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0213CONTENTS

WHAT'S NEW IN PROCESS TECHNOLOGYFEBRUARY 2013

6 Choicesinautomatedleveldetection Choosingtherightinstrumentforthejob

10 Newproducts

12 Hotproductsonline

22 Analysersamplingsystems Verifyingfluidflowforreliabilityandaccuracy

38 AsIseeit Becomeanengineeringentrepreneurtoday

ON THE COVER

Paperless calibration systems made with

the combination of documenting calibrators

and calibration software improves quality

and cuts costs. The business benefits are

significant for companies that use software-

based calibration systems when compared

with manual, paper-based systems.

Whi le using a manual, paper-based

system requires little or no investment

in new technology or IT systems, it is

extremely labour-intensive and means that

historical trend analysis of calibration results

becomes very difficult. In addition, accessing

calibration data quickly is not easy. Paper

systems are time-consuming, they soak

up lots of company resources and manual

(typing) errors are commonplace. Dual effort

and the re-keying of calibration data into

multiple databases become significant costs

to the business.

The business benefits of a paperless

calibration system are significant. The whole

calibration process - from initial recording

of calibration data through to historical

trend analysis - will take less time, while

mistakes and manual errors will be virtually

eliminated. In turn, this means that operators,

engineers and management will have more

confidence in the data, particularly when

it comes to plant audits. In addition, this

greater confidence in calibration data leads

to a better understanding and analysis of

business performance and KPIs (particularly

if the calibration software is integrated with

other business IT systems such as a CMMS)

leading to improved processes, increased

efficiencies and reduced plant downtime.

AMS Instrumentation & Calibration Pty Ltdwww.ams-ic.com.au

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There are many technologies available today for the automated measurement of the level of a material in a vessel. All the available techniques work when applied correctly in the appropriate situation.

6 WHAT'S NEW IN PROCESS TECHNOLOGY - FEBRUARY 2013 www.ProcessOnline.com.au

CHOICES IN AUTOMATED LEVEL DETECTIONGlenn Johnson, Editor

PART 1

FEBRUARY 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 7www.ProcessOnline.com.au

CHOICES IN AUTOMATED LEVEL DETECTION There are many level measuring

situations in which virtually any measuring technology will work, but there are also many cases

where some technologies will work while most others will not. Generally speaking, it is a case of the more difficult the process environment or material, the more costly and complex the level technology.

This article is an overview of those com-mon technologies and techniques that can be considered ‘automated’ instrumentation. Manual level measurement gauges are not covered.

Head versus heightLevel measurement techniques can be cat-egorised into two broad categories. One is ‘head measurement’, which is based on the force of the process material pushing down on a measuring device, and ‘height meas-urement’, which is based on measuring the distance to the upper surface of the material.

Head measurementFor head measurement, there are two basic categories: one is the measurement of the weight of the process vessel or tank and the other is the measurement of the pressure applied by the material in the tank. Of these, measuring the weight of the vessel (usually performed with load cells under the tank supports) can give an accurate measure of how full the tank is, given that the density of the material is known - and it works for both solid and liquid measurement. The only risks of error here are electrical interference with the load cells, and vibration - the vessel needs to be shielded from vibrations, which may be transferred to the load cells, leading to spurious measurements.

Measuring the pressure exerted by the contents of the tank is generally only suitable for liquids, but there are various methods of doing so, depending on the measuring conditions and material.

Height measurementHeight measurement means measuring the distance of the top surface of the material (liquid or solid) from either the top (most common) or bottom of the vessel. Various forms of contact-based and non-contact methods are used, and some permit the detection of multiple levels simultaneously (liquid interface level measurement) where two materials of different density are present, one floating on the other. All methods have

their pros and cons, and the correct method must be chosen based on the conditions of the process and the properties of the process material.

Point level versus continuousSometimes we want to know the fill level of a vessel at all levels, to measure the quan-tity of material available. In other cases we are only interested if the level falls below a certain point, perhaps to trigger refilling, or if it exceeds a certain point, to prevent overflow, or to stop a filling process. The first is called continuous level measurement and requires a method that is constantly seeking or following the top surface level of the material. The second is called point level measurement and uses instruments or sensors located at appropriate heights in the vessel that are triggered when the material level passes that point - in other words there is a change of the conditions surrounding the sensor.

ChallengesDepending on the liquid or solid to be measured, the design of the vessel and the conditions of the process, various challenges may be encountered.

The design of the vessel must be taken into account, not only for its shape (in some cases the geometry of the vessel affects the level calculation), but also for internal structural features such as seams, supports and ladders, which may obstruct certain types of measurement.

In some cases, the material may be so corrosive or flammable, or the vessel may be so hot or cold that no form of instrument can enter the vessel. In these cases, nuclear level measurement may be the only solution.

SolidsFor solids, the nature of the solid and the way it behaves in the vessel affect the measure-ment. Obviously, using head measurement by measuring the weight of the vessel eliminates all issues of the material properties, but this is not always practical, such as in the case of very large silos. Surface height measure-ment of solids presents various challenges:

• Surface dynamics - The filling and emp-tying of the vessel results in a sloping top surface (the material has an ‘angle of repose’), that makes it difficult to de-termine the ‘average’ top level (Figure 1). Also, particle size has an impact on the

© iStockphoto.com/36clicks

8WHAT'SNEWINPROCESSTECHNOLOGY-FEBRUARY 2013 www.ProcessOnline.com.au

effectivenessofnon-contactmethodsofmeasurement,duetounevenreflectionofsound or radio waves.

•Tensile forces-Forcesintallsolidssiloscanreachmanytonnes.Asthevesselisfilledoremptied,thematerialcancausedamage to measurement devices.

•Dust and noise - Dust filling the spaceabovethematerial,aswellassoundandelectromagnetic noise, are common insolidsvessels and can have detrimentaleffectsonvarioustypesofmeasurementmethods.

•Material build-up - Some instrumentsare particularly sensitive to materialbuild-up that can interfere with radioor electronic measurements or clog upmoving mechanisms.

LiquidsWhile liquids usually provide a nice flatsurface for surface measurement, theremay be other challenges surrounding theparticular liquid that will affect what typeof level measurement is used.

• Corrosion-Someliquidsarehighlycor-rosivesocontactmethodsofmeasurementmay not be appropriate, since the liquidwill damage the instrument. Corrosivevapours may also be present above theliquid, so non-contact instruments needto be protected.

•Agitation-Insomeprocesses,theliquidisagitatedinthevessel,oragitationoc-cursduringfillingandemptying,givingamoving level, as well as having impactonsometypesofmeasuringinstrument.

•Density change-Measurementmethodsthatdependonasteadymaterialdensity

maybeaffectedbythechangeofdensitycaused by temperature fluctuations.

•Foam -Surface foamona liquid (whichmaybethereforvariousreasons,includ-ingagitation)cancausesomenon-contactmethods to be inaccurate by presentingmultiple interfaces.

•Vapour-Inclosedvessels,vapourbuild-upabove the liquid can cause interferencewithnon-contactmethods,andforsomepressure-basedheadmeasurements,cancause increased pressure, resulting in alevel reading that is too high.

•Multiple interfaces - Some vessels willcontain immiscible liquids of differentdensities,sothatonetendstofloatontheother.Somemethodsofmeasurementareusefulfordetectingtheinterfacelevelaswell as the total level, but this dependson the properties of the liquids and themeasurement method.

•Material build-up - As for solids, someinstruments are particularly sensitive tomaterial build-up that can interferewithelectronic and radio measurements orclog up moving mechanisms. For liquidapplications,thiscanbeaproblemwhenthe liquid isviscous or sticky.

Methods of interfacingWiththeexceptionofvesselweighingmethodsandnucleonicmeasurement,mostmethodsofmeasurement involvesomeformofcon-nectionwith the insideof thevessel, if notwith the material itself.

Tank bridlesOnemoretraditionalwayofattachinginstru-ments inthecaseof liquidmeasurement isthe same way that visual level indicators

have traditionally been configured. A bridle(also known as an isolating column or by-pass pipe) is a vertical pipe connected tothe side of the vessel, typically with twoconnections to the side of the vessel (highand low), orwith onehighon the side andoneatthebottom(Figure2).Becauseundermostcircumstancesthefluidinsidethebridlewillriseandfallequallywiththelevelofthefluidinthevessel,thebridlecanbeusedasthe location to apply the level instruments,althoughinmostcasesinstrumentsareplacedintheirownbypasspipeornozzleattachedtothebridle.Therearemanyadvantagesinusing a bridle:

• Fewer connections-Thetank,oncebuiltwith a bridle, need never be tamperedwith to add instrumentation.

•Simpler changes-Changestotheinstru-mentationonthebridledonotaffectthevessel.

•Avoids obstructions-Internalstructuresinthetankhavenoeffectoninstrumentsattached to the bridle.

•Overcomes turbulence and foam - Inanagitatedvessel,thebridleprovidesacalmsurface for level measurement.Itshouldberememberedthattankbridles

donotalwaysreflecttheactuallevel.Exam-ples may be where the level has exceededthe upper end of the bridle, or where twofluidsarepresent,inwhichcasetheinterfacelevel in the bridle will probably not matchtheactualinterfacelevel,ormaynotappearin the bridle at all.

Direct connectionWhile non-contact methods of continuouslevel measurement such as radar can be

Leveldetection

Figure 3: Rotary paddle switch. (Source: Monitor

Technologies)

Figure 2: Examples of tank bridle use. (Source: Magnetrol)

Figure 1: Angle of repose.

FEBRUARY 2013-WHAT'SNEWINPROCESSTECHNOLOGY 9www.ProcessOnline.com.au

usedwithtankbridles,inthecaseofsolidsmeasurement (and also many liquid meas-urementapplications)aninstrumentmaybemounteddirectlythroughanopeninginthetank. In the case of liquid head measure-ment, this may involve the direct connec-tion of one or more pressure instrumentsdirectly to the side or bottom of the tank.In this case, valves may be interposed formaintenance purposes.

Inthecaseofcontinuousheightmeasure-ment for both solids and liquids, this willinvolve inserting the instrument though ahole in the top of the vessel. In this case,the risk of the detrimental effects listedabove needs to be taken into account ineach case.

Point level instrumentsThe simplest application of level sensingis for detection of levels at fixed pointsfor simple applications such as preventingoverfill or run-dry, and to start and stopfillingoperations.Allthepoint level instru-mentsdescribedbelowinvolvesomeelementwhich protrudes into the process materialand comes into contact with it.

Float switchesFloat switches use a float and magneticswitching action to switch when the floatrises or falls with a liquid level. They areonly suitable for liquids, and usually onlyfor overfill detection, and come in verticalandhorizontal orientations andcanbe topor side mounted. Their main advantageis their simplicity, but their disadvantageis the use of moving parts that can wearout, and the risk of seizing if they are notoperated frequently. For this reason, they

arenotsuitable forcritical leveldetection,especially for hazardous liquids.

Rotary paddle switchesRotarypaddlesrotateasmallpaddleandthemovement is disrupted when it comes incontactwiththeprocessmaterial.Theyareonlysuitableforsolids.Theirmainadvantageistheirsimplicity,buttheirdisadvantageistheuseofmovingpartsthatcanwearout,andtheriskofdamagefromforcesexertedby some types of material.

Capacitance point level switchesCapacitance type limit switches are staticlevel sensors, use a sensing rod insulatedfrom a ground sleeve. A capacitance isformed by the sense rod and earth exten-sion, or the metal wall of a vessel. Whenno material is present, the capacitance isdirectly proportional to the probe dimen-sionsanddielectricconstantofair( 0≈1).When material is present, the capacitancegets multiplied by dielectric constant ofthe material. This variation in capacitanceis then translated into switching output bythe device.

The main advantage is that there areno moving parts, but the material beingdetected must have a dielectric constantdifferentfromair,andliquidsmustbenon-conductive.Theycanalsobedetrimentallyaffected by static charges in silos.

Conductive point level switchesConductive limit switches work by insert-ing a rod into the vessel and applying analternatingvoltage. In the simplest design,whenanelectricallyconductiveliquidcon-tactstheprobe itmakesacircuitbetweenthe probe and the vessel wall. When thevesselisnon-conductive,aversionwithan

Leveldetection

integral ground probe can be used. Somedesignshavemultipleprobeswithdifferentlengthssothatifsuspendedverticallytheycan detect multiple levels.

Using alternating voltage prevents cor-rosion of the probe rods and electrolyticdestruction of the product. They are onlysuitable for use with conductive liquids.

Themainlimitationsofconductivelevelswitches are that contamination of theprobes can prevent detection, and theymay not be reliable if the conductivity ofthe liquid varies.

Vibrating fork level switchesApairofblades(or‘tines’)isinsertedintotheprocessvessel andmadetovibratebyapiezoelectriccrystaloscillator.Whentheprocess material comes in contact withtheforks,theresultingchange inresonantfrequencyisdetected.Theirmainadvantageover a paddle switch is that there are nomovingpartsandtheyalsoworkwithliquids.Comparedwithcapacitiveorconductivesen-sors,theconductivityofthe liquidmediumis not relevant. However, some versionshavevery long forks thatmaybeprone tobeing bent by heavy solids. They are notsuitableforsomeverylightmaterialssuchas ashes and build-up of material on andbetweentheforkscancauseinaccuracy,sothetypeofmaterialisimportantindecidingwhether to use them.

In Part 2In Part 2 of this article, we will lookatvarioustechnologiesforcontinuouslevel measurement.

Type Pointdetectionforliquids Pointdetectionforsolids

Float Yes

Paddle Yes

Vibratory Yes Yes

Capacitance Yes Yes

Conductive Yes

Radiometric Yes Yes

Table 1: Summary of point level switch applications.

Figure 4: Vibrating fork level switch. (Source: Rosemount)


NEWPRODUCTS

ANDROID INDUSTRIAL MOBILE DEVICEThe IMX-2000 from Adlink Technology is an industrial mobile handheld device utilising the Android operating

system. Combining high-performance RFID, barcode scanner and 3G/WLAN wireless transmission functions

to satisfy diverse application requirements, the IMX-2000 can be applied in a wide range of industries.

Applications include fully supported logistics management, transportation and factory automation. With

an 800 MHz processor speed, as well as high resistance to impact, water and dust, the IMX-2000

has the capacity to enhance productivity and significantly reduce costs.

The IMX-2000 utilises the Android operating system to offer a qualified and user-friendly interface.

In addition, all the data can be conveniently input directly by numeric keys into the Android system.

Designed with high-efficiency barcode scan processing capacity bundled with Reader Utility

software, data saved under 1D or 2D barcode can be accessed easily. Wi-Fi, Bluetooth, GSM,

GPS and AGPS are all integrated.

Along with the robust design, the IMX-2000 passes IP65 and 1.5 m drop tests to ensure continuous

operation after being inadvertently dropped and provides highly efficient operation even in extreme environments.

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camera, the IMX-2000 supports wireless broadband for real-time video communication and surveillance. Also, the memory

is expandable via microSD supporting SDHC up to 32 GB. With the rechargeable 3900 mAh Lithium battery, the IMX-2000

can provide long-term operation. A charging cradle is also provided along with the IMX-2000 for added convenience.

ADLINK Technology Inc

Contact info and more items like this at wf.net.au/S222

PROFINET IRT GATEWAYSHMS Industrial Networks has released a series of Anybus X-gateways that enable communication be-

tween several industrial networks and Profinet IRT. The X-gateways can connect Profibus and CANopen

to Profinet IRT with fibre-optics, and ControlNet, EtherNet/IP and DeviceNet to Profinet IRT with copper

cabling. They help plant owners and machine builders to migrate to Profinet without making changes

to their existing machinery.

The X-gateways copy I/O data between any industrial network and Profinet IRT. Gateway settings

regarding, for example, I/O sizes are configured in a Windows-based terminal interface which means

no programming is necessary.

The Profinet interface of the X-gateway works as an I/O device on the Profinet IRT network and supports

up to 220 B of I/O for both input and output data. The gateway’s baud rate is 100 Mbps (full duplex)

and uses two RJ45 connectors (copper) or two SC-RJ connectors (fibre) allowing installations in line

or ring topology. The integrated 2-port IRT switch eliminates the need for expensive external switches.

Global Automation Asia-Pacific

Contact info and more items like this at wf.net.au/R927

PROCESS CALIBRATORThe 7526A Precision Process Calibrator from Fluke

Calibration is a benchtop process calibrator designed

to simplify calibration of temperature and pressure

process instrumentation by incorporating an isolated

measurement channel, letting users source and measure

simultaneously.

It can be used to easily calibrate all types of sensors and

instruments, such as RTD and thermocouple readouts,

pressure gauges, temperature and pressure transmitters, digital process simulators, data loggers and multimeters.

The calibrator simulates and measures nine RTD and 13 thermocouple types, accurately measures pressure

to within 0.008% of reading when combined with Fluke 525A-P Series Pressure Modules, sources and measures

DC voltage from 0 to 100 V to within 0.004% of reading, sources DC current from 0 to 100 mA, accurately

measures DC current to within 0.01% from 0 to 50 mA and supplies 24 V DC loop power.

Fluke Australia Pty Ltd


Domino iTech A tried&true way to LEAN yourlabelling and coding operations.

Today’s business is about LEAN operations, process improvement and achieving 100% quality. The new Domino iTech range allows users to control multiple technologies from a single touch point, and provides maintenance staff access to common parts for all equipment. Achieving LEANER operations, Domino’s iTech range allows the use of common parts, software and control pads for continuous ink jet, laser, thermal ink jet, thermal transfer overprint and print and apply technology.

Domino introduces iTech: Common parts, software and control pads for all coding technologies.

Contact us to find out more about the Domino iTech range.

Phone: 1300 467 446 | Email: [email protected] | Web: www.insignia.com.au

http://www.insignia.com.au


HOT PRODUCTSON WWW.PROCESSONLINE.COM.AU THIS MONTH

>

>

INTELLIGENT UPS

The UPS-IQ mounting rail UPS power supply now

has data communication capabilities for integration

with control networks.

Phoenix Contact Pty Ltd

WF.NET.AU/S746

PXI EXPRESS CHASSIS

The NI PXIe-1085 PXI-Express chassis is claimed to

be the industry’s first all-hybrid PXI Express chassis.

National Instruments Australia

WF.NET.AU/R852

DIGITAL PRESSURE SENSORS

The AHLBORN FDAD33 and FDAD35M high-precision pressure

sensors include an integrated A/D converter and signal conditioner.

Bestech Australia Pty Ltd

WF.NET.AU/S743

>INLINE DENSITY METER

The Anton Paar L-dens 427 density meter allows

users to upgrade a volumetric flow measurement

system to mass flow measurement.

B-R Controls Pty Ltd

WF.NET.AU/S528

>

E-STOP PUSH-BUTTONS

The expanded range of Pilz PITestop push-buttons is designed

to make it easier to select the right E-STOP solution.

Pilz Australia Industrial Automation LP

WF.NET.AU/S409

>

http://www.fluke.com.au


PANEL PCThe Kontron V Panel Express panel

PC is now available with the Intel

Core i7 dual-core processor. Compared

to its predecessors, this version offers nearly

double the performance and is suitable for industrial high-

performance applications, with a processor speed of 2.2 GHz (2.9

GHz in turbo mode) and up to 8 GB DDR3 memory.

With its 100% passive cooling concept, the panel PC needs neither a fan

nor a fan filter to be replaced and is therefore completely maintenance free.

Optimal shock, vibration and temperature resistance are all standard features of

the panel PC family, as is EMI protection. The V Panel Express is available in

sizes from 12.1 to 19″, serving the increased demand for larger display sizes.

The front panel is made of stainless steel and offers IP65 protection against

dust and water spray. The resistive touch display, with LED backlight, enables

reliable operation even when working with gloves and pens. Optionally, the

front panel can be designed to cater to customers’ specifications, including

individual branding.

For applications with less performance demands, a version is available with

the 1.4 GHz Intel Celeron 827E single-core processor. Interfaces include five

USB ports, a 10/100 LAN port, a 10/100/1000 LAN port, two RS232 ports and a

DVI-I video port. With up to two PCI Express slots, customer-specific extensions

can be integrated. In terms of storage media, either up to two SATA hard disks

or especially robust Compact Flash media can be housed.

Kontron Australia Pty Ltd


NEWPRODUCTS

OSCILLATION ANALYSISExpertune’s PlantTriage software has been en-

hanced with tools to extend its oscillation analysis

features. The software automates the engineering

analysis, completing a Fourier transform and

identifying key periods of oscillation. The software

then filters the information so only the most likely

sources of the problem will be identified.

The oscillation analysis tools are fully inte-

grated into PlantTriage’s web browser interface,

and a preconfigured Problem-Solver report for

oscillation analysis is included. The report can

be viewed online, emailed, exported to Excel,

or even scheduled for email delivery whenever

PlantTriage finds a significant issue. No program-

ming or SQL skills are required.

The cycle detection and analysis tools are

included with all PlantTriage systems, version

11.01 and higher. Existing PlantTriage users

receive the features at no charge, as part of

their software maintenance agreement.

Daesim Technologies Pty Ltd


PID CONTROLLERThe Red Lion PAX2C PID controller

is the most recent addition to the

PAX2 Series. It is designed to im-

prove flexibility and ease of use for

process and temperature control. Applications can be found in the food and beverage, plastics,

packaging, energy and gas industries, as well as in heat treatment and glass processing.

The PAX2C has field-installable, plug-in option cards to simplify configuration by enabling

customers to customise their own controllers. This type of flexibility eliminates the need to

order additional products to meet changing application requirements.

The dual-line, 3-colour display provides at-a-glance visual representation of up to 16 changing

alarm conditions with seven programmable colour zones and is customisable to allow users

full access to bar graphs, annunciators, colour zones and display mnemonics.

The universal input accepts current, voltage, resistance, temperature and process signals

all in the same unit, and the universal power supply accepts AC or DC power, and is ready

to plug in ‘out of the box’ for fast, easy installation regardless of power polarity.

Easy programming, firmware and software upgrades are performed using a built-in USB con-

nector and Red Lion’s Crimson software to support both current needs and future requirements.

Control Logic Pty Ltd


MICRO SERVO CONTROLLEROmron Electronics has released an updated series of

micro servo cont ro l le rs , the CP1L-E . Bu i l t

on the CP1L platform, the CP1L-E now offers

an ethernet port, two analog inputs and pulse

I/O as standard features. A maximum of six

100 kHz counter inputs (two with quadrature input)

and two 100 kHz pulse outputs can now be config-

ured on all CPUs.

The programming software incorporates a library of

function blocks to handle servo control functionality.

A range of functions is supported, including simple

absolute or relative moves and interrupt feeds. Simple

position control utilising a VSD is also possible, where

the control loop is closed through the controller, which

utilises its built-in, high-speed I/O.

CP1L-E CPUs are available in a choice of 20, 30 or

40 I/O and support all the logic functions expected in a

modern PLC. Programming is via IEC 61131 3-compli-

ant software and supports online editing. Expandability

is possible by the addition of extra modules or boards

that plug into the CPU. External RS232 and RS485

communication modules can be inserted for Modbus

RTU or other connections.

Omron Electronics Pty Ltd


http://www.emersonprocess.com


Higher reliability for your processes From relay module to threshold value switch – Phoenix Contact o�ers you certified products for easy expansion

uoy snaem sihT .snoitcnuf ytefas foare always on the safe side. Do you have any questions about functional safety? An addition to products, we also o�er you training on this topic.

For additional information call 1300 786 411 or visit phoenixcontact.com.au

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Functional and safe processes

Switch – convert – transmit with safety!

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NEWPRODUCTS

MOBILE BULK BAG FILLING SYSTEMThe latest mobile bulk bag filling system from Flexicon features an

integral metal detector/separator and a tilt-down conveyor/feeder

for dust-free filling at multiple locations.

The system detects metal in the free-fall stream of material en-

tering the filler and then ejects it through a chute that discharges

into a removable drum at the rear of the unit.

The filler is also equipped with fill head height adjustment to

accommodate all popular bag sizes; an inflatable cuff to seal the

bag inlet spout; a blower to remove bag creases prior to filling;

load cells for filling by weight; a vent port for dust-free air displace-

ment during filling; pneumatically retractable bag hooks; and an

automated vibratory densification/deaeration system to maximise

capacity and stabilise the bag for storage or shipment.

The first bulk bag filler to receive USDA acceptance, it is con-

structed of 316 stainless steel, finished to sanitary standards and

configured with full-length forklifting tubes allowing it to be moved

throughout the plant.

The conveyor’s inlet hopper includes an air displacement vent with cartridge filter that is equipped

with a reverse pulse cleaning system that dislodges accumulated dust with short bursts of com-

pressed air, returning the dust to the hopper on a timed cycle, maintaining operating efficiency.

The programmable controls are housed in a stainless steel NEMA 4X enclosure with touch

screen that graphically displays filling functions.

Flexicon Corporation (Australia) Pty Limited


http://phoenixcontact.com.au


NEWPRODUCTS VALVE CONNECTORSHirschmann has released the GDM series field-attachable valve connectors that can be

used to supply power to components such as solenoid valves, pressure sensors and

temperature sensors, or to connect them to a data network. Circuit protection ensures

that downstream circuitry cannot be damaged by excess voltage or electromagnetic

fields. Versions with built-in LED status indicators (with or without circuit protection) are

also available.

Depending on the version of the valve

connector, additional features include

IP68 protection, an operating temperature

range of 40 to +90°C and high shock

and vibration resistance.

The type A connectors, also available

with integrated strain relief conforming to

UL 2238, are easy to connect due to their

greater height. Depending on the connec-

tor version, cable diameters of between 4

and 14 mm with a conductor size of up

to 1.5 mm2 can be used. The housings

are also characterised by features such

as acid resistance or biodegradability.

The easy-to-grip housings ensure safe

handling.

The connectors are available with black or transparent housings, depending on the

circuitry, and with two or three poles plus PE. The rated voltage is between 12 and

250 VAC/VDC, depending on the version, and the rated current between 1 and 10 A.

Soanar Limited


TEST MANAGEMENT SOFTWARENational Instruments has introduced NI Test-

Stand 2012, the latest version of its automated

test management software. With its modular

process architecture, NI TestStand 2012

helps engineers increase the flexibility and

throughput of their automated test systems,

by making test set-up easier, expanding test

and reporting flexibility, and making it pos-

sible for engineers to simultaneously test and

report during parallel testing.

Asynchronous result processing makes it

possible to continue testing devices while

simultaneously generating reports or data

logging, and the plug-in architecture facilitates

advanced customisations, including multiple

report formats, with minimal code changes.

NI Idea Exchange Community-requested

features have also been included that reduce

development time, including drag-and-drop

code module files for step autogeneration,

and improved array and string manipulation.

National Instruments Australia


CONTROL LOGIC SIMULATION UPDATEMathWorks has announced an updated version of Stateflow in R2012b

that simplifies control logic design. Stateflow Editor, state transition tables

and MATLAB as an action language are designed to help engineers build

applications like supervisory control, task scheduling and fault manage-

ment more efficiently.

Updated features include Stateflow Editor to access the Simulink model

and Stateflow diagrams in the same window through tabs and, to assist

with state diagram editing using smart guides, transition indicator lines,

drag margins and just-in-time error notification.

State transition tables are now available to build and edit state machines

using a simple structured interface with automatic completion, syntax correc-

tion and diagnostic checks. Using MATLAB as the action language makes

it easy for MATLAB users to build state machines and flow charts, and the

integrated debugger helps step through logic and identify design problems.

MathWorks Australia


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


NEWPRODUCTS

PLANT MOBILITY SOLUTIONHoneywell has released Experion Mobile Access, a mobility applica-

tion that provides secure remote access to Honeywell’s Experion

Process Knowledge System (PKS) through mobile computing

devices. Experion Mobile Access enables field operators to view

and respond to live information from Experion PKS while they are

on rounds or inspecting the plant.

To meet plant and field operators’ need for fast and easy ac-

cess to plant data, the company has developed Experion Mobile

Access, which works securely with the Experion PKS architecture

and the company’s OneWireless Network. This software applica-

tion provides seamless field data access for plants with complex

processes and expansive footprints that rely on a large mobile

operator staff for proper operations, and to support the availability

of process equipment.

It is designed to help field operation teams find and avert process

conditions that could affect production output. Recent cases stud-

ies have shown that an average-sized refinery or chemical plant

can see up to $1 million per year in savings, a 15% improvement

in mean time between failure of assets and a 10% reduction in

maintenance costs.

Experion Mobile Access leverages Experion Distributed System

Architecture (DSA), including Experion eServer technology to deliver

data to field operators throughout the facility. Its web-based user

interface has been optimised for small mobile devices, such as

industrial handhelds commonly employed by workers during their field

rounds, but also other devices such as smartphones and tablets.

Honeywell Limited


PROFIBUS/MODBUS TCP GATEWAYThe Moxa MGate 5101-PBM-MN

gateway provides a communi-

cation portal between Profibus

devices (such as Profibus drives or

instruments) and Modbus TCP hosts. All

models are protected with a rugged metallic casing,

are DIN rail mountable and offer optional built-in optical isolation.

The rugged design is suitable for industrial applications such as

in oil and gas, power, process automation and factory automation.

Moxa’s AutoScan function can automatically detect all connected

Profibus slave devices and their available I/O modules to quickly

complete gateway configuration, after which an easy-to-read data

mapping table is created to assist in the configuration of Modbus

TCP master settings.

The MGate 5101-PBM-MN provides a web console and telnet

console for remote maintenance. Each also supports encrypted

communication protocols such as HTTPS and SSH for preventing

unauthorised access.

The MGate 5101-PBM-MN has dual power inputs for greater

reliability. This higher level of reliability makes these Profibus

master to Modbus TCP gateways suitable for demanding indus-

trial applications.

Madison Technologies


ROBOT MOTION CONTROLLERAdept Technology has announced its latest SmartController EX.

This lead-free, high-performance distributed motion controller,

designed for use with Adept robots, features a high-speed

processor and updated software. With more processing power

and faster communication, the controller can increase a robot’s

cycle speeds by up to 5%.

The product features Gigabit ethernet and a processor that is

10 times more powerful than the previous generation. Four times

more memory further enhances performance and the 2 GB SD

memory card slot adds functionality, allowing users to easily transfer data between controllers, capture log data and back

up data to a PC. The controller’s Adept eV+ software is built around a robust real-time operating system. It is seamlessly

backwards compatible with V+ code and integrates with Adept’s vision-guidance technology for optimal robotic performance.

The company designed the controller for use with Cobra s-series SCARA robots, Viper six-axis robots, Quattro parallel

robots and Python Linear Modules. It is backwards compatible with the company’s CX controller - users can use the same

connectors and code and easily transition.

The product comes with an optional T20 Pendant. This handheld device provides a user interface in an ergonomic and

rugged package. Designed for both right- and left-handed users, the gripping and holding positions enable comfortable,

fatigue-free operation. Compared to previous generation pendants, the T20 is lighter and features a more colourful interface

to ease use.

Adept Technology International Ltd


We help engineers keep the World running

For 75 years, We’ve helped engineers keep

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Jon Ewen, Purchasing Offi cer at Weta Workshop, says, “The main reason we turn to RS Components is that they havesuch a wide range of products all in one place.” What’s more, RS Components’ quick delivery times means that most orders arrive the next day, which is vital in the fi lm industry.

The nature of Weta’s work means that they have a wide and varied requirement, as no two projects are ever the same. With an unrivalled range of electronics and maintenance products, RS Components is perfectly placed to meet this need.

“WITH SUCH A WIDE RANGE OF PRODUCTS, RS CAN OFFER ALTERNATIVES THAT KEEP US MOVING FORWARD.”

Jon EwenPurchasing Offi cer, Weta WorkshopWellington, New Zealand

Innovative solutions for forward-thinking businessesThrough an enduring commitment to exceptional service,RS Components enables companies like KK Electrical to work smarter and more effi ciently. The New Zealand-based electrical contractor relies on us to supply its specialist automation requirements. Owner Ken Sullivan says the benefi tsRS Components brings to his business are absolute supply certainty and quick next-day delivery#.

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Ken SullivanOwner, KK ElectricalChristchurch, New Zealand

# Please refer to your local RS online site forlocal delivery terms and conditions.

SINCE 1937, PUTTING OUR CUSTOMERS FIRST HAS MADE US THE WORLD’S NUMBER ONE*

WE HELP ENGINEERS KEEP THE WORLD RUNNING

1937

1937JH Waring and PM Sebestyen establish Radiospares in London.

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2012

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* RS Components is the trading brand of Electrocomponents, the world’s leading high-service electronics and maintenance distributor with sales revenue of £1.27 billion as of 31 March 2012.

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No matter how sophisticated a fluid analyser system may be,itwillbeineffectiveifasampleflowfailstoreachtheanalysersensor or if the sample is contaminated or stale. The mostadvancedsystemsintheworldcannotprovideaccurateresultswithout a valid fluid sample.

SYSTEMS

Sam Kresch, Product Manager, Fluid Components International (FCI)

VERIFYINGFLUIDFLOWFORRELIABILITYANDACCURACY

ANALYSER

Gaschromatographs,massspectrometers,opticalspectrom-etersandphotometersarea fewexamplesofanalysertechnologiesapplied inprocessandplantsystemsthatneedsampleflowassurance. It isanacceptedindustry

best practice that sampling systems have some type of flowmonitor to assure valid samples and analysis.

Failingtomonitorfluidflowtotheanalysermayresultincon-taminatedproductbatchesanddischargingregulatedsubstances.The costs of analyser failure are potentially huge in terms ofaffecting product materials, damage to equipment, regulatoryfines, liability and more.

While there are a number of fluid flow monitoring technolo-gies on the market, immersible thermal dispersion technologycombinedwithpackagingandsensordesignsoptimisedforsam-plingsystemshasemergedasthenewbest-in-classtechnology.Thermal dispersion mass flow sensors have proven themselvesfordecadestobeextremelyreliable inotherdemandingprocessand plant applications - often in relatively close proximity toanalyser systems.

Recent developmentsThe trend towards mounting the sample-handling system at theprocess has greatly enhanced process efficiency. Recent devel-opments in packaging and speed now make it possible to runanalyser systems more efficiently, utilising the real-time informa-tiontoprocessonline inbatchmode.Developments incontinuousflow reactors combine with analytics and new sampling systemsto improve reaction times. More and more systems now provideanalysis of the process in real time, making the integrity of thereadings that much more important to the process success. Theideal flow monitor should provide the form, fit and functions thatwill accommodate both these new-generation analyser systemsand traditional legacy and hybrid designs (Figure 1).

Dependingontheanalysertype,samplingfluidisoftentransportedin 1/8″ to ½″ tubing. Most systems typically draw small samplesin¼″ tubes.Alsogrowing inpopularityaresystemsbasedontheindustry-standard SP76 manifold. SP76 is an ANSI/ISA standardapproved in 2002, which is supported and has been adoptedworldwide by major chemical and refining companies (Figure 2).

SAMPLING


SP76 and NeSSI basicsLeading the way for the SP76 standard is the New Sampling/Sensor Initiative (NeSSI) organisation, initially created in 1999throughdiscussionsinaCenterforProcessAnalyticalChemistry’s(CPAC) oil and petrochemical focus group. Other organisationshave embraced and are promoting NeSSI/SP76, including theInternational Forum for Process Analytical Chemistry (IFPAC)and the Federation of Analytical Chemistry and SpectroscopySocieties (FACSS).

Each block of a typical SP76 train is 1.5 x 1.5″ square andeffectivelybecomesaconvenientplug-and-playmodularsurface-mountinterfacefornumeroussamplingsystemcomponents(Figure3).TheNeSSIgroupremainsactive inadvancingenhancementsfor the process analysis community. Beyond the initial physicalinterface of the SP76 manifold itself, the group has definedprogressive levels of sophistication, known as Gen. I, II and III,that provide for digital bus communications, hazardous locationapproval types and the Sensor Actuator Manager (SAM).

Flow technologiesRegardless of the analyser fluid sampling system configuration,flow monitoring is essential to ensure proper analyser operation.Therearenumerousmethodsandtechnologiesavailabletomonitorsampleflowonareal-timebasis.Thesecanbemechanicalspringorgravityloadedpistons,variableareatypes,differentialpressureand thermal mass flow.

In most cases, a simple relay contact or solid state outputchange is all that is desired to indicate a reduction or absenceof flow at a predetermined setting. A recent trend is driving theoutputrequirementstoincludeananalogordigitalcommunicationsignal to monitor the sample flow rate throughout the flow range.This allows operators to better predict flow declines due to dis-ruptionscausedbycloggingfilters,linecontaminationfromfoulingfluids,leakyorfailingpumps,andothertimeandwearsusceptiblecomponents in the system.

Mechanicaldevicesnormallyhavetheadvantageofnotrequiringpower to operate; however, a minimum number of wires are stillrequiredtotransmitanelectronicsignal (contactclosure)backtothe control system. As these devices are triggered by the forceof theflowstreamsuch that specificandfixedapplicationdetails,includingthesampledfluid’sdensity,viscosity, temperature,pres-sure, flowrateand, if non-adjustable type, the trippoint,mustbeknown and be specified when ordering them.

Furthermore,becausesprings,magneticcomponentsandsealsareall inthewettedflowstream,theirmaterialcompatibilitymustalsobeevaluatedbythespecifyingengineer.Whilemechanicalde-viceswithfactoryfixedtrippointscanbeoneofthe lowerpricedsolutions, those with adjustable trip points are often double thecost and approaching the price of some of the more robust andsophisticated technology solutions mentioned later.

Theleadingdrawbackandmostfrequentuserissuewiththesemechanicaldevicesistheirsusceptibilitytostickingovertime.Asallmechanicaldesignshavemovingpartsintheflowstream,con-taminatingfluidscanbeaserioussourceoffuturefailure.Foulingcontaminantscanprogressivelybuildupovermonthsoryearsandareonlydetectedwhenother failures in thesystemaredetected.

These devices can also have nooks and crannies that are ex-posed in the flow stream as they displace the flow path volume.Inadditiontobeinganotherareasubjecttoclogging,theycantrapprevioussamplesorpurgemediawhichcancontaminatesubsequentsamples. Piston-actuated devices also have no continuous visualindicationofnormalorabnormalflowconditions fortheoperator,other than their preset trip point.

Variable area metersVariableareametershavetheadvantageofcontinuousvisualdis-play of flow; however, they are also susceptible to sticking overtimeinmanyfluids.Theirlongertermreliabilityisoftenaconcern

Instrumentation&sensors© iStockphoto.com/Johan W. Elzenga


expressed by analyser users. Adding a magnetic pickup to provideanelectronicrelaytriporananalogoutputaddssignificantlytotheircost.Variableareameterstendtotakeupmorevaluableenclosurespace than desired as they are very orientation dependent; andtheirflow inputandoutputaccessaretypicallyondifferentplanes.

Differential pressure (DP) devices can be a sound technologyto monitor analyser flow rates. Even in the small line sizes and atvery low flow rates associated with analyser sampling systems, aproperly sized orifice and sensitive pressure transducer can yielddesirableresults.ThetwomaindisadvantagesofDPtechnologyare:

1. Its limited flow rate turndown capability.

2. The large errors incurred at the low end of the flow rate readings.

Very often it is the low end that is critical for sample flow as-surance and flow monitoring in analysers and sampling systems.Unfortunately, optimising the flow range to the low end of DPsensors can result in an appreciable pressure drop and poor flowmeasurement performance at normal flows.

Similar to piston-driven switches and variable area meters, DPflowmonitorsmustbeselectedknowingthedensityandaspecificallynarrowflowraterangeofthesampleprocess.TherearelimitedDPdevices designed for the SP76 manifold. They require at least twoblockspacesandarethemostexpensiveofallthemonitoringdevices.

Solving the problemsAnidealflowmonitorforananalysersamplingsystemwouldbeonethatcanbeadaptedonsiteandadjustedspecifically in theapplica-tion. In addition, a more robust flow sensing technology married toflexible and user programmable electronics, which can be specifiedwithout detailed and finite validation of process variables such asdensity, viscosity, flow range, fluid type, etc, also would alleviate apainpointfortheanalysersystemsupplierandsiteengineeringteam.

Flowmonitorsdesignedwiththermaldispersiontechnologymatchupextremelywellwiththeidealuniversalusecriteriatosupportananalyser sampling system. Depending on the manufacturer’s flowelement and electronics design, they can be set up by the user insitu to assure the field engineer a successful, first time correct in-stallation.Thesedevicesmaybeconfiguredinthefieldtooperatein

gases or liquids at almost any density or viscosity with no specialconsideration at timeof ordering.

Therearetwomajortypesofthermaldevicesonthemarket.Onetype utilises a capillary bypass technique and is better known as amassflowcontrollerorMFC.MFCsdivertaportionofthemainflowintoasmallbypassandsensetheheattransferofflowingfluidinthebypass channel. This technique can bevery effective; however, thecapillarytubeishighlysusceptibletocontaminationandcloggingandshould only be considered for use with clean or pre-filtered fluids.Capillarybypassflowmonitorsaregenerallyapplied in labuse,andagencyapprovals(eg,FM,CSA,ATEX,IECEx,etc)foruseinhazard-ous, explosive environments are rare. Flow range selection is alsoimportantwhen specifyingMFC type flowmonitors.

Immersible thermal dispersion technologyTheother typeof thermal dispersion flowmonitoring device is onethatusesthermowells intheflowstream,sometimesreferredtoasimmersible-type. These typesof devices typically apply heat to onethermal sensor relative to a second thermal sensor measuring theprocesstemperature.Thetemperaturedifferencechangeswithflowrate.Inthecaseofgases,themeasurementisdirectlyrelatedtomassflow. Immersiblethermalflowmonitorsareveryeffectiveoverwide

Figure 1: Typical sampling system.

Figure 2: FCI FS10A mass flow meter mounted on an SP76 manifold.

Instrumentation&sensors

REGARDLESS OF THE ANALYSER FLUID

SAMPLING SYSTEM CONFIGURATION, FLOW

MONITORING IS ESSENTIAL TO ENSURE PROPER

ANALYSER OPERATION.


flow ranges in gases andover smaller lowflow ranges in liquids.Thermaltechnologyisparticularlyadvantageousinprocessanalyser

systemsbecauseithasnomovingpartstowear,stickorfoul.Withtheir tiny thermowells and wetted materials typically made of 316Lstainless steel or Hastelloy alloys, they are highly compatible andwell suited to application inmost analysers and sampling systems.

The thermal probe can be threaded into industry-standard tubeteebranches(eg,Parker,Swagelok,Circor)(Figure4)orevenintoasingleblock inthepreviouslymentionedSP76manifold,resulting inminimaldeadspace.Therearenocavitiestotrapprevioussamplessosampleintegrityisalwaysthehighest.Anotherkeycharacteristicof thermal flow monitors for analyser applications is their superiorsensitivity to lowflow rates.

It is not uncommon to find analysers requiring preheated or hotprocessfluids.Asthermaldevicestypicallydonotrequireelastomerseals, and can be easily configured with the sensor element andelectronics separated (remote), they are often the best and onlysolution forhigher temperatureservice requirements -up to260°Ciscommon.Otherfeaturesmayincludeindicatorsordisplaysoftrippointstatusandflowrates, isolatedSPDTalarmcontactandanalogor digital output tomonitor flow trends.

Perhaps the most important benefit of some types of thermaldevices is their ability to be field set and field adapted by the userforinexact,unknownorchangedprocessandapplicationconditions.Preciselyandcompletelydefinedprocessconditionsandfluidvariablesareoftenlackingduringthepreliminarydesignandengineeringphase.Variations intubingconfiguration,flowdirection layout,ambientandfluidtemperatureconditions,pressureanddensityvariations,viscosity,flowrange,fluidtypeandtrippointsarevariablesthatareoftenonlyfinallydeterminedafterinstallationandsitecommissioning.Thermaldispersionflowtechnology-basedproductswithsmartelectronicscanprovidemaximumfield adjustability and site adaptability.

ConclusionsFlow sensors and monitors are just one of the components re-quired in complex process analyser and sampling systems. Whilethere are several flow monitoring technologies available that canbe considered, their diversity can make proper selection a majorchallenge.Thequestionbecomes,whichflowtechnologyisoptimumfor the particular type of analyser application and its operatingenvironment?

Properlyselectingaflowsensorforananalysersamplingsystemcan take an inordinate amount of an engineer’s time because ofthe complex factors that must be reviewed. Consideration mustbe given to:

•diversity in measuring range•fluid type and condition compatibility•temperature and pressure condition suitability•outputs and user interfaces•approvals for Ex locations•site adaptability and adjustability•tube tee and SP76 compatibility•dimensions, weight and orientation•total installed cost

Even then there is still worry about whether or how well thechosenflowmonitorreallyfunctionswhenthesystemiscommis-sioned, launched and put into operation. A flow monitor that isadaptableandcanbesitesetformostanyfieldconditionvariables,suchasthosebasedonimmersiblethermaldispersiontechnology,providesmaximumconfidencethattheanalysersystemwillperformas expected upon installation.

AMS Instrumentation & Calibration Pty Ltd


Instrumentation&sensors

Figure 3: Integral mounting on an SP76 platform.

Figure 4: FCI FS10A mass flow meter mounted in a tube tee.


Your analysis has to be right.

YOU DESERVECOMPLETESOLUTIONSYOU CAN BEFULLYCONFIDENT IN.

Hach is your resourcefor expert answers,outstanding support,and reliable, easy-to-useproducts.

AUS: 1300 887 735

NZ: 0800 50 55 66

hachpacific.com

270x88mm HACH PACIFIC_PROCESS TECH:8.25x10.75 WEAU OPT 1/8/13 7:13 AM Page 1

Though used like a print mark sensor, the Sick ML20

sensor requires no optical marking on the package,

instead detecting a taught-in design pattern. In future,

the label on beverage bottles or chocolate bars and

packaged chips can be in the right spot even without

a registration marking.

The ML20 uses a novel method for detecting

contrast patterns. In the process, the sensor is

taught a pattern sequence, eg, the graphic images

or lettering, which is then detected at a scanning

rate of up to 7 m/s, resulting in the output of a

switching signal. Even if the labels have a complex

design or the machine is operating at high speed,

the ML20 detects nearly any pattern with accuracy

and stability.

MARKLESS LABEL SENSOR

PRODUCTSINSTRUMENTATION & SENSORS

The metal housing of the sensor provides a high

level of ruggedness, and it is easy both to integrate

in machines and to commission. The sensor works

reliably even if the image patterns are intricate or

the process varies.

When changing label or foil reels, the sensor

avoids unnecessary cutting loss and waste, since

pattern recognition is active right away, enabling

use of the material starting immediately after the

beginning of the reel. In some packaging pro-

cesses, for instance when labelling bottles, there

are additional savings of the additional material

previously used exclusively for the print mark. The

markless technology allows savings up to 5% of

material per label.

Sick Pty Ltd


http://www.hachpacific.com


Sinclair & Rush Pty Limited51 Wellington StreetRiverstone NSW [email protected]: (02) 9627 5156 Tel: (02) 9627 3211

C A P S P L U G S C O V E R S M A S K I N G

www.stockcap.com1800 003 211FOR FREE SAMPLES AND A CATALOGUE CALL

Nobody has a greater range of Flexible Vinyl Caps and Plugs thanSTOCKCAP. And they’re in stock now for immediate delivery.Ideal to protect, mask or insulate components from shipping, storage orprocessing damage, STOCKCAP Flexible Vinyl Caps and Plugs fit snug toseal out moisture, oil and dirt. Choose from thousands of sizes, shapesand colours all at the industry’s most competitive prices.So if you need Caps or Plugs in stock, get ours ex-stock.

SUBMERSIBLE PRESSURE TRANSMITTER FOR LEVEL MEASUREMENT

The LH-20 submersible pressure transmitter is a

slender, high-performance instrument, with a diam-

eter of only 22 mm and an accuracy of up to 0.1%,

even in harsh operating conditions.

As a result of numerous options and functions,

the level probe is suitable for almost all applications

in level measurement with full media contact. The

LH-20 exhibits a very low temperature error and is

available with a parallel temperature output signal,

HART communication and a scaleable measuring

range. For the highest resistance to media, the probe

is available in a stainless steel or titanium version,

with PUR, PE or FEP cable.

In the specific design variant for drinking water ap-

plications, the device meets the KTW and ACS regula-

tions for drinking water conformity. The probe is also

available in an explosion-proof version.

WIKA Australia


THERMAL MASS FLOW METERS

Sierra Instruments has introduced the QuadraTherm 640i/780i

thermal mass flow meter series. With its sensor design

advancements, coupled with a proprietary iTherm algorithm, the

780i inline version achieves gas mass flow rate measurement

accuracy of ±0.5% of reading above 50% of the full scale (air).

Traditional thermal sensors have two sensors - one tem-

perature sensor and one velocity sensor, each in a separate

probe. QuadraTherm introduces four sensors - three precision

platinum temperature sensors and one no-drift DrySense

mass velocity sensor, which uses a proprietary manufacturing

process to improve accuracy and long-term stability.

The QuadraTherm sensor isolates forced convection

(the critical variable for measuring gas mass flow rate) by

calculating and then eliminating unwanted heat-transfer

components like sensor stem conduction, one of the major

causes of false flow readings. The result is a fundamentally

different gas mass flow rate calculation using all pertinent

variables for a precise, stable and accurate thermal mass

flow measurement.

The product is available in two models: the 640i inser-

tion and 780i inline. The range has a no-drift sensor and a

multivariable output for mass flow, temperature and pressure

(optional). It measures all inert and all non-condensing clean

gases as well as flammable gases (methane, propane, hy-

drogen, and digester gas). Repeatability for mass flow rate

is ±0.15% and gas accuracy is ±1°C.

Procon Instrument Technology



http://www.stockcap.com


SENSORS FOR HYGIENIC ENVIRONMENTS

The Banner Engineering QM26 and QMH26 photoelectric

sensors are designed specifically for the food and beverage

and pharmaceutical industries. The sensors’ design con-

siders Hazard Analysis and Critical Control Point (HACCP)

principles for hygienic manufacturing processes, and they

are designed to work in areas where the sensors may come

in contact with food or materials. They are suitable for

harsh washdown environments with high pressure, extreme

temperatures and chemicals.

The QM26 is housed in a non-toxic 316L stainless steel

housing and can survive high-pressure washdowns and

temperature cycling, ranging from -30 to 60°C. The sensor

is ECOLAB certified for inexhaustible sensor life in chemi-

cally cleaned environments and is intended for splash zone

areas. The QM26 also features easy side-mounting for quick

set-up and installation.

The QMH26 has all the advantages of the QM26; however,

it is designed with minimal grooves and crevices, leaving

no room for bacteria to hide and multiply. It is self-draining

for clean-in-place (CIP) applications. The sensor’s hygienic

mounting shape reduces contamination risk, making it a

suitable sensor to place in contact zones.

Micromax Pty Ltd


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COMPONENTS

CONTROLCOMPONENTS

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ControlComponents

RH AND TEMPERATURE TRANSMITTERS

Maintaining reliable RH measurements in harsh or corrosive environments is notoriously difficult as the conditions

themselves degrade the sensors and equipment, often in short tim periods. To provide a solution to this

problem, Michell Instruments has released the DT722 RH and temperature transmitter.

To best meet specific application needs, the DT722 series is available in digital (DT722) and

analog (DT722-X18) models. The digital electronic platform version gives high-performance

measurement and RH accuracy and delivers reliable, consistent and accurate results even

over changing ambient conditions.

The DT722-X18 is an analog through-path measurement device with high mechanical

toughness. Field adjustment is quick and easy, making it a good choice for use in all

types of aftermarket service and it is already in service in the nuclear industry.

The transmitters have been designed for use in severe industrial environments. They offer

a strong, stainless steel housing providing protection against rough handling or accidental

damage, IP65 (NEMA 4) ingress protection, and a probe that can withstand temperatures

up to 150°C.

The transmitters are for duct mounting in the most suitable place for the application. They have

high chemical resistance for longer use in contaminated areas and are available with a selection of filter

materials to afford best protection to the sensors based on specific environmental conditions.

AMS Instrumentation & Calibration Pty Ltd



http://www.ccezy.com.au

http://www.smcaus.com.au



FLAMEPROOF TEMPERATURE TRANSMITTERS AND ASSEMBLIES

Moore Industries’ temperature transmit-

ter assemblies are certified ANZEX

Ex d IIC T6 for use in flameproof

(explosion-proof) applications.

Transmitters are approved with

spring-loaded and fixed sensors

specially designed to meet stringent

certification requirements. The spring-

loaded sensor model is used to push

and hold the temperature sensor probe tip

securely at the bottom of the thermowell. The fixed

sensor model probe is permanently welded to the

bottom of the nipple when the assembly is installed

without a thermowell.

Analog and smart ready-to-install temperature

assemblies are available with a wide variety of RTD

and thermocouple sensors, thermowells and fittings.

Moore Industries Pacific Inc


MECHATRONIC FLOW SENSORS

ifm efector’s SBT series mechatronic flow

sensors can be used for flow ranges

from 0.3 to 25 L/min at pressure

ranges of up to 15 bar.

The sensors function on the prin-

ciple of the spring-supported piston:

the piston, located in the valve seat

in the housing, is lifted by the flowing

medium against the spring resistance.

The mechatronic measuring principle

enables response times of less than 10 ms.

At the same time, the spring resistance forces the piston

to return to its original position with decreasing flow. This

ensures position-independent installation of the flow sensor,

preventing backflow.

Due to the temperature decoupling of the transducer from

the electronics, some versions of the sensor are suitable

for media in high-temperature applications of up to 180°C.

The sensors can be set intuitively and provide an analog

output signal.

ifm efector pty ltd


Honeywell SmartLine pressure transmitters are designed to make it easier to support field devices and promote

plant reliability with their efficiency-enhancing features, such as a graphic display capable of showing process

data in graphical formats and communicating messages from the control room. SmartLine transmitters also feature

modular components to simplify field repairs and reduce inventory required to make those repairs.

The display supports graphical process data in easy-to-read trend lines and bar graphs while also providing

a platform for operator messages, comprehensive diagnostic warnings and loop status for maintenance. These

capabilities are part of the transmitter’s Smart Connection Suite, and allow control room operators to send

messages to the display to make it easier and faster for field operators to identify the correct transmitter

and determine required maintenance tasks. When integrated with Honeywell’s Experion Process Knowledge

System (PKS), the transmitter can also display its maintenance mode - telling field operators if the control loop

is in a safe state to perform maintenance. Installation is made easier with the smart display - three buttons

at the top of the transmitter are used with the graphic display to completely configure the transmitter with no

external handheld devices required.

The modular design streamlines maintenance by allowing replacement of individual transmitter components instead of the

entire unit, even in hazardous locations. This design reduces plant life cycle costs by providing purchasing flexibility, lowering

inventory costs and reducing maintenance and repair work.

Other safety and efficiency features include enhanced security alerts and wiring polarity insensitivity.

Honeywell Limited


SMART PRESSURE TRANSMITTERS

http://www.dartinstruments.com.au

Two GreaT Companies. one BriGhT FuTure.How do you create a global company built for the future? By combining two powerful histories in pursuit of a bold vision—to help companies around the world contribute to healthier, safer environments. Building on the achievements of Pentair and Tyco’s Flow Control businesses, comprised of Valves & Controls, Thermal Controls and Water & Environmental Systems, the new Pentair delivers exceptional depth and expertise in filtration and processing, flow management, equipment protection and thermal management.From water to powerFrom energy to constructionFrom food service to residentialWe’re 30,000 employees strong, combining inventive thinking with disciplined execution to deploy solutions that help better manage and utilize precious resources and ensure operational success for our customers worldwide. Pentair stands ready to solve a full range of residential, commercial, municipal and industrial needs.

pentair.com/valves

http://pentair.com/valves



AERATION ANALYSER

Endress+Hauser’s Liquiline CDC80 optimises aeration

times in the biological stage of wastewater treatment.

This is the stage that is energy-intensive as most oxy-

gen blowers are operated in a time-based manner or

using only a simple form of oxygen control.

The analyser allows the aeration process to be run

according to the wastewater ammonium load, which

is far more efficient. It monitors ammonium load and

controls the oxygen blowers so the aeration process

only runs until the ammonium value has reached a

predefined lower set limit.

The product also determines the oxygen setpoint

value, which is adjusted dynamically depending on

the ammonium load, so the plant can be attuned

to different load situations. This leads to optimised

operating times for nitrification and denitrification, and

reduced energy consumption. Phosphate precipitant

dosing can also be controlled by the device, ensur-

ing efficient phosphate conversion and saving on

precipitant and costs.

The product can connect to existing instrumentation

and be easily integrated into existing process control

systems. Additionally, if the company’s Memosens

technology is used, calibration values and measured

values can be digitally transferred to the transmitter

without interference. A remote access function is

available for even faster and easier maintenance - a

safe VPN channel allows monitoring and change of

parameters.

Endress+Hauser Australia Pty Ltd


The Turck LI inductive linear position sensor has an enhanced

electronics architecture that increases the effective output rate

of the sensor from 1 to 5 kHz. In conjunction with the short signal run time

(130 µs) and the highly resolved SSi output, the inductive linear position sensors

can achieve the performance of potentiometers but without their disadvantages.

Unlike potentiometers, the LI sensors offer permanent protection to IP67,

provide non-contact measuring and are wear-free. The magnetic field im-

mune sensors are suitable for measuring axes with high-speed controls

such as those used in injection moulding machines. Other application areas

include axis measurement in packaging machines, presses or machine tools.

With the high speed and precision of the sensor (system resolution of

1 µm), machine builders can keep the position error in motor control ap-

plications to a minimum. As with all inductive linear position sensors, the

high-speed variant has very short blind zones and can tolerate up to a

4 mm offset of the positioning element (perpendicular to the measuring

axis). As well as the high-speed variant with an SSI interface and 16-bit

resolution, the analog variant of the sensor will also be offered in the future

with the higher output rate of 5 kHz. The analog sensor has a 0-10 V or

4-20 mA output. All LI sensors continue to be available in 10 measuring

lengths from 100 to 1000 mm. An 8-pole M12 connector is used for the

connection.

Turck Australia Pty Ltd


INDUCTIVE LINEAR POSITION SENSOR

http://www.techrentals.com.au


NewZealandboastsaworld-classdairy industrywithannualexportsin excessofNZ$11 billion.This successcanbe largely attributed totechnological advances inboth farmingpractices andmanufacturingtechniques.KeystrengthsofNZ’sdairy industry include its all-grassfarmingsystem,large-scaleprocessingandhighlevelsofR&D.Withareputationforprovidingproductsthatcomplywithrigoroushealthandsafetystandards,theNZdairyindustry isforecasttobenefitfrom continued growth andproductivity for many yearstocome.

Cheeseproductionisoneofthemostcomplexinthedairyindustry,involvingavarietyofprocessestoachievethefinalproduct.Automatingprocessesin cheese manufacture canimprove a manufacturingplant’s productivity to meetincreasingdemand.

Accurate control andcustomisationofmanufacturingprocesses is necessary foroptimal large-scale qualitycheese production. Skilled engineers andtechnologists are required to designingmanufacturing processes to produceconsistentproductcharacteristicsthatmeetcustomers’expectations.Advancesinprocessandmotioncontroltechnologyhaveallowedprocessesthathavehistoricallybeenmanuallyoperatedinacheesemanufacturingplanttobeautomated,improvingefficiencyandsafety.

When an i n te rna t i ona l cheesemanufacturerdecidedtoautomateitscheeseslicingprocesses,itcalledonCheeseSolutionsNewZealandLtd(CSL),aleadingNewZealandOEMmachinebuilder,todesignasystemtomeetitsspecificrequirements.CSLutilisedthedesigncapabilitiesoflong-standingsystemintegrationpartnerIntegratedAutomationLtd(IAL)todevelopasolutionthatwouldmeetthemanufacturer’srequirements.

Recentadvances inmotioncontrol technology takecheeseslicingtoawholenewlevel.Theprojectrequirementwastotakeanindustry-standardblockofcheeseandsliceittospecifieddimensionsandweight.When looking forproductson themarket thatcouldachieve this, IALdecidedtousethecontrolprocessorcapabilitiesofControlLogixfromRockwellAutomation.

Thechallengewastoprovidethecustomerwithacompletecheese-slicingproductionlinethatcouldtakea20kgblockofcheeseandpassitthroughanumberofmachinestobreakitdownintosmallerblockswhichwouldthenbeslicedtoformtheendproduct:asliceofcheesemeasuring90x90x2.5mm.Thesolutionlayinprovidingprecise,high-speedsynchronisedmotioncontrol.

An important part of thiswas accurate control of the portioningprocesstoensuretheproductwascutaccuratelywithminimalwastage.According to Stephen Cotter, Solutions Architect - Motion Control,RockwellAutomation,“WhiletherestofthisplantutilisesproductsolutionsfromRockwellAutomation,thisnewmachinerequiredadditionalmotion

Slicing cheese with automated precision

controlcapabilities.”ThenewL73processor,whichhasfasterprocessingcapabilitiesandimprovedmotioncontrol,wasused.“It’scertainlytheprocessorforthejobbecauseit’suptospeedtocontrolthemotionatthecheese-slicingbusinessside,”continuedCotter.

Theapplicationdependsonprecisemotioncontrolandtiming.Theblockofcheesehastobeindexedpreciselybecausetheslicingisperformed

with a rotating knife.Movementofthecheeseandrotatingbladeneeds to be coordinated as thespeedatwhichthecheesemustmoveisdependentonthedensity,weightandsizeofslicerequired.To achieve this, ControlLogixrequired a sample code witha particular CAM profile thatthe Rockwell Automation OEMteam developed in Singapore.ControlLogix provided thesingle control platform with

RSLogix5000designandconfigurationsoftware.

“In addition to thea d v a n c e d c o n t r o lcapabilities required,buildingthismachinealsorequiredacomprehensivemechanical design toensure the machine’smechatronic systemis reliable enough tocarry out the tasks ofslicingtheproduct,”saidDonovanRyan,Director,IAL.“Therewasnootherchoice but to go with

thenewL73processor in this high-speedmotion application; everymillisecondwascritical.”

Safetywasalsoaconsideration.Themechanicaldesignofthecheese-slicingmachineensurestherotatingbladewasprotectedfromoperatoraccess at all times.Maintenance requirementswereminimal as theengineerswerealreadyfamiliarwiththeLogixtechnology.

Thecheeseslicerprovidesthemanufacturerwiththeflexibilitytoadjustthecheese’sthicknessautomatically.Bycheckingtheweight,thethicknessoftheslicecanbeadjustedbychangingtheCAMprofiletoaccountforthedensityofthecheese.“ThissolutionprovidesthecustomerwiththeabilitytoaccuratelyperformtotherequiredvelocitywiththeeaseofintegrationusingRSLogix5000motioncontrolcommands,”saidCotter.

Asconsumerdemandincreases,automationandprocesstechnologyhelp improve productivity in the cheese industry. The benefits ofautomatingthecheesemanufacturingplantextendbeyondtheamountofproductonthesupermarketshelf.Establishingclean,efficientandautomatedprocessesminimiseswastageof natural resourceswhileprovidingindustrywithawaytomeetincreasingcustomerdemandsforqualitydairyproducts.

Rockwell Automation Australia


© iStockphoto.com/photovideostock


The Hach Sonatax sc with sc200 controller is designed to help

with sludge extraction and the management of recirculation, and

provide warnings of potential solids washouts or process upsets by

continuously measuring the sludge blanket level. Its digitised probe

eliminates interference and features a quick LED system check. If

connected with the sc1000 controller, graphical display of sludge

profile is also available.

The Sonatax sc offers reduced maintenance with an innovative

wiper design, and a built-in position sensor can be used to resume

measurements after skimmer passes. The same sensor can also

compensate for angle when the probe is not mounted exactly vertically.

High accuracy is achieved by automatically scanning a range of

frequencies to find the ideal settings for the solids concentration for

the application. Built-in software disregards signals reflected from

tank structures such as pipes and rods. Automatic temperature

compensation ensures the ultrasonic measurement is unaffected by

seasonal changes in water temperature, making seasonal calibra-

tion unnecessary.

A visual performance LED indicator light on the probe provides

quick glance assurance of proper performance. Troubleshooting,

particularly in applications with multiple sludge blanket level probes

connected to one controller, is quick and easy.

Hach Company


ULTRASONIC SLUDGE MEASUREMENT

OVAL GEAR FLOWMETERS

Dimak provides a range of oval gear posi-

tive displacement flowmeters which provide

high levels of accuracy and repeatability for

a wide range of most clean liquids irrespective

of viscosity and conductivity, including fuel

oils, additives, chemicals, food bases, paints,

viscous emulsions, insecticides, alcohol and

solvents, either pumped or gravity-fed.

The oval gear flowmeters come in sizes from 4

to 100 mm in aluminium, stainless steel and ductile

iron for flow ranges from 0.04 L/h to 1500 L/m.

The range offers modular process connections and there is no requirement for flow

conditioning. They have bi-directional flow capability and a wide turndown, and all-metal

rotors give high stability.

Dual outputs (reed and Hall effect) are standard, as well as a hyperpulse high-

resolution pulse output, with optional quadrature pulse output. Hazardous area versions

are also available.

Trimec Flow Products Pty Ltd



http://www.daanet.com.au/secomea

FEBRUARY 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 35www.ProcessOnline.com.au

Yokogawa has enhanced the ADMAG AXR two-wire magnetic flowmeter. This enhanced flowmeter has

been certified for use in safety integrity level 2 (SIL2) applications and it supports the latest HART 7

protocol, eliminating the need for convertors to connect with HART-compliant control systems.

HART 7 also supports and automatic alarms when the device’s settings are modified or a problem

is detected by self-diagnostics.

The ADMAG AXR flowmeter uses a dual-frequency excitation method, with low-frequency

excitation that ensures stable measurement of flow rates and high-frequency excitation that

delivers high noise resistance, thus realising stable measurement in a wide range of fluid con-

ditions. This high-performance two-wire flowmeter can be used in both monitoring and control

applications. Its installation and maintenance costs are significantly lower because two-wire

magnetic flowmeters do not require a dedicated power supply unit and use only a single pair

of cables. Their low power consumption also reduces running costs. In addition, explosion-

proof types suitable for installation in hazardous areas are now available for the entire range,

covering bore diameters from 25 to 200 mm.

Yokogawa Australia Pty Ltd


MAGNETIC FLOWMETERS


DIFFERENTIAL PRESSURE INSTRUMENTS

Emerson Process Management has introduced a significant number of

enhancements to its Rosemount 3051 pressure instruments. The first of the

enhanced capabilities is a standard reference accuracy of ±0.04% of span down

to a 10:1 turndown. This improvement drives the total performance in typical

operating conditions to ±0.12% of span.

The Power Advisory Diagnostics feature is a predictive diagnostic tool that

allows users to identify electrical loop issues, at the instrument or anywhere

in the loop, before they cause a loss of measurement. With simple three-step

activation and guided troubleshooting, users of all experience levels can easily

implement this diagnostic to help prevent costly outages and minimise the

time spent diagnosing and resolving the root cause of a measurement issue.

The company has added a local operator interface (LOI) to the product,

designed with straightforward menus and both internal and external con-

figuration buttons for on-the-spot commissioning - even in hazardous areas.

The enhanced instrument also offers selectable HART revision capability

(HART5 and HART7) to deliver the latest features to those that are ready to

take advantage of the latest HART revision while ensuring seamless integra-

tion with any installed host, asset management system or configuration tool.

The product now also offers SIL2 certification, allowing users to avoid extra

shutdowns for safety testing. Emerson also provides full documentation for

efficient SIS compliance. Users can add Power Advisory Diagnostics to SIL2-

certified transmitters to improve safety throughout their entire electrical loop.

Emerson Process Management


http://www.metromatics.com.au


SAFETY CONTROLLERThe Pilz PNOZ m B0 is an updated base unit for the PNOZmulti configu-

rable control system.

The base unit has the ability to be expanded on the right-hand side

with I/O modules, which can be used as both inputs and outputs. Users

benefit from increased flexibility in engineering. At a width of 45 mm,

the base unit saves space in the control cabinet and also provides an

integrated, illuminated display with individually customised texts, enabling

rapid commissioning as well as diagnostics. The resulting PNOZmulti 2

control system can be used for safety and standard applications in all

engineering sectors.

The base unit has a total of 20 safe inputs, up to eight of which can be

configured as standard outputs. Also available are four safe semiconduc-

tor outputs and four safe test pulse outputs, up to four of which can be

configured as standard outputs. Fewer unit types are needed as a result,

enabling hardware and storage costs to be minimised.

The base unit can be expanded with a maximum of two I/O modules. These provide a total of 16

inputs and 8 semiconductor outputs. The new configurable control system is suitable for applications

up to and including SIL CL 3 and PL e.

Pilz Australia Industrial Automation LP


NEWPRODUCTS

ETHERNET RADIO MODEMSWeidmüller has released its WL Series of long-haul ethernet radio modems. Designed

specifically for industrial use, the rugged and robust, upright WL units have a very

narrow footprint. At 40 mm wide, the units provide user convenience while saving on

space to help users build networks quickly and efficiently.

The series incorporates a range of models including a 2.4 GHz, 5 GHz and

900 MHz option. The high-throughput modems provide connectivity for line-of-sight

distances from 5 up to 20 km.

All models have an in-built routing function and blacklist/whitelist for controlling traf-

fic. A built-in signal strength tester measures both bandwidth and the signal strength

between two radios. In addition, all units include dual diversity antenna connections

and a choice of different antenna accessories to help customise the installation.

The WL Series provides remote wireless I/O mapping where up to 31 I/O units can

be daisy-chained to a transceiver at each end. A selection can be made between

digital, analog and combinational input and output types of I/O units.

The 2.4 GHz model can be set up in a mesh network topology providing redundancy and greater reliability.

Each transceiver also has a built-in conversion for serial Modbus RTU to Modbus TCP.

DIN rail-mounted and operating from 10-30 VDC supply, the plug-and-play WL models provide easy configura-

tion through a built-in web interface and feature LED status indicators.

Weidmuller Pty Ltd


http://www.veederline.com.au

http://www.industrialsoftware.com.au


NEWPRODUCTS

INFRARED TEMPERATURE SENSORThe PyroMini infrared pyrometer from Calex Electronics has a miniature sensing head measuring 18 x 45 mm, making it suitable for mounting in tight spaces. The high ambient sensing head is capable of withstanding temperatures of up to 180°C without water or air cooling and has a measuring range of -20 to 1000°C.

Manufactured from 316 stainless steel and sealed to IP65, the PyroMini sensing head is suitable for the food and pharmaceutical industry, as well as automotive manufacture and many other industrial measurement and control applications.

The non-contact temperature sensing head utilises a low-noise interconnecting cable (available in lengths from 1 to 30 m), making it resistant to interference from external electromagnetic fields such as those encountered with dynamic moving machines like robot arms.

The backlit touch-screen interface provides a large, bright display of the measured temperature in digital format as well as in a graphical view that shows the history of the measured temperature, date and time. In alarm conditions, the display changes colour to provide an immediate and obvious alarm indication.

When in data logging mode, the PyroMini records the temperature related data to a MicroSD card. With a 2 GB MicroSD card, the user can store 28.4 million time and date stamped readings, which provides almost one year’s worth of data at the fastest possible sample rate of one per second.

Output options include an analog 4-20 mA temperature-related retransmission, as well as RS485 Modbus and two alarm relay outputs.

Heastern Industries


INTEGRATED SERVO DRIVE MOTORThe Allen-Bradley Kinetix 6000M integrated drive motor combines servo drive and motor technologies in a compact, on-machine package, using the MP-Series food-grade servo motor and Kinetix 6000 multi-axis servo drive technologies.

Moving servo drives out of the control enclosure and onto the machine delivers significant space savings, while reducing cabling. The integrated drive-motor system is claimed to reduce panel space required by up to

60% for a typical 8-axis system. Additionally, the number of cables exiting the control enclosure is reduced by as much as

75% because a hybrid/network cable daisy chain re-places the individual power and feedback cables.

The drive-motor is designed to integrate seam-lessly with the Kinetix 6000 and Kinetix 6200 multi-axis servo-drive systems and features an integrated drive-motor power interface module that mounts directly to a standard Kinetix 6000 power rail. The mounting flange and shaft di-mensions of the integrated drive-motor units are identical to the MP-Series motors of the same frame size, minimising the mechanical changes needed to use integrated drive-motor technology.

The system is suitable for applications such as packaging, converting, print and web machines. It

meets the needs of food and beverage packaging and handling applications by offering features geared

for the industry, including enhanced sealing techniques, corrosion-resistant materials and coating appropriate for food environments.

The drive motor is available in three different frame sizes, offering optional

holding breaks and SIL2/PLd safe torque-off functionality.

Rockwell Automation Australia


http://www.bintech.com.au


AS I SEE IT

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 engineer ing with worldwide engineering education business IDC

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

Printed and bound by Webstar +61 2 9748 0020Print Post Approved PP255003/00198ISSN No. 0819-5447

All material published in this magazine is published in good faith and every care is taken to accurately relay information provided to us. Readers are advised by the publishers to ensure that all necessary safety devices and precautions are installed and safe working procedures adopted before the use of any equipment found or purchased through the information we provide. Further, all performance criteria was provided by the representative company concerned and any dispute should be referred to them.Information indicating that products are made in Australia or New Zealand is supplied by the source company. Westwick Farrow P/L does not quantify the amount of local content or the accuracy of the statement made by the source.

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September 2012 total CAB audited circulation (Aust + NZ)7,419 readers (83% personally requested)

Contact the editor

BECOME AN ENGINEERING ENTREPRENEUR TODAY

Almost on a daily basis, you read about Australian manufacturing (and even mining) businesses shutting down.

After the hammering of the recent ‘Great Recession’, companies are rapidly reduc-ing tangible assets - buildings, machines and, inevitably, people such as high-cost engineering staff. And we know that there is a massive amount of outsourcing going on - meaning jobs go elsewhere, often overseas. This is all happening today and will eventually impact on you in some form.

The days of expecting a job for 30 to 40 years, say, from one company are rapidly diminishing as competition intensifies. I clearly remember starting out in the diamond mining business as a junior engineer with thousands of other highly skilled engineering professionals working for this one company. It had been around for over a hundred years and we all believed it would be around for many more years. Today, it is a poor shadow of itself with only a tiny number of engineers and technicians. An unbelievable situation when one considers how dynamic and profitable it was only 20 years ago.

We thus need to approach the problem of employment from a different angle and create engineering jobs ourselves. And employ others. Engineering professionals have the innate technical prowess to make things. Add in creativity to the mix and an understanding of what the market wants and you could have a winning product or service within months. Admittedly, you may work long hours and be exposed to some stress along the way.

But the winners are individuals which we refer to as engineer-entrepreneurs and companies that come up with new products and services which the global community wants. And keep coming up with new prod-ucts or improvements to existing products. Otherwise they also die.

We thus need the engineer-entrepreneur to conceptualise and design new products and services. A product doesn’t have to be something totally unique or new; a slight improvement on an existing product, service or process can also be a winner. This ap-

plies to you whether you are working for another company or for yourself. Seek out opportunities to innovate and create new products and services. In this way you can extend the life of your company and your career.

It should be noted that as an engineer-entrepreneur, there is a chasm between successfully operating a startup company and a small business. The much vaunted business schools tend to gloss over the differences and treat both as the same, but they are totally different. One key difference is that a startup company often has a brilliant product which has incredible possibilities, but no actual market (at present) - so the startup has the additional challenge of get-ting the product to market.

Engineering professionals also have to be ferociously self-sufficient, self-sustaining and lifelong learners responsible for staying in business. They also have to be prepared to learn from their customers in optimising their creations so that they are economi-cally viable. Often we hear things from our customers that we don’t want to hear. Inevitably, engineer-entrepeneurs must be prepared to have a high threshold of toler-ance to repeated failure and the ability to persist to success.

Above all - you have to believe in yourself.As George Lois points out: Creativity can

solve almost any problem. The creative act, the defeat of habit by originality, overcomes everything.

List (A) Job Function

1 Management - Corporate/General2 Management - Manufacturing/ Engineering/Specialist3 Engineer - Electrical4 Engineer - Electronics5 Engineer - Process6 Engineer - Project7 Purchasing/Procurement8 Technician - Maintenance/Service9 Technician - IT10 Technical Officer11 Scientific Officer - R&D12 Scientific Officer - QA13 Consultant14 Contractor/Tradesperson15 OHS/EHS16 Education/Training17 Student-Undergraduate/Apprentice18 Analyst19 Sales/Marketing

List (B) Industry

1 Agriculture/Rural 2 Building/Construction 3 Chemicals/Allied Products 4 Communications Systems 5 Defence/Military 6 Education 7 Emergency Services/Law Enforcement/Security 8 Engineering Services 9 Environmental Services 10 Finance/Banking/Insurance/Legal 11 Food Industry - Bakery12 Food Industry - Beverages13 Food Industry - Confectionery14 Food Industry - Dairy15 Food Industry - Fruit & Vegetables16 Food Industry - Meat 17 Government - Federal18 Government - State19 Government - Local20 Health/Hospital 21 Instrumentalities (eg CSIRO) 22 IT - Networking23 IT - Security24 IT - Storage25 IT - Wireless26 Laboratory - Analytical27 Laboratory - Clinical/Medical28 Laboratory - Life Sciences29 Logistics/Transport/Warehouse 30 Manufacturing 31 Mining32 Oil/Gas/Coal33 Packaging34 Processing35 Retail/Wholesale/Hire36 Service/Maintenance37 Telecommunication38 Testing/Certification (eg NATA)39 Utilities

http://www.mitsubishielectric.com.au

what’s new in process technology feb 2013

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