Professional Documents
Culture Documents
NO 12 DECEMBER 2011
27
Chemicals & plastics | Wireless | Operator interfaces & HMI Temperature | IT in manufacturing
contents
24
COVER STORY
EDGE-TO-CORE INDUSTRIAL ETHERNET SOLUTIONS
40
26
CHEMICALS & PLASTICS
29
BUILDING MANAGEMENT
32
WIRELESS
40
RELAYS
42
IT IN MANUFACTURING
50
OPERATOR INTERFACES & HMI
54
TEMPERATURE
GENERAL
04 06 16
20 22 57
56
29
OUR COVER
For over 20 years, industrial system integrators have relied on Moxa products in device networking applications around the globe. See this months cover story on page 24 for more on the latest additions to Moxas extensive range of edge-to- core switch solutions for comprehensive industrial Ethernet platform implementation.
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www.instrumentation.co.za December 2011
welcome
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NEWS DIGEST
S2M, an SKF Group Company, has announced the signature of a 2-year contract with MAN Diesel & Turbo, Aker Solutions Norway and Statoil. S2M will equip subsea compression trains with SKF magnetic bearings and their associated electronics in a rst of its kind project for the sgard gas eld in the Norwegian Sea. The project will involve placing 2 compressors on the seabed to maintain discharge pressure in the pipeline and compensate for the falling suction pressure as the reservoir is depleted in the next few years, thereby boosting the gas ow. SKF magnetic bearings were selected for their capability to operate in these severe conditions with very high reliability, including remote monitoring. They will maintain the motor compressor shaft systems in position and are oil-free, frictionless and virtually maintenance-free: features which are vital in compressors installed at a depth of between 200 and 300 metres, rendering them too deep for divers and accessible only by remote operated vehicles.
Honeywell executive Norm Gilsdorf was recognised at this years centennial celebration of Purdue Universitys School of Chemical Engineering. Gilsdorf, president of Honeywell Process Solutions, already awarded the title of Distinguished Engineer Alumnus in 2010, was honoured with an Outstanding Chemical Engineer Award, and is a featured speaker in the schools Centennial Seminar series.
His presentation, titled Have Chemical Engineering Degree Will Travel, will highlight the often-overlooked career benets of pursuing chemical engineering degrees and the important role engineers can have in advancing technology that will be energy ecient, safe and sustainable. In addition to being named a top alumnus, Gilsdorf is also being inducted into the College of Engineering Cooperative Education Hall of Fame.
With the theme Exchanging Ideas. Creating Solutions, Emersons rst European Global Users Exchange will be held from 29-31 May 2012 at the Hotel Maritim, Dsseldorf, Germany. Tailored to meet the needs of users in Europe, the Middle East and Africa, delegates will learn about best practices and see how colleagues are meeting new regulatory requirements, increasing yields, improving eciency and reducing costs with enhanced automation. The European event will follow the same format as the October 2011 Emerson Global Users Exchange held in Nashville, USA. The event will include workshops, presentations, industry forums, short courses, technology exhibits and product roadmaps. Delegates will be able to choose from themed presentations in English, German and Russian.
We are delighted to announce the details of the rst Global Users Exchange for our many users across Europe and others who will join us from other regions, said Bob Sharp, President, Emerson Process Management Europe. The Emerson Global Users Exchange is much more than an industry leading technical conference. It is a community of manufacturing leaders committed to extracting the most from their automation investment and sharing their learning with each other. The event also provides an opportunity for delegates to understand what their peers, other suppliers and customers in the industry are doing to compete in these dynamic times. Attendees will be provided with a unique opportunity to touch and experience the breadth of innovative Emerson technologies all in one place. An important element of the event is the opportunity it provides to network
with other delegates and industry leaders to make the right connections. Delegates will also be able to meet with the experts behind the technologies and learn how innovative technologies can be put to work. The Emerson Global Users Exchange organisation is now looking for users to share their experiences and expertise with their process automation peers by giving a presentation, workshop or short course at the event. Presenting at the Global Users Exchange provides a unique opportunity for users to showcase their company and its successful operational practices.
For more information contact Mark Tapson, Emerson Process Management, +27 (0)11 974 3336, mark.tapson@emerson.com, www.emerson.com
In July 2011 Moeller and Eaton, two established and respected names in the electrical sector, came together as Eaton, a global organisation delivering solutions to support customers in running their systems more productively and cost eectively. The Moeller logo is being replaced by the Eaton logo on all products and packaging. These changes will ow through the supply chain throughout 2011 with a target completion date of 1 January 2012. The products will have the same form, t and function and carry the same order codes, providing customers with the reassurance of continuity of supply and build quality. The former name will appear as the Moeller series on the product rating and carton labels in recognition of the value the Moeller brand has brought to Eaton. In terms of organisation, product and production techniques, Moeller has been fully integrated into Eaton over the last two years. Moeller facilities have been adopting the Eaton Business System, a single continuous improvement system covering work processes, tools and tooling during this time. The two companies are now well on the way towards unifying their product branding and packaging.
For more information contact Rob Hare, Eaton Electric, +27 (0)11 824 7400, robhare@eaton.com, www.eaton.com
Further entrenching its commitment to bridging the skills gap in the eld of electrical engineering, Siemens has taken its Cyber Junkyard Challenge to schools in the Eastern Cape. This Junior Cyber Junkyard Challenge has been undertaken in partnership with Port Elizabeths Nelson Mandela Metropolitan University (NMMU). Says Martin Taverner, BU manager motion control at Siemens: In 2011, our aim is to establish a relationship between Siemens, NMMU and high schools and colleges in the area, hence the introduction of the challenge at a school level. Our hope is that these relationships will help to encourage learners at this level to consider electrical engineering as a career path after school. In the Junior Cyber Junkyard Challenge, learners had to design, build and programme a fully functional water tank system. They needed to implement the principles of ow rate and volume calculation in addition to basic logic and the principles of level control. By taking part in this project learners gain
hands-on experience that will assist them when applying to universities, they learn about electrical design, mechanical manufacture, level control within a tank process, industrial automation programming and closed loop control systems all at a junior level, Taverner explains. Nine schools entered the challenge and through our partnership with NMMU, each team was allocated R10 000 to design and manufacture its system. Final judging took place in October with the winning teams receiving a host of electrical equipment, as well as bursaries donated by NMMU. The Eastern Cape served as a pilot, Taverners ultimate objective is that the Junior Cyber Junkyard Challenge will be held annually and open to schools nationwide.
For more information contact Keshin Govender, Siemens Southern Africa, +27 (0)11 652 2412, keshin.govender@siemens.com, www.siemens.co.za
SEWEURODRIVE BEERFEST
From left: Ute Bormann, Managing Director; Tobias Nittel, SEW-Eurodrive Germany; Renee Rose, General Manager of Communications.
SEW-Eurodrives annual Beerfest is held each year at venues across the country to say thank you to all the companys customers for their support. The event has grown over the years and this year the Johannesburg gig moved osite for the rst time to Rand Airport. The osite venue allows SEW to grow the event in line with its customer base. Approximately
800 people attended the customer event in Johannesburg. It was also held in Cape Town and Nelspruit. In total 1400 SEW customers were entertained with good music, good food and good beer.
For more information contact Renee Rose, SEW-Eurodrive, +27 (0)11 248 7000, rrose@sew.co.za, www.sew.co.za
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Svanesso, known locally as the braai angel, surrounded by staff before being put into storage.
On 10 October 2011, Endress+Hauser ocially launched its new Sandton head oce building project: Cementing the future together. Svanesso, a sculpture by Swiss artist Claire Ochsner donated to the Sandton oce by Klaus Endress at the ocial opening of the Conference Centre in October 2004, has been removed for safe keeping. The project was originally intended to begin
in 2010, but due to the economic crisis had to be postponed. For a long time now it has been clear that we would outgrow our current building and in order for us to meet the growing demands of the market, we needed to invest in a state-of-the-art building for sales and services in Sandton, says MD Rob MacKenzie. Over the past 25 years, the people for process automation has developed from a nich
provider of level instruments, sold via an agency, to a R300 million Broad Based Black Economic Empowerment (BBBEE) company and a major supplier of products, services and solutions for process measurement technology.
For more information contact Hennie Blignaut, Endress+Hauser, +27 (0)11 262 8000, info@ za.endress.com, www.za.endress.com
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At a special ceremony during the Skills Development Summit held at the CSIR in September, DesSoft was among the companies and individuals who were honoured with Achiever Awards for outstanding contributions to skills development. At a time when the shortage of skills has reached almost crisis proportions in a number of areas of the national economy, now more than ever those who are making a dierence by providing South
Africa with the necessary skills pool must be recognised for their leadership and applauded for their eorts, said Awards director, Dylan James. The summit was sponsored by the worlds top mining group, BHP Billiton.
For more information contact Justin Alberts, DesSoft, +27 (0)12 644 2974, justin@dessoft.co.za, www.dessoft.co.za
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Honeywell has signed a memorandum of understanding with engineering and research rm Virthualis to develop a 3-D simulation solution to improve operator training and plant safety. Under the agreement, Virthualis 3-D visualisation technology, MindSafe, will be linked to Honeywells UniSim simulation tool, providing a holistic virtual environment that can be used to design, analyse and verify plant operations, as well as to prepare operations teams for safe, reliable and ecient manufacturing. We see many of our clients struggling to recruit operations sta with the right mix of skills, so we are pleased to be in a position to deliver a strong engineering and training solution that can bridge the competency gap, says Elgonda La Grange, global consulting services director, Honeywell Process Solutions. The fusion of Honeywell and Virthualis technologies enhances our existing simulation business with additional expertise and a 3-D learning environment to evaluate and train operators to respond to critical plant conditions. Honeywell is the ideal partner because our oerings are complementary and we share the same passion for process safety, reliability and eciency, says Simone Colombo, president, Virthualis. Together we are delivering a solution that can support the lifecycle of a plant, from design through to decommissioning, by empowering engineers to design and implement, and operators to learn and test their skills to control the process safely, prevent accidents and manage emergencies in a realistic environment.
For more information contact Debbie Rae, Honeywell Southern Africa, +27 (0)11 695 8000, hsa@honeywell.com, www.honeywell.co.za
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of handling up to 192 slaves with refresh time down to 100 s and less than 1 s jitter. It achieves high accuracy for multi-axis synchronisation thanks to its distributed slave clock mechanism. It is simple to set-up with automatic address assignment for slaves and cost eective to install as it uses standard shielded Ethernet cables and connectors. In line with Omrons social and global policy, Sysmac meets global standards such as EC Directives, cULus, Lloyds and NK and is designed and manufactured with clean and recyclable material.
For more information contact Terry McIntosh, Omron Electronics, 086 066 7661, terry_lynn_mcintosh@eu.omron.com, www.industrial.omron.co.za
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PORT ELIZABETH
PLC Introduction 1 (PL1): 5-6 Mar Logic Systems 1 (LS1): 13-14 Feb Logic Systems 2 (LS2): 15-16 Feb
For more information contact Terry McIntosh, Omron Electronics, 086 066 7661, terry_lynn_mcintosh@eu.omron.com, www.industrial.omron.co.za
DURBAN
PLC Introduction 1 (PL1): 30-31 Jan Enhanced PLC 2 (PL2): 1-3 Feb Logic Systems 2 (LS2): 14-15 Dec
CAPE TOWN
PLC Introduction 1 (PL1): 13-14 Feb
APPOINTMENTS
Clinton Seager.
Elizabeth Graskie.
Gys Snyman.
Honeywell has appointed Clinton Seager as Automation Training College leader: sub-Saharan Africa.
Schneider Electric SA has appointed Gys Snyman as vice president: energy eciency.
15
SAIMC NEWS
Johan Maartens.
VACATION
Many of us will be taking leave over this Christmas period. May you have a safe journey and come back revitalised for the work that lies ahead in 2012. Ina and I would like to wish each and every one a blessed Christmas and may 2012 bring you the desires of your heart as you continue on your way through this life. In the greater scheme of this, our time on earth is short but worth every second. Make the most of it. To the Committees: I would like to thank you from the bottom of my heart for the wonderful work you have done this year. We had our dierences but as they say: If everybody agrees only one person is doing the thinking. To the families of the committees: I would like to thank your families for putting up with your participation in the SAIMC. Without your support the SAIMC would not have been able to look back on a very successful year in which all three of our targets were reached well, we are still working on one and that is the First Lego League trailer that still needs some modications to accommodate all the equipment.
Secretariat SAIMC, Tel: 08610 SAIMC, +27 (0)11 431 3802 (international callers only), Fax: 086 616 0141, admin@saimc.net
www.saimc.net
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Durban branch
At the October technology evening, which was kindly hosted by Honeywell, account manager Tony White took us through Virtualisation in Industrial Control. We learnt about the key benefits and value that it can bring to business and Tony also shared some practical experience for builds and migrations of existing physical platforms to a virtual server.
FORTHCOMING ATTRACTIONS
The December Technology Evening will be hosted by Yokogawa who will provide specialist speaker, Bruce Bonte. Bruce is a qualified instrument mechanician with 22 years experience in the process control and instrumentation arena. He joined Yokogawa earlier this year and is currently training facilitator for Africa. It is in this role that Bruce will be looking at A Model to Combat the Skills Shortage. Wednesday 7 December 17:30 for 18:15 Westville Country Club 1 Link Road Westville Please contact Kevin McElroy on 0832519993 or kevin@eastcoast.co.za if you have any queries.
YEAR-END FUNCTION
The Durban branch annual function was held at The Heritage Theatre on 22 October. It was a complete sell-out and gave companies the opportunity to entertain customers in a relaxed and fun networking atmosphere. Committee member Paul Sikhakhane did a fine job as Master of Ceremonies, introducing acting Chairman Vinesh Maharaj, guest speaker Ed Boje and SAIMC President, Johan Maartens, all of whom had some interesting things to say about the industry, education and of course the role of the SAIMC in the past year. The Durban committee introduced a new award this year to recognise contributions from industry and it went to Nico Marneweck from Yokogawa for Best Technology Presentation 2010/2011. The food was great and the entertainment was a tribute to the much-loved country rock group, The Eagles. The band really entertained on the night doing justice to one of the biggest-selling US acts in history.
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SAIMC NEWS
SAIMC Banquet
Members spent an enjoyable evening at the prestigious Rand Club where they were wined and dined in style. The guest speaker was Dr Anthony Turton, an expert on water resource management, who was named Environmentalist Of The Year in 2010. He gave an entertaining and thoughtprovoking expos on the strategic water quality challenges that South Africa is facing. Seen here enjoying the banquet are President Johan Maartens and his wife Ina as well as Past President Johan van Jaarsveldt and his wife Beverley.
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GENERAL
Members are requested to update their contact details (especially cell phone numbers) in order to be kept informed about branch activities. We also urge our members to communicate directly with the branch leadership in order to voice opinions, direct queries and make requests for improvement. The leadership is there to serve members, but needs members to contribute towards this initiative. The 2012 AGM process will be underway shortly.
Cape Town: Selvan Murugan at selvanm@ssi.co.za, Mobile: +27 (0)83 297 7620 Durban: Vinesh Maharaj at vmaharaj@cubetech.co.za, Mobile: +27 (0)83 792 6518 Johannesburg: Andrew Bharath at Andrew.bharath@za.yokogawa.com, Mobile: +27 (0)83 758 1908 Richards Bay: Vinesh Maharaj at vmaharaj@cubetech.co.za, Mobile: +27 (0)83 792 6518 Secunda: Peter Zietsman at Peter.Zietsman@eskom.co.za, Mobile: +27 (0)83 310 7925 Vaal: Solly Mabitsela at solly.mabitsela@sasol.com, Mobile: +27 (0)83 381 9962 Zambia: Rodgers Kayombo at rodgers.kayombo@kcm.co.zm Council: Ina at Admin@saimc.net, Mobile: +27 (0)82 440 8957
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JIM PINTO
Sensors
JIM PINTO
Jim Pinto is an industry analyst and commentator, writer, technology futurist and angel investor. His popular e-mail newsletter, JimPinto.com eNews, is widely read (with direct circulation of about 7000 and web-readership of two to three times that number). His areas of interest are technology futures, marketing and business strategies for a fast-changing environment, and industrial automation with a slant towards technology trends.
Smart, networked sensors will soon be all around us, collectively processing vast amounts of previously unrecorded data to help run factories, optimise farming, monitor the weather and even watch for earthquakes. Many people (including me) think that wireless sensor networks can become as important as the Internet. Just as the Internet allows access to digital information anywhere, sensor networks will provide remote interaction with the physical world.
Against the backdrop of the war on terrorism, work is progressing on a nationwide sensor network that someday could provide a real-time early-warning system for a wide array of chemical, biological and nuclear threats across the US. With a $1 billion budget in 2004, the US Department of Homeland Security is doing a signicant amount of new development, plus coordinating the eorts of key scientists at national labs. The core technology relates to materials, sensors, networks and chips. Field trials of prototype networks are already starting. MEMS and nanotech will be used to create several low cost, highly accurate biological and chemical sensors. On the networking front, peer-to-peer networks with multilevel security and quality of service guarantees will span wireless, wired and satellite links. Within a few years, these technology developments will impact commercial markets, bringing huge new opportunities in other areas.
APPLICATIONS
Immediate markets include industrial automation (process control), defence (unattended sensors, real-time monitoring), utilities (automated meter reading), building automation (HVAC controllers). Within the next few years, distributed sensing and computing will be everywhere homes, oces, factories, automobiles, shopping centres, supermarkets, farms, forests, rivers and lakes. Even accurate weather prediction will be revolutionised through widespread wireless sensors. In a at or declining industrial automation marketplace, expect big growth from wireless sensor networks. Get your company involved. Or, join a company that is involved.
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SYSTEM INTEGRATORS
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SYSTEM INTEGRATORS
SYSTEM INTEGRATORS
The full System Integrators tables can be found in the 2011 Instrumentation & Control Buyers Guide under the section Services (Industrial). Please contact Jane 031 764 0593, e-mail: jane@technews.co.za or Tina 011 543 5800, e-mail: tina@technews.co.za for more information on inclusion in this section.
SYSTEM INTEGRATORS
ABACUS AUTOMATION
Tel: (031) 702 5767 sales@abacus-automation.co.za www.abacus-automation.co.za
FESTO
Tel: 08600 FESTO (33786) sales.interaction@za.festo.com www.festo.com
SYSTEM INTEGRATORS
PSY SYSTEMS
Tel: (011) 782 5449 paul@psysystems.com www.psysystems.com
HYBRID AUTOMATION
Tel: (031) 573 2795 info@hybridautomation.co.za www.hybridautomation.co.za
AUTOTRONIX
Tel: (031) 705 0400 or (016) 422 7644 sales@autotronix.co.za www.autotronix.co.za
IRITRON
Tel: (012) 349 2919 marie.herbst@iritron.co.za www.iritron.co.za
SYSTEMS ANYWHERE
Tel: (011) 024 5491 info@systemsanywhere.com www.systemsanywhere.com
CUBE TECHNOLOGIES
Tel: (031) 764 6081 info.rsa@cubetech.co.za www.cubetech.co.za
PROCESS DYNAMICS
Tel: (011) 394 5412 systems@process-dynamics.co.za www.process-dynamics.co.za
SYSTEM INTEGRATORS 23
COVER STORY
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Complete solutions support converged applications such as video surveillance. Industrial-grade reliability, completely fanless, with industrial certication and approvals. Core layer - high bandwidth 10GbE industrial core switches: Full Gigabit L2/L3 networking capability. Up to 24 or 48 1GbE connections. Up to 4 10GbE ports. Distribution layer industrial modular rack mount and DIN-rail switches: Flexible modular design.
High port density. Ideal for control room and outdoor cabinet operations. Edge layer compact, standalone DIN-rail switches: 5 to 19 ports, FE to full GE, managed and unmanaged switches. Cost-eective solutions. Advanced L2 networking capability.
For more information contact RJ Programmable Techniques, +27 (0)11 781 0777, info@rjprogtech.co.za, www.rjprogtech.co.za
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BUILDING MANAGEMENT
Hot or cold air leaks from buildings, systems and equipment result in energy wastage. However with a small amount of training it is possible to use a thermal imager to spot the abnormal temperatures which lead to energy waste. Unlike regular digital cameras that capture images of the visible light reected by objects, thermal imagers create pictures by measuring infrared energy or heat. The thermal imager then assigns colours based on the temperature dierences it measures. This works best when the imager is in the hands of someone with a good working knowledge of the structures and systems being scanned, who can then interpret the temperature variances seen on the camera. A typical scan can show energy saving opportunities of up to 15%, with varying degrees of repair investments. Thermal imaging experts suggest that building owners, building managers and facilities engineers inspect the following systems to identify energy losses.
BUILDING ENVELOPE
Building envelope refers to the building structure as well as the climate controls within it. The envelope is what separates the outside environment from the inside, and it is frequently imperfect. The degree of temperature variance may be very small one or two degrees. The best time to scan is when the outside temperature is at least 10C higher or lower than the inside temperature. Thermal loading or other environmental factors could also mask or distort potential problems. Exterior walls should not be scanned when the sun is shining on them and roofs should be dry and free of water or ice. Inspections should be performed
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BUILDING MANAGEMENT
HVAC SYSTEM
The heating, ventilation and air conditioning (HVAC) system is usually one of the biggest energy consumers within a facility. What to scan Ductwork and registers: Even the highest rated HVAC system wastes energy without a well sealed duct system. With
infrared technology the thermal pattern of air loss or gain in ducting can be seen and registers can be monitored to determine whether heating or cooling output is optimal. Fans and blowers: These mechanical elements are motor driven. Mechanical imbalance will manifest itself in overheated bearings and other components.
Thermal images of these systems can also identify shaft misalignment in couplings between the motor and fan. Electrical connections: A loose or corroded connection increases resistance at the connection, resulting in overheating. Anticipated savings Studies indicate that
commercial buildings with constant air volume systems often experience energy losses from air leakage of as much as 33%. Also, studies indicate that air supply temperature dierentials due to conduction losses can be as great as 6C. Considerable savings can be achieved with duct sealing and insulation remedies.
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BOILERS
Boilers are the heart of steam and hot water heating systems. What to scan Refractories: Thermography makes possible in-service monitoring of the condition of refractory linings. Leakage of outside air: This condition is dicult to pinpoint with diagnostic technologies other than thermal imagers and it can lead to substantial ineciencies. Boiler casing insulation: Look for heat loss from damaged insulation. Fan motors: Check for impeded airow, electrical unbalance, overheated bearings and failing insulation. Pumps: Look for hot bearings, leaking seals and motor faults. Valves: Thermography can identify blocked valves that are nominally open and leaking valves that are nominally closed. Electrical connections: Look for loose or corroded connections that increase resistance. Anticipated savings In boilers, major energy losses associated with stack losses as well as radiation and convention losses typically represent 10 to 20% of fuel input, depending upon fuel type. Insulation and boiler economisers can reduce these losses.
ELECTRICAL SYSTEMS
Electrical systems can waste money as components degrade and resistance increases. What to scan Distribution panels: Check for unbalance in circuits and loose and corroded connections at breakers, contacts, fuse clips and busses. Transformers: Monitor high and low voltage bushing connections, cooling tubes and cooling fans and pumps. Look for overheated connections, comparatively cool cooling tubes and hot or cool pumps. Be aware that if the temperature of one electrical leg on a transformer is signicantly hotter than the others that leg may be failing. Lighting control circuits: Check all wiring splices and connections at fuses, switches, and xtures. Be aware that thermography can also be used to monitor low voltage control circuits. Anticipated savings According to some estimates, lighting accounts for about 20% of all electricity use in the USA and more than 40% of electricity use in oces, stores, and other commercial buildings. While complete retrots of lighting systems are producing phenomenal returns on investment, keeping lighting controls such as time clocks, photo sensors and occupancy detectors operating properly will help save energy.
CONCLUSION
Thermal imagers have come down so far in price that most facilities can recoup the cost in terms of energy savings within six months. Incorporating thermal imaging into a regular maintenance programme contributes to eciency as well as helping a maintenance team to identify and prevent expensive electromechanical failures.
For more information contact Val Verwer, Comtest, +27 (0)11 608 8520, info@comtest.co.za, www.comtest.co.za
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WIRELESS
CONVERGENCE DRIVERS
Large end-users have put pressure on the IEC/PAS 62591 and ISA100 groupings to provide a convergence route map. There are sound commercial and operational reasons for such convergence and the advantages of such convergence appear to be mutually benecial for both end-users and vendors. From an end-user perspective the benets include: A wider choice of eld instrumentation since the vendor
WirelessHART Device
Field device Adapter
ISA-100.11a Role
2
Device
Field device. Adapter.
Role3
Data provider and/or consumer. Converts the (wired) legacy device protocol to ISA-100.11a protocol enabling the combination to become a data provider and/or consumer. Provisions devices that are set to factory defaults to enable them to join a wireless network. Provides, inter alia, wireless network range extension. Provides the interface between the wireless network and the backbone (plant) network Gateway Forms the interface between the wireless industrial sensor network and host network (Typically Ethernet). Also acts as a protocol converter for the host protocol (Foundation Fieldbus, HART, Modbus ...). Responsible for overall network, device and communications management. Implements either Router or Backbone router role. Facilitates secure system operation. Key management and authentication. Often the security manager and system manager will be implemented in a single device.
Native WirelessHART device. Typically functions as data producer and/or consumer and router. Adds wireless capability to existing wired HART device Adapters and eld devices. Typically functions as data producer and/or consumer and router. Used to join a new instrument to an existing WirelessHART network and possibly to read eld device PV and/or diagnostics.
Handheld
Provisioning device.
Router. Access point Provides the interface between the wireless mesh network and the Gateway. Provides the connection between wireless and the host network. WirelessHART to host interfaces such as Modbus Probus Ethernet. May also perform network manager and security manager functions. Backbone router.
Gateway
Gateway.
Network Manager
Builds and maintains the mesh network. It identies the best paths and manages distribution of slot time access. Manages and distributes security encryption keys. It also holds the list of authorised devices to join the network
System Manager.
Security Manager
Security Manager.
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pool becomes the totality of IEC/PAS 62591 and ISA100 manufacturers. A more competitive supply side environment, for the same reason. Lower on-site maintenance spares holdings because (large) end-users would not need to hold both IEC/ PAS 62591 and ISA100 eld instrument spares. Reduced investment in training since they would not need to train on both systems. Reduced investment in infrastructure since they would not need to hold, for instance, hand-held devices for provisioning wireless devices. Overall reduced lifecycle costs. From a vendor perspective the benets include: Faster global adoption of wireless technology since endusers would not be stuck in the choice dilemma. In an October 2010 report1 from ARC Advisory Group the potential revenue increase resulting from faster adoption was postulated at up to hundreds of millions of US Dollars. A larger potential market since they would be able to market to all potential instrument purchasers.
CONVERGENCE STATUS
Both ISA100 (Working group WG12) and NAMUR have active programs in place to determine roadmaps to convergence and there is a working communication channel between NAMUR and ISA on the subject. The ISA100.12 convergence subcommittee initiated a Convergence User Requirements Team that submitted reports both to ISA and to NAMUR in 2010. NAMUR produced report NE133: Wireless Sensor Networks: Requirements for convergence of existing standards, addressing the issue. In 2010 NAMUR also entered into discussion with WIA-PA with a view to that standard also being included in convergence discussions. Can 1 340 000 000 (thats approximately 20% of the worlds population) ever really be wrong?
ISA100.11a offers a vaster coverage and broader view of process automation solutions Gengyun Wang
Table 2. Blue team and Red team key players in each corner.
WirelessHART ABB Elpro Emerson Endress+Hauser Pepperl+Fuchs MACTek Phoenix Contact Siemens
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WIRELESS
perhaps more emphasis was put on embedding security into the standard and that IPv6 addressing is embraced. Unlike WirelessHART, ISA-100.11a supports the concept of sensor network subnets, oering greater expansion potential. A detailed technical comparison of WirelessHART and ISA-100.11a performed as part of Gengyun Wangs MSc thesis4 concludes that ISA100.11a oers a vaster coverage and broader view of process automation solutions and cites aspects such as latency minimisation, management of QoS, security and object orientation. Table 1 shows typical devices and device roles for each of WirelessHART and ISA-100.11a. Unfortunately, with the nal draft of WIA-PA only released in October 2011, there is insucient information in the public domain to include comparative details for WIA-PA. Figures 1 and 2 respectively show typical system architectures for WirelessHART and ISA-100.11a. The terminology and purpose of devices diers a little between the standards, and in many cases a single device may perform multiple roles (for instance a WirelessHART Gateway may actually embody Adapter, Gateway, Security Manager and Network Manager), so Table 1 and Figures 1 and 2 should be considered as comparative guidelines only. Readers should refer back to the standards themselves for a deeper understanding of these roles.
At the same time there is the growing concern about eavesdropping on industrial wireless for the purpose of sabotage. Over and above the use of 128-bit security keys, which help to foil eavesdropping attempts, secure industrial wireless uses channel hopping, slow channel hopping, channel whitelisting and blacklisting. These channel hopping communication strategies are handled by the Network Manager or System Manager and there are some signicant dierences in the complexity and congurability of channel hopping strategies between WirelessHART and ISA-100.11a.
CHANNEL HOPPING
One of the challenges that secure industrial wireless communications has to address is that of ever-increasing trafc on the unrestricted 2,40 GHz ISM band on which all of these industrial wireless standards are built. This same band is shared by Zigbee, Wi-Fi, Bluetooth, smartphones, wireless telephone handsets, security cameras, baby monitors, remote controls and a plethora of other devices. Simply put: the airwaves are crowded in this band.
Andrew Ashton has electrical, mechanical and business qualications and has been active in automation and process control since the early 1980s. Since 1991 he has headed up a company that has developed formulation management systems for the food, pharmaceutical and chemical manufacturing industries and manufacturing solutions involving the integration of various communication technologies and databases. Developed systems address issues around traceability, systems integration, manufacturing eciency and eectiveness. Andrew is a contributing editor for SA Instrumentation and Control.
REFERENCES
Reference Organisation 1 ARC Consulting 2 3 4 Resource ARC Brief: ISA100 and Wireless Standards Convergence HART Communication Foundation The Components of WirelessHART technology International Society of Automation ISA-100.11a-2009: Wireless Systems for Industrial Automation: Process control and related applications Chalmers University Of Technology Report No. EX036/2011: Comparison and Evaluation of Industrial Wireless Sensor Network Standards ISA100.11a and WirelessHART URL http://www.arcweb.com http://tinyurl.com/5rm2zmv http://tinyurl.com/6dg3jas http://tinyurl.com/6bo6dnc
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WIRELESS
ETHERNET ALTERNATIVES
In cases like these it is necessary to look at an alternative communication medium to copper or bre optic cabling, such as wireless. Wireless communications come in various forms. Wireless can be used for relatively short distances up to approximately 3 km, in which case 802.11, more commonly known as WiFi, will be recommended. To set up wireless over slightly longer distances than WiFi, up to around 12 km, WiMAX, also known as 802.16/e, is the common choice. To reach distances greater than this, cellular or satellite connections can be investigated. These allow connectivity to reach almost any location on the globe, depending on the application. One of the most obvious advantages when using WiFi, or any wireless communications technology, is the lack of cables. When an overow meter 3 km away from the main network needs to be connected in order to send an update once every hour, it is not feasible to lay thousands of rands of cabling. In these situations wireless communications can save time and money. However, there are disadvantages to
WI-FI
802.11 wireless communications do not need to be licensed, which can be both an advantage and a disadvantage. Other advantages are that there are no hidden costs, and 802.11 hardware can simply be purchased and installed at the users discretion. The disadvantage, however, is that interference can be caused by other
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surrounding wireless devices as it is legal for anyone to setup their own wireless. For this reason a site survey including a wireless frequency scan is essential when planning for a wireless installation. A frequency scan will show what frequencies are being used in the area, and the installer can then determine which frequency to use so as to avoid interference. In more populated areas it is worth performing frequency scans every few months to make sure that no new wireless systems have been put in place that could cause interference. WiFi is not considered the strongest or most stable of links, and so should not be used for critical applications where a link failure could cause major problems, site shutdowns or even death. However, in cases where noncritical remote connections are required, 802.11 wireless can be an excellent time and money saver.
WIMAX
WiMAX, or IEEE 802.16, provides a wireless mesh network with a much greater range than 802.11 wireless up to 12 km radius or more, depending on the hardware. WiMAX also does not require line-of-sight, although bandwidth and performance may be aected in a non-LoS scenario, depending on the environment. The 802.16e Enhanced standard also calls for an allowance for WiMAX subscribers to be able to travel at up to vehicular speeds of 120 km/h and to be able to cross over to dierent WiMAX base stations without renegotiating the link. This is dierent to 802.11 wireless which has to renegotiate the link to each new access point as it moves around. This means that for applications such as VoIP (Voice over IP), 802.11 it is not suitable if users need to hold calls whilst moving around the site. However, 802.16e will allow this movement between dierent WiMAX base stations without dropping the call. The disadvantage to 802.16 (which again could also be an advantage) is the requirement that frequencies be licensed for specic areas before they can be used. This licensing is handled by ICASA, the regulator for the South African communications sector, or the equivalent body in countries other than South Africa. This licensing can prove to be a time consuming task, and also raises the cost of the solution. However, having a licensed frequency means that interference from an outside source cannot happen legally. This means that interference on a WiMAX link is less of a concern than with 802.11 WiFi. Finally WiMAX will require regular renewals of subscription fees for the licensing of the frequencies, unlike WiFi which is a once o payment for the hardware (not counting spares or possible repairs on the hardware).
addition if any one of the links has a problem, the end device would be unreachable. The use of WiMAX or WiFi is not even an option in this case. In these situations either cellular or satellite links would be an option, both having their own advantages and disadvantages. They can be used almost anywhere to gain network connectivity. Cellular communications will still require a cellular tower within range to get a connection, but nowadays most areas will have cellular towers in range. For satellite, all that is needed is an unobstructed view of the sky. However, both of these technologies come with disadvantages. Unlike WiFi they incur monthly costs. Cellular connections require the user to pay for the amount of data transferred, whilst satellite connections require a monthly rental cost. Also, both of these technologies rely on a third party and the end user does not have direct control in the case of problems.
WIRELESS
Although wireless might not always be the rst choice, especially in mission-critical applications, it can be one of the best methods when transferring non-critical data from remote sites, or areas where physical cabling is not feasible. However, the use of wireless links should only be considered after proper planning and consideration of all the factors involved. Site surveys are essential in order to properly assess the installation requirements prior to purchasing of equipment, and professional installers must be used to ensure the antennas are correctly mounted so as to provide a strong and stable link.
For more information contact Tim Craven, H3iSquared, +27 (0)11 454 6025, info@h3isquared.com, www.h3isquared.com
CELLULAR OR SATELLITE
In some cases WiFi or even WiMAX cannot achieve the distances needed. A single camera or PLC in a remote area 100 km away from a network would need many dierent WiMAX links, all back to back, in order to use WiMAX. The expenditure required to set this up and the ongoing maintenance required would not be feasible. In
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WIRELESS
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WIRELESS STANDARDS
In developing a universal standard for industrial automation wireless networks a number of challenges emerge, not least because most licence-free wireless networks use the same 2,4 GHz bandwidth and many sensor networks are based on the IEEE 802.15.4 standard. Clearly there are concerns about co-existence and interference leading to reliability and latency problems and about multiple protocols sharing the same bandwidth.
OBSERVATIONS
In open terrain with no obstacles a range of 600 m can be expected in pipeline applications, a higher antenna position improves communication quality, a range of 50-100 m can be expected near to plant steelworks, a range of >50 m can be expected inside infrastructure and inside plant steelworks a range of <<50 m can be expected. Users have concerns about security with the potential for jamming, sabotage and the compromising of network privacy, but also want systems that are open, backwards compatible, interoperable and cost eective to implement. One thing is certain: the industry must strive to establish a global standard that covers communication from sensor to control room, is designed with security in mind and is end-user driven. Unfortunately, this ideal scenario is unlikely to occur in the immediate future since two standards are currently being used by dierent industry players Wireless HART and ISA100.11a. Although the two have some features in common, in reality they are very dierent. In particular, the scope of ISA100.11a is much wider. Whereas Wireless HART focuses on monitoring from WI HART enabled eld instruments, ISA100.11a oers the scope to cover everything from eld instruments to control-room integration. Moreover, it is compatible with a variety of protocols including Foundation Fieldbus, Probus, Modbus and others as well as HART. It allows over 1000 devices in a network compared to only around 250 with Wireless HART. Yokogawa is committed to supporting ISA100.11a as a preferred single international standard. In addition the ISA99 Security for Industrial Automation and Control Systems standard will be implemented to warrant overall security and privacy.
have been carried out to establish the characteristics of 2,4 GHz wireless transmission within typical environments such as reneries and chemical plants, from which a number of important lessons have been learned: 2,4 GHz radio is sensitive to the presence of obstacles (pipe work and other metal structures, for example); wireless is unlikely to be aected by the local climate and response time is a useful indicator of the radio transmission conditions. As a result of this experience, Yokogawa is pressing ahead with the development of wireless-based eld instruments and access points as the initial stage of a total solutions approach. It is implementing partnerships with other organisations to facilitate aspects such as the integration of auxiliary sensors as well as mobile worker networks, integration of surveillance camera systems and long-haul inter-plant connections. A lesson learned from conducted wireless sensor eld trials and real project implementations of mobile worker networks is that obstacles may aect the reliability and hence the quality of service of the network. Specically, the proper location of access points and other devices and the possible need for inclusion of repeaters should be assessed beforehand. This is particularly critical for the successful operation of the mobile worker network where roaming is essential. It is expected that wireless sensor networks will gradually be adopted by the process industry. Although ISA100.11a is designed to accommodate control applications, initially the majority of applications will be for monitoring due to battery life limitations. In existing installations the benets are obvious: measurements for process monitoring and condition monitoring can be added where the existing infrastructure cannot accommodate them. State of the art Greeneld sites are expected to be equipped with intelligent instruments that are mostly connected through wired instrumentation systems such as Foundation Fieldbus, but with several wireless networks for process and condition monitoring present.
SUMMARY
Yokogawa is committed to the emerging wireless technologies as a way forward in implementing total solutions with wireless sensor networks as a key element in providing DCS and plant asset management Anywhere, Anytime. The Yokogawa values of openness, inter-operability and reliability will be provided by systems based on the ISA100 standard with Yokogawa assuming total wireless solution responsibility.
For more information contact Johan van der Westhuizen, Yokogawa SA, +27 (0)11 831 6300, johan.vanderwesthuizen@za.yokogawa.com, www.yokogawa.com
WIRELESS STRATEGY
Yokogawa has developed Star, Mesh and a combination of the two networks, with the emphasis on self-healing network congurations and high security levels. It is also investigating long battery life for eld operation and longer sensing ranges (up to 5 km). Field trials
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RELAYS
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In order to meet the increasing demand for safety standards in modern industries, many end-users are looking for methods to eliminate the need for electrical sta to open MCC cubicles in order to determine the nature of a motor trip or to adjust motor protection setting parameters. NewElecs KE range protection relay can have an optional door mounted fault indication display as well as an infrared data acquisition and transfer facility (IRDA) that is both inexpensive and easy to use. A transceiver IRDA is simply attached to a communications cable that connects to a laptop. The housing on the IRDA is magnetic to fasten to the door mounted RDU so that the operating sta may adjust, read and save data directly. The KE is an advanced motor protection relay that is also capable of recording real versus apparent power utilisation for analysing motor ecacy. It has outstanding protection benets that include earth insulation lockout, user selectable instantaneous or IDMT earth leakage tripping characteristics, programmable limitation to start attempts and up to 2000 event records as well as a separate listing of the last 60 faults together with current and voltage details. In ameproof applications, the IRDA saves time since the ameproof door need not be removed to achieve the results mentioned. For utilisation underground, NewElec has developed an explosion proof version of the IRDA that allows the operator to download motor information to a USB memory stick device.
For more information contact Luc Dutrieux, NewElec, +27 (0)12 327 1729, sales@newelec.co.za, www.newelec.co.za
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IT IN MANUFACTURING
SOLUTION REQUIREMENTS
To achieve the expressed goals, Imana Foods would rely on a scalable system design where there was to be minimal data duplication between the ERP and production systems. The ERP system would still be responsible for the queuing and prioritising of work orders. All incoming raw materials needed to be lot managed and scanned into their respective storage locations for tracking into the blenders. This would need to be done for all materials used in the more than 150 recipes in Imana Foods range of products. Bags of work in progress from the blenders needed to be individually weighed and tagged with bar-coded labels for tracking through to the packing lines. Full traceability would then be achieved by ink jet coding the nished product. One of the most important requirements of the system was that it should guide operators on what to do when, so that printed instructions would no longer be necessary. The scada system would verify all transactions and would be the source of daily shift reports, says Irvine.
BACKGROUND
Prior to this project, team leaders had no clear visibility into the blending operations. Blenders worked from instructions printed manually from the ERP system, says Murray Irvine, project engineer at IT Dynamics. This meant that the work schedules depended on the reliability of a printer, and the recipe integrity on the reliability of the operator. On the ingredient side, while every eort was made to stick to a rst-in-rst-out transfer of raw material, this was not always guaranteed and stock discrepancies were identied at the end of every month. There was no real traceability.
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and backward genealogy of materials, equipment and production events. The Sequencer object coordinates tasks that must be executed in a certain sequence or order of operation. It is designed to congure, execute and manipulate a sequence of operations associated with attributes from multiple application objects running within an industrial application. The Sequencer exposes a comprehensive set of attributes that allows users to create SmartSymbols and regular InTouch animations to monitor and control the Sequencer operation. PEM, FMM and Sequencer are now all part of Wonderwares Equipment Operations Module. Mobile computers for use by the operators and mobile label printers were both sourced from Intermec due to good service levels, pricing as well as being the only supplier that could support both narrowband and broadband. On the technology front, Imana Foods chose barcodes over an RFID solution. This decision was based on price and the fact that RFID as a technology is not yet mature enough to give an easy, viable solution. For wireless networking with the mobile computers and printers, broadband was chosen because narrowband could not cope with the InTouch-based operator interface even though graphics and complex displays were eliminated.
Figure 1.
IMPLEMENTATION
Because of the scope of the project, many disciplines and skills would be required including a project manager, engineers, business analysts, software developers, network engineers, instrumentation technicians, network administrators and technical support personnel. Figure 1 shows the system topology. The MPI network was expanded to include the blenders, resulting in 22 PLC nodes being connected to the Wonderware system. The blending area was set up for a wireless infrastructure with handheld PCs and wireless label printers. The handheld PCs are running a managed InTouch application through Microsoft Terminal Services which resides on the Application Object Server. The oce computers are connected via the Wonderware Information Server portal to allow viewing of custom and PEM reports. The system is fully integrated with the companys ERP system which passes the recipe information to the formula manager which is queried for each ingredient on a bag-by-bag basis in order to load the blender. The PEM objects store acknowledged data from the operators and provide the traceability for lot-tracked raw materials as well as for nished goods. The Sequencer object is used to sequence the blend process. The ERP system is sent the resultant blending process information in order to close the loop and monitor stock levels and any accounting variance anomalies. In addition, custom reports calculate equipment utilisation from time data captured in the Wonderware production database. The most important item of information supplied by the system is the raw material lot tracking data as fed into the blenders, says Irvine. This is giving Imana Foods a far greater level of control than previously.
On the handheld units, the blender operators are shown the recipe details as well as an ingredient by ingredient breakdown of what they have to scan or acknowledge as having been fed into the blender. The blender is on load cells which register its weight increase as it is loaded. There are built-in timers that capture the total blend time as well as any additional mixing times that may be required. When being unloaded, platform scales underneath the blenders register the weight of the ooaded bag and this data is captured by the PEM objects.
BENEFITS
HACCP certication was achieved within three months of going live. Better insight into the blending operation in the factory from a material usage variance point of view. Improved raw material stock control. Real-time blend closure in the ERP system. Factory procedural deviations are highlighted. More consistent product quality from following recipes exactly. Improved management of the physical blending process. Proper temperature control of sensitive blends.
CONCLUSION
Imana Foods has achieved all its initial project goals and has ambitious plans for expanding and extending the capabilities of the system. This was made possible through the use of a exible platform in the hands of a very capable project team which amply demonstrated that technology is no longer a barrier to achieving business and operational objectives.
For more information contact Jaco Markwat, Wonderware Southern Africa, 0861 WONDER, jaco.markwat@wonderware.co.za, www.wonderware.co.za
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IT IN MANUFACTURING
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wide operating temperature range from -40 to 70C, no fan or other moving parts and a full metal IP40 enclosure. The WeOS operating system has been developed as a cross platform solution. Available on the Westermo RedFox, Wolverine, Lynx and Falcon products, it provides a future proof and scaleable solution for industrial networking requirements. Low power requirements results in a reduction in running cost over the life of the unit and a footprint size
of only 100 x 50 mm makes the unit easy to incorporate into machines and existing applications. A wide operating range of 19-60 VDC increases the scope of suitable applications.
For more information contact Bob Petrie, Throughput Technologies, +27 (0)11 705 2497, bob@throughput.co.za, www.throughput.co.za
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IT IN MANUFACTURING
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The dierence between the CAT6A and CAT6A components that are available in the market should be noted. In a 10 Gb network a reliable and high quality data transfer channel is only obtained when using CAT6A components.
For more information contact Sean Hadley, Phoenix Contact, +27 (0)11 801 8200, seanh@phoenixcontact.co.za, www.phoenixcontact.co.za
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MARKET DRIVERS
Increasingly, HMI platforms help users visualise key metrics and KPIs, such as overall equipment eectiveness (OEE) and energy savings, to help them quantify the benets of
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their automation investments. These users are all too aware of global competition and escalating energy costs, as well as the need for automation equipment that can help them achieve more exible production, while reducing environmental impacts. However, users must go through a business justication process before they can replace their existing, less ecient equipment. This business justication requires clear metrics regarding the return on investment (ROI) and return on assets (ROA) of each purchase. Increasingly, they use their new HMI platforms as the digital dashboard to visualise and quantify these metrics.
components and performing extensive burn-in testing, so reliability should not become an issue until well along in the platforms service life. Software reliability, however, is not measured as a direct function of time. It is achieved by eliminating design faults and performing extensive functionality testing and debugging. Unlike hardware, software reliability does not diminish over time. However, software reliability can be aected each time an upgrade is made. This has been an argument that bodes well for the HMI platform, as the embedded software has been included as part of the extensive functionality and burn-in testing is performed prior to delivery to the user. As a result, the HMI platform is not subject to continuous software upgrades that could negatively impact reliability.
OPERATIONS MANAGEMENT
End user companies are increasing their agility by accessing and visualising real-time information and applying it to speed up and improve operations. They are also integrating business, manufacturing, and production within the operations management realm. These users are deploying operations management solutions based on industry standards to standardise visualisation and IT infrastructure across multiple facilities. This standardisation of visualisation is a driving force in the growth of HMI platforms. These users seek to reduce IT and engineering costs by implementing rapidly deployable and easy-to-manage visualisation applications. They want to take the pain out of expanding and managing disparate systems by transforming their HMI platforms into enterprise-wide collaboration tools, without disrupting their current operations.
MAINTENANCE
A key reason that HMI platforms are growing in popularity is their ability to lower maintenance time and expense for OEMs and end users. HMI platforms that support automation and enterprise applications can provide the control room operators and maintenance technicians with information to speed up maintenance operations and reduce interruptions. These HMI platforms provide maintenance crews with access to the companys maintenance management system at either the control room level or directly at the machine, equipment, or unit level. Some HMI platforms are congured to incorporate HMI, conguration procedures, programming languages, and maintenance procedures. This provides a common interface, and allows the user to achieve the operational benets of transparent integration between each domain. ARCs upcoming latest worldwide HMI Software study, along with ARCs worldwide Operator Interface Terminal study, addresses in depth many of the issues and trends relating to HMI platforms.
For more information contact Paul Miller, ARC Advisory Group, +1 781 471 1126, pmiller@arcweb.com, www.arcweb.com
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Phoenix Contact has expanded its range of VMT 3000 panel PCs to include a device with a 26 cm (10.4 in) high resolution display with IP65 protection. This display was specically developed for use under harsh industrial conditions and has a resolution of 1024 x 768 pixels. The panel PCs have an attractive enclosure manufactured out of solid die-cast aluminum. As a result of the dust protected and waterproof enclosure with IP65 protection, these panels are weather resistant and are insensitive to humidity and moisture. They can also be used in extreme temperatures ranging from -20 to 550C, which allows them to be employed outdoors as well as in refrigeration systems. Another option is a sunlight readable display which allows them to be used in direct sunlight. The panels are especially energy ecient thanks to their Intel-Atom platform, a combination of a highly integrated chipset and a power saving processor. The Atom processor can either be clocked at 1.1 GHz or 1.6 GHz, and has a thermal design power (TDP) of 2.5 W. The lower power consumption is also noticeable in the lower amount of heat generated. The device does not require a fan. This means that users get a fully edged industrial PC equipped with an industrial grade touch screen and all of the relevant interfaces. It can be used for years as an energy ecient operating console for machine related use.
For more information contact Andre Kemp, Phoenix Contact, +27 (0)11 801 8200, andrek@phoenixcontact.co.za, www.phoenixcontact.co.za
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TEMPERATURE
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PRODUCT NEWS
Turcks Q-track family of linear position sensors has been expanded to include the newest QR14 and the Q17 models. Measuring just 14 mm and 17 mm in height, the compact, non-contact inductive sensors deliver dependable, repeatable measurements in applications with spacing limitations and harsh environments. Operation is based on the RLC resistance inductance capacitance principle. Unlike potentiometric or magnetostrictive technologies, the sensors incorporate precisely manufactured printed emitter and receiver coil systems. The emitter coils are activated with a high frequency AC field and produce an inductive RLC circuit with the positioning element. The element is inductively coupled with the receiver coils, which are arranged so different voltages are induced in the coils, depending on the position of the actuator. The voltages serve as a measure for the sensor signal. Q-track sensors deliver maximum measuring
spans, with minimal blind zone and high resistance to EMI/RFI noise interference. The low profile design and rugged housing make the Q-track sensors the preferred choice for versatile linear positioning applications, said Marty Cwach, Product Manager, Turck. Our ability to repackage technology into new housing designs enables us to deliver smaller sensors that suit the widest variety of application and spacing requirements. Superior to alternative technologies, the innovative design, linearity and repeatability of the Q-track sensors eliminate the performance failures commonly experienced with other technology options. The RLC principle of operation used in the Q-track linear position sensor is highly immune to noise interference and is inherently weld field immune. Since the position element does not contain a magnet, it can be used in metalworking applications because it will
not attract ferrous debris, which would affect the operation of a magnetostrictive sensor. Additionally, the inductively coupled position element provides noncontact position feedback. This is ideal for use in applications with constant motion, such as pinch rollers, cylinder position, web tension control and pitch control. Along with these advanced design features, the compact, durable construction increases functional flexibility. The QR14 and Q17 include both current and voltage outputs, eliminating the need for two separate sensors and offering greater convenience and cost efficiency. The fully potted and sealed IP67-rated housing protects against moisture and dust in demanding environments.
For more information contact Rodney Topham, RET Automation Controls, rodney.topham@retautomation.com, +27 (0)11 453 2468, www.retautomation.com
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PRODUCT NEWS
The H250 M40 flowmeters, based on the variable area principle, are versatile and can be used for gases as well as conducting and non-conducting liquids. The sturdy all-metal version ensures high resistance to pressure, temperature and product, and can withstand extreme usage and ambient conditions. The device features a completely modular design enabling it to be individually configured for virtually any requirement, from pure analogue use without auxiliary power to integration into a fieldbus system. The H250 is available in nominal sizes DN15 - DN100 in various materials and connection variants. Typically, variable area flowmeters are installed upright in rising mains and the product must flow through them from bottom to top which can lead to extra expense. The H250 M40 on the other hand, offers freedom in terms of layout as there are special versions of the device that can be used for horizontal and even fall pipes. All electronic components are designed to be intrinsically safe and non-sparking and can be used in gas and dust explosive areas. Optionally, the same components with a safety lid can be installed as devices in explosion-proof enclosures. In this way, a single device can comply with different regional explosion protection strategies. All product variants offer category IP66/IP67 protection.
For more information contact John Alexander, Krohne SA, +27 (0)11 314 1391, johna@krohnesa.co.za, www.krohne.com
The wide selection of compact, bearingless encoders presented by Baumer at the Interlift trade fair provides particularly promising solutions for lift engineering. The absolute encoder MHAD (photo) is one of the highlights in the Baumer portfolio of rotary encoders without integral bearings. It combines the product benets of narrow dimensions with the functional capabilities of an absolute encoder. The unit is easy to t into tight spots where installation space is conned and thanks to its large through-hollow shaft the encoder does not consume any space at the shaft end while allowing installation anywhere on the motor shaft. MHAD is a member of the HDmag encoder family which excels through non-contact magnetic sensing, absolute reliability and maximum availability. MHAD unites high-precision absolute and incremental signals in a single device. The
current position will be output as absolute value with 16-bit resolution, while an additional incremental signal (8192 steps per turn) provides speed feedback. The large permissible tolerances of 1 mm on radial and axial displacement as well as air gap allow for safe and quick installation. An LED provided at the encoder acts as activity indicator and at the same time as an installation aid. The encoder platform provides IP67 protection in its standard congurations, withstands operating temperatures between -40 and +85C and due to its robust design andmmagnetic sensing technique provides dependable operation not only in dust and humidity but also during severe shock and vibration.
For more information contact Temperature Controls, +27 (0)11 791 6000, sales@tempcon.co.za, www.tempcon.co.za
with one output either 0-10 V in a 3 wire system or, 4-20 mA, in a 2 wire system for continuous monitoring.
For more information contact Allpronix, +27 (0)11 795 9500, sales@allpronix.com, www.allpronix.com
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Universal Technic of France has expanded its range of AC/DC current probes. The large jaw clamp can accommodate circular conductors up to 83 mm in diameter and busbars of 100 x 64 mm or 122 x 54 mm. Current ranges are up to 7500 A. The mid-size jaw can accommodate circular conductors up to 50 mm in diameter and has the capability of measuring currents up to 2000 A. The smallest clamp has a jaw which can accommodate conductors up to 15 mm in diameter and measure currents up to 300 A.
Clamps are available operating o their own internal batteries or alternatively they can be powered by the analysing equipment via a cable. Various terminations can be supplied such as BNC, D01 and 4 mm safety plugs. Hall eect techniques are employed, ensuring high accuracy and a wide frequency response.
For more information contact Mervyn Stocks, Denver Technical Products, +27 (0)11 626 2023, denvertech@pixie.co.za, www.denvertech.co.za
For more information contact National Instruments, +27 (0)11 805 8197, ni.southafrica@ni.com, www.ni.com/southafrica
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As the steel industry continues to strive for more effective plants with 100% availability, Hansford Sensors remains are committed to helping customers monitor plant machinery effectively. Typical areas include rolling mills, drives, gearboxes and cooling towers. Before getting too involved in what technique is to be applied, consideration needs to be taken to whether the application requires offline or online monitoring. Within the Hansford Sensors range of products, the AC sensor (HS-100 Series) has been designed to withstand the harsh conditions that exist in the steel industry. There is also supporting hardware that can be used to connect to a local interface box (HS-SE) for offline readings using a data collector or permanently installed equipment (420 mA accelerometers, HS-420 Series) that can be connected to a PLC for trending and logging. More sophisticated systems involve looking at velocity and bearing conditions. In this example, the standard AC sensors (HS-100 Series) connected back via a vibration module (HS-500 Series) can be used to protect the machine. When used with the vibration module (HS-510), the output can be displayed and alarmed locally and also connected back to the PLC. Wireless options are also available. Within the Hansford range of accelerometer products there are a selection of different mountings and connection methods, including armoured, silicon and fire retardant styles. Consideration must also be made to the practicality of the installation and in areas where the machine may need to be accessed it is recommended that sensors with a separate cable assembly are used.
For more information contact Temperature Controls, +27 (0)11 791 6000, sales@tempcon.co.za, www.tempcon.co.za
Banner Engineering has introduced the U-GAGE M25U ultrasonic sensors. These are opposed mode ultrasonic sensor pairs specically designed for use in sanitary environments. The sensors, rated IP69K and IP67 (NEMA 6), are constructed of heavy duty 316 stainless steel, allowing them to withstand the high pressure washdowns, severe temperatures and aggressive cleaning chemicals common in food and beverage applications. With a smooth barrel housing free of threads, gaps or seams that could accumulate debris they allow thorough cleanup with minimal eort. IP68-rated washdown cordsets and FDA compliant brackets are also available to ensure reliable, long lasting performance in the harshest environment. The M25U is the ideal solution for challenging applications such as cleanin-place procedures that require reliable sensing in washdown environments. It
delivers all the advantages of conventional ultrasonic sensors utilising sound waves to detect the presence of targets while providing the most durable, robust design on the market. The ultrasonic technology also allows the sensor to reliably detect clear objects. M25U sensors can be wired for either normal or high speed. Normal speed oers a longer sensing range, while high speed provides a shorter response time, ideal for high speed counting applications. Applications include presence detection of clear or coloured containers during sanitising; food process monitoring; position monitoring; and aseptic bottling in contained environments.
For more information contact Rodney Topham, RET Automation Controls, +27 (0)11 453 2468, rodney.topham@retautomation.com, www.retautomation.com
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With a current-carrying capability of up to 125 A and cable cross-section sections of up to 35 mm, the PC 35 series of PC board connectors from Phoenix Contact have one of the best specications in the market. Since the plugging and unplugging forces of these connectors are quite low, the connectors can be connected to devices even those with high power rating in a user-friendly manner. The conductor connection is implemented by screwing the tension sleeve tight. The two- to six-pin plug connectors are factory equipped with a screw ange that reliably connects it to the base strip. The screw ange can also be used as a panel feed-through on the base strip side and
provides an additional hold within the device. For pitch sizes of 15 mm, the connectors have received unrestricted 600 V UL approval in compliance with UL1059 (1000 V in accordance with IEC). Using the inverted versions of the IPC 35, shockprotected device outputs as well as free hanging cable-to-cable connections and board-to-board connections are possible. The plug connectors and base strips are also available in a four-pin version with a professional-grade shield connection.
For more information contact Sean Hadley, Phoenix Contact, +27 (0)11 801 8200, seanh@phoenixcontact.co.za, www.phoenixcontact.co.za
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The new wireSENSOR MK-88 extends the Micro-Epsilon portfolio of ultra compact draw wire sensors. As a low cost alternative to the aluminium based standard industrial range, the MK series excels in its compact design, its glass fibre reinforced plastic construction and its low price for large quantities. In particular it offers an outstanding balance of sensor size and measuring range. Wire lengths of 2,3 m, 3,5 m or 5 m open the door to applications that used to be exclusive to larger and more expensive sensors. Sensors with potentiometer based interfaces are available (420 mA, 0-10 V, 0-1 k). For OEM projects, all common incremental and absolute digital interfaces or fieldbuses may be used.
For more information contact Elton Murison, Esteq Engineering, +27 (0)12 809 9500, e.murison@esteq.com, www.esteq.com
Vision sensors in Omrons new FQ range consistently deliver crystal clear images even with the most challenging of targets. They feature one-touch control via a simple and intuitive menu system that eliminates the need for complex instructions and specialist know-how and oers outstanding simplicity of installation and set up. The rst products of this type to employ HDR (high dynamic range) technology, FQ vision sensors incorporate full colour processing with up to 16 million colours, built-in polarising and halation lters and integrated high-intensity LED lighting. These features enable them to provide stable inspection even with highly reective, low contrast and similarly dicult targets. They also cope easily with piece-to-piece variation between targets, and with target misalignment.
So that users can select a sensor that accurately meets particular requirements, Omron supplies its new FQ vision sensors in versions with elds of view from 7,4 to 300 mm. All models have an IP67 ingress protection rating, making them suitable for use in the tough operating environments. As an aid to integration with modern industrial control systems, Omron FQ vision sensors feature industry-standard connections for trigger and I/O signals, as well as Ethernet connectivity. For applications requiring more than one vision sensor, multiple units can readily be networked together and controlled from a single point.
For more information contact Terry McIntosh, Omron Electronics, 086 066 7661, terry_lynn_mcintosh@eu.omron.com, www.industrial.omron.co.za
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Gigavac has announced the new GXL14, the rst release in the GXL line of latching contactors able to switch voltages from 12 to 750 VDC and AC. With a continuous duty rating of 350 A, the GXL14 expands on Gigavacs GX line of EPIC sealed contactors that feature a compact, lightweight design in an environmentally sealed package. The GXL14 latching line of contactors, operate without continuous coil power. This feature is preferred in applications such as solar power, power backup systems and vehicle systems operating on battery power. By conserving the power normally required to operate a standard relay, the GXL series allows the user greater exibility in design. The GXL14 was developed for the transportation and bus industry including
recreational vehicles, emergency vehicles and mining equipment, as well as solar power and power back-up systems. The GXL14 measures 57x60x115 mm and comes with easy-connect chassis level power terminals that allow for installation without the need to bend large power cables or develop special bus bars. It can be mounted in any position and used in harsh environments at temperatures from 55 to 85C. An optional SPST-NO auxiliary contact driven o the main armature gives true indication of the main contact position.
For more information contact Denver Technical Products, +27 (0)11 626 2023, denvertech@pixie.co.za, www.denvertech.co.za
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As each component is a part of an innovative modular system, Wenglors InoxSens range of hygienic optical sensors is ideal for use in the food, beverage and pharmaceutical industries. The system integrates sensor, mounting and connector technology to save time during installation, cleaning and maintenance. There are no recesses or crevices so water, chemicals and contamination run o completely without damaging the shell. The housings are of rugged medical quality V4A stainless steel. InoxSens is rated to IP68 and IP69K
protection and also provides mechanical protection for all standard cable types. A wide variety of Wenglor sensor devices make up systems such as scanners, OCR readers or vision sensors, illumination devices, colour sensors., print mark sensors, reex sensors for measuring tasks or contrast recognition or retro-reective light barriers for recognising clear glass.
For more information contact Anastas Schnippenkotter, ASSTech Process Electronics & Instrumentation, +27 (0)11 708 9200, info@asstech.co.za, www.asstech.co.za
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info@acdc.co.za sales@allpronix.com pmiller@arcweb.com info@asstech.co.za c.muller@beckhoff.com gerhard.greeff@bytes.co.za info@comtest.co.za vmaharaj@cubetech.co.za ettienne@switches.co.za denvertech@pixie.co.za robhare@eaton.com info@za.endress.com e.murison@esteq.com info@h3isquared.com hsa@honeywell.com chris.cronje@ifm.com info@instrotech.co.za johna@krohnesa.co.za info@microsep.co.za info@neweventsltd.com ni.southafrica@ni.com sales@newelec.co.za terry_lynn_mcintosh@eu.omron.com sales@pandf.co.za info@phoenixcontact.co.za info@randci.co.za rodney.topham@retautomation.com info@rjprogtech.co.za jacqui.gradwell@schneider-electric.com sales@shorrock.co.za keshin.govender@siemens.com samantha.joubert@skf.com info@smoothedge.co.za info@surgetek.co.za sales@tempcon.co.za bob@throughput.co.za drives@varispeed.co.za john.groom@za.vega.com sales@wika.co.za jaco.markwat@wonderware.co.za info@za.yokogawa.com
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55* 58 50,51 64 44 12,45* 29,30,31,47* 22 56,61,stitched insert* 51*,59,63 8,21* 7*,11,14 62 35*,36,37 13,49 54,64 63 41*,58 27*,28 11* 59 40*,41 40,62 61 49,52,61 28*,54 IFC*,5*,13*,57,60 OFC*,24,25 10,45,53* 52 8,9*,48 64 26* 63 56*,58,60 46,47 30* 26 3*,59 42,43,OBC* 6,31*,38,39,62
*denotes advertiser
For more information on these and other suppliers please see www.ibg.co.za