What’s New in Process Technology May 2013

http://www.fluke.com.au

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

ny

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

http://www.swagelok.com

ON THE COVER 0513CONTENTS

WHAT'S NEW IN PROCESS TECHNOLOGYMAY 2013

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

NOW in DIGITAL!

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

The Fluke VT02 Visual IR Thermometer

bridges the gap between low-cost IR

thermometers and higher priced thermal

imagers and allows you to see beyond

temperature at a price that’s equally

groundbreaking.

Now, instead of the tedious tasks of taking

and recording multiple, individual tempera-

ture readings, you get the complete picture

with a blended visual and thermal image

of your target area.

Using hyper-thin pyroelectric technology,

Fluke discovered a way to push the limits

of this technology pioneering an array

dense enough to create an infrared heat

map. In the past, blending has been the

exclusive territory of thermal imagers but

not anymore. It’s standard with your new

visual thermometer.

Measure with confidence, detect issues

instantaneously, pinpoint with hot and cold

markers, document problems with Smart-

View software and troubleshoot efficiently.

With the Fluke VT02 Visual Thermometer,

you get the visual image of exactly what

you are measuring. So whether you are an

electrician, electrical contractor or work in

HVAC, industrial maintenance, automotive

or general maintenance, the Fluke VT02

Visual Thermometer will help you meas-

ure with confidence, diagnose problems

instantly and expand your business.

Fluke Australia Pty Ltdwww.fluke.com.au

4 Improving the bottom line Reducing the cost of compressed air

10 Hot products online

12 New products

38 As I see it Waste opportunities - transforming waste energy

into cost-saving and sustainable processes

4 WHAT'S NEW IN PROCESS TECHNOLOGY - MAY 2013 www.ProcessOnline.com.au

IMPROVING THE BOTTOM LINEREDUCING THE COST OF COMPRESSED AIRClayton W Fryer, IMI Norgren, Littleton, Colorado

© iS

tock

phot

o.co

m/p

olyg

raph

us©

iSto

ckph

oto.

com

/ Tim

TheT

oolm

an

MAY 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 5www.ProcessOnline.com.au

Countless attempts at making end users aware of the costs to produce compressed air have largely been ignored. It seems

that operations managers are concerned with the power consumption of a couple of 60 W light bulbs, but couldn’t care less about the power required to run a 400 hp compressor. Let’s put this into perspective - one horsepower equals 745.7 W. You can light 4971 light bulbs with the same power it takes to run a 300 kW compressor. Indeed, the single largest electrical appliance in a manufacturing plant may be the compres-sor motor.

Compressed air costs are typically hid-den in the operating overheads of most companies, therefore any overhead cost reduction immediately falls to the bottom line in the form of profit. The real test of this improved bottom line is determining the additional sales a company must generate to produce a similar profit.

Real costsExperts in the compressed air field suggest the cost to produce compressed air varies from $0.15 to $0.40 per 1000 standard cubic feet (SCF)1,2, depending on geographical location. In spite of these estimates, a large sector of the user public fails to complete the simple calculations to determine what a machine will require in terms of standard cubic feet per minute (SCFM) of compressed air, let alone for an entire year or the life of the equipment. In order to improve the bottom line with pneumatics, we must also expose three popular pneumatic myths:

• Myth 1: Compressed air is free• Myth 2: Pipe size = Right size• Myth 3: If a little bit’s good, a whole

lot’s better

Myth 1: Compressed air is freeIn the past most people wouldn’t take the time to determine the cost of the compressed air required by an actuator for a year. It is ironic that hydraulic system designers have to do the calculations in order to determine the size of the power unit required to op-erate hydraulic cylinders. For far too long, little effort has been made to recognise the

similarities between hydraulic and pneumatic systems. Typically, fluid power people have defended the differences between hydraulic and pneumatic systems. By recognising the similarities we can design and service the two mediums from similar perspectives, including the need for safety, conservation, component sizing and cost justification.

There is a developing interest in de-termining the cost of compressed air in a pneumatic system. We are beginning to see users specify 60 psig as the maximum pressure range for a pneumatic system. Pneumatic component manufacturers are somewhat paranoid about discussing the cost of compressed air for fear they might encourage customers to apply a substitute for compressed air. Since compressed air is readily available, affordable, clean and has less force hazards than hydraulic power, it seems reasonable that compressed air will continue to be applied in the industrial sector.

Real common senseTo properly apply pneumatic components in a system, the first component to be consid-ered is the actuator. We have seen a large number of cylinders grossly oversized result-ing in poor actuator performance, wasted compressed air and high initial component costs. Oversizing an actuator by one bore size can result in a 50% increase in the cost of compressed air required for the application. If the cylinder is sized to move more than twice the load at the design pres-sure, the cylinder speed will be adversely affected and the cost of compressed air will also increase. Using this simple observation can result in significant savings.

If care is taken at this step of the design process, every component upstream of the actuator (valves, conductors, fittings, filters, regulators and lubricators) will have a better chance of being correctly sized and applied. A good and correct start in the process is essential to having an efficient system.

Real calculationsA cylinder flow calculation is required for a number of reasons. It takes into consideration the force required to move the load at the

The cost of compressed air continues to be a very elusive subject in industrial applications. The notion that compressed air is free is a common misconception.

© iS

tock

phot

o.co

m/S

impl

yCre

ativ

ePho

togr

aphy


specified pressure, the extend and retract stroke volumes of the cylinder, the cycles per minute, the operating air pressure and a conversion to SCFM. SCFM is the value used by most pneumatic fluid power manu-facturers to apply the correct components in a system. SCFM is also linked to valve sizing using the flow coefficient (Cv).

Once the cylinder flow calculation is completed, the designer can determine the correct tubing, fittings, valves and the filter, regulator and lubricator (FRL) for the appli-cation. In spite of the obvious benefits this information provides, we find few designers attempting these critical calculations.

In a typical circuit (Figure 1) comprising a double-acting pneumatic cylinder, a five-port, four-way valve and two flow controls, the typical approach to sizing exposes another popular pneumatic myth.

Myth 2: Pipe size = Right sizeIf the cylinder selected had a 1/2″ pipe port, most installers would apply 1/2″ flow controls, 1/2″ pipe and fittings, a 1/2″ valve and, quite possibly, a 1/2″ FRL! This approach leads to oversized, high-priced components and higher long-term operating compressed air costs over the life of the equipment. As a result, oversizing components occurs frequently and quickly leads to another popular pneumatic myth.

Real-life exampleLet’s consider the following example. We have a cylinder load that requires 2.2 kN of force to move in the extend direction only. The retract stroke has no effective load.

We want to move the load 30 cm and be able to do this at 30 cycles per minute, eight hours per day, five days per week, 50 weeks per year. The cylinder will be operated on a horizontal plane. Compressed air pressure is 80 psig (552 kPa). Of course, we want this cylinder to move as fast as possible (AFAP)!

Real solutionThere are five steps required to accurately calculate a cylinder flow rate (in SCFM). The calculations are necessary to achieve accurate results. After the calculations are completed the system designer has the information needed to make sound, cost-effective decisions that include downsizing components and conserving compressed air.

Step 1: Size the cylinder for maximum performanceThis is the stage in sizing a cylinder where we find many designers throwing in a lit-tle extra safety factor to cover breakaway forces of a cylinder (if a little bit’s good, a whole lot’s better!)

Based on common practice and the ori-entation of the cylinder, we have found the range of the force multiplier to be between 1.25 to 2 times the load3 being moved, at the specified pressure. This range of values will provide adequate force compensation in the calculations and need not be exceeded.

To size the cylinder for maximum perfor-mance (quickest stroke time) we will apply the x2 rule. Multiply the load by two and apply the correct cylinder at the specified pressure. In this case, 2.2 kN x 2 = 4.4 kN. Using the formula, force is equal to pressure

times area (f=pA), we solve for the cross-sectional area we need for the cylinder bore. To solve for the area, the formula looks like A=f/p. 4.4/552= 0.008 m2 = 80 cm2 is the cross-sectional area of the bore needed to move our 2.2 kN load as fast as possible! This is very close to a standard ISO bore of 100 mm (78.5 cm2). It is IMPORTANT to note here that any larger bore size will move slower at 80 psig and any smaller bore size will also move slower. Use a 100 mm bore cylinder.

Step 2: Calculate total volume per cycleTotal volume per cycle requires some exami-nation of the cylinder we will be applying. We need to recognise that the extend stroke volume will be more than the retract stroke volume on a typical double-acting, single-rod cylinder, due to the volume displacement of the rod.

Since we’ve selected an ISO 100 mm bore cylinder we will apply the standard 25 mm rod (after we’ve checked to avoid cylinder rod buckling!). Extend volume is equal to the bore cross-sectional area times the stroke length.

78.5cm2 x 30cm = 2355cm3

Retract volume (compensating for the rod) calculation is:

(78.5cm2 – 4.9cm2) x 30cm = 2208cm3

Total volume per cycle is therefore:

2355cm3 + 2208cm3 = 4563cm3

For a 125 mm bore the total volume per cycle is:

3681cm3 + 3440cm3 = 7121cm3

That’s a 56% increase over the volume of the 100 mm bore cylinder!

Step 3: Calculate total volume per minuteMultiply the total volume per cycle by the number of cycles per minute:

4563cm3/cycle x 30cpm = 136,890cm3/min

Figure 1: Typical valve/cylinder/flow control circuit.

OVERSIZING AN ACTUATOR BY ONE BORE SIZE

CAN RESULT IN A 50% INCREASE IN THE COST OF

COMPRESSED AIR REQUIRED FOR THE APPLICATION.

Fluid power


Step 4: Convert to cubic feet/minute (CFM)

136,890cm3 ÷ 16.387cm3/in3 ÷ 1728in3/ft3 = 4.83CFM

Step 5: Convert CFM to SCFMThis conversion reduces the cylinder flow calculation to the necessary and required terms.

To make this conversion we must recog-nise the compression ratio of the compressed air being used in the application. Compression ratio is the working pressure expressed in absolute terms and converts compressed air to standard conditions (14.7 psia, 36% RH and 20ºC temperature). In most industrial applications, the ambient temperature and relative humidity can be ignored since these variables have little impact on the calculations. Our compression ratio (CR) calculation is:

(80 + 14.7) ÷ 14.7 = 6.44

Multiplying the CFM by the CR = SCFM:

4.83 CFM x 6.44 CR = 31.1 SCFM

An SCFM of 31.1 for this application seems fairly harmless until you complete the compressed air cost evaluation. The cylinder flow calculation provides the neces-sary information (SCFM) to more accurately determine the flow coefficient (Cv) and the proper FRL for the system. Without the cylinder flow calculation, sizing the rest of the components in the system will be accomplished empirically (trial and error approach) or by using Myth 2.

With the cylinder flow calculation com-plete, we can move on to the real cost of compressed air for the application and sizing the rest of the components in the system.

Real power requirementsMost compressor representatives will use a few rules of thumb to determine the com-pressor capacity required for an application. Depending on the type of compressor used,

compressors are typically rated to deliver four to five SCFM per horsepower as a rule of thumb. Most compressor representatives will also strongly recommend a duty cycle of 50% to 75% (rule of thumb), again depending on the type of compressor. Duty cycle is the percentage of time the compressor motor is generally running under loaded conditions. In our application, at 50% duty cycle and at 4 SCFM/hp, a 31.1 SCFM application will require an additional compressor capacity of 11.6 kW!

(31.1 SCFM ÷ 4 SCFM/hp) ÷ 50% duty cycle = 15.55 hp (11.6 kW).

Real compressed air costsIf we carry our SCFM calculations out to the number of SCF per year, per shift, pretty soon we are talking about some serious compressed air usage! Consider how many minutes there are in an eight-hour day, five days a week, fifty weeks in a year: 120,000 min/year per eight-hour shift (That’s 360,000 min/year for three shifts!)31.1 SCFM x 120,000 min = 3,732,000 SCF/yr.

The 125 mm bore cylinder would require 48.5 SCFM or 5,820,000 SCF/yr. If your average cost per 1000 SCF is only $0.25, the cost of compressed air to operate this one 100 mm bore cylinder for one shift, for the year is an incredible $933, and obviously, if your cost of compressed air is $0.50/1000 SCF, your annual cost would be $1866.00.

For the 125 mm bore, air consumption costs jump to $1455 (at $0.25/1000 SCF) and $2910 (at $0.50/1000 SCF). Over a 55% increase for one bore size increase.

Real concernThe cost of compressed air actually used is a major concern for most manufacturing companies. If we could reduce the com-pressed air consumption in our system by 30%, most CEOs, CFOs and plant engineers would leap at the opportunity. Let’s con-

sider another approach to our application.Since our 2.2 kN load is only being

moved in the extend direction, we could consider lowering the air pressure to return the cylinder. For example, say we were able to lower the return pressure from 80 to 20 psig. How would that im-pact on the total system air consumption?

If you recall from Step 2 above, the retract stroke volume was 2208 cm3 per cycle, or about 48.4% of the total cy-cle volume. Without taking you through the additional calculations, the com-pressed air cost for the extend stroke at $0.25/1000SCF is $481.43/year.

Again, without going through the cal-culations, it can be shown that by chang-ing the pressure on the return stroke to 20 psig the compressed air consumption is reduced by 30%, therefore saving 30% in compressed air costs overall for this actuator.

Even if the price of a 1/2″ regulator was $50, you would be able to expect a payback on the cost of the regulator in about two months.

Please keep in mind this example is for only one 100 mm cylinder. How many cylinders are you applying? What is your cost of compressed air?

When we examine the application even closer, we are able to save even more in initial costs by properly sizing the valve, the fittings and tubing by the use of the flow coefficient (Cv). It is sufficient to say the use of Cvs to size a system is rea-sonably accurate and provides an element of cushion in most system calculations.

There are other approaches to conserv-ing compressed air in typical applications. If cylinder speed is not important, using a force multiplier between 1.25 and 2 times the load will result in smaller cylinders and less air consumption. Applying single-acting cylinders could significantly reduce the long-term cost of compressed air.

Fluid power©

iSto

ckph

oto.

com

/pol

ygra

phus

© iS

tock

phot

o.co

m/ T

imTh

eToo

lman


Real system CvUsing Cvs we can evaluate the typical circuit of Figure 1 for potential bottlenecks. Each component in the circuit has a Cv. With some effort it is possible to determine the Cv of the cylinder port, Cv of the flow control (in both the free flow direction as well as the WIDE OPEN controlled flow direction), Cv of the piping/tubing and fittings and the Cv of the directional control valve. The System Cv is ALWAYS going to be less than the com-ponent with the smallest Cv in the system.

A strong recommendation here is to make the most restrictive component (‘the weak-est link’)4 in the system the most expensive component (usually the directional control valve). This will minimise the initial cost of the components in the system. It is fair to say that a 1/2″ directional valve will cost more than a 1/4″ valve. The difference in pipe or tubing cost is marginally different.

Real savingsWith dual pressure savings, you can see the fast payback on applying additional regulators. More impressive savings can be realised by finding the leaks in the compressed air system and eliminating them. We have seen reports suggesting compressed air losses due to system leaks and artificial demand range from 20 to 45%!5

Compressed air leaks, left unattended, will continue to grow in size and flow due to the abrasive effect of the air-line contamination and particulate matter continuing to attack the leak orifice.6 The sooner leaks are discovered and repaired, the less waste there is in power required to produce the compressed air. Less wasted air reduces operating costs and can justify the expense of a maintenance patrol to quickly repair air leaks.

Real maintenanceAfter all of this discussion to reduce the operating costs associated with wasting compressed air, we must mention another, less obvious, source of waste. Users should regularly check for excess pressure drop across air filters. By applying pressure drop indicators (also called service life indicators or delta P indicators) and changing filter elements with greater frequency, you will avoid the escalating cost of the pressure drop across the filter element. Electronic and mechanical pressure drop indicators are commercially available to provide reminders to service the filter elements on a regular basis. Using pressure switches to monitor regulated pressure in the system will avoid surpassing the x2 multiplier, ensure efficient use of compressed air and provide optimum performance of the system.

In hydraulic systems, a pressure drop across a filter has serious consequences affecting the entire hydraulic power unit adversely. Poor maintenance on hydraulic filters results in catastrophic failures. In hydraulic systems, leaks are quickly repaired due to the obvious hazards and cost asso-ciated with hydraulic oil. Rarely does poor maintenance on a pneumatic filter result in catastrophic failure. However, excessive pressure drop across a pneumatic filter is an ongoing operating cost that is hidden from view. In pneumatic systems, leaks are often ignored until they become so annoying (uncomfortably loud), or they have caused such a significant system pressure drop, that they must be repaired.

SummaryIf you don’t care about the cost of compressed air in your plant, don’t do the calculations, and you will perpetuate the three pneumatic myths! Consider the similarities between

I F YOU REDUCE YOUR

COMPRESSED AIR OVERHEAD

COSTS, AVOID OVERSIZING

COMPONENTS AND DESIGN

YOUR SYSTEMS TO OPERATE AT

AN OPTIMUM PRESSURE, YOU CAN IMPROVE

SYSTEM PERFORMANCE AND IMPROVE THE

BOTTOM LINE.

pneumatic and hydraulic systems, rather than the differences.

If increased profits are of interest to you, then you’ll find a hidden profit centre in the cost-effective use of compressed air. If you reduce your compressed air overhead costs, avoid oversizing components and design your systems to operate at an optimum pressure, you can improve system performance and improve the bottom line. The first step to recognising the potential savings available to you is completing these simple calculations.

With a little time and effort, you can make a big improvement on your bottom line with pneumatics.

Norgren Pty Ltd

Contact info and more items like this at wf.net.au/T629

References1. Electric Power Research Institute 1994, Compressed Air Handbook, Electric Power Research Institute, p12.2. Wagner, HH 1999, ‘Your Total Compressor Cost May Be Too High’, Plant Engineering, May 1999.3. Fleischer, H 1999, ‘Stop Oversizing Pneumatic Components’, Machine Design, June 1999, pp 101-106.4. Fleischer, H 1995, Manual of Pneumatic Systems Optimization, 1st edn, McGraw-Hill, New York, 1995, pp 25-66.5. Foss, RS 1998, ‘Improving Air System Efficiency Part 1’, Hydraulics & Pneumatics, April 1998, pp 41-68.6. Foss, RS 1999, ‘Improving Air System Efficiency Part 7’, Hydraulics & Pneumatics, July 1999, pp 33-79.

Fluid power©

iSto

ckph

oto.

com

/Sim

plyC

reat

iveP

hoto

grap

hy

AirLINE Quick: High quality,

cost effective, fast delivery

Meet AirLINE Quick. AirLINE Quick has internalised all pneumatic air channels, and integrated primary and secondary components to deliver one single complete pneumatic (or electro-pneumatic) valve bank on a stainless steel adapter plate. Unlimited modularity in valves, functions, feedbacks, I/O, and accessories, is offered, with local assembly from Bürkert’s ISO 9001 Sydney Systemhaus. The stainless steel plate mounts directly into a cabinet, effectively minimising labour for cost effectiveness and fast delivery.

Same day turn-around (on lower-quantity orders) is common.

Last year Bürkert shipped around 600 panels, and this year with AirLINE Quick it could easily be thousands. Call us, and get your valve banks served up on a plate, or mounted in a cabinet, ready to go.

Ideal for end-users, OEMs, and switchboard consultants. Designed for arduous environments, for physical and chemical resistance.

We make ideas flow

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

Served up on a plate

Pneumatics - AirLINE Quick.indd 1 5/02/2013 9:13:34 AM

http://www.burkert.com.au


HOT PRODUCTSON WWW.PROCESSONLINE.COM.AU THIS MONTH

RUGGED CONTROLLER

The Axiocontrol AXC 1050 controller has an

operating temperature range of -40 to +60°C.

Phoenix Contact Pty Ltd

WF.NET.AU/T680

>DATA RECORDER

The Hioki 8860 8-channel memory recorder

allows the user to conduct signal observations

and recordings including voltage, current and

pulse monitoring.

TechRentals

WF.NET.AU/T444

SAFETY INTERFACE MODULES

The PDP20 allows series connection of various sensors up

to Category 4 of AS4024, four sensors per module.

Pilz Australia Industrial Automation LP

WF.NET.AU/T683

>

>

POWER CONDITIONER BACKPLANE

The Diagnostic Power Conditioner (DPC) Backplane for

FOUNDATION Fieldbus H1 provides up to four segments with

redundant power and communicates diagnostics via ethernet.

Turck Australia Pty Ltd

WF.NET.AU/T498

>

http://www.net-safety.com


NEWPRODUCTS

ROD ACTUATORSThe compact, heavy-duty To-

lomatic IMA integrated linear

servo actuator is now available

with additional ball screw offer-

ings that more than double the

speed range, from 610 mm/s

to 1473 mm/s, and is CE/UL

approved.

Designed for long life in high-duty

cycles, the IMA delivers high force in

press fitting systems; accurate positioning

and quick response in valve and process control; compact,

lightweight spot welding; and smooth velocity fluid dispensing.

When supplied with the optional food-grade white epoxy coating

and stainless steel components, the IMA provides corrosion

resistance, ingress protection and bacterial growth protection

for food and beverage industry applications.

The IMA integrates a servo motor into a ball or roller screw-

driven actuator to provide efficient high force in a compact,

lightweight design. The IMA55 high-force servo linear actuator

with roller screw option boosts its thrust capability to 30,470 N.

The long-life design eliminates the need for couplers, adapt-

ers, belts and gears and allows for easy relubrication without

disassembly.

Available in four sizes, the IMA line of integrated-motor rod

actuators features stroke lengths from 76 to 457 mm.

Pneumatic Products


VIBRATION TRANSMITTERThe Model 640B01 from IMI Sen-

sors is a 4-20 mA output vibration

transmitter for permanent installation.

It has a measurement range of 0 to

25.4 mm/s peak and a frequency

range of 3-1000 Hz.

The vibration transmitter will

interface directly to PLCs, DCS

or SCADA control systems and

operates off standard 24 V loop

power. It installs quickly and pro-

vides an easy, cost-effective means

of continuous 24/7 monitoring and

protection of critical machinery,

helping to reduce downtime.

While 4-20 mA sensors cannot

perform diagnostic tasks, they

provide early warnings that help

maintenance technicians avoid cata-

strophic failure. Raw vibration or temperature output signal

options and intrinsically safe options are also available.

Some typical applications include critical pumps and mo-

tors, cooling towers and fans, slow speed rolls, and rotary

and screw compressors.

Thermo Fisher Scientific


THERMAL IMAGING CAMERAThe VarioCAMhr from Infratec is a high-resolution camera for high thermal imaging

performance. It has a modular device concept that permits the camera equipment

to be custom designed and enables the user to upgrade the camera for universal

use in varied areas. Thermographic images are displayed with high quality in an

adjustable, high-resolution colour viewfinder which simultaneously provides an

overview of the current measuring conditions.

The camera has replaceable, fast rechargeable Li-Ion batteries and very low power

consumption which ensures a long working autonomy of the camera. It is offered

with various detector formats and temperature-measuring ranges, which can be

extended. It is supplied with high-quality infrared lenses, tools of the thermography

software suite IRBIS 3 and a wide range of accessories.

SciTech Pty Ltd


VIBRATION SWITCHThe Series VBS vibration switch is compact and uses two

easy set-up dials that adjust the maximum RMS velocity set

point and false trip time delay. The Series VBS is intended

to continuously monitor the changes in a machine’s

vibration level.

The switch takes real-time RMS vibration input and

provides a 4-20 mA analog output of velocity as well

as a switching output for when an alarm value is

exceeded. It features easy set-up and operation, and

no software is required.

Applications of the vibration switch include motors,

pumps, fans, engines, compressors, centrifuges,

generators, turbochargers, gearboxes and conveyors.

Dwyer Instruments (Aust) Pty Ltd



NEWPRODUCTS

ETHERNET STRAIN RELIEFDesigned for use with ethernet cables, the IE-CFK-05

DIN rail-mount cable strain relief provides support

and relief for these cables once they are attached

to industrial switches. This support reduces cable

fatigue and helps improve the longevity of the con-

nection point at the switch.

The device is manufactured from glass fibre rein-

forced plastic. Strong and durable, it can withstand

harmonic oscillations in vibrating applications. This

makes it particularly suitable for use with moving

machinery and equipment that experiences high

levels of vibration.

The device is suitable for use with the IES10 and

IES20 series, and each unit holds up to ten cables

simultaneously (two in each locating groove). It mounts

directly to the DIN rail and curves to overlap the front

face of ethernet switches. Weidmuller standard end

brackets are included with each unit.

At 130 mm high, the unit is compact and lightweight

making integration to secure the cables simple.

Weidmuller Pty Ltd


SERVO DRIVEThe MicroFlex e150 servo drive is de-

signed to control a wide range of motion

applications from simple point-to-point

motion to advanced motion. The servo

drive combines ethernet technology,

advanced multitasking programming

and single-phase operation in a com-

pact package.

The MicroFlex e150 can operate from

105 to 250 VAC single- or three-phase

and is available in multiple current and

power ratings. The drive is designed

to control a wide range of demanding

motion applications, such as cutting

and forming, pick and place, packag-

ing, pharmaceutical/life sciences and laser/

water-jet/textile cutting machines.

The embedded ethernet interface offers EtherCAT

for real-time control of multiaxis systems and with addi-

tional software EtherNet/IP, Modbus TCP and Raw Ethernet,

enabling control possibilities with other controllers such as PLC

and industrial PCs.

ABB’s MicroFlex e150 is a highly intelligent drive offering Mint programming as

standard. Mint is a multitasking language that is tailored for motion applications. This

simple but powerful programming language within Mint WorkBench PC tools provides

control of communications, logic, motion and HMI interactions. It allows a fast and

simple set-up and can be packaged into a single data file suitable for email should

support assistance be required.

The drive meets the latest European machinery standards for safety with the Safe

Torque Off (STO) feature included as standard in accordance to IEC 61800-5-2, SIL3 PLe.

ABB Australia Pty Ltd


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


Cutting-edge train unloader automation boosts Fortescue’s export capabilities

From humble beginnings in 2003, Fortescue has grown into the world’s fourth-largest iron ore producer. Its first mining operations started at the Cloudbreak mine in August 2007 with the construction of all mine, rail and port infrastructure reaching completion in 2008.

A critical part of the port infrastructure was the company’s train unloader, which was put into operation in April 2008 when Fortescue unloaded its first train at the Herb Elliott Port, near Port Hedland in North Western Australia. In 2010, Fortescue approved an ambitious expansion to triple production to 155 mtpa. The US$9 billion project not only includes an expansion of mining operations but an expansion of the company’s port, train unloading capacity and rail network.

For Fortescue Port Shutdowns Supervisor Brad Stillman, the company’s original train unloader, TU601 supplied by Metso, is truly at home in the harsh conditions of the Pilbara due to its sturdy construction and reliability.

“We’re not in a pharmaceutical lab - it’s a really rugged environment out here. But even so, the unloader is like a Swiss watch - everything just works. That’s why it’s my favourite piece of the plant. It is a big, heavy, powerful piece of gear that needs to be treated with respect,” he said.

On the back of the reliable performance of its first Metso train unloader commissioned in 2008, Fortescue awarded Metso Mining and Construction a contract to supply two more identical systems.

The first of the two new unloaders (TU602) was commissioned ahead of schedule in mid-September and the second (TU603) in November 2012.

Fortescue’s General Manager - Port, Gerhard Veldsman, says it was crucial that TU602 was delivered on or ahead of schedule and that the ramp-up had to go well, because the business was experiencing a “real bottleneck” when it came to unloading trains.

“It was delivered two weeks early, which was fantastic. The original ramp-up schedule was meant to be eight weeks, but we shortened that to six and we did it in four,” he said.

The early delivery of the second train unloader resulted in Fortescue being able to dump 580,000 tonnes of unbudgeted ore in September, said Veldsman.

“At $100 a tonne, that’s $58 million in extra revenue that we hadn’t counted on. So the early delivery helped cover our capital investment!” he said.

Mark Shirley, Operational Readiness and Commissioning Manager at Fortescue, adds, “Train unloader two is hugely important to the business, taking us to between 110 and 115 million tonnes capacity. TU603 is also one of the critical parts in our supply chain; if you’ve only got two train unloaders and you lose one, you’ve lost 50% of your capability,” said Shirley.

Fortescue’s railway is the heaviest haul line in the world, with a 40-tonne axle load capacity. The company’s rail infrastructure operates 24 hours a day, seven days a week. Each train is around 2.7 km long and carries up to 32,800 tonnes of iron ore in 240 freight cars.

Trains arriving from the mine sites are moved through one of the unloaders. During unloading, two wagons are simultaneously unloaded every 90 seconds. The unloader clamps and then inverts the wagons, rotating them through 150°. This is done without uncoupling the wagons as each pair of wagons has a swivel coupling at either end. Prior to each operation, the wheels of the train are locked in place to prevent the train moving during the rotation cycle. The contents of the wagons are dumped into a chute that feeds an apron feeder which transports the ore onto a conveyor feeding one of the facility’s stackers.

Each unloader consists of three main parts: the indexer, the tippler and the train holding devices.

The indexer is a rail-mounted vehicle that is dedicated to advancing the train through the unloader, two wagons at a time. This heavy-duty workhorse moves back and forth along a short track located at the entry to the unloader. It is moved by 13 vertically mounted drive units that turn pinions via gearboxes to pull it a long a rack mounted in the middle of the track. A retractable hydraulic arm is inserted between the wagons to push the train along by two wagons at a time.

The tippler is a rotary machine that is made up of two unloading cells. Each cell comprises the main cell structure, a drive unit and support roller assemblies, as well as a braking and lubrication system. The tipplers are located in an enclosure which is part of a pressurisation and dust extraction system.

Each cell is equipped with train rail sections and onboard hydraulic clamps that hold the wagon in place as the cell rotates during the unloading cycle.

Coordinating the three parts of the train unloader with their myriad sensors, motors and hydraulics has been accomplished through the use of a GE Fanuc RX3i PLC. The motor starters, VVVF equipment and associated I/O are located in the switch room.

The field I/O located around the plant is connected back to the PLC via Profibus fibre optic. A GE Fanuc Cimplicity SCADA terminal in the unloader’s control room displays plant status.

While the automation of each train unloader is rather complex and is managed by a stand-alone system, each train unloader also has to coordinate with the control of the other port equipment such as apron feeders, conveyors and stackers.

More details of this project can be read in a longer version of this story, online at http://www.processonline.com.au/case_studies/60237.

Metso MineralsContact info and more items like this at wf.net.au/T644

http://www.weidmuller.com.au


NEWPRODUCTS

MAGNETIC INCREMENTAL ENCODER

The ASM POSIROT magnetic position

sensor range has been expanded with

the combination PMIS4/PMIR5, devel-

oped specifically for rotary applications.

The advantages of this combination

are high EMC protection, large guiding

distance tolerance and a superior signal

performance up to 327,680 pulses/360°.

The incremental, non-contact measuring

system consists of the sensor head PMIS4

and an incremental magnetic ring PMIR5. The sen-

sor head is made of a fully enclosed, shielded metal housing. It offers

high protection against electromagnetic interference, thermal overload,

and operating temperature range of -40 to +85°C and has a protection

class of IP67. The PMIR5 magnetic ring comes in three sizes with flange

sizes of 83, 133 or 233 mm. They are available with decadic, binary or

degree division and reach correspondingly 131,072 pulses/360°, 196,608

pulses/360° or 327,680 pulses/360°. Since the system operates magneti-

cally, it is unaffected by contamination from oil and dust. For this reason

it is suitable for use in harsh, dusty industrial environments.

Automated Control Pty Ltd


WLAN ETHERNET ADAPTERP h o e n i x C o n t a c t

now offers an indus-

tr ial WLAN ethernet

adapter for integrating

ethernet-capable devices

into WLAN IEEE 802.11a/n

networks (5 GHz frequency band).

The adapter has an IP67 enclosure rating and comple-

ments the WLAN ethernet adapters (WLAN clients) for the

IEEE 802.11 b/g WLAN standard (2.4 GHz frequency band).

An integrated antenna has been developed to provide

a high level of robustness for wireless communication in

reflective industrial environments. New functions such as

DCP, LLDP and Profinet prioritisation increase performance

when used in automation networks. Application areas for the

WLAN ethernet adapters include locations in which moving

or mobile ethernet-capable devices such as controllers,

terminals or I/O modules are to be integrated wirelessly

into the main ethernet network.


Contact info and more items like this at wf.net.au/S921

VALVE TERMINAL

PLUG-INMany users in the fields of

small parts assembly and the

electronics industry, as well as the food and

packaging industries, in which a high flow rate for a

small unit volume are important, can benefit from the

modularity of the VG series of valve manifold systems.

The VTUG valve terminal plug-in for the VG range from

Festo offers multiple variations and a highly simple and

inexpensive fieldbus connection for all standard field-

buses and ethernet as well as IO-Link. The fieldbuses

are quick and easy to replace as the fieldbus nodes

are screwed onto the valve terminal. This is particularly

suitable for machine and system manufacturers who

offer their machines and systems in modular design,

so providing them with electrical modularity and high

pneumatic flexibility.

Festo Pty Ltd


http://www.metromatics.com.au

http://www.advantech.net.au


NEWPRODUCTS

MOTOR SHAFT GROUNDING RINGThe Aegis SGR conductive microfibre shaft

grounding ring is designed for predictive and

preventive maintenance programs on VFD-

controlled AC motors and large DC motors.

By protecting bearings from electrical damage,

the SGR extends motor life, preventing bearing

noise, downtime, and costly motor repairs and

replacements. The Aegis SGR prevents bearing

damage by channelling shaft currents to ground.

Conductive microfibres inside the SGR provide

the path of least resistance, allowing these shaft

currents to discharge safely to the motor frame.

Preventing shaft current damage (in many cases

for the life of the motor), the Aegis SGR simplifies predictive and preventive maintenance

programs for motor repair shops, maintenance contractors, HVAC service contractors and

in-house maintenance departments. Unlike conventional shaft grounding brushes, the

SGR’s conductive microfibres work with virtually no friction or wear; are unaffected by

dirt, grease, or other contaminants; and last for the life of the motor, regardless of speed.

A mounting kit simplifies installation of the SGR on any NEMA or IEC motor and provides

clearance for motors with shaft shoulders, slingers, bearing caps or end-bell protrusions.

Secured with three mounting screws and standoff posts, the entire assembly covers less

than 12 mm of the motor shaft.

Morgan AM&T

www.morganamt.com.au

TEMPERATURE INDICATORSThe Noshok 820/821 Series digital

temperature indicators are a suitable

replacement for bimetal, liquid-bulb

and glass thermometers in applications

including pharmaceutical, food prepara-

tion, utilities and municipal, refineries,

chemical and petrochemical plants,

paper mills and hydraulics.

The series uses a PT100 RTD Class

A element for temperature sensing and

has a M12 (5-pin) plug or 36″ integral

cable electrical connection. They feature

a large 4-digit LED display and a 4-20

mA programmable linearised output

signal. They are also field reprogram-

mable with an optional PC interface

module and software, which includes

a security feature to prevent accidental

reprogramming.

A self-calibration feature helps ensure

accurate and stable performance, and

an optional fully programmable switch

output (relay or transistor) is available.

The temperature indicators come in

various mounting configurations, are

IP65/NEMA 4 rated and have a 316

stainless steel construction.

AMS Instrumentation & Calibration Pty Ltd


CONVEYOR SYSTEMThe FlexLink X65 conveyor platform has been designed

to reduce TCO and is claimed to offer twice the strength

compared to the standards of today, which has an effect

on the service life and maintenance intervals of systems

installed. In addition, the layouts can be made simpler as

fewer drives and transfers are required for a given layout due to the increased maximum conveyor length.

The X65 conveyor is designed for low friction, low power consumption and a long service life. With

the addition of more efficient drive technology, power consumption is 8-44% less compared to previous

high-efficiency drive units by FlexLink, depending on the configuration. X65 is also capable of double

the speed compared to previous conveyor generations, at up to 120 m/min. There has also been sig-

nificant noise reduction and improvements in operator safety. In most common applications, the noise

level of X65 is on a typical office level, and compared to the industry standards, it is up to 80% less.

For automated single piece flow applications, the X65 pallet conveyor system offers standardised

functions for the handling of products up to 3 kg. The pallets and functions are prepared for the

integration of process control systems, such as track-and-trace and MES functionality.

FlexLink Systems


http://www.dartinstruments.com.au

http://www.powerflo.com.au


A clear view on water production for Wellington

In 2008, the New Zealand Ministry of Health issued revised drinking water standards for drinking water safety. To comply, water treatment facilities must track, save and provide monthly reports on water production, intake and discharge levels. At the same time, water providers need timely usage reports to make sure municipal customers can properly budget and forecast for city water needs.

As one of the largest water producers in New Zealand, the Greater Wellington Regional Council (GWRC) understands these requirements well. The GWRC is responsible for supplying clean water to more than 10% of New Zealand’s population. Drawing water from lakes, rivers, wells and aquifers, the council is the wholesale water treatment provider for the cities of Lower Hutt, Porirua, Upper Hutt and Wellington.

In order to comply with the changing regulations, the GWRC required a reporting solution which can provide accurate and timely reports generated f rom da ta au tomat ica l l y retrieved from its existing water treatment production and control system infrastructure. As a result, the GWRC was not on ly ab le to comply with government reporting requirements, but it was also able to leverage real-time production data to improve water treatment distribution, and better inform internal and external stakeholders on water production and usage.

The GWRC employs the most advanced water treatment system in New Zealand with a supervisory control and data acquisition (SCADA) system that runs four entirely automated water treatment plants, 15 pumping stations and more than 180 kilometres of pipeline.

However, collecting process data from disparate data sources proved challenging, especially since data needed to be stored in a reliable time series archive for analysis and reports. Lily Wang, data analyst for GWRC, explained that it was time consuming to manually extract and organise data from different sources within the water treatment system for required governmental compliance reports. A faster, more accurate and automated reporting system was needed; one that could generate predetermined reports automatically and share them with authorised groups. This system also needed data validation capability as well as the ability to retain 10 years of data.

“After comparing several options, Rockwell Automation provided the most advanced and impressive capabilities, meeting or even exceeding all our data collection and reporting requirements,” commented Wang.

GWRC implemented FactoryTalk Historian Site Edition (SE) and FactoryTalk VantagePoint Enterprise Manufacturing Intelligence (EMI) software onto GWRC servers. The historian provided ready connectivity to GWRC plants’ automation system controllers, with the capability to automatically pull tags directly from different controllers via interface nodes. Tags are then stored in the FactoryTalk Historian server for the required 10-year retention period. Once stored, this information is available to be retrieved

for trending comparisons and other analysing and reporting purposes.Using FactoryTalk VantagePoint EMI software, the GWRC’s data

management system is able to schedule and produce 11 automatically generated reports to provide information on weekly and daily water consumption, discharge, intake, water quality and reservoir levels, as well as reports on lake storage volumes and total flow volume.

Analysts like Wang, water production/maintenance engineers and operators, business managers, marketers and GWRC committee members charged with water supply management and regional strategy have access to this data from any location. Secure login via a web browser brings each stakeholder to a single portal where they can access predetermined dashboards and charts.

Facility operators have visibility of real-time consumption data for validation that usage levels are as expected. If demand peaks, more

water can be supplied from other plants. Business managers are able to make comparisons on year-to-date usage versus the previous year to ensure billing forecasts based on past usages are accurate or to update expected revenues.

“The FactoryTalk software suite’s high level of integration and compatible connectivity to existing hardware and software components in our plants and business system has given us the ability to pull reliable data from a wide variety of sources,” Wang said.

Data is now more quickly available and accurate. “Reports

that used to take me the better part of a week to create and several more days to validate can now be produced in a few minutes or even seconds,” claims Wang.

As a data analyst, Wang checks water intake and production data every day. “With real-time data immediately available, it’s as easy as doing a balance check.” In the summer of 2012, during one daily validation, more water was taken in than what was fed into the drinking-water system, signifying a leak. Wang was able to immediately contact the maintenance engineers responsible for the appropriate plant and direct them to the relevant pipeline to find and fix the leak. The problem was discovered and solved before the leak was noticeable to production engineers or developed into a larger issue. Wang added, “Our data system is so reliable now that we’ve made it public.”

The GWRC now offers a live map of the current rate of water supply, which is updated every 15 minutes. As residents are now able to see water use by city over a monthly, quarterly and annual basis, the GWRC hopes a public that is more informed about water production and usage will better conserve water, especially in times of peak demand.

The GWRC has rolled out this same scalable solution to track system-wide chemical and power usage. “We have a firm grasp on our chemical and power inputs,” explains Wang. “We can optimise the control system to get the best information to our business managers so they get the best value from our budget.”

Rockwell Automation Australia


http://www.systems22.com.au


IS 8 SERIES

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

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

■ View finder and 2x external temp displays.

■ Multifunctional numeric or graphical display.

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

■ Robust die-cast aluminium housing.

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

NEWPRODUCTS

DIGITAL INDICATORThe West 8010+ digital

process indicator provides

a high-contrast, high-visi-

bility display. The indicator

is designed for optimal

ease of use in a wide

variety of temperature and

process applications.

The device provides a jumper-

less configuration, plug-in output

boards and an efficient PC configurator for quick and simple set-up.

In addition, plug-in modules allow retransmission of the process vari-

able, a designated transmitter power supply or up to four alarm relays

(latching or non-latching).

The instrument provides a user-selectable dual-colour display op-

tion with fixed red or green displays or a green to red colour change

when an alarm condition occurs.

Up to five outputs are supported and plug-in output modules are

available for SSR driver, triac, relay and linear outputs. Self-recognition

of option boards promotes simple, error-free set-up. The 10V SSR

driver output allows for driving of up to three typical SSR/SCR inputs.

Modbus and ASCII communications are supported, and multipoint

scaling and tare features are included as standard.

Automated Control Pty Ltd


EMBEDDED COMPUTING FOR AUTOMATIONThe Neousys Nuvo-1300af is a fanless embedded controller with

integrated gigabit PoE ports. Incorporating high-end Intel Core i7

processor, the controller offers high performance for arithmetic-

intensive applications, while its -25 to 70°C fanless design provides

reliability and durability.

The device integrates four gigabit PoE ports, compliant with the

IEEE 802.3af standard. Each PoE port can deliver 15.4 W of power

to a PoE device, such as a PoE camera. The controller also features

isolated PoE power, which allows users to alternatively supply the unit

from two independent power supplies, one for the PoE functionality

and the other for the computer. This minimises the risk of an external

power surge on an ethernet cable that may damage the system.

In addition, the device integrates versatile I/O interfaces in its com-

pact chassis. It has one additional GbE port for data communication

and two internal SATA ports for accommodating two 2.5″ SATA hard

drives. The device also features onboard isolated DIO and serial

ports for device control/communication.

Madison Technologies

Contact info and more items like this at wf.net.au/S979

VIBRATION SENSORThe ifm efector VNB001 is the first member

of a new series of vibration sensors. The

compact sensor monitors the overall

vibration condition of machines and

plants according to ISO 10816 and

features an onboard timestamped

history function as well as data

logging and trending.

The sensing principle is based on

the efector octavis technology, which

can also be used reliably in mobile

applications. The sensor measures the

effective vibration velocity in mm/s or

in/s. Measured value and switching status

are indicated on the LED display. Critical machine

conditions can be signalled using two switching outputs or one

switching output and one analog input.

As an alternative, the sensor can be powered via USB interface

and used as a handheld device. The product also offers rapid, easy

handling and set-up as the parameters can be adjusted directly

on the device. No additional configuration software is required.

ifm efector pty ltd


http://www.wandbinstruments.com.au

Process Control

www.automationdirect.com.auAustralia Wide: 1-800-633040New Zealand: 0-800-6330405

TECHNOLOGY THAT MAKES YOUR JOB EASIER

You need quality products at a greatprice from a solid supplier. . .. . . Since 1994 our prices have beentypically 50% less than more traditional suppliers.Since our industry-changing DVD-Catalog first hit mailboxes in 1994,we’ve been offering a better value on industrial controls by runningour business efficiently and passing the savings on to our customers. In 1999, we made it easier to research and purchase by becoming thefirst automation supplier with a 24/7 online store.We’ve made the commitment to offer the best products at the bestvalue we could deliver so you have a better choice.You insist on better serviceand you want it FREE . . .

In this uncertain economy, you need to savemoney and save time . . . we can help.

E: [email protected]: 61-7-55252053

Automation Communications Process Switchgear Pneumatics

VR4000114S4 Vibrating Fork level limit switches, 127 mmLength Material S304, Relay Output, $420

LS0001 PBT M18 Thread, -20*C ~ 80*C, NO/NC Output $20

RB2A01000S41 Guided Radar (TDR) Coaxial Rod 4-20mA OutputHART PNP NO/NC Output, S304 Probe Thread Connection : G3/4

$1,750

RA11A1S144 Bell shaped aerial, -40-150C process temperature,M20 X 1.5 Cable entrance, Standard Aluminim, IP68, 2- wire 24VDC/4-20MA, Flange DN150 PN1.6, S304 $3700

VS0001 Sensing range 0.3 - 10M, -40 - +80, 3 Wire,4~20mA $595

LS1001 Stainless Steel 19-60VC/14V-240VAC $225

SR1000A80 length 80mm 24V-240VAC $149

For over 18 years, we’vebeen helping customers turna profit by keeping costsdown and quality up.Since our beginning in 1994, as AussieDirect,our number one objective has been to deliverquality products at a practical price. We try extra hard, especially during thesetough economic times when many companiesare faced with tighter operating budgets. Our customers recognize that by using a goodproduct at a great price, taking advantage ofcustomer freindly rated service, and receivingthe fastest delivery possible, they can rely onAUTOMATION DIRECT to help with their bottomline. It’s pretty simple. Give people what you promise and they willcome back for more.

AutomationDirect’s proven process control hardware for a flexible control platform at prices that will cut your budjet!

Level

wnipeApril13_WNIPE 16/04/2013 11:25 AM Page 1

http://www.automationdirect.com.au


[email protected] www.pilz.com.au 03 9544 6300

Pilz has a wide variety of cost effective & flexible safety solutions for

your packaging machinery.

Looking for a reliable Partner for the automation of your packaging line?

We offer you a comprehensive portfolio of solutions ranging from the

small with only a handful of sensors using our new PDP technology all

the way though to the most complex of systems utilising our PSS4000

safe automation platform.

Talk to us today about your packaging safety requirements!

Economical & Scalable...

NEWPRODUCTS

WEB 2.0-ENABLED RTUCSE-Semaphore has introduced a compact

remote terminal unit (RTU) that integrates cyber-

security protection and wireless communications

with SCADA functionality. The TBox LT2 RTU is an

all-in-one unit featuring a web server, 3G wireless

communications, and a complete cyber-security

application suite, all integrated with programmable

automation, alarm notification, data logging, and

ethernet communications in a single, rugged module.

The decentralised architecture on which the

TBox RTU line is built provides up to 50% cost

savings over other systems that seek to combine

PLC, communications and SCADA components.

The self-contained system provides everything needed to

create automation and monitoring of installations and enables easy crea-

tion of push and multi-platform communications strategies. Users have

complete access to alarms, live conditions and historical data on their

mobile devices, tablets and PCs.

TBox LT2 RTU communications include ethernet, RS232, RS485 and

USB ports, and an integral 3G wireless option. Mixed I/O configurations

include eight analog inputs, 16 digital I/Os selectable per point and, op-

tionally, two analog outputs. For installations requiring additional I/O, the

device readily expands using compact modules interfaced via ethernet or

RS485. The highly scalable, futureproof processing platform is based on

an ARM9 CPU running at 400 MHz. The memory configuration includes

32 MB Flash, 64 MB SDRAM, 1 MB SRAM and a Micro SD card with

up to 32 GB capacity. TBox systems are easy to configure and offer dra-

matically reduced costs versus traditional PLC and SCADA architectures.

CSE-Semaphore Pty Ltd


ANTIVIBRATION SERVER CABINETThe V-Rack series of

antivibration rackmount

server cabinets is avail-

able in three different mod-

els: V-Rack-660, V-Rack-960 and

V-Rack-1560.

The V-Rack-660 features a form factor of 6U, a load capacity of up to

80 kg, and measures 700 (W) x 500 (H) x 600 (D) mm, while the V-Rack-960

has a form factor of 9U, and measures 653 mm high. The third model,

V-Rack-1560, has a form factor of 15U, and measures 920 mm high.

The V-Rack series features a rugged shockmount design, and is

constructed from high-quality aluminium and steel. It creates a space

for hardware to be safe from virtually all disruptions, including constant

vibration or incidental impact. With optional front and rear lockable doors,

the internal hardware is safe from theft or tampering.

ICP Electronics Australia Pty Ltd


http://www.pilz.com.au


NEWPRODUCTS

ORBITAL WELDING CALIBRATION UNITThe Swagelok M200 portable calibration unit delivers on-site power supply main-

tenance, providing added convenience, reduced costs and improved efficiencies

that can cut servicing time lines from days to minutes.

The calibration unit allows for immediate calibration of a Swagelok welding system

M200 power supply. Many quality systems require orbital welding power supplies to

be calibrated periodically. Traditional calibration processes are completed off site at a

designated service location, leaving operations idling or needing to incur extra expense

with rental equipment. Portable calibration helps minimise downtime, which is key for remote

or secured environments, such as offshore oil drilling platforms, power plants and government

sites that cannot easily arrange power supply transport to and from service centres.

The portable calibration unit is designed with enhanced technology focused on promoting efficiency through the welding process.

On-screen navigation on the power supply prompts users to initiate the calibration process. The calibration unit then performs various

diagnostics and measures output levels. The calibration unit is designed to specifically calibrate based on critical welding variables,

including current (automatic calibration to ensure proper current output for future welds), voltage (provision of simple, on-screen

adjustments to match actual values with expected values) and travel speed (electrode travel speed is verified and adjusted real

time via the operating software, eliminating the need for frequent calibration).

The verification is displayed and documented as part of the calibration software, making documentation easier for users.

Swagelok Corporation


INFRARED TEMPERATURE SENSORTemperatures up to 1350°C can be measured with the new infrared temperature

sensor from ifm efector. It also offers an integrated display and operating

unit. Easy push-button programming ensures quick use. Additionally, the

sensor features scratch-resistant precision lenses for minimum sensitivity

to scattered light.

Infrared temperature measurement is used where temperatures can only

be measured without contact. The sensors detect emitted infrared radiation and

outputs a temperature signal. If the detected temperature is above the set switching

threshold, the switching output is set and the switching status of the LED is displayed.

The switching thresholds and output configurations can be set and easily reproduced by

means of the button and the display. Clearly visible LEDs always indicate the switching status. During operation the

display shows the current measured value percentage.

ifm efector pty ltd


http://www.efic.gov.au


NEWPRODUCTS

ISOLATION AMPLIFIERSThe Phoenix Contact Mini Analog isolation amplifier series has been expanded

with new modules.

The sensors, two new temperature transducers for resistance thermometers and

thermocouples, meet all relevant international standards. A DIP switch allows users

to quickly set the two transducers and the modules can be easily configured for

extended functions and monitoring via the robust S-Port interface using a free software tool.

A new frequency transducer transforms speed pulses from below 1 Hz up to 80 kHz into an analog signal. The module supports

NAMUR sensors as well as NPN and PNP outputs. The transducer is quickly configured via a DIP switch and with the intuitive ‘Teach-

In Wheel’ for freely setting measuring ranges.

In addition, a new fault monitoring module provides transparent error logging for multichannel applications with up to 80 modules that

are connected via the rail-mounted connector. If an error is detected internally or in the signal input of a transducer, it is reported via

the rail-mounted connector. The fault monitoring module then displays the error via an NC contact, eliminating the need for a compli-

cated individual evaluation. If the system is further equipped with the new feed terminal, it can detect and report power supply failures.



REMOTE TERMINAL UNITSSixnet RTUs (remote terminal units) are configured by using Sixnet’s

windows-based toolkit and offer the programming flexibility of either

C or ISaGRAF Open programming software which encompasses

the following IEC61131-3 languages: Sequential Function Chart,

Ladder Diagram, Structured Text, Instruction List, Function Block

Diagram and Flow Chart.

With a Linux operating platform and open protocols such as Modbus, DNP3

and SNMP, the RTU provides the user with the flexibility to interface to a wide

range of devices and with an operating temperature range of -40 to 70°C ensures

reliability in harsh environments. The RTUs can also be supplied from a 10 to 30 VDC

supply making them suitable for use on battery-powered systems. The I/O capacity of the RTU can be expanded by

adding Sixnet EtherTrak-2 or third-party I/O modules which can be interfaced to the RTU either serially or via ethernet.

The RTU can also be interfaced to a radio system or to other technologies such as the company’s industrial cellular

routers making them suitable for installation on either existing or new networks

Control Logic Pty Ltd


COMPACT RIGHT-ANGLE GEAR UNITWith a torque range for smaller applications of up to 180 Nm, the W series Spiroplan gear

unit is the smallest, most compact and least expensive servo right-angle gear unit series

SEW-Eurodrive has ever manufactured.

The single-stage Spiroplan right-angle gear unit is available in models W10, W20, W30,

W37 and W47. It can be used as a stand-alone gear unit for direct motor mounting or

for mounting on the motor using the low backlash adapter. The series is also available

in different output versions: either with a shaft and key or with a hollow shaft and a

keyway. Both versions are available with a flange-mounted design. When combined

with the CMP series of synchronous servomotors, the gear unit acts as a gearmotor.

High precision, dynamics and high torque are offered in this compact version.

With the servo Spiroplan right-angle gear unit, SEW-Eurodrive has created a cost-

optimised drive solution with consistently low rotational clearance and a continuous

positive shaft-hub connection. The wide variety of drive versions provides the user with

maximum flexibility and an economic option for their application.

SEW-Eurodrive 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.tic.toshiba.com.au


Oil refinery well isolated

In process plants with explosive areas, intrinsically safe (Ex-i) interfaces form a bridge between the control centre and the installed field sensors and actuators. The primary task of Ex-i signal isolators is to safely limit the energy conducted into the Ex area to an amount that is below the minimum ignition threshold of the surrounding explosive atmosphere. According to the design specifications of the EN 60079-11 standard for intrinsically safe explosion protection, these signal isolators need to ensure that all the parameters affecting intrinsic safety - such as the maximum no-load voltage, maximum short circuit current and maximum power - are adhered to even during malfunctions.

As part of ongoing plant upgrades, Oil Refinery Oberrhein (MiRO) has recently introduced a new automation solution in its blending plant. One of the changes was to replace the Blend Ratio Control concept (BRC) with an Experion Blend Controller system (EBC) from Honeywell. This changeover entailed replacing the control system’s I/O level, which is located in the central switchgear room. For the functional specification of the Ex-i interface level, which was also being upgraded, the MCR planners defined the following main goals:

• Lowest possible component width so that there is minimal use of control room space, with ample spare room for future system extensions.

• Less product diversity in order to minimise warehousing and documentation costs.

• Suitability for safety-oriented measuring and control circuits.Following a period of extensive testing of Ex-i solutions, the

planners decided that the MACX Ex products from Phoenix Contact were best suited to their requirements. No matter if it’s single-channel or dual-channel HART-compliant repeater power supplies and output isolating amplifiers, NAMUR switching amplifiers, signal duplicators, solenoid drivers or temperature transducers, all MACX Analog Ex modules are just 12.5 mm wide. This means that up to 45% less space is used on the mounting rail compared to the usual module widths of 16-22.5 mm.

The MACX analog Ex interfaces have been developed for use in safety-oriented circuits that comply with EN 61508 and have been certified accordingly by external inspectors such as TÜV Rheinland. The interfaces all qualify for SIL 2, some even for SIL 3.

The 30 decentralised blender stations located at MiRO’s Karlsruhe plant are classed as Ex zone 1 and in parts as Ex zone 0. The field instruments, which consist of various flow meters and HART-capable 4-20 mA control and separator valves, are required to provide intrinsically safe explosion protection. The blending process also entails pump control and the analysis of tank level gauges, signalling contacts and 4-20 mA signals coming from the analysis station’s two-wire transmitters. The field instruments themselves were not exchanged as part of the plant upgrade. The signals’ point-to-point connections are provided via four-core cables up to 600 metres long. These start at the honeycomb routing terminals located in the blending plant’s central distribution station. From this station, the signals are directly routed to the Ex i isolator level, where they are passed through approximately 750 analog Ex signal isolators and then processed via C200 and C300 controllers.

The Ex i isolators are arranged into device groups of 16 and mounted in open routing frames on DIN rails. The frames, which are built in-house at MiRO, have a very compact design and are easy to maintain, so the small form factor of the MACX isolators made them perfectly suited.

Highly precise signal processing is crucial for proper operation. Rolf Bechtold, Project Engineer in Automation Technology at MiRO, confirms the MACX devices’ excellent signal quality: “The isolating amplifiers with transistor outputs, used for analysing the counter pulses, convinced me due to their clean edges. So far, we have not encountered any processing issues with the C200 counter cards from Honeywell.” Bechtold adds, “The MACX isolators can be used flexibly and cover all our requirements with a manageable number of product types. This is an important advantage in terms of device standardisation.”

The MACX MCR-EX-SL-RPSSI-I Ex-i repeater power supply offers a supply Ex-i input for two-wire transmitters to convert signals from the analysis station and also a non-supply Ex-i input for the 4-20 mA signals from the flow meters. The device passes on the HART-transparent 0/4-20 mA signals to the passive and active analog C300 input cards. Says Bechtold: “This flexibility was fantastic for migration within a running system, and it also provides a number of advantages for wiring. Again, it is very useful to us that the isolating amplifiers feature two relay or transistor outputs. Thanks to the MACX devices’ Ex properties, we were able to retain all of our field instruments. This would have been much less straightforward using any other range of Ex isolators available on the market today.”

The MACX Analog Ex isolators turned out to be a perfect match for MiRO’s requirements. This is proven by how well the blender upgrade has been performing in production over the past 18 months.




NEWPRODUCTS

TESTING SOFTWARE PLATFORMVeriStand 2012 is the latest version

of NI’s configuration-based software

environment with an open, intuitive soft-

ware interface for developing real-time

testing applications. Engineers can use the 2012 version of NI VeriStand to

perform high-speed data acquisition and logging and to find useful data

faster during post-processing with additional data logging flexibility. They

can get up and running faster using new hardware configuration utilities

and NI SC Express integration makes acquiring conditioned measurements

easier than ever before.

The product supports real-time model execution from a variety of model-

ling environments and has an open, extensible architecture to create custom

code modules or incorporate custom user interfaces. It also offers built-in

test automation using the Stimulus Profile Editor and integration with the

NI hardware I/O library, including FPGAs, embedded networks, machine

vision, RF and a range of multifunction data acquisition modules including

instrument-grade I/O.

National Instruments Australia


DRIVESUnidrive M is designed specifically for manufacturing auto-

mation applications and each model has been tailored to a

specific application. Control Techniques’ Unidrive M offers a

wide variety of functionality and solutions for motor control

applications with a range of 0.25 kW to 1.2 MW. Voltage

ranges available are 100-120, 200-240, 380-480, 500-575

and 500-690 V.

Users can select from seven levels of functionality and

Intelligent Machine Architecture (IMA) allows the devices to

be linked together through ethernet, enabling easy integra-

tion into machine designs. Motor control supports standard

induction, permanent magnet, servo and linear motors in

open or closed loop configurations.

Onboard real-time ethernet with hardware-based Precision

Time Protocol (IEEE 1588 V2) provides fast and flexible

communications and synchronisation. Fast installation and

start-up, intuitive keypads, software tools and easy cable

management minimise installation costs.

The units fit existing mountings and cable connections,

with trouble-free parameter transfer for existing Control

Techniques’ Unidrive SP and Commander SK users.

Control Techniques Australia Pty Ltd


http://www.techrentals.com.au


We’re getting social!

www.ProcessOnline.com.au/social

We are providing more opportunities for you to stay up to date with all the latest industry information from the social networks of your choice.

Follow us and join the conversation with thought leaders from your industry.

NEWPRODUCTS

SIS DIGITAL VALVE CONTROLLERThe Fisher Fieldvue DVC6200 SIS digital valve controller responds

to safety demands, and features partial stroke and position monitor-

ing capabilities for the final control element in a safety instrumented

system (SIS). Intelligent automatic partial stroke valve testing provides

improved safety and reliability versus traditional pneumatic and jammer

partial stroke methods.

The DVC6200 SIS combines the field-proven, linkage-less, non-

contact feedback design of the DVC6200 and DVC2000 platforms with

the safety demand and automatic partial stroke testing capability of

the DVC6000 SIS. The DVC6200 SIS has been evaluated to the latest

version of IEC 61508 (2010) and is certified as a SIL 3-capable device

for both 4-20 mA and 0-24 VDC power settings.

An integral position transmitter is available with the DVC6200 SIS and is capable of reading valve position even on

loss of power to the digital valve controller. The position monitoring safety function has been evaluated independently

from the digital valve controller safety function and is SIL 2 capable.

Partial stroke valve testing can be used in service to safely increase the period of time between proof-testing the

final control element. Additionally, the DVC6200 SIS confirms solenoid operation and captures useful diagnostic data

during a trip event.

Emerson’s DeltaV SIS provides out-of-the-box tools that allow direct access to the DVC6200 SIS diagnostics and

partial stroke data, and the ability to set up and run the partial stroke tests automatically.

Emerson Process Management



NEWPRODUCTSREFRIGERANT COMPRESSED AIR DRYERSCompAir Australasia has an-

nounced the FX series of energy-

efficient refrigerant compressed

air dryers. With flow capacities

from 0.5 to 90.10 m3/min, the FX

series can satisfy the requirements

for clean and dry compressed air

for a wide variety of applications

and industry sectors.

For flow capacities up to 1.6 m3/min the FXS series models produce

pure, clean and dry compressed air from a simple, yet robust refrigerant

dryer design. High-quality compressed air is assured due to good dew-

point performance under all conditions. These models are suitable for

point-of-use applications such as in hospitals and laboratories as they are

both quiet in operation and have a small footprint. A static condenser and

waste heat recovery system further ensures an energy-efficient solution

with the lowest operating costs.

The larger FXR series models, for flow capacities starting at

2.5 m3/min, utilise an advanced stainless steel plate heat exchanger as well

as advanced separation and refrigeration technology for optimum life cycle

costs as well as dependable and energy-efficient operation. For absolute

control, monitoring and diagnostics on the larger FXT series models, the

System Control Monitor II can be incorporated. This LED display provides

key information such as chiller inlet and discharge refrigerant temperatures,

allowing for an energy-efficient refrigerant compressed air dryer solution.

The FX series from CompAir are easy to install and simple to connect.

Flow capacity ranges from 0.5-90.10 m3/min. R-134a or R-407c refrigerant

is used in all of the FX series models.

CompAir (Australasia) Limited


EMBEDDED SYSTEMThe TANK-820-H61 embedded

system from IEI Technology features

a second-generation Intel Core

H61 low-power desktop processor,

onboard 2 GB DDR3 memory and a

DDR3 SO-DIMM slot, supporting up

to 10 GB memory. The device also

offers flexible PCI/PCIe expansion

slots, and with dual PCIe GbE LAN

and RS232/422/485 serial ports, it

provides powerful communication performance.

The device accepts wide-range DC power input,

9-24 V, allowing it to be powered anywhere. It also has an easy-to-install,

hot-swappable fan module to ensure that a PCI/PCIe expansion card with

high power consumption can operate under high-temperature conditions.

Several I/O options are available, including 2x USB 3.0 ports, 4x USB

2.0 ports, a SATA 3 Gbps port, 2x GbE LAN ports, a VGA port, a DVI-I

port, a line-out and a mic-in connector. The device is designed to oper-

ate efficiently in harsh environments and is able to resist strong vibration,

making it suitable for installation in mobile applications.

ICP Electronics Australia Pty Ltd


TORQUE SENSORSWith the compact 8661 series

of torque sensors, burster is

extending its portfolio of prod-

ucts to include the acquisition

of static and rotating torques

over the range from 0.05 Nm up to

200 Nm. In addition to its highly accu-

rate measurements - down to 0.05% of full

scale - the 8661 series offers a high level of reliability and security.

An optional, integrated USB interface also provides the travel-

ling user with easy, mobile display and documentation of the

measured values.

The torque sensor is suitable in fields such as precision and

micromechanics, test-bed equipment for electric motors, or in the

motor vehicle industry, where torque and the associated angular

position and rotation speed are important process magnitudes.

It is also suitable for laboratory research and development projects in

medical technology, in the chemical industry, and in quality control.

ADM Instrument Engineering Group


http://www.ccezy.com.au

PROCESS CONTROL | AUTOMATION | INSTRUMENTATION | SAFETYPROCESS CONTROL | AUTOMATION | INSTRUMENTATION | SAFETY

•Brisbane June 17

•Gladstone June 18

•Mackay June 19

•Townsville June 20

To register or for more info visit: www.regionalroadshows.com.au

If you work in mining, minerals, metals processing, utilities, food and chemical manufacturing and processing then the Process Technology Roadshows are designed for you. Don’t miss out ...

NEW TRAINING SESSIONS FOR 2013

• Engineering quiz on process instrumentation with prizes

• Substation automation

• Perform basic troubleshooting of a typical industrial ethernet system

• Simulate and troubleshoot a Modbus/TCP master communicating with a Modbus/TCP slave over IEEE 802.11 (Wi-Fi)

• Design and construct your own closed circuit TV (CCTV) system for a mine site and analyse the network traffic

• Troubleshoot a tuning problem with your Flow Loop

• Use Tunnelling to connect a local OPC* client to a remote OPC server via the internet

Includes FREE:• Access to exhibition• Training sessions - NEW• Lunch and networking drinks• Product demonstrations • Prize draws

Training by:Supported by:

Coming soon ... to a city near you!

NOW IN ITS 9TH YEAR

Previous Exhibitors include:

ProcessTechnologyRoadshows 20

13 S

ERIES

http://www.regionalroadshows.com.au


NEWPRODUCTS

FIELD METROLOGY WELLThe Fluke 9190A Ultra-Cool Field Metrology Well is a small, lightweight and

accurate dry-block calibrator. It is suitable for pharmaceutical, biomedical and

food processing applications that demand strict quality control and regulatory

process compliance. This includes on-location validation and calibration of

RTDs, thermocouples, thermometers and other temperature sensors.

The 9190A conforms to EURAMET cg-13 guidelines for best measurement

practices for temperature dry-block calibrators. This means its specifica-

tions for accuracy, stability, axial (vertical) uniformity, radial (well-to-well)

uniformity, loading and hysteresis have been thoroughly and carefully

defined and tested.

The 9190A has a wide temperature range (-95 to 140°C) to cover the

coldest and warmest temperatures required in pharmaceutical, biomedical

and food processing applications. Operating at ultracold temperatures is not

typically available with a calibration bath. The 9190A uses no bath fluids,

which keeps cleanrooms clean, makes it easier to transport and delivers

faster heating/cooling rates. It offers best-in-class temperature stability

(±0.015°C) for consistent and accurate results.

A ‘process’ option is available that features 4-20 mA connectors, a reference thermometer input and a

4-wire PRT/RTD input with an accuracy of ±0.02°C. It also has a reference sensor control to minimise the

effects of the axial gradient when a reference PRT is aligned with short sensors.

Fluke Australia Pty Ltd


WIRELESS NETWORK UPDATEHoneywell has announced the availability of OneWireless Network

Release 210, which incorporates several features that make wireless

technology easier to deploy and operate, and result in lower deploy-

ment and operational costs.

Enhanced features in Release 210 include over-the-air field device

provisioning and a Gateway General Client Interface (GCI) made pos-

sible by the ISA100 standard; and native integration of OneWireless field

networks into Honeywell’s Experion Process Knowledge System (PKS).

With the over-the-air provisioning feature, field devices can now be

configured and commissioned without having to invest in handheld

devices or needing to perform provisioning locally at the device. The

result is faster and less costly deployment and improved worker safety.

The GCI feature, enabled by the ISA100 standard, allows operations

to continue using legacy protocols and proprietary applications while

making it easier to wirelessly expand those applications throughout the

plant. The GCI also allows third-party client applications to communicate

natively using proprietary or common field protocols with wireless field

instruments over the ISA100 network.

Integration of ISA100 field device networks into Honeywell’s Experion

PKS eliminates data mapping, non-value-added engineering and sim-

plifies HMI display creation. It also allows field process alarms to be

displayed on Experion’s Alarm Summary to provide operators with the

data they need to make decisions. Tight integration with Experion also

allows field operators and maintenance technicians to use Wi-Fi-enabled

handhelds to securely access process data in real time from the field.

Honeywell Limited


http://www.zigsense.com.au


NEWPRODUCTS

MOTOR CONTROLLERThe Allen-Bradley

SMC-50 smart mo-

tor controller includes

a newly designed

three-phase, fu l ly

solid-state, silicon-

control led recti f ier

(SCR) power structure.

It is designed to address the

motor control needs of OEMs and end us-

ers seeking a more economical alternative to drives and more

advanced control than across-the-line starters.

Rated at 200-690 VAC, and from 90 to 520 A, the SMC-50

controller is suitable for controlling motor speed and torque in

a range of normal-duty applications, including pumps, compres-

sors and short conveyors, as well as in heavy-duty applications,

such as rock crushers, wood chippers, centrifugal fans and

long conveyors.

The SMC-50 smart motor controller’s design improves volt-

age output to maximise efficiency of motor starts and stops.

For application scalability, it features nine standard starting

modes, six stopping modes and several slow-speed functions.

The linear-acceleration starting mode offers the lowest starting

current profile per start, consistent acceleration time and en-

hanced control over both torque and speed. Regardless of the

starting mode chosen, the SMC-50 controller stores the actual

motor start time and peak current value to assist in set-up and

process optimisation.

The SMC-50 smart motor control ler also uses the

Allen-Bradley smart motor braking feature, engineered with

automatic zero-speed shut-off to quickly stop a motor without

the need for additional hardware or feedback devices.

Rockwell Automation Australia


GAS ANALYSERThe Precisive 5 is a compact hazardous area-compliant package

for unattended hydrocarbon process and natural gas analysis,

using Precisive’s tunable filter spectroscopy (TFS) platform.

Precisive specialises in unattended, all-optical process

monitoring sensors for a variety of natural gas, LNG/LPG/

BOG, combustion, emissions and biogas applications.

Quantitative analysis of alkane gases, specifically C1 to C5

(methane, ethane, propane, butanes and pentanes), and other

light hydrocarbons is important in a variety of applications,

including BTU measurement and quality analysis of natural

and biogas products.

The predominant measurement technique until now has been

gas chromatography (GC), which has the ability to separate

individual compounds with high selectivity, albeit with its slow

response and high infrastructure requirements. For faster

measurement requiring only a single heating value measure-

ment, residual oxygen calorimetry is often used.

The Precisive 5 gas analyser requires no carrier gases, no

calibration gases and offers fast-response analytics without

compromising accuracy, repeatability, linearity or stability in

the presence of interferences. Faster-response multicomponent

analysis provides significant cost savings and efficiency gains

in power generation applications. Measurements take seconds

rather than minutes with GC-based systems.

A Modbus communications interface enables remote and

unattended deployment without constant operator intervention.

Novice users can become very proficient with minimal training.

The Precisive 5 is compliant with North America Division

System (Class1Div2, Groups A/B/C/D, T4, Type 4X), North

America Zone System (Class1, Zone2, Aex nA IIC T4, IP66,

Ex nA IIC T4, IP66), European Zone System (EX II 3G n IIC

T4 Gc) and worldwide certification to IECEx standards.

Australian Dynamic Technologies Company Pty Ltd


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


NEWPRODUCTS

BOX PCThe EPS-QM77E box PC is powered by the third generation Intel Core i5/i7 processors

and is a small footprint embedded computer designed to be both fanless and

ruggedised. It supports up to 8 GB of DDR3 memory, dual display with DVI-I and

HDMI, 5.1-ch audio and dual Intel gigabit ethernet ports. It also provides an mSATA

and two SATA interfaces, four USB 3.0 ports, two USB 2.0 ports and two serial ports.

EPS-QM77E withstands industrial operation environments for temperatures between

-10 and +60°C. It also supports a 9-19 V input range, with an anti-interference capability and

protects the computer from overload. Product reliability and stability are certified by industrial product

quality tests, including antivibration of up to 5 grms and antishock of up to 50 grms. While rugged, the chassis

offers easy maintenance and integration. There is an access door from the bottom side to allow easy installation

of storage drives and memory. The design and placement of the internal SBC allows for minimal cabling to

lower the number of connections and points of possible failures. In addition, the optional table-mount bracket

allows easy mounting. The EPS-QM77E is compatible with a wide range of operating systems.

Backplane Systems Technology Pty Ltd


EXPLOSION-PROOF LEVEL METERThe PD6801 ProtEX level meter from

Precision Digital is an easy-to-read,

4-20 mA, loop-powered, explosion-

proof meter designed for safe or

hazardous environments, such as

oil wells or chemical storage. The

meter has FM, ATEX, CSA and IECEx

approvals and is housed in a rugged,

cast aluminium NEMA 4X enclosure.

SafeTouch through-glass buttons

allow operation without removing

the cover, ensuring the integrity of

the unit. Operating temperatures

range from -40 to 75°C.

The PD6801 features an upper

display that is 1.5 cm high and

shows level. The lower display is

1 cm high and shows volume, per

cent or a custom tag programmable

for any seven alphanumeric digits.

The backlit meter is easy to read

from a distance, under various

lighting conditions, and from wide

viewing angles of up to ±40°.

Four sensors in the PD6801 op-

erate as through-glass buttons for

programming and operation without

removing the cover in hazardous

areas. These SafeTouch buttons

are standard and allow high- or

low-level alarm acknowledgement

while being designed to prevent

unintended triggers.

A 20-segment tank level indica-

tor provides a quick view of height

and will flash to alert operators

about alarm conditions. It can be

scaled independently of the analog

input scale. For non-linear signals,

such as measuring the volume of

odd-shaped tanks, the PD6801

features multipoint linearisation up

to 32 points. The level and volume

scales can use different numbers of

linearisation points.

Precision Digital Corporation

http://www.predig.com

http://www.ap.emersonprocess.com


NEWPRODUCTS

COMPRESSED AIR FILTERSHigh filtration efficiency is the prerequisite for high air quality while a low-pressure drop

helps to save energy. To that end, Atlas Copco recently released its latest generation

DD+, PD+, DDp+ and PDp+ filters.

Micro-glass fibre filter media and a six-layer wrapped construction ensure high-purity

filtration and a guaranteed performance over the filter lifetime. Moreover, the performance is in-

dependent of the relative humidity. The perforated stainless steel metal cores were enhanced to

ensure high mechanical strength and drastically reduce the risk of implosion.

Compared to the previous generation, the pressure drop of the new DD+ and PD+ filters has been

reduced and at the same time the oil aerosol carryover decreased by more than 20%.

These DDp+ and PDp+ dust filters have extremely high particle removal efficiencies of 99.92%

and 99.98% respectively.

The filters are now fully certified according to ISO standards by notified bodies, both in-house as

well as in external labs. This third-party certification ensures customers the air quality they require

and improved energy savings.

Atlas Copco Compressors Australia


ENCLOSURE COOLERSVortec enclosure coolers keep electrical and electronic enclosures cool, clean

and protected and are a low-cost alternative to expensive, high-maintenance

air conditioners - while avoiding contamination with dirty, humid air that

can be introduced by fans.

Today’s small, compact multifunction electronic controls, variable speed

drives, servos and programmable logic controllers can be sensitive to

heat and contamination. Smaller cabinet sizes make temperature control

difficult and prone to premature failures. Excessive heat will cause digital

displays to misread, controls to drift and breakers to trip below rated

loads. The result is productivity lost due to machine or line shutdowns.

Vortex enclosure coolers maintain a slight pressurisation of the cabinet to keep

electrical and electronic components clean and dry; and most are thermostatically

controlled to maintain enclosure temperatures within a specified temperature range.

Vortec offers multiple types of enclosure coolers to meet the needs of different applica-

tions, all available in a variety of cooling capacities and ratings.

Knight Pneumatics Pty Ltd


http://www.veederline.com.au

http://industrialsoftware.com.au

http://www.weidmuller.com.au


AS I SEE IT

Ed Sugay i s Head of Energy Efficiency, Siemens Ltd. Before h e a d i n g S i e m e n s ’ En e rg y E f f i c i e n c y portfolio in Australia, Ed was Siemens’ Global Director o f Energy & E n v i r o n m e n t a l So lu t i ons f or As ia Pacific. Ed brings 20

years’ experience in energy generation and energy efficiency, as well as an MBA from the University of California.

Printed and bound by Webstar +61 2 9748 0020Print Post Approved PP100007403ISSN 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.

A.B.N. 22 152 305 336

Head Office

Cnr. Fox Valley Road & Kiogle Street,

(Locked Bag 1289)

Wahroonga NSW 2076

AUSTRALIA

ph: +61 2 9487 2700 fx: +61 2 9489 1265

www.westwick-farrow.com.au

ph: +61 3 9381 2952

Editor

Glenn Johnson

[email protected]

Chief Editor

Janette Woodhouse

Publisher

Geoff Hird

Art Director/Production Manager

Julie Wright

Art/Production

Tanya Scarselletti, Colleen Sam, Jeanette Teuma

Circulation Manager

Sue Lavery

[email protected]

Copy Control

Mitchie Mullins

Advertising Sales

NSW/QLD - Nicola Fender-Fox

ph: 0414 703 780

[email protected]

VIC/SA/WA - Lachlan Rainey

ph: 0402 157 167

[email protected]

NZ - Gemma Burr

ph: 0800 44 2529

[email protected]

USA - Huson International Media

East Coast ph: +1 212 268 3344

West Coast ph: +1 408 879 6666

[email protected]

UK - Huson International Media

ph: +44 1932 56 4999

[email protected]

Asia - Lachlan Rainey

ph: +61 (0) 402 157 167

[email protected]

Subscriptions

For unregistered readers price on application.

If you have any queries regarding our privacy

policy please email

[email protected]

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

Contact the editor

WASTE OPPORTUNITIES: TRANSFORMING WASTE ENERGY INTO COST-SAVING AND SUSTAINABLE PROCESSES

Around half of the primary energy consumed in industrial processes is currently wasted. Even steel

produced by recycling scrap metal in electric-arc furnaces, for instance, requires approximately 370 kWh per metric tonne. In this type of furnace an electric arc is struck between several electrodes. The resulting heat causes the steel to melt before emit-ting a mixture of gases at up to 1700°C - a huge waste that might otherwise be used in the process or to generate electric power.

Predictions suggest that around 50% of costs from operating a mine, for example, will come from energy use, making it even more of an incentive for industries to reduce energy consumption as well as manage its waste more cleverly.

When considering energy efficiency, one often thinks of energy-saving technologies for lighting, heating and air conditioning, for example. But energy efficiency is so much more than this - it’s about reducing consumption while at the same time mak-ing the most of waste energy by using it in other parts of the process (for example, to preheat combustion air or serve another thermal load) or by condensing it to gener-ate electricity.

Research has shown that up to 20% of the energy needed for melting scrap metal could be recovered from waste heat. That would reduce CO2 emissions per metric tonne of steel by about 40 kg. Current systems emit about 270 kg of CO2, 220 kg of which results from power generation. This means that CO2 emissions from a typical 120-tonne furnace could be reduced by more than 30,000 tonnes annually.

While it makes sense to recover waste heat, most industrial waste heat is still not captured for re-use and unfortunately, around half of the primary energy con-sumed in industrial processes and energy generation currently goes to waste. Part of the problem is that there are still hardly any economically practical and technically

mature processes available for waste heat below 300°C.

But in a thermal management study, Siemens has identified a process called Organic Rankine Cycle (ORC) technology - particularly suitable for recovering waste heat from furnaces in the glass industry, diesel or gasoline engines, gas flaring at refineries as well as gas turbines in com-pressor stations. The non-polluting organic medium used in this process ensures optimal efficiency for low waste-heat temperatures and low power. In a trial at Moscow State University, the ORC technology produced about 800,000 kWh of extra electricity per year with an efficiency of about 20% and a payback within three years.

In addition to producing electricity, waste heat can also be used to clean and demineralise water through an evaporation and condensation process. This not only generates new freshwater for re-use but at the same time reduces the amount of waste-water that might otherwise go to sewage. Paper mills, soft drink bottling plants and other industries where wastewater cannot be readily disposed via a sewage treatment plant could potentially benefit from this type of technology.

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.controldevices.net

What’s New in Process Technology May 2013

Documents

Transcript of What’s New in Process Technology May 2013