularlyatremotesites.Forinstance,headofficehasthelatestupdatesforenterpriseapplicationswhiletheoffsiteofficeisstillrunningaversionthathasbeensuperseded.Theriskinthisscenarioisthatthe improvedsecurityfeaturesthatareavailableinthemostrecentupgradearenotappliedelsewhere,butbotharestillconnectedviathesamenetworkinfrastructure,creatingpotential‘holes’inthesecurityblanket.Itishere - computer hardening - that the thirdlayer of the onion model takes effect. Thisstrategy can help ensure that all sites arerunning the same versions, that they havebeenfullytestedpriortoimplementation,andunusedorredundantapplications,protocolsand services are removed.

Thefourthlayer,application security,pro-videsauthentication,authorisationandauditsoftware,restrictingusersaccordingtotheiraccesslevelandtraining.Manyindustriesthatrely on batch and ingredient control, need

to provide a method of recording activityaround a process, such as who changedthe ingredients, when it occurred and whoauthorisedthechange.These recordsneedto be logged and regularly audited, whichcanhelpensurethatnobreachesaremade- intentional or otherwise.

The most internal layer of defence-in-depthdealswithdevice hardening-protectingtheactualcontrollers,drives,motors,valvesand other automation and control devicesfrom intrusion and security breaches, andapplying change management and disasterrecovery procedures.

Zoning the networkThedefence-in-depthstrategygivesasystem-aticapproachtosecurityfromoneendofthebusinesstotheother,butdoesnotprovideacomprehensiveframeworkforprotectingtheinformationflowthroughoutthenetwork.TheISA-99approachestablishesaManufacturingNetwork Security Framework, allowing theoverall plant and enterprise network to bebrokenintolevelsand‘zones’.Each‘zone’isdefinedasanaggregationofresourceswithsimilarprocesses,accessrequirements,riskpointsandsecuritystrategies.Forexample,enterprisefunctionssuchasemail,intranet,planning and logistics are grouped into the‘Enterprise Zone’. The manufacturing zonewillcontaintheplant-flooroperationalhard-wareandsoftwaresuchasproductioncontrol,process history and other decision-makingtoolsforproduction.Thefinalzone,the‘CellZone’isasubsetofthemanufacturingzone

AS WITH MANY COMPANY-WIDE STRATEGIES,

THE SUCCESS OR FAILURE WILL BE DEPENDENT

ON TRAINING, MONITORING, MAINTAINING AND

VALIDATION. THE MOST SOPHISTICATED SECURITY

MEASURES WILL NOT WORK IF PASSWORDS ARE

NOT REGULARLY UPDATED, ACCESS DOORS ARE

LEFT WEDGED OPEN, USB DEVICES ARE NOT

AUTOMATICALLY SCANNED FOR POTENTIAL VIRUSES,

AND SOFTWARE IS NOT EMPLOYED TO ONLY ACCEPT

‘KNOWN’ USB DEVICES.

Figure 1: The ‘onion model’ describes the strategic defence-in-depth ap-proach to ensuring that security covers all aspects of plant and enterprise.


andcontainsoperator interfaces,batchanddiscrete controllers, sensors, drives, actua-tors and robotics.A fourth and crucial zone exists betweentheEnterpriseZoneandManufacturingZone,known as the demilitarised zone (DMZ).Actingasabufferzonebetweenenterpriseand plant, it enforces security strategieson information passing between the twonetworks. Information cannot communicatedirectly between enterprise and plant andmust terminate or originate in the DMZ. Akeycomponenttofacilitatetheeffectivenessof the DMZ is a firewall on each side.

Effective security strategiesAs with many company-wide strategies,the success or failure will be dependenton training, monitoring, maintaining andvalidation. The most sophisticated securitymeasures will not work if passwords arenot regularly updated, access doors areleft wedged open, USB devices are notautomatically scanned for potentialviruses,andsoftwareisnotemployedtoonlyaccept‘known’ USB devices. Many of the securitybreaches that occur daily do not alwaysoriginate from outside sources - many aredue largely to poor personnel practice andprocedures. Training staff on security poli-cies and procedures must be incorporatedinto the whole business infrastructure if itis to be successful.

Theimplementationofsecuritymeasuresraises some valid concerns, particularlysecurity of devices sourced from suppliers

and validation of their operation. Ongoingcollaborations between companies such asRockwell Automation and Cisco Systemscontinue to develop and provide validatedequipmentthat iscompliantwiththeguide-linesandstandardsderivedbyISA,NISTandDHS.Implementationandmaintenancestrate-giesarethereforeintegratedintoautomationsupplier products and services, whether itis for ethernet or some other proprietarynetwork or protocol.

Companies must undertake risk as-sessments and estimate the probability ofa security breach to determine the levelof protection required in proportion to thecritical nature of the control or process.The use of firewalls, patch managementstrategies, business continuity plans, intru-sion detection and protection systems willneed to be implemented across the plant.The level of security an individual processmay require is dependent on the perceiveddamageasecuritybreachmaycause.Decid-ing what course of action should be takenin the event of a security breach will alsoneed to be considered.

It istheresponsibilityofboththe ITandengineering departments to ensure that allfacets of the security strategy are in placeanduptodate.Protectionoftheplant,basedonperceptionofacceptablerisk,willneedtobe in accordance with company policy andindustrystandards.Evaluationofthesecuritysystemisachievedthroughauditing,monitor-ing and re-evaluation of all components sothe whole system is adequately maintained

in order to deal with current threats andalsohavetheabilitytorespondtothethreat.

As automation and processing systemsmove away from isolated components ofprocessing and enterprise, to operate overasingleplant-widenetworkenvironment,thelevelofriskforsecuritybreachesincreases.To implement, manage and maintain a suc-cessful security system is to recognise thepotential hazards, assess the risk and de-terminethesecurity requiredandgaugetheimpact on business operations if a securitybreachoccurs.

Integratingsecurityintotheoverallnetworkarchitecture will greatly enhance the abilitytoapplysecuritymeasuresacrossall facetsofbothplantandenterprise.Usingstrategiessuchasdefence-in-depthandzoning(creatingaDMZ)helpensurethatnotonlyaredevicessuchasswitchessecure,butmanagementcanbe confident that their business is meetingthe standards and recommended practicesto complywith regulatorybodies.

To successfully implement a securitysystem is to establish corporate strategiesand policies so all personnel are trainedin its use and application. Maintaining andmonitoringthesystemcanhelpthesystemoperate with minimal impact of known se-curity risks, both internal and external, aswellashavingthecapabilitytohelpprotectagainst new threats.

Rockwell Automation Australia

Contact info and more items like this at wf.net.au/P236

Figure 2: Conceptually, the company network is broken into levels based on complex-ity, operational behaviour and security risk. The use of the demilitarised zone provides the plant floor with a security buffer to the enterprise network.

Networksecurity


NEWPRODUCTS

IP67 SMART CAMERASThe NI 177x range of smart cameras features a 1.6 GHz

Intel Atom processor for increased processing power and an

IP67 rating to protect the hardware from dust and water. The

cameras also have a real-time operating system to deliver

the reliability and determinism needed on a production floor.

Using the Intel Atom processor, the 177x range can deliver

processing speeds four times greater than previous models.

They also have updated sensor options, including VGA,

1.3 MP and 2 MP in colour and monochrome as well as

5 MP in monochrome. A strong mechanical housing, M12

connectors and lens cover make the cameras dust and water

resistant and suitable for environments with washdowns.

The cameras include four digital input and four digital

output lines and support several industrial communica-

tion protocols including RS232 (serial, Modbus serial) and

ethernet (TCP/IP, EtherNet/IP, Modbus/TCP). The cameras

also include a VGA video out connection for monitoring

inspection images.

The NI 177x smart cameras are shipped with NI Vision

Builder for Automated Inspection (AI) 2011 software, a

menu-driven, interactive environment for configuring,

benchmarking and deploying vision systems. The cameras

can also be programmed using NI LabVIEW graphical

programming and the NI Vision Development Module

for advanced customisation and integration with

other National Instruments hardware.

National Instruments Australia

Contact info and more items like this at wf.net.au/L830

DUAL-MEMBRANE PH ELECTRODEThe InPro 4850i inline pH electrode is designed specifically for the requirements of the chloralkali

industry. The electrode incorporates a sodium-sensitive glass membrane that uses the brine

present in chlorine production as a reference. This reference system is hermetically sealed,

providing a barrier against oxidising agents.

The electrode does not have a diaphragm, therefore poisoning of its sodium reference system

is impossible. This design ensures stable measurement and eliminates sensor drift.

It also uses Mettler Toledo’s intelligent sensor management (ISM) technology that converts

the analog measurement signal into a low-impedance digital signal that is immune to electrical

interference, ensuring 100% signal integrity and stability. ISM technology also offers sen-

sor self diagnostics, precalibration of sensors and plug-and-measure start-up

to simplify installation and maintenance tasks.

Mettler Toledo


MULTICHANNEL DAQ SYSTEMThe TMR 200 data acquisition system from TML,

Japan, is a compact multichannel data acquisition

system that enables the use of a combination of

various sensor inputs according to measurement

purpose.

A high-speed sampling rate of 100 kHz is possible

and sensor input units include not only analog I/O for

strain, voltage, temperature, etc. but also digital I/O

for CAN, voice/GPS and a telemetry interface unit.

Up to 80 channels can be used at any one time.

Real-time histogram analysis (option) as well as

waveform recording is available. The colour LCD unit

makes data acquisition possible without a computer,

while interfacing with a computer allows for more

sophisticated histogram analysis.

The vibration tolerance of the system and its

small size make it suitable for use on board a ve-

hicle. Battery operation is also possible, as is data

recovery at power interruptions and measurement

restart at power recovery.

The data acquisition system is compatible with

large-capacity CF cards, and the data

acquisition system also has USB

and LAN interfaces.

Bestech Australia Pty Ltd


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NEWPRODUCTS

SAFE I/O MODULEThe 0942 UEM 612 I/O module from Lumberg Automation is

designed for use with the LioN-Link decentralised Fieldbus

system. It fulfils protection class requirements IP67 and has

four digital M12 slots with a higher limit on the output voltage,

permitting 2 A per line and 6 A in total. These outputs are

designed for safety-related applications up to performance

level D, making this I/O module suitable for failsafe control

of actuators or - following a complete switch-off of the

24 V output power supply - reliable emergency OFF functions.

Terminal equipment can be connected directly to the I/O

module so there is no need for terminal boxes, which

are comparatively expensive and complicated to install.

This makes it possible to implement cost-effective safety

solutions that can be used, for example, in mechanical en-

gineering applications or in the assembly and handling sector.

Depending on the selected LioN-Link bus coupler, this I/O

module can be used in ProfiNet, Profibus, DeviceNet or CAN-

open networks. Setup of the modules is simplified because

LioN-Link systems do not use slave address assignments

and do not require terminating resistors. The sturdy housing

measures 182.4 x 30 x 28.4 mm (L x W x H) and weighs

200 g. The module’s other features include a temperature

range of 10-60°C, high vibration and shock resistance and a

power supply configured for a voltage range of 19-30 VDC.

Belden Australia Pty Ltd


STRAIN-GAUGE AMPLIFIERFutek Advanced Sensor Tech-

nology has released its

upgraded CSG110 strain-

gauge signal amplifier. 95%

of the amplifier’s parts have been revised, reduc-

ing noise output, increasing bandwidth and implementing co-amps.

The amplifier is now CE approved to the highest criteria, making

it compliant for all medical, industrial and consumer applications.

Output noise has been reduced to ten times less than that of the

previous model. Short-circuit protection has also been added and

DIP switches have replaced the soldering of the internal components,

making the CSG110 free of any lead-based materials and therefore

RoHS compliant. This 1 or 10 kHz amplifier has the option of being

modified to support 25 kHz.

Metromatics Pty Ltd


RADIATION-BASED BELT WEIGHERWeighTrac is a radiation-based sensor for precise determina-

tion of the feed rate of bulk solids. It measures contactlessly

with the help of gamma radiation and is suitable for mass

flow measurement on conveyers. Its frame construction al-

lows simple installation and retrofit.

WeighTrac is the radiation-based alternative to mechanical

belt weighers: it delivers the current flow rate as well as the

summed throughput of bulk solids on conveyor belts or in

screw conveyors. The radiation-based measuring method

detects material flow reliably, even on wide conveyor belts.

WeighTrac can also be retroactively installed on existing

conveyance systems without great effort.

Radiation-based flow rate measurement is based on radia-

tion absorption by layers of bulk solids - these attenuate the

gamma radiation in proportion to the quantity and density

of the material. WeighTrac calculates the

mass throughput from the intensity of

the incoming radiation and the speed

signal from the tachometer.

The Vega plics instrument concept,

in conjunction with WeighTrac, makes

setting up and operating a flow rate

measuring system simple. Setup and

commissioning of the system is easily

carried out on a PC with the help of DTM/

FDT technology supported by intuitive

menus and intelligent assistants. As an

option, the indicating and adjustment module PLICSCOM

can be used for on-site indication of the measured value.

VEGA Australia Pty Ltd


Some people don’t understand the importance of selecting a high performance control valve in their process plant. We do.Some people think that all valves are created equal. We don’t.

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Best in Class Products. Highly Experienced Engineers. Always Striving to be Better.


Nanofiltration increases water production capacity at beverage plant

A six-month project, completed by OvivoAustralia in just 12weeks,hasenabledtwolarge beverage companies to increase theirproductioncapacityby420%.

ThejointventurebetweenFrucorNZandSlade’sBeverages inThomastown,Victoria,wastoincreasetheproductionofwatersupplybyinstallingananofiltrationsystem.ThishasallowedfortheproductionofanewrangeofVEnergydrinksandotherproductsusingwaterdirectlyfromthepotablesupply.

The client required a 30 m3/h supply ofconsistent quality demineralised water toensurethatflavourswerenotaffected.Thenanofiltration systemwas recommendedbyOvivoAustraliaduetoitssmallfilterporesizewhichisfineenoughtoremovecontaminatingflocculantsanddivalentmetalions.

Theprocess,designedtotakefeedwaterfromMelbourne’spotablewatersystemandtreatittoremovefineflocculentparticlesanddissolved metal impurities, was completedbyOvivoAustraliawiththesupportofVan-Der-Molen GmbH, a member of the Ovivowatergroup.

The integrated nanofiltration plant andpermeate transfer system was delivered atthe end of May 2011. As well as removingthe impurities,thesystemalsoallowsforaconsistentqualityofproductwaterintermsofhardness,TDSandpH.Thisenablestheclientto accurately control the flavour as well asthecarbonationprocessinsoftdrinkmaking.

Analysis of local potable water samplesshowedTDSlevelsof100mg/L.Thesystemwas designed to reduce these to less than55mg/LandmaintainaconsistentpHof6.2to6.5.Thesystemwasalsodesignedforan82-85% recoveryof the potablewater feedutilising a 3-stage, single-pass treatmentprocess.

The nanofiltration plant utilises mainswaterpressuretofeedthroughapretreatmentprocesswhichinvolvesPIDcontrolleddosingof antiscalant and SMBS for membraneprotection.AdditionalcartridgefiltrationpriortotheNFplantisinplacetoprotectagainstparticulatesfromdepositingonthemembrane.A15kWverticalmultistagepumpdrivesthe

36m3/hfeedtotherequiredpressuretopushthewaterthroughthemembranes.

The generated permeate is maintainedbelowan80µS/cmconductivitysetpointbyadischargeconductivitymeter.Permeatewhichisabovethislimitisdischargedtosewerviaanoff-specvalvetomaintainaconsistentqualityproductinthepermeatetank.Thepermeateisstoredinaproducttankbeingdeliveredtotheclient’sprocessesviatwoVSDcontrolledcentrifugal pumps. An integrated recyclesystem is implemented to allow delivery ofpermeate fromtheproducttankbacktothenanofiltrationplantforuseintheCIPprocess.

As the feed water is potable water, thedischargeTDSonthebrinesideisextremelylow. TDS levels in the discharge are only370mg/LwithapHof7.8,whichhasmeantthewatercanberecycled.

Ovivo provided an online quality controlsystem to ensure all water delivered waswithinthe85µS/cmqualityspecification.

Theintegratedcontrolsystemmeanstheplant operates as a self-contained turnkeyplant and HMI software includes a CIPprocedure walkthrough feature to removethe riskofoperatorerrorduringmembranecleaning.

As well as the challenge of meeting a12-week delivery schedule, Ovivo Australiafaced a second test of having to increasethepackagesizewhenproductstoragewasaddedtotheprojectscopeanddeliveredwithjust four weeks remaining. An integratedautomaticproducttransferpumpingsolution,includingthreepumpsandasecondaryVSDcontrolpanelandupgradestotheexistingNFcontrolpanel,werealsoaddedtothescopeanddeliveredwithin10days.

There are a number of benefits ofnanofiltrationoverareverseosmosissystem.Nanofiltrationusesasmallenoughfilterporesizetoremovecontaminatingflocculantsanddivalentmetalions,andthewaterqualitystillcontainsvitaldissolvedsaltssothat itdoesnot require significant remineralisation forhuman consumption. The energy requiredperunitofproductislowerandthereislowercapitalexpensein implementation.Also,theproductwater,duetoitshighquality,canbeusedforboththemanufactureofthebeverageflavouringaswellasthecarbonatedmake-upwater.

Ovivo


http://www.pca-aus.com.au


NEWPRODUCTS

SERVOMOTOR TERMINALThe EL7201 servomotor terminal for the EtherCAT

Terminal system is designed for highly dynamic

positioning tasks. It integrates a full servo drive in-

cluding an encoder system into a 12 mm terminal.

The terminal is suitable for the direct connection of

servomotors up to 200 W, and combining it with

servo motors from the AM3100 series enables the

implementation of an inexpensive servo axis. Due

to the high torque and the high, stable speed, this

drive solution is suitable for pick-and-place applica-

tions and for use everywhere that high dynamics,

compact design and exact positioning are required.

The complete integration of the drive technology into

TwinCAT automation software enables programming

and configuration to be carried out conveniently in

one tool. As a result, engineering is simplified and

diagnostics are improved. TwinCAT PLC provides

the user with a multitude of software function blocks

which, due to their high degree of abstraction, can

be applied to the different types of axis for a wide

variety of functions.

Beckhoff Automation Pty Ltd


CUSTODY FLOW COMPUTERThe FloBoss S600+ is a panel-mounted fiscal flow

computer designed specifically for hydrocarbon

liquid and gas measurement where versatility and

accuracy are high priorities. It allows multistream,

multistation applications to be configured for si-

multaneous metering of gas, wet gas, crude oil,

refined products, LPG and NGL. The computer

has two full duplex high 100 Mbps ethernet ports

and nine serial ports as standard, which provides

greater metering and integration capability. With

Coriolis and ultrasonic meters being increasingly

utilised in the field, the S600+ has been designed

to further enhance these metering technologies.

The extended data logging and archiving pro-

vides additional security and reduced operational

costs for remote sites. In the event of a

supervisory system failure, data integrity

and audit trails are maintained.

The computer provides an in-built web

server with improved security that allows

for remote diagnostics, report access

and configuration.

Emerson Process Management


http://www.ams-ic.com.au


PRESSURE CALIBRATORThe Crystal nVision Pressure Calibrator 30 bar is an intrinsically

safe NATA-certified pressure calibrator. It displays real-time

recorded data graphically on a high-resolution screen and

can be used to download the data during testing.

The pressure calibrator allows users to zoom and scroll

within specific events to observe the repeatability and

performance of pressure safety valves. The device also

logs and displays 500,000 data points on two sensor

modules simultaneously.

It comes configured with an MA20 current, voltage

and switch test module and 30 bar pressure module,

and includes a hand pump and CPF (finger tight to

700 bar) fittings. It is capable of ten readings per

second and has an accuracy to 0.025% of reading.

The enclosure is IP67 rated.

TechRentals


DSL PROFIBUS EXTENDER WITH SURGE PROTECTIONThe DSL Profibus extender from

Phoenix Contact is designed to enable

straightforward integration of remote

Profibus devices at data rates of up to

1.5 Mbps. The extender has two DSL

connections per device. This means

that, in addition to point-to-point con-

nections, the extender can also be

used to establish line structures with

up to 30 devices.

To protect the communications modules, surge protection is required

for both DSL connections. The DIN rail-mountable DSL surge protector

offers two a/b connections per screw terminal. When designing a line

structure, users therefore need only one surge protector per intermediate

station, saving space in the control cabinet and lowering costs.

Phoenix Contact Pty Ltd


DISTRIBUTED MODULAR I/O SYSTEMBalluff’s new generation of distributed modular I/O can be

used in a cost-effective way to replace standard slice I/O

and distributed I/O solutions. Offering IP67 protection and

industry-standard connectors, many types of control data

can be collected. Using standard 3-conductor cables, up to

four slave devices can be connected to each master block,

which communicates over the industrial ethernet network to

the controller.

In lieu of a backplane, each I/O device is connected to

an industry-standard M12 port, creating an IP67 connection.

With the ability to be installed within a 20 m radius from the

master device, slave devices can be easily distributed across

the machine. Utilising a widely accepted and open point-to-

point technology, IO-Link, a distributed modular I/O system

is fieldbus independent, easily configured and vendor neutral.

Types of distributed modular I/O slave devices that are avail-

able include discrete I/O, analog I/O, valve manifold control,

industrial RFID processors and heads, and specialty sensors

for measurement, position or colour detection.

Industrial ethernet master blocks are available with EtherNet/

IP or Profinet protocols. EtherNet/IP masters support daisy-

chain connections with a built-in switch as well as support the

Device Level Ring (DLR) topology for easier troubleshooting.

Profinet blocks support Fast Start Up (FSU) as well as the

Link Layer Discovery Protocol (LLDP) for easy set-up right out

of the box. Both master devices have easy-to-use, lockable

push-button displays for quick set-up and provide webpages

for configuration or diagnostics purposes.

Balluff-Leuze Pty Ltd


NEWPRODUCTS

http://www.metromatics.com.au

http://www.EmersonProcess.com/PumpHealth


HOT PRODUCTSON WWW.PROCESSONLINE.COM.AU THIS MONTH

>>

>

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WIRELESS REMOTE NETWORK MODULEThe WNM wireless network module pro-

vides a low-cost wireless communications

link between field sites that are in rugged

or impassable terrain, at distances of up

to 48 km.

Moore Industries Pacific Inc.

WF.NET.AU/P246

WIRELESS ACCESS POINTThe APXG-Q5420 industrial

wireless access point is de-

signed to enable M2M equip-

ment to become the centre of

a self-sufficient Wi-Fi network.

Interworld Electronics & Computer Industries

WF.NET.AU/L927

THERMAL DISPERSION FLOW SWITCHThe Series TDFS thermal dispersion flow

switch indicates whether the flow rate is

above or below a user-set flow rate with

NO and NC NPN outputs.

Dwyer Instruments (Aust) Pty Ltd

WF.NET.AU/P223

HIGH-TEMPERATURE PRESSURE TRANSMITTERThe Keller Series 35X HTC pressure transmitter

is primarily designed for hot media in biotech-

nology and food industry applications.

Bestech Pty Ltd

WF.NET.AU/P164

SOUND AND VIBRATION SUITE The latest version of the NI Sound and Vibration

Measurement Suite software provides a comprehensive

collection of analysis and signal processing tools for

noise, vibration and harshness (NVH) testing, machine

condition monitoring (MCM) and audio test applications.

National Instruments Australia

WF.NET.AU/L952

Little on size, Large on performanceIntroducing the new L Series programmable controller

proven performance / global strength / cost effective solutionswww.mitsubishielectric.com.au or call us on 02 9684 7777


NEWPRODUCTS

How do you improve reliability and still save money?

Improve reliability with UE electronic pressure and temperature Switches. Available for hazardous locations the One Series provides precise control and features Plugged Port detection.

■ Solid State design with no moving parts■ Field programmable for set point and deadband control■ 2-Wire design is a drop-in replacement for mechanical switches■ IAW®(I am working) self diagnostics■ Pressure ranges to 4500 psi/Temp. ranges to 1000°F

Pryde Measurement Pty LtdPh: 1800 688 211 [email protected] ❘ Sydney ❘ Brisbane ❘ Perth

UE Solid State Pressure Switches

FANLESS PC WITH HAZARDOUS AREA APPROVALAcromag’s rugged I/O Server

industrial PC is now UL/cUL

listed with approval for use in

Class I Division 2 Groups A, B,

C, D hazardous environments

containing volatile substances.

Already ruggedised for com-

puting in sites subject to ex-

treme temperatures, shock

and vibration, the Acromag

I/O Server industrial PC now

has Underwriters Laboratory (UL) certification for Class I Division 2 Group

A, B, C, D hazardous locations with volatile substances. This UL approval

permits use of the I/O Server fanless embedded computer and its plug-in

I/O modules in environments with flammable liquids, gases or vapours.

UL’s Class I Div 2 certification is often required for electronics deployed in

chemical, oil, gas, mining and other manufacturing facilities.

With the higher safety rating, the I/O Server can be installed closer to

sensors and actuators to reduce installation costs for monitoring and control

of automated machinery. Additionally, the I/O Server has no internal cables

and conduction cooling removes heat without open vents or fans for more

reliable operation from -40 to 75°C.

Metromatics Pty Ltd


SHIELDED ETHERNET PATCH CABLESWeidmuller’s Cabinet Line Cat6A shielded ethernet patch

cables are suitable for use in industrial and manufactur-

ing environments or where electrical noise is present.

Purposely designed for industry, the cables feature

overall screen with foil around each twisted pair and

shielded plugs to help combat the excessive electrical

noise that is often found in industrial environments.

The cables are low-smoke zero halogen type, in accord-

ance with IEC 60754-2, IEC 60332-1/UL 1581 FT2, and

come in various lengths from 0.5 to 25 m for easy use.

They are available in a range of colours for quick and

easy identification. Straight cables come in grey, blue,

black, yellow, green, red and magenta.

The company has also released 90 and 270° angled

cables that are available in grey and suitable for tight

bend radius in cabinets.

Weidmuller Pty Ltd


UPDATED HISTORIAN SOFTWAREThe CitectHistorian V4.30 and Vijeo Historian V4.30 are now compatible

with the latest Microsoft technology platforms, helping boost overall

performance and responsiveness of the system.

With an easy-to-use interface and active data transfers, CitectHis-

torian and Vijeo Historian can push data from the control systems

to the business systems. This means the appropriate levels of plant

detail is provided for process evaluation and decision making by

senior management.

Key characteristics of V4.30 include: full compatibility with Micro-

soft Windows 7; full support for Microsoft Windows Server 2003 R2,

Microsoft Windows Server 2008 R2 and Microsoft SQL Server 2008 R2

(standard edition); both 32- and 64-bit operating system support; and

enhanced reporting functionality with the new Dundas chart controls

available in SQL Server 2008 Reporting Services (SSRS).

The Dundas chart controls are able to support new chart types and

provide more control over chart axes and formulas. The improved user

interface makes it easier to create and work with charts, resulting in

enhanced data layout, visualisation and text formatting. The Dundas

chart controls also offer Dundas Gauge, which adds dashboard and

score carding features to the reports.

Schneider Electric (Australia) Pty Ltd


• Upgrade critical central processing unit

(CPU) which takes account of recent

technological advances.

• Multi-stream Configuration, multi-station

applications metering of gas, wet gas, crude

oil, refined products, LPG & NGL’s, etc.

• Extended data logging facilities.

• Increased communication capability,

serial and Ethernet.

• Unprecedented support for global

measurement standards.

T 1300 553 051

E [email protected]

W EmersonProcess.com/Remote

http://www.EmersonProcess.com/Remote

20WHAT'SNEWINPROCESSTECHNOLOGY-FEBRUARY 2012

CORROSIONMONITORINGBREAKINGDOWNTHEMISCONCEPTIONS

Thelatesttechnologylinkscorrosiontoprocessconditionsmoredirectly and immediately. It also allows corrosion depreciationto be assessed in much shorter time intervals with the abilitytocontrolandmitigatethe rateofdamageandmoreaccuratelyfactor in its true economic impact on plant operations.

Sridhar Srinivasan, Global Business Leader, Honeywell Corrosion Solutions, USA


Instrumentation

Increasingproductivityandreducingcostsisthecatchcrywe’veallheardtimeandtimeagainascompaniesareforcedtoturntonewtechnologiesandbusinesspracticestomeettheirobjectives.

The process control industry has not been isolated fromthis activity; however, new productivity and cost reduction ideashavebecomemoredifficulttoidentifyasplantandprocessactivitybecomesmoreintricateandcomplexinordertoreducemanpowerand expensive overheads. Corrosion control is just one of thoseareas. With a high potential for productivity improvement or costcontainment,managingcorrosionwithintheprocesscontrolindustryhastakenaslowbutsteadymovetowardsnewmeasurementtoolsthatmoreaccuratelyassessandmanagecorrosioninanumberofdifferentenvironments.It’sinterestingtoseethatthisslowrateofpick-upcanmost likelybeattributedtoconventionalthinkingthat:

•replacingplantassetsseverelydamagedbycorrosionissimplya cost of doing business;

•reactingtocorrosionproblems istheeasiestandonlyknownapproach within the market.

Many engineers in the chemical process industries (CPI), forexample,seecorrosionona‘straight-linebasis’intermsofrepair,maintenanceandreplacementduringfixed-intervalturnaroundinspec-tions.There isalsoagenerallyheldmisconception thatcorrosionoccursatarelativelyconstantrateovertime.Inreality,amajorityofcorrosionexperiencesintheseprocessesactuallyoccursduringshort periods when specific process conditions develop.

Buthowcananengineerknowthiswithouttherighttoolsandinstrumentationemployedtodeterminethis?Here,newtechnologycan assess corrosion deterioration in real time, using the plantcontrol and automation system.

The value of corrosion depreciationTomanyCPIengineers,corrosionissimplyaroutinepartofplantoperationsandacostofdoingbusiness.Acorrosionspecialist iscalledwhenaproblemarises.Oncetheproblemissolved,theplantoperatesmoreor less asbefore, until thenext upset occurs.Themajor impactofcorrosiontothebusinesslies incostsassociatedwith lostproduction,health, safetyandenvironmental issues, andlegalliabilities.Thisisotherwiseknownas‘corrosiondepreciation’.

Thelatesttechnologylinkscorrosiontoprocessconditionsmoredirectlyandimmediately.Italsoallowscorrosiondepreciationtobeassessedinmuchshortertimeintervalswiththeabilitytocontrolandmitigate the rateof damageandmoreaccurately factor in itstrue economic impact on plant operations.

New technology allows corrosion monitoring to be assessedvia the plant distributed control system (DCS), whereby corro-sion measurement is coupled to a suite of key, real-time processvariables. This process can lead to gains in many parts of thecorporate balance sheet.

What’s new in corrosion monitoring technology?Theemergenceofonline,real-timecorrosionmonitoringhasmadeit possible to improve the relevance of corrosion measurements.Thisapproachalsoreducesthemanualeffortandthehighexpense

required to obtain this information. Most importantly, corrosioninformation can be obtained quickly, sometimes in a matter ofminutes, and in amanner consistentwith that used for collectingother key process data.

This approach utilises existing data acquisition and automa-tionsystems found inproduction facilities.Forexample, theplantDCS isused tomonitor andcontrol processes, trendkeyprocessinformation,andmanageandoptimisesystemproductivity.Corro-sion monitoring can be integrated into this system, and the datacanbeautomatedandviewedwithotherprocessvariables (PVs).Theadvantagesofthisapproachoverstand-alonesystemsinclude:

•Increased cost effectiveness;•Decreased manual labour to achieve key tasks;•Agreaterdegreeofintegrationwithin-placesystemstorecord,

control and optimise efficient distribution of important infor-mation(corrosionandprocessdata,relatedworkinstructionsand follow-up reports) among different groups required forincreased work efficiency and ease of documentation.

Offline measurementCorrosioncouponshaveunderpinnedindustrialcorrosionmonitoringformorethan50years.Couponsmustbepre-weighed,distributedtoremotelocations,installed,retrieved,examined,cleanedandre-weighed before the data is processed. Therefore, a good deal ofcorrosionengineeringandrelatedtechnicalstafftimeisconsumedwithmanualandoftenroutinetasks,aswellaswithmanipulatingand viewing historically averaged, offline data. Coupon measure-ments are offline, labour intensive andnotvery easily configured.

Online measurementInsomecases,corrosionprobesusedtomonitor industrialplantsand pipelines are connected to field data loggers that take corro-sion rate measurements over a period of weeks or months. Thisapproach is often referred to by corrosion engineers as “onlinemonitoring”,despitethe factthedatacannotbeaccessed,viewedor acted upon in an online, real-time manner. These techniquescanretrospectivelyidentifypeakcorrosionratesandtimeperiods.

The current perception is that there is a high per-point costassociated with conventional corrosion monitoring approaches,largely due to the high cost of a separate infrastructure and thelarge commitment of time and labour. Additionally, there is a lowperceivedvaluebecausethedataishistoricalandisviewedweeksandmonthsafterbeingobtained.Giventhisperception, there isatendency to limit resources for corrosion monitoring because theapproach is expensive with only a limited chance of success. Italso continues to surprise us thatwhilemanyplant operators tryto squeezeout a 1-2% improvement in efficiency andproductivitywhentheyarestaring into the faceofdouble-digit cost reductionimprovementsthroughcorrosioncontrol,particularlyiflostproduc-tion opportunity is included.

Online, real-time measurementFeedbackfromreal-timecorrosionratedataandadjustedchemicaldosagecanofferadditionalgainsinefficiencyandreducedoperat-ing costs, as well as extended run time. Corrosion monitoring has©

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Instrumentation

developed from a manual, offline process to an online, real-timemeasurement (Figure 1).

Theinitialdrivingforceforthismigrationisthebenefitofautoma-tion; that is, reduced time and effort to obtain corrosion data withhigh data reliability. Corrosion monitoring takes on new meaningwhen it canbeviewedat ahigher frequency (withinminutes) thatis consistent with the way process variables are measured. Moredata leadsto increasedstatisticalrelevance,quickerresponsetimeand a greater ability to understand corrosion in the context of theprocess being monitored.

Theseconddriverforthismigrationistheabilitytointegratethecorrosion data immediately with process data. This is done in anautomatedmanner,withintheplantDCS,ratherthanbythemanualmethods traditionally available to the corrosion engineer. Some ofthe usual PVs that are used and measured in CPI control systemsinclude the following: temperature; pressure; flow rate; chemicalinjectionrate;moisturecontent;valveactuation;levelmeasurement;and analytical data, such as pH, dissolved oxygen and others.

Corrosion transmittersIf we take a multivariable corrosion transmitter, for example, thetransmitteremploysasuiteofautomatedelectrochemicaltechniquesthatrunintheonboardmemoryofasingletransmitterandareusedtocomplementoneanother.Thistransmitterproducesgeneralcor-rosion rate data by combining linear polarisation resistance (LPR)measurement and harmonic distortion analysis (HDA) for greatercorrosion-rate accuracy, where:

•LPR involves the measurement of the resistance to a pulsedvoltage between electrodes immersed in the corrosive solu-tion, whereby the resistance calculated is inversely related togeneral corrosion;

•HDA is the technique used in combination with LPR wherebyalternating voltages are applied to an arrangement of threeelectrodes and the primary frequencies and harmonics of theresulting currents are analysed.

The transmitter also provides completely new information ob-tained on the localised nature of corrosion from electrochemicalnoise(ECN)measurements.TheseECNmeasurementsincludesmallcurrentsandvoltagesgeneratedatthecontactsurfacebetweenthecorrosivesolutionandthevessel,andprovideagoodtechniqueforthe detection of pitting corrosion.

Whenjoinedinanautomatedcycle,thesetechniquescanprovidetwo critical, operator-level corrosion PVs at a similar frequencyofmeasurementasexpectedforcurrentprocessvariables.Theseoperator-level corrosion PVs are:

• Corrosion rate: LPR corrosion rate adjusted for a measuredBvalue (see below) determined by HDA;

• Pitting factor: Derived from ECN and LPR measurements,providingathree-decade logarithmicscaleranging fromgen-eral corrosion, through a cautionary zone, to localisedpittingcorrosion.

TwoadditionalPVscanalsobeprovidedthroughtheprocesscon-trolsystemforspecialistobservation,diagnosticsandintervention:

B value: Also called the Stern Geary constant, the B value isderivedfromHAD,involvingthereal-timemeasurementoftheanodicand cathodic Tafel slopes. This value is used to adjust the LPRcorrosionrateswiththeelectrochemicalprocessesinthesystem.

Corrosion Mechanism Indicator (CMI): Indicating conditionsand trends of passivity in stainless alloys, corrosion inhibition orscale formation.

Inadditiontothesetypesofreal-timemeasurements,theremaybe a need to include other online-compatible measurements intothe process control and automation system, when they can bringadditional value or longer-term corroboration for uses in assetassessment and integrity evaluation.

Thesecorrosion assessment techniques are evenmore attrac-tive if theycanbeeasilyautomatedandcoupledwiththemoderncommunicationmethodssuchaswirelesstechnologies.Techniquesinclude electrical resistance corrosion measurements, ultrasonicthickness,pulsededdycurrentandfibre-opticstrainmeasurement,as well as other ancillary techniques that may become availableas these complementary technologies develop.

BenefitsThroughtheintegrationofcorrosionwithmodern,industrialprocesscontrol technologies,anarrayofsubstantialoperationalandcost-saving opportunities become available. Discussions with refineryoperations and corrosion personnel also show the key benefitswhen deploying these new technologies:

•Increasedabilitytoprocesscrudeswithhighermargins-lead-ing to large savings and increased profits.

•Reduced cost of unscheduled shutdowns.

Figure 1: Corrosion monitoring has evolved from off-line to online and online, real-time measurements


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Instrumentation

•Improvedassetreliabilityresulting in improvedrun length-upto 10% reduction in maintenance costs.

•Improvedunitoperationasaresultofbettercorrosionmonitoringthat may result in a 2% increase in throughput, or potentiallythe ability to process more of a lower quality feed.

•Reducedhealth,safetyandenvironmentalexposureresultingfromfewerunscheduledemissionstotheenvironment-3%savings.

•Improved safety record as a result of fewer shutdowns - 5%reduction in cost.

•Savings due to optimised chemical cost resulting from bettermonitoring - 10% reduction.

•Increasedoperatoreffectivenessbybringingthecorrosiondataonlineandinthecontrolroom.Thisleadstoimproveddecisionmaking with new insights and improved issue resolution time.

ConclusionCorrosion behaviour in process environments has a number of

IF WE TAKE A MULTIVARIABLE CORROSION TRANSMITTER,

FOR EXAMPLE, THE TRANSMITTER EMPLOYS A SUITE OF

AUTOMATED ELECTROCHEMICAL TECHNIQUES THAT RUN

IN THE ONBOARD MEMORY OF A SINGLE TRANSMITTER

AND ARE USED TO COMPLEMENT ONE ANOTHER.

influencingfactorsthatcanvarywithtimeandcausedynamiccor-rosionevents.The long intervals associatedwith inspections andoffline measurements do not give the operator the opportunity tocorrelatecorrosiondaytripswithoperatingandprocessparameters,ultimately making control a difficult proposition.

To make gains in productivity, corrosion control must becomepartofeveryone’sjobfunctioninasimilarmannertoqualitycontrolor safety, and the corrosion specialist can provide key real-timeinput to significant corrosion situations as they occur.

By implementing an appropriate and correspondingly dynamicmeans of corrosion appraisal, chemical manufacturers can bettermanage industrial processes and related corrosion preventiontreatments,minimisecorrosionupsetsand failures,andmaximisethe availability of the plant assets.

Honeywell Limited



NEWPRODUCTS

PRESSURE TRANSMITTER FOR OEMSWIKA has designed its O-10 pressure transmitter for indus-

trial applications anywhere in the world, and it is suitable

for customers with high volume requirements.

The O-10 works with a measuring range of from 0-6 bar to

0-600 bar. A wide choice of pressure connections, electrical con-

nections (including DIN-A) and output signals is also available.

With the O-10 pressure transmitter WIKA is aiming mainly

at manufacturers of pumps, compressors and hydraulic

systems who have an annual requirement of more than

1000 instruments of identical specification. The minimum delivery

quantity is 50 pieces.

If required, the O-10 can be ordered with the customer’s own

company logo and model designation.

WIKA Australia


CUSTOM-BUILT VALVE AUTOMATION CONTROLSRotork Fluid Systems supplies a range of custom-

built, locally engineered and manufactured pneu-

matic and hydraulic control panels. The range

provides control panel solutions for arduous

applications in hazardous areas and corrosive

environments.

The company specialises in stainless steel

control components, fittings and tube. The valve

actuator control panels are fabricated and tested

in Bayswater, Victoria, and services include liaison

with customers to develop an approved engineered

solution; schematic layout diagrams and general

arrangement CAD drawings for customer approval

prior to manufacture; final ‘as-built’ general ar-

rangement drawings; individual testing for every

control panel; third-party inspection and testing, as

required; and compliance certification to meet SIL

and hazardous area requirements, including IEC Ex.

Rotork control panels are supplied for new

installations on complete actuator systems, and

retrofit solutions to all makes and models of

installed actuators.

The company’ Site Service team offers on-site

inspection and audit of the customer’s require-

ments to determine the best solution. This often

involves space restrictions, upgrading hazardous

area equipment to latest standards and general

improvements in the materials and workmanship of

installed equipment. The team also offers complete

on-site installation, commissioning and training

to ensure satisfactory handover and trouble free

start-up. Extended warranty is available where the

team is engaged in installation and commission-

ing activities.

Rotork also provide logic panels, high-pressure

gas reduction panels and other related systems

that control the flow of air, liquids or gases.

Rotork Australia


COMPRESSOR SILENCER HOODBoge has recently enhanced its small C series range of screw com-

pressors up to 15 kW. The compact C 10 LDR to C 20 LDR are now

available with Boge’s super silencer hood, making this range suitable

for point-of-use applications.

The Boge C series screw compressors are already very quiet in opera-

tion, emitting very low sound pressure levels. However, where an even

quieter operation is required, such as at point-of-use, Boge has introduced

a sound insulation hood as an optional extra. This hood encloses the

screw compressor, creating a virtually

silent operation at just 61 dB(A).

The Boge C 10 LDR to C 20 LDR,

directly coupled screw compressors are

mounted on a horizontal compressed air

receiver with a refrigerant dryer, provid-

ing a complete compressed air centre.

The directly coupled C series models

up to 15 kW are efficient and quiet in

operation requiring only a minimum

footprint. Available in the standard

pressure of 8 and 10 bar, output ca-

pacities range from 1.060 to 2.280 m³/min

and motor power from 7.5 to 15 kW.

Boge Compressors Ltd


http://www.dartinstruments.com.au

http://www.krohne


NEWPRODUCTS

33 years of experience in Food & Beverage

CCEZY.COM.AUTAKE CONTROL

02 9542 8977

Flow, Level & Pressure

COMPONENTS

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ControlComponents

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Process Sensors for Food & Beverage

Hygienicsolutions? Switch to Sitron

Sitron Flow, level & PreSSure SenSorS• Sanitary Designs

• No moving parts – longer life• AC, DC and Universal

powered models• Relay or Analogue

output available• Tri-Clamp, threaded & flanged connections

ENCODERS WITH SSI INTERFACEUpdated versions of the Posital Optocode encoders with SSI interfaces have been released,

which now include support for additional output drivers for incremental signals (RS422/TTL

and push-pull/HTL), resolutions of 1024, 2048, 4096, 8192 or 16384 PPR

per output, a reference impulse and an extended voltage range covering

4.5 to 30 VDC.

Additional diagnostic functions can be implemented via an alarm bit for

self-diagnosis of the Opto-ASIC and hardware/software monitoring. They are

suitable for use in wind power applications, where both rotor speed and the

absolute position of the rotor must be determined.

The encoders retain features of previous models, such as the integrated

preset function that allows users to assign a preset value to the current posi-

tion of the shaft. A version with a hardware preset push-button featuring two

integrated LEDs for easy status and error diagnosis is optionally available.

The synchronous serial interface enables the operation of up to 10 en-

coders on one data line. They are based on a single-turn sensor with an

integrated Opto-ASIC which provides a resolution of 16 bits per revolution.

Additionally, a maximum of 16,384 revolutions (14-bit) can be registered in

multiturn mode. Available as solid, hollow and hub shaft versions, the units can be fitted with

a connector or a cable exit. They provide a maximum transfer rate of 2 MHz and e n s u r e

cycle times below 25 µs. The housings of the encoders provide

IP65 protection (IP64 on the shaft side, up to IP66 with an

optional shaft seal).

Plant Control & Automation


FISCO APPROVED FIELDBUS SYSTEMThe MooreHawke Route-Master field-

bus system has a new ATEX approval

(FM pending) as a redundant intrinsically safe fieldbus system permit-

ting the connection of any mix of FISCO and Entity devices.

A Route-Master system consists of up to eight trunk isolator modules

in a 19-inch rack, each connected to one or more RM100 fieldbus

device couplers. This combination is now approved suitable for any

mix of FISCO and Entity field devices. The RM100 rack incorporates

hot-swappable and load-sharing redundant DC power cards and full

galvanic isolation. Intrinsically safe approvals extend to IEC Gas Group

IIC (NEC Groups A and B), with up to 350 m per segment.

The duplex FISCO Route-Master gives a calculated MTBF of

468 years, and also allows the full FOUNDATION Fieldbus network

length of 1900 m with 120 m spurs.

RM100 device couplers have auto-resetting short-circuit protection,

automatic segment termination to eliminate common installation errors

and commissioning delays, and LED status indicators. MooreHawke’s

short-circuit protection method prevents segment failure caused by

multiple device faults. A ‘fold-back’ technique automatically removes

fault loads from the segment and does not permit any current flow

to those devices until faults are corrected. Manual termination is also

offered at the user’s request.

Moore Industries Pacific Inc


http://www.ccezy.com.au

http://www.daanet.com.au


POWER SUPPLIEST h e d i p - c o a t e d

Quint Power power

supply units have

an adjustable output

voltage from 18 to

29.5 VDC, output currents of 5, 10, and 20 A and are capable

of tolerating 100% humidity.

Input voltages from 85-264 VAC or 90-350 VDC supply

the three single-phase devices. The three-phase module with

20 A nominal output current can be operated on networks

with 3x 320-575 VAC or 450-800 VDC. Offering an efficiency

of up to 93%, the devices generate minimal heat loss, thus

not only saving energy but also extending the service life of

the components. The wide temperature range of -25 to +70°C

makes the unit suitable for use in a variety of applications.

In addition to the usual industrial approvals, the dip-coated

modules with nominal currents of 5 A and 10 A conform to

EN 60079-15 (ATEX directive). They can be installed in a

potentially explosive area in which Category 3G equipment is

required (II 3 G Ex nA nC IIC T4 Gc). The modules are also

IECEx certified (Ex nA nC IIC T4 Gc). All Quint Power devices

comply with UL standard ANSI/ISA 12.12.01 as well as the

specifications for Class I, Division 2, Groups A, B, C, and D

(Hazardous Locations).

Phoenix Contact Pty Ltd


COMPRESSOR PROTECTION FOR HARSH ENVIRONMENTSIn harsh mine site and construction environments, most variable-speed

compressors available in the Australian marketplace may struggle

with high heat, humidity and dust levels. The result can be frequent

breakdowns or shutdowns, costly component failures or expensive

preventative maintenance.

CAPS Australia has released its Harsh Environment Efficient VFD

Option (HEEVO) to suit Ingersoll Rand compressors from 11 to 350 kW.

The HEEVO is suitable for mining, timber and other rugged industries

where high dust loads are common. The option is also appropriate

for applications operating in offshore, marine and similar environments

where humidity is the main concern.

The sensitive nature of variable speed drive compressors means

that normally they are more at home in a clean plant room than in a

harsh environment where reliability is the top priority. Achieving reli-

ability normally means compromising on efficiency.

The HEEVO enhances the overall IP rating of the compressor’s motor

and electrical components so that there is protection against entry of

dust that is in sufficient quantity to interfere with satisfactory operation

of equipment, and protection against extreme humidity, heavy seas

and jets of water from all practical directions.

CAPS Australia Pty Ltd


http://www.advantech.net.au


NEWPRODUCTS

Contact a Hach Pacific office near youfor direct order and sales support:

AUS: 1300 887 735NZ: 0800 50 55 66

www.hachpacific.com

Innovative ProcessInstrumentation

Integrated Lab Solutionsand Chemistries

ExpertSupport

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Products. Support. Expertise.

When you buy direct from Hach Pacificyou will receive access to the largest offeringof the highest quality lab and process water

analytics as well as outstanding serviceand application support. Hach is your

trusted partner in water analysis.

270x88mm HACH PACIFIC_WWF 9/6/11 9:31 AM Page 1

ETHERNET SWITCHBelden has extended its Hirschmann product range

with a 9-port version of its Octopus OS20 switch

series, providing Fast Ethernet ports (10/100base-Tx)

with vibration-resistant M12 connections in D-coding.

Further features include a robust IP67-rated metal

housing and an extended temperature range from

-40 to +70°C.

The Octopus also meets EMC and fire protection

requirements for use in rail vehicles. As the switch

can be cascaded in any way, decentrally structured

automation networks with short transmission paths

can be implemented with the respective terminal

devices.

The Hirschmann basic software is installed on this

layer-2 switch, supporting both various management

and security functions and fast redundancy methods

such as HIPER-Ring, MRP and RSTP.

The switch is designed for wall mounting, and

can be quickly put into operation. Configuration is

possible either via a command line interface (CLI),

DHCP relay agent option 82, HiDiscovery or the

ACA11-M12 EEC auto-configuration adapter.

RMON, port mirroring and LLDP (Topology

Discovery 802.1ab) are provided for diagnostics.

A floating signal contact signals alarms independently

of the data network. The switch also has LEDs on

the front that display both the device and network

status, and the data transfer and power supply.

Information can be retrieved via a serial V.24 inter-

face or the ethernet ports. The switch is monitored

and configured via SNMP, a standard web browser

or the Hirschmann Industrial HiVision network man-

agement software.



http://www.hachpacific.com


Coca-Cola Hellenic reduces energy consumption by 75%Reducingenergyconsumptionisoneofthemost important requirements today whenmodernisingmachinesandsystems.Often,there is great potential for saving energy-which,intheend,meanssavingmoney.

Coca-ColaHellenicAustriaisthelicensedbottleroftheCoca-ColaCompanyinAustria.When the company decided to modernisea transport line in its bottling plant inVienna, reducing power consumption andreducing CO2 emissions were the mainpriorities.Additionalrequirementsincludedstandardisingthedrivevariantsthatareusedin order to simplify the stocking of spareparts and facilitating a fast restart of thesystemaftertheconversion.Thefinalgoaloftheretrofitwastosimplifymaintenance.

SEW-Eurodrive GmbH and Coca-ColaHellenic Austria have long shared a closepartnership. And this isn’t just due to thefact that the companies are located nearone another in Vienna. The companieshave long engaged in regular businesscontactregardingstandardgearmotorsandfrequencyinverters.ItwasbecauseofthisthattheSEWViennaemployeeswereabletorecognisethenumerousbenefitsthatthemechatronic drive system would have tooffer the client, Coca-Cola Hellenic. Withdetailed energy consumption calculations,SEW-Eurodrivewas able to show that thetransport system could attain the highestlevelofenergyefficiencyusingMovigear.

In less than six months, the leadersof the beverage company managed toorganisethechangeoveroftheirbeverageline - from filing the budget and takingcareof the technicalplanning, all thewayto fully utilising the narrow time windowfor the conversion. By the beginning of2010, itwastime:thecompanywasreadyto modernise transport line 2a. This linelinksthebottlingplantforCoca-Cola,FantaandSpritetothepalletisingsystemviathepackaging machine. PET bottles holding

0.5 to 2.5 L are handled in this area.Previously,thelinewasdrivenbystandardline-powered gearmotors. As part of themodernisation,thecompanyreplacedatotalof39gearmotors-somewithinverters,butmostwithout-aswellasthecontrollerforthedrives.

Insteadofusing24Vswitchcontactortechnology for line-powered motors, thecompanyoptedforProfibusinterfaces.Thisallowstheoperatortochangethespeedasrequiredandadjust itpreciselytosuittheprocess.Inaddition,theProfibusinterfaceoptimisesthesystem’sabilitytoshutdownthelineincaseofajamandminimisesidletimes.Thesemeasuresresultinanoticeablereductioninpowerconsumption.

The Profibus transmits the controlsignals from the PLC to the drive andtransmits current diagnostic and statussignalsfromthedrivetothecontroller.TheuseofProfibusalsoofferscompletelynewdiagnostic options. The operator now hasmuchmorethanan I/Odisplay: thespeedand current are displayed on a keypad,allowing the operator to check whethermechanicalcomponentsaremovingfreely,and, should service be required, the faulttypeisdisplayed.Busoperationalsoallowstheoperatortorecordthecurrentforgeneralmonitoring purposes and serves as anindicatorofcapacityutilisation.

With the Movigear system solution,power supply and communication arehandledusingSNItechnology(SingleLineNetwork Installation). This allows energyandcommunicationtransferinoneshieldedcable, thereby decreasing the number ofcomponents required while significantlyreducing the installation cost. The actualmechanicalconversionofthesystemtookplace over an extended weekend, fromFridaymorning toSundayevening. In thisshort period of time, the old drives weredisconnected and mechanically removedand the new drives were mechanicallymounted, electrically installed and startedup.OnMondaymorning,productionstartedupagaininthebottlingplant.

Withthecompletesystemsolution,Coca-ColaHellenicAustriawasabletoreducethepowerconsumptionofthetransportlinebyasensational75%(incomparisonwiththetechnologypreviously inuse).Thismeansthat the investment pays for itself in lessthan one year. Extrapolated from a five-daymeasurementoftheamountofenergyconsumed,thenewsystemwillgenerateanestimatedsavingsof41tonsofCO2annually.

These savings were achieved by multiplemeasurescarriedout inparallel;however,SEWdrive technologyplayedamajor roleintheseresults.

Erwin Langela, Manufacturing Directorof Coca-Cola Hellenic Austria, explains,“ForCoca-ColaHellenic, itwasalwaysanimportantprioritytooptimiseproduction,notonlyeconomically,butalsoecologically.Forthisreason,weweresearchingfordifferentways to reduce our CO2 footprint, whichserves as a measurement of the effect ofourdailyactivitiesontheenvironmentandclimatechange.SEW-Eurodrivesuggestedreplacing thedrives inourconveyorbeltswiththeMovigearmechatronicdrivesystem.Now,half a year later, independent auditsshow we were able to reduce our powerconsumptionby75%.Thattranslatestoanannualreductionof41tonsofCO2.Wewanttokeepgoinginthisdirection.NotonlydowewanttoimplementtheMovigearsystemin Vienna - we plan to use it in Edelstal(Austria)aswell,andwewanttouseSEWtechnologyinthebottlingofourRömerquellemineralwater.”

Thanks to these amazing results, uponthe start of the new application, SEW-Eurodrive received another contract for asecondtransport line forPETbottleswithsoftdrinks.Aspartofthemodernisationofthisline,thefirststepistotakestockoftheexistingsystembygeneratingaparts list:howmanydrivesarecurrentlyinuse,whatthegearratiosofthesesystemsare,etc.

Coca-Coca Hel lenic Austr ia is soconfidentaboutSEWdrivetechnologythatthecompanynowspecifiesMovigearasthedrivesysteminitscallsforbidstosystemdesigners.

SEW-Eurodrive Pty Ltd



NEWPRODUCTS

WIRELESS AP/BRIDGEThe Moxa AWK-3121

is a 3-in-1 industrial

wireless AP/bridge/client that is

suitable for applications such as

power automation, transportation

automation, and oil and gas ap-

plications. It supports multiple

IEEE 802.11 standards and higher

security levels, including wireless

communication in the 5 GHz band.

The Moxa AWK-3121 is also

WPA2-enabled and highly secure

for wireless networks that use

Advanced Encryption Standard

(AES) technology. Features include

redundant DC power inputs, Power-

over-Ethernet, RS232 console man-

agement support, two digital inputs

and one relay output, and a wide

temperature range from -40 to 75°C.

The AWK-3121 provides higher

security levels of authentication and

authorisation for increased safety.

Security features include 802.11x/

RADIUS, AES, TKIP support, and

disabling of SSID broadcasts, as

well as IP packet filters to prevent

hacker attacks.

The AWK-3121 also supports

STP/RSTP (IEEE802.1d/w) allowing

the AWK-3121 to prevent network

looping and to increase system

availability by setting a redundant

path.

Madison Technologies


DISTRIBUTED I/O SYSTEMTurck has released the 4AI4AO-VI analog I/O module, which is compatible with

two of the company’s BL distributed I/O products: BL67 and BL Compact sys-

tem. Featuring four analog inputs for current or voltage and four analog outputs

for voltage, the module provides both control and feedback in one package.

The 4AI4AO-VI is designed for use with Turck’s BL67 modular I/O system and

BL Compact system. BL67 combines all of the flexibility of an in-the-cabinet I/O

system with modularity, ruggedness and connectorisation, while the BL Compact

system is an on-the-machine solution that obtains and transmits signals via diverse

fieldbus protocols, without requiring a protective enclosure. Supporting both M8

and M12 I/O connectors and offering compatibility with a variety of communication

protocols, such as EtherNet/IP, DeviceNet, CANopen and Modbus TCP, the BL

family provides a high degree of I/O versatility for a wide range of applications.

For enhanced application compatibility, the 4AI4AO-VI is ruggedly constructed to withstand diverse environ-

mental challenges. Operating in temperatures ranging from -40 to 70°C, rated to IP67 and UL listed, the module

provides optimal performance in applications that yield extreme temperatures, moisture, shock or vibration.

Turck Australia Pty Ltd


http://www.georgefischer.com.au


10KEYSTEPSINSELECTINGANDUSINGTHEMJeff Allison, Pepperl+Fuchs Inc

Overthepastdecade,photoelectricsensinghasundergoneasteadytransitioninwhicholder,conventionalsensors are being replaced by an innovative technology called background suppression (BGS).

BGS is a more efficient method of sensing that doesn’trely on how much light is reflected to the sensor’slight-sensitive receiver, but rather on where the lightis reflected on the receiver.

This endows BGS with certain unique sensing capabilities.Themost obvious is its ability to disregardmachinepanels, beltconveyorsorothermaterialsbehindwhatistobesensed.Italsoconsistentlysensesobjectsregardlessofcolourorreflectivity,soglossyMylarisdetectedsimilarlytobrowncorrugatedcardboardor even black matte painted surfaces. BGS can precisely detectleading edges and small items, such as springs or screws. BGSsensorsalsosimplifysensingbyremovingthecostandclutterofreflectors and two-housing, through-beam arrangements.

Selecting and setting up the best BGS sensor for an applica-

BACKGROUNDSUPPRESSIONPHOTOELECTRICSENSORS

tion doesn’t have to be difficult if the following ten key pointsare kept in mind.

1. Infrared has better performance than visible red.When selecting a BGS sensor, an infrared (IR) light sourcealways produces superior sensing performance over a sensorwith a visible red light source. Sensors with IR emitters havehigher power and lower colour sensitivity than their visible redcounterparts. This means they can be used at greater sensingdistances and can sense different objects more consistently. IRemitters are more efficient and can be driven with higher cur-rent pulses compared to visible red versions. The best sensingperformance in background suppression is accomplished withfixed-range, short-distance sensors with IR emitters.


In Figure 1, the left chart shows the adjusted detectiondistance compared to the actual sensing distance for white,grey, and black objects using a BGS sensor with a visible redlight source.At anadjusteddistanceof 700mm, themeasuredsensingdistancevariesbyapproximately150mmdependingonwhat colour is present. The right chart shows the same for aBGS sensor with an infrared source. This results in a sensingdistance variation by colour that can be just one third that ofvisible red versions, at the same distance.

In fact, the only advantage to using a visible red emitter iswhen a visible light spot is needed to align the object to bedetected.Alignmentcanbemoredesirablethansensingperfor-mance insomeapplications,especially if the itemtobesensedis small or is sensed through an aperture.

Sensors

2. A fixed background is better than no background.BGSsensorsaredesignedtocomparetwosignals:lightreflectedfromnearobjects(suchasthematerialbeingsensed)andlightreflected from far objects (namely, the background).

Whenadefinedsignal froma fixedbackground ispresent, itminimisestheeffectofdisturbances intheapplication,suchasdustparticlescollectingonthesensor’slensinadirtyenviron-ment.Thereflectedsignalfromthebackgroundiseasiertoseeand compare (as opposed to no reflected signal) if there is nobackground object present.

3. No background is best for detecting small objects.Equally important, a BGS sensor should always be selected soitslightspotissmallerthantheobjectsitwilldetect.Thisisforgood reason: if the sensor’s light spot isn’t completely coveredby the object, then the object reflects some of the sensor’slight,butabackgroundmaterialcanreflecttheremainderof it.Andbecausethesensordeterminesobjectpresencebasedonacomparison of reflected light from the near field and far field,it is possible for a small object to not be seen if the sensor’slight spot does not cover enough of the object.

BGSsensorsareavailablewithlaserlightspotsorfinefocalpointstodetectitemsthatareassmallasjustafewmillimetres.

4. Tilting the sensor at a slight angle is best to sense shiny objects.Especially when sensing a highly reflective material such asglossypackagingoraMylarweb, it isbesttopositiontheBGSsensorsoitsopticalaxisisapproximately5degreesoffperpen-dicular to the detection plane. In Figure 2, scenario (a) showsthat a very reflective object can result in glaring or blinding,in which the reflected light beam floods the receiver and cov-ers both receiver elements. But mounting the sensor with theslight angle as shown in scenario (b) of Figure 2 reduces theglaring reflection considerably, so the object can be detected.

5. Adjust or mount a BGS sensor from the background, not the object.After a BGS sensor has been selected and is installed in theapplication, it may be necessary to adjust its sensitivity sothat the object to be sensed is in the detection field and thebackground is beyond the maximum sensing distance. This isnormally accomplished using a potentiometer on the sensorhousing.Turning itclockwiseeffectively increasesthedistancefromthesensorwhereitdetectsobjects,whileturningitcoun-terclockwise decreases this distance.

Acommonmistakeistoplaceanobjecttobedetectedinfrontof the sensor and adjust the sensitivity just to the point where©

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that object is sensed. But because there is a slight differencein sensingdistancesbasedoncolour (asshown inFigure 1), itis possible that a darker object might not be detected.

Instead, it isbesttoadjustthesensitivitytothebackground,ratherthantotheobject.Thisallowsthegreatestrangeofobjectcolourstoberepeatedlydetected.Thatmeansturningthepoten-tiometeruntil thebackground is sensed, then turning it slightlyin the opposite direction until the background is not sensed.For tamperproof models with no adjustment, the potentiometeris replaced by physically positioning the sensor relative to theobject.

6. Movement direction can be a factor in how BGS detects.Although a less common occurrence, the direction an objecttravelsthroughthesensingfieldofaBGSsensorcandetermineif it is detected. Three simultaneous conditions could result ina brief moment where the object is not sensed. In this sce-nario,theobjectmustmove intheplanedirectlyatthesensingthreshold, have a high-contrast pattern (such as black-white),and move parallel to the emitter-to-receiver axis. With theseconditions, a BGS sensor may not detect the object. This isbecausethesensor’slightspotstraddlesthehighcontrastsuchthat the dark portion reflects less to the near element receiver

compared to what the light portion reflects to the far elementreceiver.Turningthesensororobjectby90degreesormovingthe object closer to the sensor remedies this situation. This isknown as the Pepita effect.

7. BGS sensors optically ‘burn through’ many transparent media.By design, a BGS sensor has a small light spot size comparedto conventional sensors. The smaller the light spot, the morelikely it is to pass through - rather than be reflected from - aclearor transparentobject likeshrinkwrap.Thiscanbecalledoptical ‘burn through’. As such, BGS sensing is not optimisedtoalwaysdetect transparentobjects. Instead,awide-beamdif-fuse or a retroreflective sensor specifically designed for clearobject detection are the best methods of sensing transparentfilms, wraps, glass and other objects.

On the other hand, BGS sensors can often be used whenmounted directly against a clear Plexiglas or glass shield todetect an object on the other side.

8. BGS sensors are not contrast sensors.BGSsensorsare,bydesign,notforcontrastsensing.Acontrastsensorisadifferenttypeofsensorthatisusedtodetectdiffer-ences in colours, such as when sensing registration marks on

Figure 2: Effect of tilting the sensor for shiny objects (image not to scale).

Figure 3: If a high-contrast object, such as the white-black cylinder in this image, is to be detected at the sensing threshold, the sensor should be positioned in a specific way. a) It should not move parallel to the axis on which the emitter and receiver lenses are located. b) It should move in another axis, either toward or away from the sensor or perpendicular to the emitter and receiver axis.

Sensors

Figure 1: Effect of object colour on sensing distance.


a web to trigger a cut. In fact, BGS sensors are closer to thepolaroppositeofcontrastsensors,asthe formerare intention-allydesignedtodetectvariouslycolouredobjects,fromtotestopapers to circuit boards, at a similar distance.

9. Hysteresis < black-white difference < maximum sensing distance.A helpful rule of thumb for BGS sensors is the relationshipbetween some of their specifications. Hysteresis is the differ-ence between the distance at which an approaching object isseenandthedistanceatwhicha retreatingobject isno longerseen. Hysteresis is typically very tight for BGS sensors. Theblack-white difference is the disparity between the maximumdistanceatwhichablacktestobjectissensedandthedistanceat which a white test object is sensed. It is a good indicationofthesensor’ssensitivitytocolours.Andthemaximumsensing

distance is thedistancebeyondwhichnoobjects aredetected.Hysteresis is typically smaller than black-white difference, andboth are smaller than the maximum sensing distance.

10. Be aware of not only maximum sensing distance but also minimum.WhilethemaximumdistanceatwhichaBGSsensorcanseeanitemiscertainlyimportant,itcanbeeasytooverlooktheminimumsensingdistancespecification.Generally, theminimumsensingdistance, also called blind range, is only a few millimetres toa few centimetres. For applications that require sensing up tothe sensor’s face, a related technology, background evaluation,may be a better alternative.

Pepperl+Fuchs (Aust) Pty Ltd


BGS CAN PRECISELY DETECT LEADING EDGES AND

SMALL ITEMS, SUCH AS SPRINGS OR SCREWS. BGS

SENSORS ALSO SIMPLIFY SENSING BY REMOVING

THE COST AND CLUTTER OF REFLECTORS AND TWO-

HOUSING, THROUGH-BEAM ARRANGEMENTS.

Sensors

http://www.powersuppliesaustralia.com.au


FLOWMETERThe Influx FloTrak metal VA flowme-

ter is designed for the measurement

of gas and liquid. Fluid passing

through an orifice within the tube

causes a profiled float to assume

a position where the forces created

by flow are balanced by the weight

of the float. A magnet in the float

is sensed by the FloTrak system,

providing a direct reading flow

rate scale, optional alarms or a

4-20 mA output.

The flowmeter is installed in a vertical line with flow upwards and

is normally supported by the surrounding pipework. Several styles of

instrument are available. As a direct reading indicator it provides clear

indication over a 100 mm long scale, and can be scaled to suit exact

process conditions. As a flow alarm unit, the direct reading indicator

also provides one or two fully adjustable setpoint trips, for connection

via an interface unit. As a flow transmitter, it provides a 4-20 mA loop

output proportional to percentage of reading.

The flowmeter has simple construction and is rugged and easily installed.

It is claimed to have a stable zero point unaffected by installation and

low hysteresis. Gas damping is fitted as a standard on gas ranges, and

alternative flange connection ratings and types are available on request,

as well as special calibrations or flow ranges. Approvals include EEx ia

IIC T6 and EEx nA T6.

Duff & Macintosh


TEMPERATURE TRANSMITTERSThe Yamatake advanced temperature transmitters, models ATT60 and ATT70, are

field instruments that convert inputs from thermocouples, mVs and resistance

thermo-bulbs into analog (4-20 mA) and digital signals and transmit them to receiv-

ers. Various parameters can be remotely set, and self-diagnosis can be performed

through the Smart Field Communicator (SFC). They can also

execute two-way communications between the SFC, or

HART 375 communicator, and, via DE protocol, with the

TDCS3000 or 3000X and a database, thus facilitating

self-diagnosis, range resetting and automatic zero

adjustment. Settings, adjustments and self-diagnosis

can be done easily by SFC or HART communicator.

The following models are available: the Advanced

Temperature Transmitter with FOUNDATION Fieldbus Model ATT60; the Smart Tem-

perature Transmitters (Integral Sensor Type) Model ATT61/71; Temperature Sensor

Model ATT90; and Metallic Protecting Well for Temperature Sensor Model ATT9X.

ThermoPLUS handles all thermal sensors, and any temperature range can be

set as required within the one transmitter, thus giving the optimum range for a

given process. The transmitters are available with a range of flexible sensor types,

thus reducing engineering work costs.

The two-wire system of the models ATT60/70 requires no compensation wires or

field cables, and the system has a self-diagnostics function. They can also work

with abnormal ambient temperatures of -40 to 85°C.

AMS Instrumentation & Calibration Pty Ltd


http://www.bintech.com.au


NEWPRODUCTS

ETHERNET SWITCHES/ROUTERSThe RADiFlow 3080, 3300 and 3700

switches/routers from RAD Data Com-

munications offer enhanced security, with

an integrated, service-aware firewall per

port, and can handle temperatures from

-40 to 75°C without fans.

The integrated firewall on each port of the RADiFlow

switches provides a network-based distributed security

solution equivalent to the use of personal firewalls on all

the systems. The firewall is ‘application aware’ in that it

inspects the contents of the data packets according to

the rules of the industrial protocol used. It operates on

user-defined access rules for each end device up to the

level of the industrial protocol command. In addition,

the switches provide an integrated set of security tools

so that a complete, in-depth defensive solution can be

readily deployed.

The enhanced security features of the RADiFlow are

of particular value in nationwide infrastructure applica-

tions that have a wide geographic distribution of small

unmanned facilities since, in such situations, an attacker

that successfully gains access to a single remote loca-

tion can maliciously manipulate the behaviour of all the

devices in the network.

Other features of the RADiFlow switches/routers in-

clude: up to 28 GB ethernet throughput; RS232/RS485

interfaces; redundant power supply; network resiliency

using MSTP/RSTP, or G.8032 rings; 802.3ad link aggre-

gation; IP routing supporting OSPF; multicast routing

using IGMP snooping; secure IPSEC VPN tunnels and

industrial protocol gateway capability.

NSC Group Pty Ltd


EXTENDED DRIVE RANGERockwell Automation has extended the power range of its Allen-Bradley

PowerFlex 755 AC drives to 900 kW and added 690 V ratings. The new

drives are suitable for a variety of heavy industrial applications and provide

users with increased application flexibility, advanced diagnostics and a

common DC bus option.

The common DC bus option allows users to connect the AC

drive to a common DC bus configuration, which takes

advantage of different drive cycles to share energy. In this

configuration, a DC bus acts as a common energy source

that feeds energy from a generating load to a motoring

load. Managing energy from a shared source increases

overall system performance and reduces losses - ultimately

improving the application’s energy efficiency.

This latest frame size includes an embedded ethernet

port and five option slots, so users can tailor it to their

application. Option modules include I/O, feedback, safety,

additional communications and an auxiliary power supply.

A convenient rollout design allows easy access to the drive

for fast installation and maintenance. The drive’s converter

and control pod can remain in the unit while the inverter

is rolled out, so control wiring can remain connected.

In addition to the extended power range, a firmware

upgrade for all PowerFlex 755 drives will include interior

permanent magnet motor control and a ‘stop dwell’ feature

to help prevent a motor from coasting to a stop.

Rockwell Automation Australia


http://www.techrentals.com.au


NEWPRODUCTS

FREE SUBSCRIPTION!What’s New in Process Technology is FREE to qualified ICT industry professionals in Australia & New Zealand.

To continue receiving your free copy you will be asked to register every three years.

Quick registration @ www.ProcessOnline.com.au/subscribe

10 GB ETHERNET SWITCHThe CP6930-RM is a 10 gigabit ethernet rackmount

switch supporting up to 32 ports. It is hardened to

meet high shock and vibration, EMI and extended

temperature ranges. Multiple configuration options

provide SFP+, SFP, RJ45 and M12 connectors.

Based on the Kontron 10 gigabit ethernet Compact-

PCI Switch CP6930, the Kontron CP6930-RM provides

a ready-to-run rackmounted unit including redundant

AC or DC power options. The non-blocking, fully

managed L2/L3 10 gigabit ethernet switch provides

up to six ports 10 GbE and up to 26 ports 1 GbE.

Up to six 10GbE ports are directly accessible on

the front via SFP+, plus two 1 GbE ports over SFP.

A second variant, the CP6930-RM-24, is preconfigured

with front interface modules for an additional twelve

1 GbE ports over RJ45. On request, M12 connectors

are available for extremely demanding environments.

The CP6930-RM switch provides features

such as IP forwarding, L2 and L3 multicast, quality

of service and VLANs. The feature set has been

extended to facilitate common management and

configuration tasks in embedded and rugged en-

vironments, including reliable software updates in

the field, replication of configurations over multiple

devices, dual boot images with roll-back capabilities

and write protection of internal memory.

Kontron Australia Pty Ltd


MULTIPLE-PORT FIREWALLSThrough Belden, Hirschmann is

introducing the Eagle20-0400

and Eagle30-0402 multiple-port

firewalls which claim to deliver

significant cost savings while

achieving greater link speeds.

They are claimed to be the first

firewalls on the market in a con-

vection-cooled DIN rail housing

that supports six LAN ports and

WAN connectivity.

This extended number of ports

enables users to deploy a single

device instead of having to use

multiple Eagle20s.

Because Belden has focused on the needs of industrial networks, the

Eagle20-0400 and Eagle30-040 bring a number of key benefits over

current options by offering multiple ports, gigabit ports and WAN

connections. They also have a greater temperature range, more

flexible deployment possibilities and offer wider voltage ranges.

The Hirschmann Eagle20-0400 firewall supports four 100 Mbps

ports, while the Eagle30-0402 firewall supports four 100 Mbps ports

and two 1 Gbps SFP ports. Initially, the hardware release will support

ethernet ports only. A later hardware release will also support WAN

connections, including ADSL, SHDSL, VDSL, E1/T1 and UMTS.

The LAN and WAN boards have been designed in-house to support

industrial specifications. This enables the product to support non-standard

voltages such as 72 VDC. The devices are delivered ‘modular from the

factory’, so they can be delivered with the required combination of LAN

and WAN ports.



http://www.sick.com.au


now available online!

NEW White Papers

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

Are water operators as safe as they could be?During the September 2011 Water Industry Operators Association

meeting in Victoria, Hydro Innovations conducted a survey of

operators and other water industry professionals as part of the

official competition program. This paper summarises the findings

of the survey and details explanations for them.

Automated Test Outlook 2011: Key technologies and methodologies impacting the test and measurement industryThis report details key trends, methodologies and technologies

impacting test engineering organisations in every industry. The

Automated Test Outlook combines input from academic and industry

research, business intelligence and customer advisory boards. Read

this white paper for more information.

Machine vision inspection: benefits, applications and vendor selection tipsIn recent times, the technology options for machine vision inspection

systems have increased, the cost of these solutions has reduced

and hence the adoption has dramatically increased. These solutions,

if implemented wisely, can provide a competitive advantage for

manufacturers as well as provide cost savings.

How to minimise losses in converter-fed induction motorsThis study presents a technique developed to minimise losses in

totally enclosed fan-cooled (TEFC) induction motors fed by frequency

converters in applications with constant torque loads, especially at

low speeds, in which the ventilation system is inefficient.

DAQ SOFTWARE DEVELOPMENT TOOLThe DAQ Navi application for configuring

PCI, USB and PCI-104 data acquisition

devices has been released. The DAQ

Navi application includes the Software

Development Kit, Device Driver and Device

Test Utility with User Guide to replace the previous multiple drivers,

device manager and SDK.

DAQ Navi allows users to configure and run basic parameters

through Visual Studio.net, or users can use class libraries to write their

own device functions using C/C++, C#, VB.Net or Delphi, therefore

providing a more robust method of controlling devices. An improved

device driver allows the DAQ Navi to be installed on Microsoft 32- and

64-bit Windows 7, XP and Vista to allow for easy migration between

systems, thus making it more cost effective and faster for multiple

system integrations.

The Device Test Utility provides testing tools and parameter settings

for analog input reading, waveform display and DO control. Informa-

tion such as pin assignments, signal connections and specifications

can be viewed from within the application as well. The integrated user

guide contains programming reference material, example programs and

introductory videos to help users get the most from this application.

Advantech Australia Pty Ltd


FANLESS PC SYSTEMICP Electronics has

announced the release

of IEI’s Tank-800-D525

3-slot fanless embed-

ded system.

The Tank-800-D525

comes fully equipped with

an Intel Atom D525 1.8 GHz dual-core

processor. The system supports multiconnec-

tivity with four USB 2.0, one SATA 3 Gbps, two Gb ethernet

LAN ports and six COM ports. Flexible PCI/PCIe expansion

slots are provided to satisfy customisation requirements.

System memory is provided via a 204-pin 800 MHz DDR3

SDRAM SO-DIMM Slot (maximum to 2 GB), while onboard

1 GB of DDR3 memory is provided.

The Tank features an extended temperature fanless design

supporting -20 to 70°C, a redundant dual 9-36 VDC input

and a CompactFlash socket.

The Tank-800-D525 is suitable for installation on moving

objects with its antivibration and antishock design.

ICP Electronics Australia Pty Ltd



NEWPRODUCTS

HIGH-DENSITY WATERPROOF CONNECTORSFischer Connectors has announced

a high-density miniature circular inter-

connect solution. The Fischer MiniMax Series

increases the performance of rugged devices,

handling more mixed signal and power connections,

while saving space, weight and costs.

Fischer MiniMax Series offers high pin density,

housing a combination of twenty signal contacts

(0.5 A) and four power contacts (5 A) in one single

connector, providing three times more pins compared

with standard Fischer connectors of a similar size.

Its ultraminiature size saves more than 40% space

and 75% in weight, compared with a standard Fis-

cher’s connector with similar pin count.

It is equipped with endurable keying as well as

visual colour coding to

avoid misconnection

and improve end-user

safety. It also incorpo-

rates a reliable and user-

friendly push-pull locking, or

quick release system.

Fischer MiniMax Series is IP68

rated, even unmated, which makes

it suitable for underwater ap-

plications, even in cases of

accidental disconnection.

It is also waterproof

down to 120 m for a full

24-hour submersion.

Soanar Limited


MODULAR SENSOR MOUNTING SYSTEMThe decision of where and

how to locate a sensor is

often not made until the

machine or equipment is

actually being constructed.

In-house fabricated fasten-

ing systems can be expen-

sive and time consuming,

so Balluff offers a line of

sensor mounting fasteners

for mix-and-match flexibility.

The fasteners are

available in plastic

or V4A stainless

steel, making the

mounting system suitable for use in challenging industrial environ-

ments and in automotive areas. The high quality stainless steel

versions also provide resistance to industrial cleaning agents

common in washdown environments.

The aluminium base holder fits nearly any manufacturer-specific mount-

ing extrusion and fully covers the slot. Also featured are knurled support

rods that provide a secure hold even for large, heavy sensors.

The system includes every conceivable accessory, including clamping

cylinders, cross-connectors and sensor holders for block-style and tubular

sensors, many designed so that, in their fastening function, they also

provide mechanical protection for the sensor. Components such as

reflector holders and adapter plates are also available.

Balluff-Leuze Pty Ltd


http://www.dwyer-inst.com.au


AS I SEE IT

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

People learn70%ofwhat they knowabout their jobs through informalmeans (US Bureau of Labor Statis-

tics - 1996). So stop pouring your moneyinto formal training without pausing toconsidertheseothermorepowerfuloptions.Not through formal courses. Or trainingworkshops.

Formal training accounts for only 20%of what people learn at work (accordingtoJayCross).Was itmoneywiselyspent?In many cases, I doubt it. Our experienceleads us to believe that a two-day shortcourse is great. The instructor is oftenvery good (and sometimes not so good).The transfer of learning is outstanding.Everyone understands the topic. But thenno one applies the learning (and it is of-tendifficult to apply to their jobs).After afew weeks, it is all forgotten - and so acompletelywasted investmentby the firm.Greatcoursemanualsandgreatinteractionwith other professionals, but that is oftenwhere the learning stops.

Skills acquired informally are generallyacquiredbytalkingtoothers,watchingwhatothers do, by trial and error - and simplybyosmosis,gettingshownorcorrectedona task they are struggling to accomplish.Engineeringapprenticesknowallaboutthisform of learning in learning often from amaster. Graduate engineers are supposedtoengageinthisformof informal learningfrommentorsbut this isoftenstill aworkinprogressandnotparticularlysuccessful.

Themostpowerfulformoftrainingistopermeateyourentirecompanyculturewithfurther informal learning by encouragingdissemination of know-how continuously.For example, when a regular problem oc-curs and the bearing of a machine keepsseizing up or an alarm trips a part of theplant,identifywhattheproblemisandthentry to make the learning experience moregeneric so that the learning experiencecan be spread to other instances. Gathereveryone around. All five technicians, thenew snotty-nosed graduate engineer, theancientmanagerabouttoretire-andthen

INFORMALTRAININGISTHEMOSTPOWERFULFORMOFENGINEERINGEDUCATION

spend five minutes showing them whatwent wrong and how to fix the problem.Andthengettheminvolved inthe learningprocess so that they can all demonstratethey understood what happened and won’tforget it. And get them to go and teachsomeone else in the firm. All informallyand at low cost - and yet a very powerfullearning experience.

A few suggestions in using informallearning:

•List all the informal training activitiesthataregoingoninyourfirm.Publicisethem, encourage and increase them.

•Permeateyourwholeworkculturewiththeideathatinformallearningisgreatandvaluable.Dothisfromthetopdown.

•Build,promoteandcreateinformalcom-munities of practice based anywherefrom the water cooler to the internet.

•Improvemeetingstomakethemlearningexperiences for everyone.

•Encourage open distribution of ideas,know-how and expertise.

Useyourownpeopleforinformallearn-ing - true engineering learning. And whenyou use formal training, ensure that youresearch both the need carefully and thatit is applied to the job effectively, linkingit in with your informal learning at yourplant or office.

Thistruecomment(alongwiththousandsof others) is attributed to Albert Einstein:“I never teach my pupils; I only attempt to provide the conditions in which they can learn.”

Steve Mackay PhD CPEng, has worked mainly in the industrial automation and data communications fields for the past 30 years and is currently Dean of Engineering with worldwide engineering education business IDC Technologies (www.

idc-online.com). Steve has also published over 30 engineering books, as both editor and co-author.

www.processonline.com.au

http://www.idc-online.com

Competence, capability, qualityThis 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.

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

Six of 500+ panels we built in 2011

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