what’s new in process technology nov 2012

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Electronic marshalling eliminates the rework, the redesign and the headaches.With DeltaV Electronic Marshalling, Emerson lets you make I/O changes where and when you needthem without costly engineering and schedule delays. Our new DeltaV CHARacterization Module

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The Emerson logo is a trademark and a service mark of Emerson Electric Co. © 2012 Emerson Electric Co.

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DeltaV EM Erase YCDT A4_Layout 1 10/18/2012 9:41 AM Page 1

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ON THE COVER 1112CONTENTS

WHAT'S NEW IN PROCESS TECHNOLOGYNOVEMBER 2012

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

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Long associated with the Consolidated range

of safety valves and Masoneilan control valve

portfolio, Powerflo Solutions has been reap-

pointed the channel partner for these products,

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Control and Safety Valves locally assembled and supported in Australia

YOU CAN DO THAT

Electronic marshalling eliminates the rework, the redesign and the headaches.With DeltaV Electronic Marshalling, Emerson lets you make I/O changes where and when you needthem without costly engineering and schedule delays. Our new DeltaV CHARacterization Module

(CHARM) completely eliminates the cross-wiring from the marshalling panel to the I/O card–regardless of signal type–so you’re no longer held to predefined specifications. All those wires, gone. All that time and engineering, gone.See how easy it can be by scanning the code below or by visiting IOonDemandCalculator.com

The Emerson logo is a trademark and a service mark of Emerson Electric Co. © 2012 Emerson Electric Co.

Another I/O change? Great.So another wiring schedule.Another marshalling design.And another cabinet...Just make it all go away!

DeltaV EM Erase YCDT A4_Layout 1 10/18/2012 9:41 AM Page 1

4 Howtomanagevaporisationinananalyticalsystem Avoidingfractionationforaccuratesampling

10 Newproducts

14 Hotproductsonline

26 Leveragingvirtualisation Achievinghigherbusinesscontinuitywithinindustrialfacilities

42 AsIseeit Extendyourcontrol:digitisationofthe

industrialworld

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HOWTOMANAGEVAPORISATIONINANANALYTICALSYSTEMDoug Nordstrom and Tony Waters, Swagelok Company

AVOIDINGFRACTIONATIONFORACCURATESAMPLING

4WHAT'SNEWINPROCESSTECHNOLOGY-NOVEMBER 2012 www.ProcessOnline.com.au

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

Iftheanalyser inyouranalyticalsystemrequiresgasbutyoursample isliquid,theonlyoptionistoconverttheliquidtogas.Thisprocessiscalledvaporisation or flash vaporisation. The objective is to convert a sampleof all liquid to allvapour instantly -without changing thecomposition.

It is not easy to vaporise a sample, noris it always possible, so make sure it’sreallynecessaryandpossiblebeforeyoutry.Youshouldalwaysanalysealiquidin

aliquidphaseunlesstherearestrongreasonsfor analysing in a vapour phase.

If you proceed with vaporisation, it’s im-portanttounderstandthedifferencebetweenevaporationandvaporisation.Evaporationoc-cursgraduallywithanincreaseintemperature.Vaporisation occurs instantly with a drop inpressure.It’snotpossibletovaporiseasam-ple by increasing temperature. Heat causesevaporation and adding more heat simplymakes evaporation happen faster.

Inamixedsample, evaporationwill allowsomecompoundstoevaporatebeforeothers,resulting in fractionation. Vaporisation, doneproperly, ensures that all of the compoundsvaporise at the same time, preserving thesample’s composition.

However, it is possible for things to gowrongwhenvaporising.Insteadofflashingthewholesample intoavapour,youcouldunin-tentionallycauseacombinationofvaporisationand evaporation, resulting in fractionation.Once a sample of mixed compounds frac-tionates, it isno longersuitableforanalysis.With fractionation,acommonscenario is forlightermoleculestoevaporatefirstandtravelon towards the analyser, while the heaviermoleculesremainbehind inthe liquidphase.Even if at some later point in the process afractionatedsampleappearstobeallgas,themixture will not be of the same molecularproportionsas itwasbefore fractionation. Itwillnolongeraccuratelyrepresenttheproducttaken from the process line.

Let’s take a closer look at theprocessofvaporisationandhowwecanmanipulatethevariables-temperature,pressureandflow-toensure proper vaporisation and an accurateanalytical result.

Understanding vaporisationTo vaporise a sample, one typically uses avaporisingregulator,alsocalledavaporiser,which is a pressure-reducing regulator withthe capacity to transfer heat to the sampleat just the right location.

Vaporisationconsistsofathree-stageprocess(seeFigure1).First,thesampleentersthevaporiserasaliquid.Atthispoint,theliquidshouldnotbebubblingorboiling.

Second, the liquid passes through theregulating orifice in the vaporiser, resultinginasevereandsuddenpressuredrop,whichvaporises the liquid.At the same time, heatisapplied,whichenablesthevaporisedliquidto remain avapour.

Third, the sample, now a gas, exits thevaporiser and travels to the analyser to beread.Due to the immediate transition to thevapourphase, thecompositionofthegas isunchanged from that of the liquid, ensuringan accurate reading.

In this delicate process, there are manyvariablesorinputsthatdeterminesuccessorfailure. For the purpose of this discussion,let’s say there are twomain setsof inputs.

Thefirstsetofinputsconcernsthecom-position of the sample. Depending on thecomposition of the sample, it will begin tobubbleandfinishvaporisingatdifferentpres-suresandtemperatures.We’llneedtoknowwhat these pressures and temperatures areto successfullymanage theprocess.

Thesecondsetofinputsconcernssettingsthat you control in your sampling system:pressure,temperatureandflow.Pressureandtemperature are controlled at the vaporiser,while flow is controlled downstream at arotameter (variable area flowmeter) andneedle valve. We set these inputs based onwhat we know about the first set of inputs.Proper vaporisation requires a delicate bal-anceof all inputs.

Evenwhenapproachingvaporisationinasystematicmannerlikethis,theprocessdoesrequiresometrialanderror,sowe’llalsotalkabouthowtodiagnoseandaddressproblems.

Understanding your sampleThebestwaytounderstandthefirstsetofinputs is with a phase diagram. A phasediagram plots pressure and temperature,showingat anypairof conditionswhetherasubstancewillbevapour, liquidorsolid.The lines indicate the interfaces betweentwo phases.


© iStockphoto.com

/HAYKIRD

I


Gases&fluids

Phasediagramsformostpuregasesareavailable on the internet, for example, athttp://encyclopedia.airliquide.com. But dia-grams forgasmixturesareverydifficult tocreate without commercial software.

Figure2representsaphasediagramfor20% hexane in pentane. When the sampleisabovethebubblepoint (blue line), it’sallliquid. We want the sample to be all liquidwhenitentersthevaporiser.Whenthemix-ture is below the dew point (gold line), it’sall vapour. The sample must be all vapourwhen it leaves thevaporiser.

Betweenthebubblepointanddewpointlines is what we call the no-go zone. Thiszone is the boiling range of the sample.Here, the mixture is in two phases, partliquidandpartvapour.Onceasample fallsinto the no-go zone, it is fractionated andnolongersuitableforanalysis.Theobjectivein vaporisation is to set the temperature,flowandpressuresothatthesampleskipsinstantly from the liquid side of the no-gozone to thevapour sideof theno-gozone.

Withpureandnearlypuresamples,thereis little to no boiling range or no-go zone.The bubble point and dew point lines areon top of each other or nearly so. Indeed,pure and nearly pure samples will converttovapourofthesamecomposition,whetherthrough evaporation or vaporisation. Someindustrial samples approach this level ofpurity and convert easily.

On the other hand, some samples havesuch a wide boiling range or no-go zonethat theycannotbesuccessfullyvaporised.Thereisnowaytoskipfromtheliquidsideoftheno-gozonetothevapoursideoftheno-gozone.Weareunabletomanipulatethe

variables - temperature, flow, and pressure- in such a way as to avoid fractionation.

Most samples fall between these twoextremes.Forexample,inFigure2,thebandbetweenbubblepointanddewpointisnarrowenoughthatwiththepropersettingswecanenablethesampletoeffectivelyskipfromtheliquid side of the no-go zone to thevapourside.Atthesametime,thebandinFigure2iswideenoughthatwecannotaffordtobecareless. Indeed, we will need to be skilfulin our manipulation of the variables or wewillendupwithasampleintheno-gozone.

Setting temperature, pressure and flowLet’s continue to work with the sample inFigure 2 (20% hexane in pentane) and seehow we can set our inputs to ensure suc-cessful vaporisation.

In general, at the inlet, we want highpressureandlowtemperature.Attheoutlet,wewanthightemperatureandlowpressure.Buttherearelimitsastohowhighandlowtheseparameterscanbe,andnotallofthemareunderourcontrolcompletely.Vaporisa-tion is basically a balancing act betweenthevariables.

Here is a four-step process for settingyour inputs:

Step 1: Determine the inlet pressure at your vaporiserThis pressure, which is fixed, is your pro-cess pressure, provided your vaporiser islocated close to your sample tap. In Figure2, that pressure is 4 bar. Higher pressureis better because it allows you to keep thevaporisertemperaturehigherwithoutboilingthe incoming liquid.

Step 2: Set your inlet temperature, or the temperature of your vaporiserThere are two objectives. First, the tem-peraturemustbelowenoughthatwhenthesampleentersthevaporiserit isentirelyaliquid and isn’t bubbling. In Figure 2, thebubblepointat4baris88°C,butwewanttobuildinacushion,solet’schoose80°C,a round number far enough away from88°C to be safe.

Thetemperaturemustbehighenoughtocontribute to the complete flashing of thesample, because when you vaporise thesample,thetemperaturedrops,inaccordancewiththe lawsofenergyconservation.Thesampletemperaturemustbehighenoughattheoutsetsothatafterthepressuredropthesampleisnotintheboilingrangeorno-gozone. In Figure 2, the vapour temperatureafterthepressuredropis60°C,justonthevapour side of the dew point line.

Step 3: Set the outlet pressure at the vaporiserYourobjectiveistodropthepressurebelowthe gold dew point line. In Figure 2, theoutletpressureissetto1.5bar.Iftheoutletpressurewereanyhigher in thisexample,the sample would fractionate.

Step 4: Set your flowFlow is set downstream at a valve androtameter, not at the vaporiser. In a sam-pling system, high vapour flow is desir-able because it moves the sample to theanalyserfaster.However,highflowcanbeproblematictoo,becausehighflowresultsin a greater drop in temperature at thetimeofvaporisation.InFigure2,thepurpleline illustrates the temperature drop. As

Figure 1: The three-stage vaporisation process. Figure 2: Phase diagram showing 20% hexane in pentane, with temperature settings.


Gases&fluids

flowincreases,thepurplelineanglesmoresharplytothe left.

Watching out for time delayWhile fractionation is one problem in va-porising samples, another is time delay.Time delay - the amount of time it takesfor a sample to travel from the processlinetotheanalyser-isalwaysachallengewhen employing avaporiser. The industrystandard for time delay is one minute, butitcantakemanytimeslongerifyou’renotcareful with your vaporiser set-up.

Timedelaycanbean issueonboththeliquidandvapoursideofthevaporiser.Onthe liquid side, the difficulty is caused bythe sample’s degree of expansion whenit is vaporised. A small amount of liquidcreates a large amount of vapour. Forexample,thevolumeofmethane increasesabout 600 times when it flashes from aliquid to a vapour. Hydrocarbons expandabout 300 times.

Withsuchadramaticdifferencebetweenthe liquid andvapourvolume, it’s easy forliquidontheupstreamsideofthevaporisertobesittingaroundforawhilebeforeitisvaporised.Forexample,withavapourflowof600mL/min,theliquidflowmaybelessthan 2 mL/min.

If your vaporiser is located near thetap, thebest solution to thisproblem is toinstall a bypass on the liquid side of thevaporiser,sothesamplebeingvaporisedisalwaysfresh.Inaddition,trytominimisethevolume of the probe and tubing preceding

thevaporiser.Lessvolume results in a

faster response.Toaddresstimedelayon

thevapoursideofthevaporiser,youmaybetempted to increaseflow,butasexplainedabove,highflowincombinationwithinsuf-ficientheatatthevaporisercouldresult infractionation,withliquidpassingthroughthevaporiser to the downstream side.

A better way to reduce time delay onthe vapour side is to minimise volume.For example, move the vaporiser closerto the analyser or build a fast loopon theliquid side.

Heat transfer in the vaporiserAnothervariableinfluencingthetemperaturedrop is the heat transfer capability of thevaporiser.Somevaporisersareconstructedinsuchawaythatheattransfersmoreef-ficientlytothesample.Whentheliquidsampleconverts to a vapour and its temperaturedrops,itdrawsheatfromthestainlesssteelsurroundingit.Thecriticalquestionis:howefficiently can the vaporiser replace thatheatandkeepitflowingtothesample?Themore heat the sample can draw, the lessits temperature drops duringvaporisation.

Insome instances, it ispossible forthevaporiser to be hot to the touch on theoutside but cold at the core inside. That’sbecausethevaporisedsampleisdrawinglotsof heat and the vaporiser cannot transferenough heat to keep up. The best solutionis to reduce the flow.

In sum, the angle of the purple lineinFigure2 is a product of the flow rateand the heat transfer capability of thevaporiser.Withagoodvaporiserandlowflow, the line will become morevertical.Unfortunately, there is no easy way tocalculate the location of the purple line,and it is not generated by any knownsoftwareprogram.Asaresult,vaporisationinvolves some approximation. As a ruleof thumb, keep the flow rate as low aspossiblewithoutcausinganunacceptabledelay in the sample’s travel time to theanalyser. It’s better to start with a lowflowrateandexperimentwithincreasingit than to start with a higher flow rate.

TroubleshootingPhase diagrams will enable you to ap-proximate temperature, pressure andflow settings, but some troubleshootingwill still be required. One sure indica-tion of a problem is poor repeatabilityin analyser results.

There are two possibilities when thesample is fractionating instead of va-porising, with Problem 1 being the morecommon:

Problem 1: Only part of the sample is being vaporisedLiquidispassingthroughthevaporiserandsitting in the tubing on the downstreamside. Eventually, it evaporates. When itdoes,itdrawsheatfromthesurroundingtubing,makingthetubingcoldtothetouchor causing frost or ice to form.

IN A MIXED SAMPLE, EVAPORATION WILL ALLOW

SOME COMPOUNDS TO EVAPORATE BEFORE OTHERS,

RESULTING IN FRACTIONATION. VAPORISATION, DONE

PROPERLY, ENSURES THAT ALL OF THE COMPOUNDS

VAPORISE AT THE SAME TIME, PRESERVING THE

SAMPLE’S COMPOSITION.

Figure 3: This steam-heated vaporising regulator features a low internal volume to improve the likelihood that all of the compounds vaporise at the same time, preserving the sample’s composition.

Figure 4: This electrically heated vaporising pressure-reducing regulator has an integral temperature controller and features a heating element that is in direct contact with the process fluid for maximum thermal efficiency.


• Signs of the problem: Vaporiseroutletand downstream tubing is cold to thetouch or has frost or ice on it. (Notethat in many cases, liquid on thedownstreamsideofthevaporisermaypassbeyondtheareaofthevaporiserand into other components, such asflowmeters and filters, where it cancause considerable damage.)

•Solution: In the approach above, yourbestoptionwouldbetoreducetheflowrate.Anotheroptionwouldbetolowerthevaporiseroutletpressure,ifthatispossible. A third option would be toincreasetheheattothevaporiser,butinthiscaseyouriskcausingProblem2 (see below).

Problem 2: The sample is boiling at the inlet to the vaporiserItisfractionatingbeforeitcanbevaporised.Lighter molecules evaporate and create a‘vapourwall’,whichpushestheliquidbackinto the process. A portion of that vapourwallthencoolsandcondenses.Finally,theliquidsamplemovesagaintowardsthevapor-iser,wherethelightermoleculesevaporate,startingthecyclealloveragain.Meanwhile,

theheaviermoleculesmoveontowardstheanalyser for an inaccurate reading.

• Signs of the problem: The inlet tubetothevaporisertwitches,sometimesviolently,andthemeasurementvaluesoscillate.

• Solution: Lower the vaporiser tem-perature.

ConclusionVaporisingaliquidsampleischallenging.Inmany sampling systems around the world,vaporisers are fractionating samples andsending unrepresentative samples to theanalysereveryminuteofeveryday.Youcandramaticallyincreaseyourchancesofsuc-cessbyresearchingaphasediagramofyoursystem’sparticularmixtureof compounds.You can further increase your chances ofsuccessbyunderstandingwhatisoccurringintheprocess-specifically,byknowingwhatthe variables are (temperature, pressureand flow) and their role in influencing theprocess outcome. With this framework inplace,youcancomeveryclosetotherightsettings,makingadjustmentsinaccordancewiththesignsandsymptomsyouobserve.

Doug Nordstrom is market manager for ana-lytical instrumentation for Swagelok Company, and he focuses his efforts on advancing the company’s involvement in sample handling systems. He previously worked in new product development for Swagelok and earned a number of Swagelok patents for products including Modular Platform Components (MPC) and the Swagelok SSV series stream selector system. Nordstrom graduated with a Bachelor of Science in mechanical engineering and has a master’s degree in business administration. Tony Waters has 45 years’ experience with process analysers and their sampling systems. He has worked in engineering and marketing roles for an analyser manufacturer, an end user and a systems integrator. He founded three compa-nies to provide specialised analyser services to the process industries and is an expert in the application of process analysers in refineries and chemical plants. Waters is particularly well known for process analyser training courses that he has presented in many parts of the world.

Swagelok CorporationContact info and more items like this at wf.net.au/R769

PANEL PCThe iBase iPPC12A7-RE is a fanless modularised

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The iPPC12A7-RE is a rugged solution for many

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The iPPC-12A7-RE can be deployed into various

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a flexible VESA mount design supports wall-mount,

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Gases&fluids

NEWPRODUCTS WIRELESS DRY CONTACT SENSOR INTERFACEThe Banner Engineering SureCross Q45

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The RD model is part of Banner’s SureCross Q45 wireless sensor family,

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designed for control and monitoring applications. The self-contained battery,

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and untethered communications, improving efficiency by monitoring and

coordinating multiple machines and processes.

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SATELLITE DATA LOGGERHalytech has announced a low-cost,

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The microSpider Satellite is suitable for

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THERMAL IMAGERS

The Fluke Ti105 and TiR105 thermal imagers

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INLINE CO2 SENSORMettler Toledo Process Analytics has launched the InPro 5500i for inline

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The device can be installed easily with a choice of process connections includ-

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The device protects itself from damage during SIP/CIP cycles or when the purge gas or

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Mettler Toledo


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NEWPRODUCTS

UPDATED DEVELOPMENT SYSTEMNational Instruments has introduced NI LabVIEW

2012, the latest version of its system design

software for engineers and scientists. Users

gain ready-to-run starting points for a breadth

of LabVIEW applications and access to updated

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their systems. These features demonstrate NI’s

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The software provides recommended applica-

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systems.

LabVIEW 2012 also features many templates

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ing, new tools for high-performance analysis

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enhancements and mobile apps for display and

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National Instruments Australia


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NEWPRODUCTSVISION SENSORSick has launched a vision sensor in the Inspector family that allows OEMs and vision integrators who

have high demands for flexibility and machine integration to easily build their own interfaces, as well as

operate the vision sensor from any computer or operator panel that contains a standard web browser.

The Sick Inspector PI50 vision sensor is suitable for applications such as solar wafer alignment and

damage detection, fiducial alignment in electronics, calibrated robot guidance in the automotive industry,

positioning control in commercial goods production and integrated quality control in packaging machines.

Due to its integrated web server, a user can operate the Inspector PI50 from a computer or operator’s

panel that contains a standard web browser. Advanced users can completely build their own operator

interface with the sensor’s web API.

The product includes an expanded toolbox for object location and positioning, and also provides tools

for quality inspection such as blob, pattern, edge and pixel counting inspection.

The sensor supports extended results and control handling over EtherNet/IP and TCP/IP. This enables

easy communication with dedicated PLCs, or simply a PC host using value-based results for machine

control and customised trend design, image triggering, external teach and reference object selection for

centralised device control and parameter modification for customised configuration handling.

The product is available in a white or IR ring light option. Both are designed with the company’s ‘Flex’

housing, providing a fast method to exchange lenses, filters and dome accessories for different optical needs.

Sick Pty Ltd


PRESSURE SENSORDue to its environmental compatibility, CO2 is increasingly establishing itself as a refriger-

ant in industrial applications.

The model R-1 pressure transmitter from WIKA now offers complete compatibility

with the requirements of CO2 refrigeration plants.

With this instrument, designed specifically for refrigeration systems, pressures

from 100 to 160 bar, which are typical for CO2 applications, can also be covered.

The hermetically welded measuring cell reduces the likelihood of leakage to zero.

Its thin-film sensor, made using sputtering technology, offers high long-term stability

and high overpressure safety.

WIKA Australia


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>

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UPDATED HYGIENIC VALVE RANGEBürkert has expanded its line of Element series

valves to include new drive sizes up to 130 mm.

Bürkert Fluid Control Systems

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LASER GAS MONITORThe LGIII uses TDLS technology and

provides non-contact and interference-free

measurement of a wide range of gases.

B-R Controls Pty Ltd

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SOLID STATE FLASH STORAGEAdvantech has released reliable flash modules

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Advantech Australia Pty Ltd

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>WIRELESS CONDITION MONITORINGThe wireless sensor network (WSN)

strain node and C Series DAQ module

can be used for predictive maintenance

to predict faults and analyse fatigue.


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TEMPERATURE CONTROLLERSThe SC58 and SC64 digital controllers are designed

for a measuring range of -80 to +400°C.

WIKA Australia

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>

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NEWPRODUCTS

QUALITY MANAGEMENT SOFTWAREInvensys Operations Management has released an updated version of its Wonderware MES software. The newest version expands existing operations and performance management functionality by adding quality management for sample data collection, statistical process control and quality results monitoring, helping to improve operational efficiency, regulatory compliance and product safety.

Wonderware MES Software 2012 with Quality reduces the cost of quality management while improving regulatory and product safety compliance by capturing complete product, equipment and process-related quality data for both automated and manual operations. The software monitors quality data in near real time so plant operators can respond faster to non-conformance conditions, quality trends and deviations, as well as to take corrective actions that minimise variations and bring quality closer to specifications. It complements existing enterprise quality management systems with sample plan execution automation, higher accuracy in shop-floor qual-ity sample data, integrated statistical process control (SPC) and enhanced work order and operational execution context.

The software now enforces manual and automatic data collection and integrates structured sampling plans, as well as includes rigorous SPC. The updated software also allows sampling plans to be dynamically generated, according to current work-order status for products, equipment and opera-tions. Execution of the sample plans can be done according to system quality specifications and the samples themselves can be automated, from equipment, control systems or instrumentation. SPC trending and charting are available for near real-time quality monitoring, and include notifications of

violations of control and specification limits.

Invensys Operations Management


VALVE MOTOR DRIVE PROCESS CONTROLLERThe West 6170+ valve motor drive process controller incorporates advanced tuning algorithms, with selectable pre-tune and self-tuning for easy set-up. The self-tune also reduces output activity to an absolute minimum without compromising control quality, thereby reducing wear and tear on mechanical components such as valves, contactors and relays.

West’s plug-and-play technology allows the user to easily add to the 6170+ controller’s features including communication by installing additional plug-in boards. Inputs, outputs, alarms and communications are all field upgradeable.

The controller has dual 4-digit LED displays and is pro-vided in a 1/16 DIN panel mount (also available in 1/8 DIN and ¼ DIN). It has a universal input for thermocouples, RTDs, DC and linear mA/V/mV, all user selectable, and supports Modbus

communication.

Automated Control Pty Ltd


TRANSPORTABLE HYDROCARBON DEWPOINT ANALYSERMichell Instruments has developed a transportable version of its hydrocarbon dewpoint analyser. The key function of this version will be to enable engineers to provide a fast response for investigations into the quality of natural gas, wherever it is needed.

The Transportable Condumax II measures hydrocarbon and water dewpoint (key indi-cators of the quality of natural gas) in the same way and to the same accuracy as the online version. The analyser is fitted into a robust transport case with rudimentary sampling system suitable for performing supervised measurement sequences.

A typical application for the Transportable Condumax II would be investigations into the performance of hydrocarbon reduction processing by natural gas producers. The analyser can be brought into operation quickly at any point in the process to help resolve issues.

Gas pipeline transmission operators usually have online hydrocarbon dewpoint analysers installed at the entry and delivery points of their pipeline network; however, the Transport-able Condumax II allows for checks of quality to be made at any point within the pipeline.

Electricity-generating companies that operate gas turbines need to be sure of the su-perheat margin between the dewpoint and delivery temperature of the fuel gas to avoid damage caused by liquid condensate in the gas, as well as avoiding environmental levies on emissions.

The Transportable Condumax II is certified for use in hazardous areas around the world,

including ATEX, IECEx, CSA and GOST, with specific local certification available.

AMS Instrumentation & Calibration Pty Ltd


http://www.weidmuller.com.au/au/ethernet


Virtual plant planning, retrofitting and maintenance

Processplantshaveuseful livesof30to50years,duringwhichtimetheyareroutinelyretrofitted.Virtualrealitysoftwaresimplifiesand helps keep track of retrofit planning and testing. FraunhoferresearchersandBASFSEare jointlydevelopingVRsolutionsfortheplantlifecycle.

With over 110,000 employees, BASF is the world’s largestchemical company. At its headquarters in Ludwigshafen, thecompanyrunsover160productionfacilities,twosteamcrackers,twogasandsteamturbinepowerplantsandonesewagetreatmentplant.Virtualtechnologiesarehelpingmakeinformationanddataoneveryplantonthepremisesavailabledigitallytoplanningengineers,processengineers,assemblycoordinators,safetyexpertsandassetmanagers.Avirtualcopyofaplantdisplayseverypossibleview,whether in graphics or figures, in drawings or simulations. Thisexpedites and improves the planning and implementation of newplantsoradditionsandretrofits.

Design reviews are an integral part of the planning process- a virtual model for design reviews realistically reproducesevery component with the information related to it. The spatialrepresentation makes hidden components or components alignedbehindoneanothereasilyviewable.

“WereviewedthedesignofaprocessplantretrofittogetherwithBASFexperts,”reportsSabineSzyler,virtualrealityspecialistattheFraunhoferInstituteforFactoryOperationandAutomationIFF.“Thespaceintheplantcanbedeterminedfarmoreeasily.Whatsoundssoobviousisreallyagiantleapinperception.”

ThedesignwasreviewedintheElbeDomoftheFraunhofer IFF’s Virtual Development and TrainingCentreVDTCinMagdeburg.

“Afterall, the6mhigh,360°projectionsurfaceprojectsalevelofaplantwhichisvirtuallyidenticaltotheoriginal.Thisgivesviewersthesensationofstandingdirectlyintheplant,”explainstheresearcher.

Thethree-dimensionaldatafromBASF’splanningtools,includingthemetadataoftheplant’sindividualcomponents,wereexportedintotheFraunhoferIFF-researchers’ special virtual reality software - theVirtual Development and Training Platform. Thisenabled plant operators, plant planners and theircolleagues,suchaspipingcontractors,equipmentandinstrument engineers, steel building contractorsorsafetysupervisorstoviewdetailsoftheplantfaithfullyreproducedatfullscaleinthevirtualmodelandclarifymanyquestionssuchaswhetheralloftheoperatingelementsareeasilyaccessibleorallthesafetyvalvesareeasilyoperatedduringaninspection.

“We are so impressed by the design reviewwith virtual reality that we have set up two VR

stationsinLudwigshafen.Thatenablesourplanningteamstheretoreviewdesignsofotherplantsanytime,”saysAxelFranke,SeniorEngineeringManageratBASF.

Aretrofitplantperformsdifferentlythanitdidpreviouslyand,intheworstcase,incorrectoperationcouldbringallplantoperationtoacompletestandstill.Continuoussafetytrainingisthereforeatoppriorityinchemicalplantengineering.Avirtualinteractivelearningenvironment is already being used for training in Ludwigshafen.Fraunhoferexpertsdesignedascenariofortheretrofitofanitricacidplant,whichenabledtheteamofoperatorstoinspectandgetacquaintedwiththeplantbeforeitscommissioning.TheFraunhoferexpertssetupamobileVRtrainingstationdirectly inthecontrolroom.Thetrainingmodulepresentsthecomplete3Dmodeloftheplant. All of the metadata such as serial numbers, temperatures,pressuresandmediaaswellastrainingmaterialscanbeviewed.Workerswereabletofamiliarisethemselveswithitsnewoperation,identifynewaccesspointsandlearnnewsafetyregulations.

TheexpertsfromBASFandtheFraunhoferIFFagreethatplantengineers will be unable to operate internationally in the futurewithoutvirtualtechnologies.BASFisworkingonintensifyingitsuseofvirtualtechnologiesinthefutureinordertomaintainitsleadershipamongchemicalplantoperators.TheFraunhoferIFFwillcontinueprovidingconceptualsupport.

Fraunhofer-Gesellschaft

www.fraunhofer.de

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

http://www.beckhoff.com/CX2000

NEWPRODUCTS


GIGABIT ETHERNET SWITCHESHirschmann has added two unmanaged gigabit ethernet switches to the Spider family.

The Spider II Giga EEC Pro, available with either five twisted pair ports or two additional SFP slots for fibre-optic

transceivers, supports QoS compliant with IEEE 802.1d. This allows prioritisation of data packets and means that

the switch can be used for Profinet applications.

The Spider II Giga EEC Jumbo is also available in two different 5-port versions, with or without SFP slots. Because

both versions can handle Jumbo Frames with up to 9014 bytes of user data, they are particularly suitable for video

applications. All switch versions conform to relevant industry standards

for shock and vibration resistance as well as electromagnetic compat-

ibility (EMC) and are built to comply with cUL508 safety requirements.

Further features include 12/24 V power supply, IP30 protection rating,

fanless cooling and an extended temperature range of -40 to +70°C.

The switches can be cascaded as often as required, permitting

implementation of locally structured networks with short transmission

paths to the terminating equipment. The twisted pair ports have RJ45

sockets and support autocrossing, autonegotiation and autopolarity.

The fibre-optic transceivers can bridge distances of up to 0.5 km

(multimode) or 120 km (singlemode) and support autonegotiation and

full-duplex mode.

The switches are designed for mounting on DIN rails, and LEDs on

the front panel indicate the device and network status.

Daanet Pty Ltd


IPHONE COMPATIBLE PORTABLE PH METERSensorex has developed a mobile accessory for pH meas-

urements. Compatible with Apple iPod, iPhone and iPad

devices, the PH-1 pH meter accessory measures and records

pH values in the lab or field for use in environmental, edu-

cational and industrial applications.

The PH-1 accessory plugs into the standard Apple dock

connector and uses a Sensorex pH electrode to measure pH

with accuracy to 0.01 pH. The free Sensorex app displays

pH, millivolts, ambient temperature and solution temperature

in real time. The CE-marked device supports one, two, three

or more calibration points and sends readings by email for

later analysis. When used with a GPS-enabled device, the

pH meter app will record measurements with both timestamp

and geographic coordinates, eliminating transcription errors

and improving efficiency.

Powered from the Apple device, the PH-1 requires no

supplemental energy source. Its pH measurement range is

0-14 pH and it operates in ambient temperatures of 0-40°C, in

solutions of 0-100°C. Data history can be grouped by date or

location and exported individually or in .csv format via email.

Envirosensors Pty Ltd


Swagelok® Pressure Regulators are now an even better choice for all your pressure regulator needs. Why? Well, alongside our proven experience and expertise, our range now covers sizes from 1/8 to 4 in. and all your regulator needs – high-fl ow capability, two-stage, back-pressure and vaporizing models. With our regulators you get accuracy, sensitivity and pressure stability. In short – total predictability. Exactly what you would expect. Visit swagelok.com/pressure.

Make the unpredictable totally predictable.

© 2

012

Sw

agel

ok C

ompa

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swa5573-10_RegAd_WhatsNewPT_210x297_ENG_v01AR_20120808.indd 1 8/8/12 12:11 PM

http://swagelok.com/pressure

WHEN THE WORLD COUNTS ON ENGINEERS, THEY COUNT ON US

Transforming imagination into realityOne of the world’s leading fi lm effects companies,New Zealand-based Weta Workshop has partnered withRS Components for over a decade. The effects specialists behind the Lord of the Rings, Avatar and the upcoming trilogy, The Hobbit, Weta Workshop is a multi-award-winning conceptual design and physical manufacturing facility that serves the world’s entertainment and creative industries.

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#.

“My local wholesaler just can’t compete with that. They might promise overnight delivery but that is rarely the case and while I might save a few bucks, it’s nothing compared to the cost of having my guys stand around idle waiting for parts to materialise,” says Sullivan.

“WHEN I ORDER THROUGH RS COMPONENTS, I KNOW EXACTLY WHAT I’M BUYING AND WHEN I’LL GET IT. THAT ALLOWS ME TO PLAN PROJECTS WITH CERTAINTY AND MEETMY COMMITMENTS.”

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.

1990International expansion into Asia and Europe begins.

1998Our fully transactional B2B website –a UK industry fi rst – supports fast, 24/7, hassle-free orders of electronics and maintenance products.

2000Electrocomponents PLC joins the FTSE 100 Index of the UK’s largest companies.

2002We are fi rst to market with a free e-Procurement tool, RS PurchasingManagerTM, saving businesses time and money.

2011Now dispatching one parcel every two seconds, we receive the ‘Operational Excellence Award’ at the prestigious Supply Chain Distinction Awards.

2012

2012RS Components wins Britain’s most coveted business award, the ‘Queen’s Award for Enterprise’.

* 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.

As the leading high-service distributor of electronics and maintenance products globally, we provide:

Widest range online & in stock

Same-day dispatch, on-time delivery

Expert local language support

Smart search, tools & platforms

Latest leading technologies

Flexible order quantities

Win tickets to the FA Cup Final with our75th Anniversary Share Your Story competition at www.rs-components.com/75

FOR ALL YOUR ELECTRONICS AND MAINTENANCE NEEDS, VISIT www.rsaustralia.comwww.rsnewzealand.com

http://www.rsaustralia.com


NEWPRODUCTS

RELAY REPEATER MODULEThe SRM Safety Relay

Module from Moore In-

dustries is a versatile relay

repeater module that has

been certified by exida for

single use in Safety Instrumented Systems up to SIL2.

The SRM is part of the Moore Industries’ FS Functional Safety

Series and accepts single contact closure inputs from logic solver

trip outputs including Moore Industries’ STA Safety Trip Alarm and

the SPA2 Programmable Limit Alarm Trip. With three contacts per

alarm input, the SRM allows for the addition of alarm contacts to

safety processes without special installation or configuration. Unlike

many other interposing relays, the SRM is a force guided relay,

avoiding the possibility of having contacts become stuck in both

Normally Open (NO) and Normally Closed (NC) positions at the

same time and avoids potential problems caused by issues such

as welded contacts.

Moore Industries Pacific Inc


PRESSURE TRANSMITTERThe Mercoid Series 3200G

smart pressure transmitter is

a microprocessor-based, high-

performance transmitter which has

flexible pressure calibration, push-

button configuration and is program-

mable using HART communication.

The Series 3200G is capable of being configured with

the zero and span buttons, so a field calibrator is not

required for configuration.

The transmitter software compensates for thermal

effects, improving performance and an EEPROM stores

configuration settings as well as sensor correction coef-

ficients in the event of shutdowns or power loss.

The Series 3200G is FM approved for use in hazard-

ous locations and offers ±0.075% accuracy with 100:1

rangeability, making it suitable for many applications.

Dwyer Instruments (Aust) Pty Ltd


COMPACT HARMONIC GEARHEADThe Nexen compact harmonic gearhead directly replaces

much larger, high-ratio planetary gearheads utilising the

latest harmonic, strain wave gearing technology. In ad-

dition to its extremely short, compact size, the harmonic

gearhead offers high torque, true zero backlash and

extremely precise positional accuracy.

Nexen’s gearing-forward design overlaps components

and allows the gearing to be integrated into the same

plane as the bearing, resulting in an extremely short and

rigid gearhead. This narrow, rigid design is combined

with a large, rugged, crossed-roller output bearing,

designed to handle all combinations of radial, axial and

overturning moment loads in a single, compact envelope.

The harmonic gearhead can fit virtually any machine

with key applications in products and machinery requiring

a minimal footprint, such as machine tools, robots and robotic arms, medical equipment,

rack and pinion systems and numerous general industrial positioning and motion control

applications. It is also very easy to integrate with a standard ISO 9409 output flange that

fits most standard components and end effectors.

Norman G Clark Pty Ltd


WE KNOW WE CARE WE CUSTOMISE FOR YOU…

ELECTRIC MOTORSDRIVES & SOFT STARTERSCONTROL & AUTOMATION

NSWToshiba International Corporation Pty Ltd2 Morton Street, Parramatta NSW 2150Tel: (02) 9768 6600 Fax: (02) 9890 7546

NEWCASTLEToshiba International Corporation Pty LtdUNIT 1 / 18 Kinta Drive, Beresfield NSW 2322Tel: (02) 4966 8124 Fax: (02) 4966 8147

QUEENSLANDToshiba International Corporation Pty LtdUNIT 4 / 20 Smallwood Place, Murarrie QLD 4172Tel: (07) 3902 7888 Fax: (07) 3902 7878

MACKAYToshiba International Corporation Pty Ltd1st Floor 41 Wood St, Mackay QLD 4740Tel: (07) 4953 4184 Fax: (07) 4951 4203

VICTORIAToshiba International Corporation Pty Ltd411 Fern Tree Gully Road, Mt Waverley VIC 3149Tel: (03) 8541 7960 Fax: (03) 8541 7970

WESTERN AUSTRALIAToshiba International Corporation Pty Ltd10 Anderson Pl, Perth International Airport WA 6105Tel: (08) 6272 5600 Fax: (08) 6272 5601

TOSHIBA INTERNATIONAL CORPORATION PTY LTD

Reliable products from reliable people!

http://www.toshiba.com.au

LEVERAGINGVIRTUALISATIONJim Frider, Product Marketing Manager, Invensys Operations Management

ACHIEVINGHIGHERBUSINESSCONTINUITYWITHININDUSTRIALFACILITIES

© iStockphoto.com

/Oleksiy M

ark


Today,manyoftheworld’stopcompaniesareusingsoftwarevirtualisationtechnologytodeliversignificantcostsavings,improvedefficiency,greateragility,enhancedsystemavail-ability and improveddisaster recovery capabilities.

Thetypicalindustrialfacility,includingmanufacturingplants,utilitiesandprocessingcompanies,hasmanyimportantsoftwareapplicationsthatcanbevirtualised.SoftwarelikeHMIapplications,processdatahistorians and manufacturing execution systems (MES) along withother analytical and reporting applications can all bevirtualised.

What is virtualisation?In simple terms, virtualisation is the creation and employment of a‘virtual’ (softwareemulated)versionofan ‘actual’versionofsome-thing.Broadlyspeaking,virtualisationcanapplytophysicaldevices,operating systems, network resources, devicedriversor anyactualthingforwhichavirtualequivalentcanbesubstituted.Virtualisationisaformofsoftwareabstraction,whichallowsuserstomanipulatethevirtualversionsofthingsinwayswhichwouldbeimpossiblefortheirphysicalcounterparts.Itisthisfundamentalabilitytomanipulatethevirtualversions of things that provides the power and flexibilitytoderivesomanybenefitsfromtheuseofvirtualisationtechnology.

Hardware virtualisationHardwarevirtualisationemployssoftwaretechnology,likethatofferedbyMicrosoftandVMware,totransformor ‘virtualise’acomputertocreateavirtualcomputerthatcanrunitsownoperatingsystemandapplicationsjustlikeaphysicalcomputer.Withvirtualisation,severalapplications and their required operating systems can run safely atthe same time on a single physical computer with each having ac-cess to the resources it needs when it needs them. Today, this isall possible with commercial off-the-shelf computer hardware andoperating systems.

At the heart of the virtualisation process is a software compo-nentcalledthe‘hypervisor’,atermfirstcoinedduringtheearly IBMmainframe days. There are two general categories of hypervisor.Type 1 hypervisors run directly on the physical host hardware andmanage ‘guests’orvirtualmachinessotheiroperatingsystemscanrun concurrently on the physical host hardware. This is achievedby intercepting instructions from the guest operating systems andresolvingthemsothattheguestsfunctionproperlyintheirvirtualisedenvironment. VMware ESXi and Microsoft Hyper-V are examplesof type 1 hypervisors. Conversely, type 2 hypervisors run on topof the host operating system and are not as commonly used withPC-based systems.

Desktop virtualisationBesides thevirtualisation of industrial applications, another area ofvirtualisationthat isgainingmomentum is thevirtualdesktop inter-face (VDI). Commonly used desktop applications and their required

Virtualisationoffersthepromiseof lower ITcostsandhigher levelsofbusinesscontinuity for industrialcompanies.Thisarticleprovidesabasic introduction tovirtualisationandhow it canspecificallybenefitindustrialcompanies.Highavailabilityanddisasterrecoveryscenariosarepresentedalongwithexpectedsystem performance targets for system downtime after an event or system failure.

system resources are contained within a VDI and accessed from anetwork server. As none of the software runs on the user’s localmachine, less costly computer equipment can be used. IT supportresponsibilities are reduced and the burden of data backup can beremoved from the user. Besides the many IT-related benefits, VDIusershavetheaddedbenefitofbeingabletoaccesstheirvirtualiseddesktop fromavarietyofotherdevices includingtheirsmartphone,tablet or homecomputer.

Virtualisation platformsManycompaniesarenowusingvirtualisationattheenterprise levelto create entire virtualised computing infrastructures that allow ITdepartmentstoautomaticallydeploycomputingresourceswhenandwhere they need them, with a minimum of manual IT intervention.Cloud-based implementations promise even more flexibility andeconomybyoutsourcingcomputingresourcestoothervendorssuchasMicrosoftwithitsAzureplatformorAmazonandothers.Virtuali-sation platforms are already providing businesses of all kinds withtremendous IT cost savings and improved infrastructureutilisation.

History of virtualisationThe high cost of mainframe computers in the 1960s led IBM engi-neerstodevelopwaysto improvetheefficiencyoftheirequipment.By logically partitioning their machines they were able to offermultitasking.Forthefirsttimemultipleapplicationscouldrunatthesame time - significantly improvingutilisation.

As low-cost, PC-based client-server architectures became thecomputing standard in the 1980s and 1990s the focus shifted toexploiting this new architecture by delivering more computing re-sources and applications to more users. Virtualisation was not atechnologyconsideredbymostITdepartments.However,bythelate1990s the sheer number of servers and desktop machines reachedthe point where virtualisation technology became viable as a costreduction strategy.

In 1999, VMware released its first virtualisation products and by2005processorsbecameavailablethatdirectlysupportedvirtualisa-tion.Today, amajorityof largecorporationsareusingvirtualisationto reduce their IT costs.

Phases of adoptionIndustrial companies often adopt virtualisation technology in twophases;wewill call themVirtualisation 1.0 andVirtualisation2.0.

Virtualisation 1.0In this first phase theemphasis is on IT andhowvirtualisation canbe used to lower IT costs, improve IT staff efficiency and improvehardware utilisation. IT works on creating virtual machines of keyapplications and consolidating themoncorporate servers. This firstphase of virtualisation allows companies to reduce their hardware

Virtualisation


costs, improve their server utilisation and improve their ability tooperateandmaintainawiderangeofsoftwareapplications.ITser-viceimprovesbecauseITtakesontheresponsibilityformanagingapplications which have been reluctantly managed by the groupsdirectly using the applications, like operations or maintenance.HMI applications, process data historians and web report serversare examples.

Virtualisation 2.0Duringthesecondphaseofvirtualisation,companiesoftendeploymultipleinstancesofthesameapplicationtoensurebusinesscon-tinuity or to improve application performancevia load balancing.

Forbusinesscontinuity,multipleinstancesofanapplication,andthedataserversfurnishingitwithdata,arerunsimultaneouslysothat if the primary application or data server fails, the secondaryapplication instance and data servers automatically take over anddowntime is minimised.

Ifsimultaneousapplicationinstancesarerunonserverslocatedin different physical locations, disaster recovery is much easier.

Someapplicationscanberuninloadbalancingmodewhentheprocessing load is shared across two or more virtual machines,improvingtheoverallperformanceoftheapplicationwithouthavingto invest in a second physical server. Benefits to IT, operations and engineeringVirtualisation of industrial applications can benefit many groupswithinabusiness.Let’sexplorethebenefitsgainedfromvirtualisationbasedonbusinessfunction,namelyIT,operationsandengineering.

IT benefitsThere are three main areas of benefit from virtualisation for theIT organisation:1. Cost reduction:Throughconsolidationofphysicalservers,vir-

tualisation allows much greater utilisation of server hardwaresofewerserversarerequiredandareduction intheenergy isconsumed in data centres. Virtualisation also extends the lifecycleofapplicationsbecausetheyareinsulatedfromhardwareorsoftwaretechnologyshifts,generatingmoreROIforthebusiness.

2. Management:Fewerhardwareupgradesarerequiredovertime,reducingcapitalexpenditurerequirementsandITworkload,andtheuseofvirtualmachines facilitatescentralisedmanagement

of applications since fewer applications reside on local serv-ers.Fastdeploymentscanbeachievedasself-containedvirtualmachines can be easily deployed without having to install therequiredoperatingsystem,prerequisitesoftwareortheapplica-tionitselfonadedicatedserver.Corporatestandardlibrariesofvirtualisedapplicationsallowthecreationofstandardisedapplica-tionconfigurationsthatdelivermaximumvaluetothebusiness.

3. Support: The implementation of virtual desktops allows muchmoreefficientmanagementofdesktopmachines,andsinceap-plicationsoftwaredoesn’tresideoneachdesktopmachine,newapplicationscanberolledouttoalargenumberofusersmuchfaster. This also allows for more effective backup procedures,since all data stays on corporate or cloud servers, effectivelyeliminating data loss.

Operations benefitsFor operations, business continuity can be achieved becausemultiple instances of the same virtual machine can run in anautomatic failover mode. If the failover instance is located in aseparatephysicallocation,disasterrecoveryisalsoenhanced.Thereduction in physical server footprint leading to a higher returnon capital and a reduction in the mean time to recover (MTTR),lowering operational cost, and thin client PCs on the plant floorrunningvirtual desktops reduce the support burden.

Engineering benefitsForengineering,developmentcostsarereducedsincefewerphysi-cal servers are required with fewer modifications needing to bemade over time to keep applications running properly. Virtualisedinstances of object-based applications, like WonderWare Arches-trA System Platform, can be developed and deployed faster thanconventionalapplications;andsincemultipleinstancesofavirtualmachinecanrunatthesametime,developerscanworkinamorecollaborative and efficient manner.

Levels of availabilityWhenwespeakabouta‘highavailability’solutionwetypicallymeana solution with redundant software and/or hardware componentsthat‘failover’toanunaffectedsystemtoenableapredefinedlevelof availability over a specific time frame.

Levels of availability are detailed in Table 1.

Figure 1: Supervisory HMI system using virtualisation for high availability. Figure 2: High availability architecture using virtual machines for automated failover.

Virtualisation


Implementation scenariosHigh-availability implementationsIt is possible to achieve Level 2 or even Level 3 availability forapplications like HMI and supervisory control using two, prefer-ably identical, hardware servers (bought at the same time) eachloaded with an identical virtual machine. Identical hardware andvirtualised applications help ensure that if a failover occurs therearenodeviationsinsystemperformanceresultingfromdifferencesin hardware or software.

To achieve Level 4 availability usually requires an investmentin fault tolerant hardware, including servers, disk systems, powersupplies and network cards. At this availability level, downtime isreducedtoverylowlevels;lessthan5minutesperyear,forexample.

Theperformanceofanyhighavailability(HA)solutionisdependenton the quality and implementation of the HA architecture.Disaster recovery implementationsWith the risk of natural disasters and a growing threat from ter-rorism, many industrial companies are exploring ways to recoverfasterfrompossiblecatastrophicdisasters.Virtualisationprovidesarealisticandpracticalwayto recovercritical applicationsandtheirassociateddatamorequicklyandeconomically.Likehigh-availabilityimplementations, if identical physical servers and identical virtualmachinesareruntogether infailovermode,but locatedindifferentgeographiclocations,aLevel2orLevel3availabilitycanbeachieved.

High availability combined with disaster recovery

The goal of a high availability and disaster recovery (HADR)solution is to provide a mechanism to automatically shift dataprocessingandretrieval foracritical industrialapplicationtoastandbysystem;for ‘normal’failurescenariostoastandbysys-tem in thesame facilityor, in theeventof catastrophicevents,to a standby system located in a different geographic location.

By combining HADR architectures, industrial applicationscan be made highly available and able to quickly recover froma disaster. SummaryToday’svirtualisationsoftwaresolutionsfromMicrosoft,VMwareand other vendors provide a cost-effective way to improve theavailabilityanddisasterrecoverycapabilitiesofcritical,industrialapplications such as HMI and supervisory systems. Standard,off-the-shelf computer hardware and software can be used tolower costs and reduce the level of expertise needed to imple-ment these types of solutions. Any manufacturer, processor orutility needs to evaluate these new approaches so that theytoo can mitigate risks and ensure continuity at their facilities.

Invensys Process Systems (Australia) Pty LtdContact info and more items like this at wf.net.au/R782

Availability Description Expected failover Details

Level 0 No redundancy None No redundancy built into the system architecture.

Level 1 Cold standbyAvailability: 99%Downtime: 4 days/yr

Primary and secondary systems, manual failover to secondary system, data periodically synchronised.

Level 2 High availabilityAvailability: 99.9%Downtime: 8 h/yr

Virtualisation used for primary and secondary systems. Disaster recovery via virtual machine systems located in geographically separate locations.

Level 3 Hot redundancyAvailability: 99.99%Downtime: ~52 min/yr

Full synchronisation of primary and secondary systems.

Level 4 Fault tolerantAvailability: 99.999%Downtime: <5 min/yr

Fault tolerant hardware, lock step failover to redundant application instance.

Figure 3: Disaster recovery architecture using virtualisation located in geographically separated locations.

Figure 4: High availability and disaster recovery architecture using virtualisation techniques.

Table 1: Levels of availability for different architectures.

Virtualisation


NEWPRODUCTSCRYOGENIC VORTEX MASS FLOWMETERSierra Instruments has introduced a cryogenic version of its InnovaMass 240 multivariable mass vortex

flowmeter for advanced, more reliable measurement of liquefied gases, including liquid nitrogen, liquid

oxygen, liquefied natural gas (LNG) and liquefied petroleum gas (LPG), at temperatures down to -200°C.

Historically gauged by inexact turbine flowmeters, liquid gas flow can now be

calculated with greater precision, since the InnovaMass contains no moving parts

that will wear out or require service - an advantage that provides stable readings

and an increased service life.

The cryogenic version has undergone extensive testing and field validation over

the last several years, proving that the meter is preferred versus traditional turbine

meters for measuring mass flow rates of cryogenic fluids down to -200°C. Using a

special cryogenic temperature RTD, mass calculations are done with the latest density

equations of state for liquid oxygen, nitrogen, argon and carbon dioxide, and it can

provide direct readings of mass flow rate, volumetric flow rate, temperature and

density. Smart electronics extends the range down to a Reynolds number of 5000.

The flowmeter can be loop powered with power in, a programmable analog output

and a HART or Modbus signal riding on the same two wires. Field-configurable

ranges, alarms, outputs and displays can be configured via six push-buttons or

via a magnet through an explosion-proof window.

Procon Instrument Technology


LARGE-CHARACTER PRINTER/LABELLERThe Linx IJ355 and IJ375 high-definition case coders are two new large-character

printers from coding and marking specialist Linx Printing Technologies. Claimed

to be able to cut production costs while maximising line uptime and print qual-

ity, the printers provide a cost-effective, easy-to-use alternative to other large-

character printers, and to the labelling or pre-printing of secondary packaging.

The printers use ReFresh ink recirculation system, have a robust design

and printhead protection technology which result in reduced downtime and

savings on consumables.

The ink recirculation system’s technology provides good print quality and

also avoids wasted ink during printhead cleaning, thus saving time and money

ordinarily wasted on purging procedures. Ink and dust that collect on the noz-

zles is removed with an air knife, an ink purge takes place, then ink from this

procedure is collected, passed through a high-performance filter to remove

impurities from the system and recirculated. Operators only need to perform

quick, simple maintenance on a regular basis in order to keep the printer in

optimum operating condition.

The tough stainless steel nozzle guard protects the printhead from possible

damage, caused by impact with the boxes on the line, while remaining close enough to the packaging to ensure print quality

is maintained.

The robust stainless steel lower casing and printhead protection mean the Linx IJ355 and IJ375 are robust enough to cope

with the most demanding production lines, delivering savings on consumables and minimising downtime.

The printers come with a full-colour LCD interface and touch-screen operator controls, with print preview and icon-based

message selection. The control unit is detachable for handheld use or for mounting in a more convenient location. A set of

robust accessories is also available from Linx to provide simple and accurate mounting of the printer onto the production line.

Matthews Intelligent Identification Pty Ltd


http://www.controldevices.net


NEWPRODUCTS UPDATED SIMULATION AND DEVELOPMENT TOOLSMathWorks has introduced Release 2012b with major up-dates to MATLAB and Simulink that significantly improve use and navigation. The Simulink Editor features tabbed windows, smart signal routing and simulation rewind while the MATLAB Desktop now includes a toolstrip that offers quick access to frequently used features and a MATLAB apps gallery. In addition, Release 2012b includes a redesigned help system with improved browsing, searching, filtering and content organisation.

The Simulink Editor simplifies modelling through capabili-ties such as tabbed model windows for improved window management; an explorer bar for navigating model hierarchy; smart signal routing to determine optimal signal line path; and debugging capabilities that rewind simulations and set conditional breakpoints on signals.

R2012b also introduces Simulink Projects for managing project files and connecting to source control software, and support for running models on target hardware such as Ar-duino, Lego Mindstorms NXT, BeagleBoard and PandaBoard.

New capabilities in Stateflow also simplify modelling. The Stateflow Editor is now unified with the Simulink Editor and includes smart guides and transition indicator lines.

MathWorks has also updated the MATLAB Desktop with two major enhancements. The MATLAB Toolstrip displays icons for the most frequently used MATLAB features, such as selecting the best plot type for data, and the apps gallery presents apps from the MATLAB product family to

allow users to perform common tasks without writing code.

MathWorks Australia


COMPACT PRESSURE SENSORSSuitable for pneumatic applica-tions in robotics and handling, ifm efector’s PQ compact pressure sensor series is now equipped with NPN circuit. Using a sealed measuring cell, these sensors detect the pressure in the vac-uum and overpressure range.

The piezoresistive silicon cell measures, depending on the selected unit, between -1 and 10 bar or -1 and 1 bar. Due to the special sealing of the measuring cell, the pressure sensors are insensitive to liquids such as condensed water and deposits that might occur in the system. The sensors have good overload resistance and an accuracy of less than ±0.5%.

The sensor’s slanted 4-digit display can be electronically rotated by 180° and read at a distance, from the front or from above. The display colour is selectable, with a green display colour for the acceptable range and red when the switching point is exceeded or not reached. Two programmable switching outputs or one switching output and one diagnostic output provide flexible use.

The sensors are easy to install by means of integrated mounting holes

and a range of mounting accessories is available.

ifm efector pty ltd


MULTICHANNEL ANALYTICAL TRANSMITTERSLiquiline CM444 and CM448 multichannel analytical transmit-ters have a rugged plastic NEMA4X/IP66/67 housing that is leak-proof and corrosion-resistant, suitable for non-hazardous applications in water, wastewater, oil, gas, chemical and power industries.

They accept inputs from up to eight Memosens digital sensors, recognising any combination of sensors and starting operation immediately. All sensors can be precalibrated in the laboratory and are recognised automatically by the transmitters.

The transmitters can be field-upgraded to accept additional inputs by plugging in additional modules. Optional cur-rent inputs are available for processing signals from other process devices such as flow, level or pressure sensors.

Outputs from the transmitters include up to eight 4-20 mA current outputs with HART, as well as ethernet, Profibus and Modbus TCP or 485 networks. An integrated web server provides remote access via any web browser.

Additional outputs include up to four relay outputs capable of switching 24, 115 or 230 VAC. The relay outputs can be used to sound alarms, start or stop cleaning functions, activate a controller or perform other functions.

In addition to actual process values provided by the sensors or analog inputs, mathematical functions can be used to calculate a maximum of six ‘virtual’ process values.

The transmitters have backlit graphic displays that alert users to errors and display load curves, as well as drop-down menus for monitoring values. The data logger can maintain up to eight separate data logbooks. It has an adjustable

scan time of 1 s to 6 h and a logbook that keeps track of up to 75 calibrations.

Endress+Hauser Australia Pty Ltd


Pneumatics

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NEWPRODUCTS

EMBEDDED CONTROLLERNational Instruments has introduced the NI PXIe-8135, which features the

quad-core 3rd generation Intel Core i7 processor and USB 3.0 connectivity.

The NI PXIe-8135 helps engineers achieve shorter test times and increase

automated test throughput, further advancing PXI instrumentation for high-

performance test, measurement and control applications.

The use of the 3rd generation Intel Core i7 processor with up to a 3.3 GHz

clock provides improved performance (up to 85% higher than

previously) and next-generation I/O technologies to

help meet the intensive processing demands of

the latest automated test and control applications.

USB 3.0 connectivity offers up to 10 times

faster instrument communication for transferring

and storing data externally. Four PCI Express

x4 Gen 2 links interface the embedded controller

to the chassis backplane providing up to 8 GBps

of system throughput for high-bandwidth stream-

ing applications.



http://www.brolton.com.au


NEWPRODUCTS

SLEWING DRIVESMotion Technologies slewing drives are gearboxes that can safely hold radial and axial loads, as well as transmit a torque for rotating. Slewing drives or drive slew rings (DSRs) are made by manufacturing gearing, bearings, seals, housing and auxiliary components into an assembled finished gearbox.

DSRs are suitable for solar applications, industrial applications such as man lifts, hydraulic machinery, telescopic handlers, digger derricks, lifts, cranes, drilling equipment and military equipment. Modular input flanges easily accommodate hydraulic, DC and servo/stepper motor inputs.

DSRs can be single or dual axis, enclosed or open, and there is a range of male drive input configurations. High-speed versions and preci-sion geared or low backlash options are available.

Motion Technologies Pty Ltd


CLOUD-BASED SIMULATION PLATFORMAutodesk, Inc has announced Autodesk Simulation 360 - a set of tools delivered securely in the cloud with a pay-as-you-go pricing model that enables any company to make simulation part of their everyday design and engineering processes.

Autodesk Simulation 360 is the latest offering to build on the Autodesk 360 cloud-based platform. By performing computationally intensive simulation tasks in the cloud, designers, engineers and analysts can test multiple ‘what if?’ design scenarios in parallel. The computational power of the cloud also eliminates the need for spe-cialised hardware, thereby removing previous limitations and helping to increase productivity.

The Autodesk Simulation 360 software portfolio includes a wide range of cloud-based mechanical, fluid flow, thermal and plastic injection moulding tools. Additional benefits include direct geometry exchange; robust meshing tools; extensive material libraries; and proven solver technology to improve simulation accuracy in the areas of greatest concern.

In contrast to traditional perpetual licensing, Autodesk Simulation 360’s pay-as-you-go model simplifies access and offers better flexibility. Autodesk Simulation 360 is now available in English and is planned to be available in other languages in the near future. For additional information on how to access Autodesk Simulation 360 and take part in the Simulation Liberation event, visit www.autodesk.com/simulation-liberation. Additional resources such as simulation experts, on-demand

videos and tutorials are available at www.autodesk.com/simulation-360.

Autodesk Australia


http://daanet.com.au/secomea


In the courseofmodernisationof oneof its stormwaterbasins, thewastewatertreatmentplantWaiblingen-Hegnachdecidedto implementradarmeasurementtechnologyfromVEGA.Thebasin,whichis5kilometresawayfromthetreatmentplant,ismonitoredreliablybythreeradarsensors.

TheemployeesofthesewagetreatmentplantatWaiblingen-Hegnach,Germany,certainlycannotbeaccusedofnotbeingclosetonature.Yettheydohavemixedfeelingsaboutspiderwebs!

Spunbeneath theultrasonic sensors, spiderwebsused to causemeasurementuncertaintiesagainandagain.Butanimalsandinsectswerenottheonlyculprits:foamandevensunlightalsohadadverseeffectson

theultrasonicmeasurement.Indeed,theWaiblingenstaffhasreallyhadenoughoffoam.Once,thewastewaterdischargefromanearbyshampoomanufacturercausedmajorproblemsfortheultrasonicmeasurementduetothehugeamountsoffoamgenerated.

Whileplanning thenew instrumentation for thestormwaterbasin,plantmanagerFrankSuraknewexactlywhathewanted.“Asamatterofprincipleweusenon-contactmethodsforwastewaterwhereverpossible.Becauseoftheoil,dirtanddebrisinthewater,ultrasonictechnologywasoftendeployed,accompaniedofcoursebytheverywell-knowndifficultiesofusingthatmethod.”Thatiswhy,inthecourseofmodernisationofthestormwaterbasin,VegapulsWL61radarlevelsensorswereusedinstead,atthreedifferentmeasuringpoints.

SinceMay2011, the instruments fromVEGAhavebeendeliveringreliable andstable readings. “It is certainlynot aparticularlydifficultapplication,but ithastofunctionreliably,”explainsSura.“Besidetheirreliability,whatreallyconvincedusaboutradarinstrumentswastheirprice,whichwashardlydifferentfromthatofultrasonicdevices.”

Allplantcomponentsareconnectedviaacontrolsystem,sotheteamworkingatthesewagetreatmentplanthasaccesstoallfunctionsatall

Reliable stormwater measurement

times.Thisisimportantbecausesuchmid-sizetreatmentplantstendtobeminimallystaffedandmanydifferentareashavetobemonitored.Aremotecontrolsystemprovidessecurity,settingoffanalarmincaseofdamageorcontaminationbytoxinsorotherhazardoussubstances.

Thestormwaterbasin,oneofatotalof 13, is5kmaway fromthetreatmentplantandsituateddirectlyonthebanksoftheriverRems.

Themeasurementdata istransmittedeveryhalfhourtothecontrolsystemviaamobilephonenetwork,andtheradarsensorsaredeployedat threemeasuringpoints.AllunitshaveExcertification, anecessaryprecautionsincefuelsorsolventscanalsobepresentinthewastewater.LocationNumber1isdirectlyintheopenstormwaterbasin.There,thesensormonitorsthelevelinthebasinand,ifnecessary,putsthedischargepumpsintooperation.

Inthenearbysewagepumpingstation,anotherradarsensorisinstalledin thepumpshaft.Previously, thismeasurementwasachievedvia apressuremeasurement.Theentirefacilityislocatedinaflood-pronearea-theRemshasasmallchannel,butalargedrainagearea,andasaresult,thewaterlevelcanrisesubstantiallywithinafewhours.That’swhythemeasuringinstrumentshaveanIP68protectioncategory,whichallowsthemtobeimmersedinfloodwaters.

Thethirdinstrumentislocatedsomedistanceaway,hiddeninthemiddleofameadow.There,avortexvalveregulatesdischargeintothesewerline.Mostofthewatergenerallyflowspastthebasin.Onlywhenthereisaheavyrain,forexample,andtherainwaterrunoffincreasestoamultipleofthenormalwastewaterflow,dothestormwaterbasinscomeintoplay.Theybufferthedirtywaterandtaketheloadoffthetreatmentplant.Thetankcontentsstoredduringtheheavyrainareforwardedtothesewagetreatmentplantlittlebylittleaftertherainevent.Toensurepropercontrolofthisprocess,thevortexvalvehastoworkflawlessly.

“Veryfewpeoplehaveanideaofwhatcanbefoundinsewage.We’vealreadyhadto removeboulders, two-by-foursandflashlights.A largetreebranchcanblockthevortexvalveveryquickly,”continuestheplantmanager.

Inthepast,someonefromhisteamalwayshadtogoandcheckiftherewasreallyablockageorifitwasjustanotherindustriousspiderthathadbuiltitswebundertheultrasonictransducer!Thisisnolongernecessary,sincearadarlevelgaugeiskeepingwatchtherenow.Furtherupgrades,includingadditionalstormwaterbasinswithinthecatchmentareaofthewastewatertreatmentplant,areplannedforthefuture.

VEGA Australia Pty Ltd


The shaft of the sew-age pumping sta-tion is located in the middle of a flood-endangered area, so the radar gauges were designed with an IP68 protection rating.

Check out this magazine’s sister website.

http://www.veederline.com


Reliable stormwater measurement

At element14, we stock the best tools from leading brands such as CK Tools, Duratool, Fluke, Knipex, Lindstrom, Stanley, Wera and Wiha, all available for same-day despatch. Our selection includes cutters, precision screwdrivers, pliers, wire strippers, measuring tapes, wrenches, tool bags and more. And, our handy online tool selector makes it easier for you to kit out your bag and bench.

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PHONE:Australia 1300 452 488New Zealand 0800 357 064

SALES:[email protected]@element14.com

TECHNICAL SUPPORT:[email protected]@element14.com

NEWPRODUCTS

LOW-COST SERVOSBased on the G5 series, the G5 Lite servos from

Omron are a cut-down version, with a number of

advanced features removed to reduce cost.

G5 Lite servos accept a single-phase 200 V

source and output between 100 and 1500 W to

a servomotor. Ready-made cables with moulded

plugs are available for plug-and-play functionality.

The matching servomotors have an optional holding

brake, to maintain position when power is removed.

The motor’s in-built encoder resolution is 20 bit, equivalent

to 1,048,576 PPR, and the drive accepts a pulse train input for

direct replacement of stepper motors.

Both positioning and fixed value speed control modes are supported, along

with eight inputs and three outputs, all with configurable functionality.

Optimum motor performance is achieved by the real-time autotuning facility,

which can run continually. Vibration can also be significantly reduced by the

enabling one of several adaptive or notch filters. Damping control is also provided

and is suitable for keeping liquid loads level during movement to avoid spillage.

Omron Electronics Pty Ltd


http://au.element14.com/tool-selector


NEWPRODUCTSLED OPEN FRAME MONITORThe IDS-3110 is a 10.4″ SVGA industrial LED open frame monitor. The open front bezel design enables flexible and customised face plates for easy re-engineering and is suitable for any embedded application. The versa-tile mounting methods include rear and VESA mounting (75 x 75 mm or 100 x100 mm). The IDS-3110 comes in two versions: IDS-3110 standard and IDS-3110E. IDS-3110 standard provides 400 nits brightness and -20 to 60°C wide operating temperature with dual VGA and DVI signal interfaces. IDS-3110E is a more economic version which supports 230 nits brightness and 0 to 45°C operating temperature with VGA signal interface only.

The IDS-3110 incorporates a simple 2-piece metal frame structure for a slim design 30 mm thick (non-touch solution) while most models are over 40 mm thick. This is a space saving of 20% and a weight reduction from 2 kg to 1 kg for non-touch solutions.

Compared to traditional CCFL backlights, LED backlights allow for thinner panel designs and low power consumption. The IDS-3110 comes with an industrial-grade panel and LED backlight which saves 20-30% on power consumption and reaches higher brightness.

The 400 nits brightness and 700:1 contrast ratio together brings much better visibility than common monitors, particularly in environments with strong ambient light. The wide viewing angle of 160° horizontal and 140° vertical provides a wider range viewing area for end users. In addition, IDS-3110’s wide range operating temperature of -20 to 60° C makes it

suitable for harsh environments.

Advantech Australia Pty Ltd


DATA ACQUISITION SYSTEMThe Dewetron DEWE2 data acquisition system allows for mutliple si-multaneous sampling Trion plug-in modules, combining the modularity of PXI with a larger front panel capable of containing eight RJ45 con-nectors for strain gauge sensors, six or eight IEPE sensor connectors, or four or eight isolated high-voltage inputs on a single Trion module.

The modules are inserted from the front of the DEWE2 chassis. Each module can be combined and exchanged directly by the user in seconds. They plug in and out using the same locking/ejector mecha-nism made popular by the PXI standard. This allows the adaptation of DEWE2 instruments for every sensor and every application quickly.

The function of each measurement channel as well of the connected sensors can be proofed easily via a system check. This results in a reduction of user errors, which saves valuable time. Different chassis, most with a battery pack for independent power supply, are available.

The series is ruggedised and provides a high channel density. Analog, digital, CANbus, GPS, counter and video signals are hardware synchronised already during the measurement, due to the built-in Sync-Clock technology.

There are instruments offering from 4 to 18 Trion slots, with or with-out a built-in computer. The DEWE2-A4 is an all-in-one platform with four slots for any combination of Trion modules, and features an Intel i7 processor running Windows 7, and a built-in display and keyboard.

Metromatics Pty Ltd


http://www.zigsense.com.au

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NEWPRODUCTS

LEAK TESTERThe Furness FCO770 leak detector is designed for inline production leak testing of automotive components, pharmaceutical products, safety pressure devices, plumbing fittings, gas appliances, medical equipment and many other categories of products. It uses the Furness flat diaphragm differential pressure transducer, and the leak test specific spool type valve block with spool position monitoring.

The detector has a full colour graphical touch-screen display. Automatic storage of test graphs and other data and test recipes, or preset test sequences, for up to 300 different products is standard. Each test recipe may include a conventional leak test and also automatically sequenced tests for blockage, ramp and dump (sealed component test) for the one product. The user can program the detector via its front panel or with a laptop or PC via its RS232, RS485, USB or ethernet interface. The I/O for communication with external devices, such as PLCs and PCs, may also be programmed via the front panel touch screen or externally via a computer.

The leak detector can be set up by the user to test with vacuum or positive pressure. The maxi-mum negative pressure range is -100 kPa (0 kPa absolute) and the maximum positive pressure range is 3 MPa (30 bar). Integral manual or automatic pressure and vacuum regulators are available. Depending on the application, an internal vacuum generator option is also available. If an external vacuum or positive pressure source is needed then the user can connect an external pressure source.

Bestech Australia Pty Ltd


INTEGRATED PNEUMATIC ACTUATORSNorgren has launched a high-performance range of cylinders, designed to significantly reduce energy usage and operating costs for OEMs and end users in a range of processing applications.

Conventional pneumatic control involves an arrangement of valves or valve islands, actuators, flow controls and sensors, along with connectors and accessories. In typical applications, up to 13 different components can be required for each actuator function. This complexity presents some intrinsic disadvantages and performance constraints. Norgren has developed IVAC (in-tegrated valve and actuator control) - an integrated unit which combines the valve, flow controls, cushioning and sensors in a single actuator package.

IVAC is a weight- and space-optimised actuator, suitable for a range of bore sizes from 40 to 80 mm, featuring an integrated valve and magnetically operated switches for complete actuator control. Able to be retrofitted or integrated within new systems, each unit requires only one pneumatic and one electrical connection, eliminating the need for multiple valve islands, components, tubing and accessories.

A number of options and varieties are available including cleanline versions for industrial cylinders, industrial slave cylinders and easy washdown, helping OEMs comply more easily and cost effectively with hygiene regulations.

The design of the integrated actuator is based on modularity to allow all components to be easily assembled and disassembled. The IVAC’s modular concept includes a special pilot module which is placed directly at the end of the actuator barrel, and the inte-gration of a pneumatic interface, position sensing, display for status and electrical connection.

Norgren Pty Ltd


http://www.metromatics.com.au


NEWPRODUCTS

HMI/SCADA REPORTING SOFTWAREOcean Data Systems and independent SCADA provider InduSoft, Inc have teamed up to offer new reporting options for InduSoft Web Studio users. With seamless access to the Dream Report application, InduSoft users gain the ability to create sophisticated reports that include tables, bar charts, pie charts and screen shots.

The option to integrate Dream Report into InduSoft Web Studio lets users easily access history data such as alarm history, trend history, OEE data and process data to generate a variety of reports in formats including, but not limited to, Microsoft Excel and Adobe PDF. Users can also automatically publish reports via a secure web portal on the internet or via an internal company intranet, using a built-in interface. This integration solution enables users to browse reports, access entire report history, generate reports on demand, configure per-report user access, save reports locally and print reports from a web client.

In addition, Dream Report’s configurable end-user interface simplifies exporting files to profes-sional databases, such as Microsoft SQL Server and Oracle. By offering check-box configuration

tools and other features, the need for programming or database development skills to communicate with database applications is eliminated.

InduSoft Web Studio with Dream Report capabilities is a highly scalable solution that can grow from simple batch reporting for a single unit to reporting for the entire enterprise. By combining report informa-tion from multiple databases into one consolidated site reporting system without duplicating the source data locally, enterprise reporting becomes faster and more reliable.

A native driver was developed by Ocean Data Systems for seamless communication with InduSoft Web.

Dominion Electronics


http://www.plchardware.com.au


AS I SEE IT

With over 15 years’ experience in industrial automation and MES, systems engineering, consulting and business deve lopment , Al ison Koh is current ly the Solut ions Market ing Manager responsible for the life cycle management

for Schneider Electric’s automation solutions offerings in Australia.

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

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EXTENDYOURCONTROL:DIGITISATIONOFTHEINDUSTRIALWORLD

In today’s real-time and highly connectedworld, digitisation is radically changingday-to-daylife.Thedigitalworldpervades

oureverywakingmomentandsometimesoursleepingmomentstoo(checkoutthepopularsnoring app!).

The world’s volume of digital data morethan doubles every two years (Source: Dis-covery Institute’s Technology and Democracy Project, January 2008). By the end of 2012,20typicalbroadbandhouseholdswillgeneratemoretrafficthanwhatflowedacrosstheentireinternetin2008(Source: AT&T).Themajorityofbusinesses(83%)believetheywillbedoingmorethan50%oftheirservicesonthecloud.

These statistics are indicative of thedigital wave that has flooded our personalworld and is now impacting our industrialworld. The industrial automation space hastraditionally been conservative, with a focusonreliabilityandhighavailability.Today,withthese principles common across the digitalworld, many production plants, facilities andindustrialbusinessesareexpectingthesamereal-time,connectedandmobiledigitalexperi-encecombinedwiththetraditionalprinciplesof data resilience and availability in order tomeet their production needs.

Technology streamlining processesComplicated,multipleworkflowsofdifferent

roles in an industrial business can be man-aged in the digital domain but the seamlessinteroperability across the entire processcontrol system enables the rapid identifica-tion of production losses and root cause,and immediate rectification of the fault - allminimisingprocessdowntime,thekeycontribu-tortoprofitability.These integratedsolutionsfeaturingenterprise-widecentralisedcontrol,mobile technologies and industrialised PCsat local control stations form the backboneof industrial digitisation. Put simply, withindustrialdigitisation,thatwhichusedtotakehours (if not days) now takes minutes.

The first critical piece of the industrialdigitisation architecture is enterprise-widecentralised control. This can be achievedthrough the consolidation of disparate site-basedmonitoring,controlandoperationsintel-ligencesolutions intooneholisticproduction

management system that operates across allsites in the demand chain.

Centralisedcontrolembedsstandardisationinautomationacrossthedemandchain-em-phasising the need for common visualisationand control standards.

The second critical piece of industrialdigitisation leveragesthestrengthofmobilitysolutions, such as tablets and smartphones,which provide the flexibility necessary whenconsolidatingoperationsforcentralisedcontrol.

Thethirdkeypieceofindustrialdigitisationarchitecture is the use of localised, industri-alised PCs (iPCs) in local stations. This iscriticaltocentralisedcontrolandthestrengthof the industrial digitisation model. It is alsoimportant for production processes requir-ing high-maintenance activities (a physicalpresence) together with the need for digitalvisibility (SCADA).

Building blocks for industrial digitisationEnterprise-wide centralised control com-

binedwithmobilitysolutionsandlocalcontrolstation(iPC)architecturesarethefundamentalbuildingblocksforindustrialdigitisation.Withtheseinplace,industrialbusinessesarelever-agingtherapidpaceddigitalworld-effectivelycombiningthereal-time,connectedandmobile,digital experience with traditional industrialautomation principles of data resilience andhigh availability.

Industrialcompaniesthattakeuptheindus-trialdigitisationchallengedrivemoreeffective,agile and ultimately profitable businesses astheir workflows are streamlined across theiroperations.

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

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