IAA August 09

Advanced Process ControlSpotlight On

Plant asset ManageMent:

EDDLSpeakingWater & WasteWater:

AdvantageTHE

Pneumatic Waste reduction:

ABusinessDecision

August 2009

www.iaasiaonline.com

MICA(P) 154/07/2009 | ISSN 0219/5615 | PPS 1561/06/2010 (028221)

ENQUIRY NO. 041

Helping you integrate machine safetyfor maximum productivity

Copyright © 2009 Rockwell Automation, Inc. All Rights Reserved.

Discover more at: www.discoverrockwellautomation.com/safety

With integrated machine safety solutions, application experience and

legislation knowledge, we can help you achieve a safer environment

without compromising productivity.

The result can be a safer future for more than just your business.

IntegratedMachine SafetySolutionsDEVICENET

ETHERNET/IP

CONTROLNET

Helping you integrate machine safetyfor maximum productivity


Discover more at: www.discoverrockwellautomation.com/safety

With integrated machine safety solutions, application experience and

legislation knowledge, we can help you achieve a safer environment

without compromising productivity.

The result can be a safer future for more than just your business.

IntegratedMachine SafetySolutionsDEVICENET

ETHERNET/IP

CONTROLNET

Rockwell Automation Southeast Asia Pte Ltd

Singapore Tel: 65 6510 6688 Fax: 65 6510 6699

Indonesia Tel: 6221 255 45200 Fax: 6221 255 45299

Malaysia Tel: 603 8997 6688 Fax: 603 8997 6699

Philippines Tel: 632 323 0588 Fax: 632 323 0561

Thailand Tel: 662 936 1500 Fax: 662 936 1510

Vietnam Tel: 848 6255 6400 Fax: 848 6255 6411

www.rockwellautomation.com/sea


Discover more at: www.rockwellautomation.com/sea

What happens if your system fails?protecting your operations with CitectSCADA built-in redundancy

By choosing CitectSCADA with built-in redundancy, whatever type of disaster recovery is planned for, it can greatly reduce lost data and downtime.

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ENQU

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054

contents

20 Plant asset ManageMent: sPeaking eDDl

2 industrial automation asia | August 2009

contentsAUGUST 2009

SECTOR SPOTLIGHT

44 Water & Wastewater: The Pneumatic Advantage

Pneumatics presents a reliable alternative to electrical automation systems in meeting the requirements of water and wastewater treatment. By Armin Muller, Festo

SOFTWARE & NETWORKS

38 Operationally Ready With RFIDForklift RFID systems are a flexible and cost-effective way to support RFID operations. By Jack Tay, Intermec Technologies (S)

ISSUES & INSIGHTS

20 Plant Asset Management: Speaking EDDLEDDL allows seamless integration of devices into a digital plant architecture that uses diagnostic intelligence for predictive asset management solutions. By Jonas Berge, Emerson Process Management

CONTROL POINT

26 Template For PerformanceAPC methods improve the plant performance in terms of productivity, cost-effectiveness, product quality, operability, availability, usability, safety and environmental protection. By Dr Otmar Lorenz and Dr Bernd-Markus Pfeiffer, Siemens

30 Optimal Trade-offsAchieving energy efficiency and environmental compliance is not a problem thanks to advanced process control. By, Eduardo Gallestey, Greg Cairns, Konrad S Stadler and Jan Poland, ABB

34 A Layered StrategyA layered optimisation solution is low risk, requires low lifecycle maintenance costs and sustains benefits in the long term. By Donald Morrison, Honeywell

52Wind Power Opportunities

38 OPeratiOnally reaDy With rFiD

www.issuu.com/easterntrademedia/docs/iaa_august09_ebook/22









ENQUIRY NO. 026

Fuji ElEctric AsiA PAciFic PtE ltd171 Chin Swee Road #12-01, San Centre, Singapore 169877

Tel: (65) 6533 0014 Fax: (65) 6533 0021Email: [email protected] Website: www.fujielectric.com.sg

Dynamic Control PerformanceMultifunctional ApplicationEasy MaintenanceEnvironmental Adaptation

contents


AUGUST 2009

IMPORTANT NOTICEThe circulation of this magazine is audited by bpa world wide. The advertisers’ association recommend that advertisers should place their advertisements only in audited publications.

IndUSTrIAl AUTomATIon ASIA (IAA) is published 8 issues per year by Eastern Trade media Pte ltd 1100 Lower Delta Road #04-02 EPL Building Singapore 169206. Tel: (65) 6379 2888 • Fax: (65) 6379 2805Website: www.iaasiaonline.com Email: [email protected]

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TemplaTe For perFormance

26

eNeRgY

48 Waste reduction: A business decisionNot only good for the environment, waste reduction also reduces production costs. By Augustine Quek

52 Wind Powered opportunitiesThe market for wind energy is on the rise as countries and companies alike warm up to its potential. By Joson Ng

FeaTuRes

54 Progression by diversificationEmploying a strategy of diversification, Harting has emerged from being a components supplier to a solutions provider. By Derek Rodriguez

56 Emerson’s Performance Without compromise SeminarInnovation and Safety, Health and Environment were core issues discussed at the Performance Without Compromise Seminar

54progression By DiversiFicaTion

Cover: Siemens
















©2009 Invensys Systems, Inc. All rights reserved. Invensys, IntelaTrac and Wonderware are trademarks of Invensys plc, its subsidiaries and affi liated companies. All other brands and product names may be the trademarks or service marks of their respective owners.

Harness your mobile workforce for aligned business success.

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EDITOR’s PAGE

Derek RodriguezAssistant Editor

Published by:

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Jonas Berge, Dr Otmar Lorenz, Dr Bernd-Markus Pfeiffer, Eduardo Gallestey, Greg Cairns, Konrad S Stadler,

Jan Poland, Donald Morrison, Jack Tay, Parul Oswal, Armin Muller, Augustine Quek, Joson Ng, Tom Fiske

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MICA (P) No. 154/07/2009

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Water is not just crucial to life, it is essential. The lack of rainfall threatens to evolve into severe drought in the monsoon territory of Bangladesh. In Africa, the shortage of water is a seemingly never ending affair.

Acquiring clean, drinkable water is so much more than turning on the tap. It involves business, technology and in some cases, politics and governments.

Shows like the Singapore International Water Week (SIWW) that took place in late June emphasise the importance of having a sustainable supply of this prized commodity, especially with the event having the backing of the local authorities. It also demonstrates how automation can play a part, not just a walk on part but in a leading capacity.

Hearteningly, the SIWW proved to be a resounding success, with an increase in exhibition floor size and number of visitors. Even more encouraging is the figure of S$2.2 billion (US$1.5 billion) – the value of deals that were signed at the event.

One significant occurance during the course of the event was the opening of the S$150 million (US$104 million) Singapore Water Technology Centre, a research and development centre conceived by a

partnership between GE and the National University of Singapore (NUS). Located within the school of engineering at the NUS, the centre aims to develop safe drinking water systems across Asia as well as solutions for low energy seawater desalination, water reclamation and efficient water reuse.

Another was the opening of Singapore’s largest water plant, the Changi Water Reclamation Plant. With a price tag of S$2.2 billion (US$1.5 billion) to build, the plant is able to treat 176 million gallons of water a day.

On an individual level, we can contribute to this cause in the way we utilise our water. By employing restraint and putting in a conscious effort to save water, we can lessen the wastage of water by a fair bit.

Acquiring clean,

drinkable water is so

much more than turning on the tap

WATERWoRLD

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Modern manufacturing has a lot of different computer systems, but many

don’t work together. Yet they all contain data that is vital to the business.

Successful businesses recognize that these systems must collaborate to provide

the complete picture, the knowledge needed to make the right decisions. ABB’s

Collaborative Production Management applications, like cpmPlus Smart Client,

Enterprise Connectivity or Knowledge Manager help you harness this data,

transform it into knowledge, and provide it to the people who need it most.

Make your systems work together.

Find out more at www.abb.com/cpm

Collaboration drives business success

Unlock the hidden value of your data.

© Copyright 2009 ABB.

Find out more at www.abb.com/cpm or email: [email protected]


Industry newsABB Opens Drive Service Hub

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Singapore: ABB has opened its drive service workshop in Singapore to provide drive service support for customers in industrial, building automation and original equipment manufacturers (OEM) segments in Asia, outside of China, India and Bangladesh.

The service workshop is one of 15 global drive service workshops that will provide workshop repair service, reconditioning service and exchange units for low voltage drives, to help customers lower operational costs and save energy, meet their growing productivity and reliability objectives, while maintaining high environmental and safety standards.

The company has set up service hubs in major markets, including Singapore, to provide a specialised customer call centre, technical support, service training, spare parts inventory, highly skilled field service engineers, drive service and repair workshop, and service sales support for the respective regions.

“The opening of the drive service

and tools, with a common set of key performance indicators.

The opening ceremony was held at the company’s Ayer Rajah premises in Singapore and was attended by more than 50 industry partners, OEMs and customers from various major industries including marine, oil & gas, pharmaceutical and electronics sectors.

workshop completes the setup of the drive service hub in Singapore and ABB is positioned to be in the forefront regionally to manage and provide timely, efficient and economical turnaround services, especially for critical drive process applications,” said James Foo, president and country manager of ABB in Singapore.

All ABB drive service hubs are equipped with similar set up, processes

APC Wins Green Enterprise IT AwardSingapore: APC was selected as a winner in the Energy Efficient Products category of the 2009 Green Enterprise IT (GEIT) Awards, presented by the Uptime Institute and co-sponsored by the US Department of Energy. Award winners were announced at a ceremony at Uptime Institute’s fourth Annual Institute Research Symposium: Lean, Clean and Green, in New York City.

The GEIT Awards honour companies that have made significant strides in creating reliable, sustainable and energy-efficient data centres. APC’s InRow cooling products with active response controls and integrated thermal containment was selected as a winner.

August 2009 | industrial automation asia 9

Industry news

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Siemens PLM Launches Software Update

Cognex Releases Connectivity Solution

Singapore: Cognex Connect enables out-of-the-box connectivity between Cognex In-Sight vision systems and virtually any major PLC, robot, HMI and Fieldbus system commonly used in factory automation.

A simple point and click configuration interface makes it possible to control multiple vision systems from any network PC, and allows users to transfer data and images to an enterprise file server or display them in the user’s own operator interface.

“Cognex Connect makes the integration of vision into any automation system very easy,” said Ettore Cucchetti, Cognex’s VP of sales, marketing and support, Asia. “Because Cognex Connect supports virtually all major PLC, HMI, robot controller or Fieldbus systems, In-Sight users have unlimited flexibility in selecting which system integrators and automation equipment providers to work with.”

The standard Cognex Connect suite of communication capabilities includes pre-configured drivers, ready-to-use templates and sample code to accelerate system set-up and ensure smooth communication with factory automation robots and controllers.

It also provides an array of visualisation options for integrating inspection images from In-Sight into a central operator interface.

Cognex Connect delivers built-in support for the following controls and communications: PLC, PC or HMI, Robots, Fieldbus. The suite of communication capabilities is supported on all Cognex In-Sight models.

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Singapore (South Asia Pacific Headquarters) Tel: 65-6442 1000 Email: [email protected] Malaysia: Kuala Lumpur Toll-free: 00 800 9898 8998 Email: [email protected] Penang Tel: 60-4-397 3788 Email: [email protected] Thailand: Bangkok Tel: 66-2-248 3140 Email: [email protected]: Melbourne Tel: 61-3-9797 0100 Email: [email protected] Sydney Tel: 61-2-9482 2999 Email: [email protected]

NEW

© 2009 Advantech Co. Singapore Pte Ltd www.advantech.com

Build Your SCADA SystemWith ADAM Modules

Advantech eAutomation offers Distributed Remote I/O Moduleswith various Interface

ADAM-4000 Series RS-485 Serial Interface Supports Modbus/RTU and ASCII Protocol Comprehensive I/O Modules (even accept direct Thermocouple and RTD Inputs) Analog Input Module capable of performing Digital Output Independently OPC Server Available

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Singapore: Siemens PLM Software has released the Teamcenter 8 software, with a wide variety of enhancements as well as new support for IBM software including DB2 Information Manager, WebSphere Application Server, Tivoli Access Manger, Tivoli Storage Manager, and Rational ClearCase.

“We recognise that in today’s difficult business environment, our customers’ focus on productivity is stronger than ever,” said Steve Bashada, VP of Teamcenter Applications, Siemens PLM Software.

“As a result, the enhancements in Teamcenter 8 are focused on three areas – individual productivity, application productivity and IT productivity.”


Industry news

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SAP World Tour 2009Singapore: SAP customers, partners, influencers and prospects convened at the Four Seasons Hotel for the Singapore stop of the SAP World Tour – one of 27 stops in the Asia Pacific Japan (APJ) region.

Diane Fanelli, senior VP of Industry Solutions Group for SAP Asia Pacific Japan, explains: “SAP World Tour is a global event, but at every stop it addresses the unique needs of companies in that particular region.”

Taking place in over 100 cities spread across more than 50 countries in Europe, Asia, North America and Latin America, the SAP World Tour has reached more than 240,000 customers, partners and influencers over the last five years, providing businesses with information on how SAP solutions can help companies of all sizes successfully transform business challenge into opportunity, becoming a ‘Best-Run’ business in the process. In Southeast Asia, the World Tour will cover seven markets, starting in Bangkok, Thailand on July 2 and finishing in Karachi, Pakistan on October 7.

Jeju Air Selects ST Aerospace For Component Support

Singapore: ST Aerospace signed a component Maintenance-By-the-Hour (MBH) support agreement with Jeju Air. The agreement is worth US$45 million. Under the agreement, ST Aerospace will provide component maintenance works on an MBH basis to support Jeju Air’s fleet of Boeing 737 aircraft over 10 years.

Within the last month, the company has added Shanghai Airlines and Primera Air as its customers for its component MBH programme. The MBH solution was initially tailored for start-up airlines and low cost carriers but it has also achieved initial successes with some traditional airlines.

Cisco Provides Sustainable Economic Opportunities Singapore: Cisco has announced Smart Connected Buildings as its latest emerging technology, a key component in delivering on its vision for Smart+Connected Communities, one of 30 key market adjacencies the company has identified.

Smart+Connected Communities addresses the growing need for sustainable energy to meet the demand of increasingly urbanised populations by providing a network-enabled blueprint for successful smart cities of the future that run on networked information. The solution builds on Cisco’s networked sustainability platform to further utilise the network to increase energy efficiency, create new tools for ‘energy-aware’ city management, and enable economic opportunity and quality of life gains for citizens.

Rockwell Automation Partners With KVC

Kuala Lumpur, Malaysia: Rockwell Automation has entered into a partnership with industrial electrical and electronics distributor KVC Industrial Supplies. The partnership agreement, which was formalised on July 1, 2009 is part of Rockwell Automation’s limited distribution strategy to better serve its customers in both the Asia Pacific and in Malaysia.

Customers in Malaysia will be able to look forward to increased levels of service for order placement and fulfillment, inquiries, technical support and customer service. Similar to distributors in North America and other regions of the world, KVC will provide added focus and value to customer relationships.

“In choosing KVC, we selected a partner with the capability and experience to enhance our strong standing in the Asia Pacific region and position us for long-term sustainable growth,” said Keiran Coulton, president, Asia Pacific. “We view our partnership with KVC as a testament to our strong commitment to the region and look forward to working closely with KVC to enhance our customer loyalty and to benefit our businesses.”

The partnership is the latest in Rockwell Automation’s efforts to improve its service to customers in the region. In January, the company opened its new Asia Pacific Customer Briefing and Competency Center in Singapore.

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Industry news

WTO & UNEP Explain Connections Between Trade & Climate Change

Geneva, Switzerland: The WTO/UNEP report on ‘Trade and Climate Change’ examines the intersections between trade and climate change from four perspectives: the science of climate change; economics; multilateral efforts to tackle climate change; and national climate change policies and their effect on trade.

“With a challenge of this magnitude, multilateral cooperation is crucial and a successful conclusion to the ongoing climate change negotiations is the first step to achieving sustainable development for future generations,” said WTO Director General Pascal Lamy and UNEP’s Executive Director Achim Steiner.

Both Steiner and Lamy urge the international community to seal an equitable and decisive deal at the crucial UN climate convention meeting in Copenhagen, Denmark in December 2009. They also urge nations to conclude the Doha trade round which includes opening trade in

environmental goods and services, a complementary track towards reducing greenhouse gas emissions to scientifically-defensible levels.

The global economy is expected to be affected by climate change. Sectors such as agriculture, forestry, fisheries, tourism and transport infrastructure which are critical for developing countries are more specifically affected. These impacts will often have implications for trade.

Opening up trade and combating climate change can be mutually supportive towards realising a low carbon economy, the new report says. Trade and trade opening can have a positive impact on emissions of greenhouse gases in a variety of ways including accelerating the transfer of clean technology and the opportunity for developing economies to adapt those technologies to local circumstances.

Rising incomes, linked with trade opening can also change social dynamics and aspirations with wealthier societies

having the opportunity to demand higher environmental standards there is evidence that more open trade together with actions to combat climate change can catalyse global innovation that can stimulate new clean tech businesses.

National policies, from traditional regulatory instruments to economic incentives and financial measures, have been used in a number of countries to reduce greenhouse gas emissions and to increase energy efficiency. The report highlights the effects that this complex web of measures might have on international trade and the multilateral trading system. In recent years, there has been a proliferation of technical requirements (voluntary standards and labelling) related to climate-friendly goods and energy efficiency. Likewise, financial support programmes for the use of renewable energies have also increased recently.

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Industry news

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Kuala Lumpur, Malaysia: Malaysia based Bumi Armada Berhad’s second FPSO (floating production, storage and

Bumi Armada’s Second FPSOand deliver first oil in the fourth quarter of 2009.

Bumi Armada was awarded this contract for a five plus five year fixed time charter for the leasing and operation of a one million barrel storage capacity FPSO more than a year ago in a tender against two other international FPSO operators.

Bumi Armada has hand-picked and trained about 70 Nigerians to man and operate the vessel. Serving on board the company’s first FPSO Armada Perkasa since its departure in 2007 are another 80 Nigerians.

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HHI Completes Delivery Of Iraqi Diesel Power Plants

Seoul, S Korea: Hyundai Heavy Industries (HHI) completed 144 units of Diesel Power Plant (DPP) delivery to Iraq. The DPPs are worth US$380 million.

The DPPs, ordered by the Iraqi government in June 2008, have a total capacity of 360MW and can provide electricity to 120,000 households. They will be installed in 12 regions, including Baghdad, and supply electricity to households and industry. It is one of Iraqi restoration work after war.

HHI has exported more than a thousand Packaged Diesel Power facilities to 23 countries throughout South Asia, the Middle East, South America, Europe, and Africa. The company has so far been contracted to supply a total of 180 DPPs worth US$420 million to Iraq.

ExxonMobil To Launch Biofuels Programme

Texas, USA: ExxonMobil Corporation announced today an alliance with biotech company, Synthetic Genomics Inc (SGI), to research and develop next generation biofuels from photosynthetic algae.

“This investment comes after several years of planning and study and is an important addition to ExxonMobil’s ongoing efforts to advance breakthrough technologies to help meet the world’s energy challenges,” said Dr Emil Jacobs, VP of research and development at ExxonMobil Research and Engineering Company.

“Meeting the world’s growing energy demands will require a multitude of technologies and energy sources. We believe that biofuel produced by algae could be a meaningful part of the solution in the future if our efforts result in an economically viable, low net carbon emission transportation fuel.”

Under the programme, if research and development milestones are successfully met, ExxonMobil expects to spend more than US$600 million, which includes US$300 million in internal costs and potentially more than US$300 million to SGI.

“While significant work and years of research and development still must be completed, if successful, algae-based fuels could help meet the world’s growing demand for transportation fuel while reducing greenhouse gas emissions,” said Michael Dolan, senior vice president of ExxonMobil. “Our new algae biofuels programme complements ExxonMobil’s ongoing efforts to reduce emissions in our operations and by consumers of our products, through both efficiency improvements and technology breakthroughs.”

“The real challenge to creating a viable next generation biofuel is the ability to produce it in large volumes which will require significant advances in both science and engineering,” said Dr J Craig Venter, CEO of SGI. “The alliance between SGI and ExxonMobil will bring together the complementary capabilities and expertise of both companies to develop innovative solutions that could lead to the large scale production of biofuel from algae.”

ExxonMobil’s engineering and scientific expertise will be utilised throughout the programme, from the development of systems to increase the scale of algae production through the manufacturing of finished fuels.

offloading) vessel is almost ready to leave for Nigeria to work for Nigerian Agip Exploration (NAE), a subsidiary of Italian oil major, Eni SpA, following a naming ceremony at Keppel Shipyard.

A 1988 converted vessel, the FPSO was named ‘Armada Perdana’. The FPSO has 45,000 BLPD (barrels of liquid per day) processing capacity and storage capacity of 1,000,000 barrels of processed oil with water and gas injection capabilities included in its topside.

The Armada Perdana is expected to arrive in the Oyo field (OML 120), 70km off the coast of Nigeria in August


Industry news

Shanghai: +86 021 6133 7770 • Beijing: +86 139 1029 [email protected] • www.n-tron.com

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Phoenix Solar To Build Photovoltaic Power Plant Sulzemoos, Germany: The Singapore branch of Phoenix Solar has won a tender to install a 250 kWp photovoltaic power plant at Changi Airport’s Budget Terminal.

The project is supported by the Clean Energy Research and Test-bedding (CERT) programme launched by the Economic Development Board and Clean Energy Programme Office. CERT aims to provide opportunities for companies to develop and testbed clean energy applications and solutions using government buildings and facilities in Singapore.

The company will use 127 kWp of First Solar’s thin film solar modules and 123 kWp of REC’s polycrystalline solar modules, together with SMA inverters for this installation. This will be South-east Asia’s first commercial airport with a photovoltaic power plant, as well as the first commercial application of First Solar modules in Singapore.

REC is constructing a fully integrated wafer, cell and module manufacturing plant in Singapore. Almost 200 kWp of those modules have already been installed locally, with another 300 kWp project under way.

The modules will be installed on the north and south face of the Budget Terminal using Phoenix Solar’s Tecto-Sun mounting system, and will cover a rooftop area of about 2,500 sq m. The solar power plant is expected to generate over 280,000 kW hours per year.

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ITC, Mitsubishi Electric Strengthen Strategic Alliance

Michigan, USA: ITC Holdings Corp, Mitsubishi Electric Corporation and Mitsubishi Electric Power Products are expanding their existing business alliance to develop and produce extra high voltage 765 kilovolt (kV) circuit breakers and 765 kV power transformers.

The companies will concentrate

on improving product development lead times, efficiency, technical design, material standardisation and lifecycle costs. Their efforts will help address a number of transmission industry challenges including the availability and supply of extra high voltage power transformers in North America.

Mitsubishi Electric will produce 765 kV transformers for use in ITC’s Green Power Express project, a 3,000-mile long network of transmission lines that will move renewable energy from remote areas in the Upper Midwest to major Midwest and East Coast population centres.


Industry news

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Honeywell To Acquire RMG Regel + Messtechnik Brussels, Belgium: Honeywell today announced it has signed a definitive agreement valued at approximately US$400 million to acquire the RMG Group. RMG will be integrated into Honeywell Process Solutions. The transaction is subject to regulatory approvals.

“Global demand for gas, specifically clean energy sources like natural gas, is growing and RMG is an established solution provider in the industry,” said Norm Gilsdorf, president of Honeywell Process Solutions.

“RMG’s technology complements our industrial platform and will ultimately enable us to provide our existing customers, as well as new customers, with broader solutions that span the entire gas supply chain.

This is an excellent fit for our business and will strengthen Honeywell’s global presence in the clean energy industry.”

GE Fanuc’s Engineering Centre Of Excellence Virginia, USA: GE Fanuc Intelligent Platforms has announced the opening of its Engineering Center of Excellence (CoE) for Oil & Gas and Safety in Luton, UK.

The centre represents an expansion of the company’s commitment to the Oil & Gas industry allowing GE Fanuc to test and provide complete solutions based on GE’s best of breed products.

The CoE will regularly host customer innovation sessions. It will be focused around process control solutions for the general process safety market, and specifically solutions aimed at the Oil & Gas industry including off shore production asset upgrades and optimisation, solutions for offshore production vessels, onshore upstream and midstream applications.

Areas of expertise will be IEC61508, communications, integration of intelligent instrumentation, and opera-tional optimisation.

Igus’ Energy Chains & Cables ISO Class 1

Köln, Germany: Reports by the IPA Fraunhofer Institute awarded a number of energy chains and cables from igus with the ISO Class 1 certification.

The igus energy chain systems ‘E6.CR’ (special material) and ‘E3’ were classified according to ISO Class 1 – IPA. Further series have been allocated to ISO Class 2 or 3. This means precise statements about possible clean-room application can be made about almost all common energy chains made by the energy chain expert.

The IPA Fraunhofer Institute has also classified igus’ ‘Chainflex’ cables especially for energy chains as ISO Class 1. These are the control cable ‘CF9’, the servo cable ‘CF27’ and the motor cable ‘CF34’.

Last but not least, the outer-tolerated pneumatic hose ‘CF Clean Air’ has also been classified ISO Class 1. This means that valid statements are available about the clean-room suitability of no less than 620 different ‘Chainflex’ cables, when all the igus cables with identical sheathing materials are taken into consideration.

Yangon, Myanmar: Chiller Energy Management System (CEMS) Engineering triumphed at the ASEAN Energy Competitions 2009 held in Yangon, Myanmar. CEMS competed for the ASEAN Best Practices for Energy Efficient Building award under the special submission category, alongside entries from companies all over Southeast Asia. Together with two other companies from Indonesia and Malaysia, CEMS emerged the winner for their technology that promotes energy conservation and energy usage efficiency.

The ASEAN Energy Competitions are organised by the ASEAN Centre for Energy to advocate the development of cutting edge technologies and energy efficiency-related innovations that will later benefit the development of energy efficiency proficiency among ASEAN countries.

The CEMS real-time Energy Management System (EMS) is specifically designed for centralised chiller air-conditioning systems to reduce energy consumption up to 30 percent.

The advanced control strategies are carried out via programmed logic components that utilise the principles of thermodynamics, heat transfer and advance mathematical optimisation, all embedded within the LabVIEW real-time application. The LabVIEW backbone enabled CEMS to deploy the power of Graphical System Design. The system relied on NI Compact FieldPoint for data acquisition, analysis, decision making and solid state controls.

NI Helps CEMS Clinch Award

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Industry news

enQuIry nO. 5120enQuIry nO. 5119

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Regional netwoRk

Hitachi Asia Ltd

Hitachi Asia (Thailand) Co. Ltd

Hitachi Asia (Malaysia) Sdn. Bhd

Hitachi Asia Ltd – Philippines Branch

Hitachi Asia Ltd

• Hanoi / Ho Chi Minh City

Hitachi Asia Ltd – Jakarta Office

Hitachi India Trading Pvt. Ltd

• Bangalore / Chennai / Mumbai / New Delhi

Regional DistRibutoRs / DealeRs

• Singapore

• Malaysia

• Thailand

• Indonesia

• Philippines

• Vietnam

• India

• Pakistan

• Sri Lanka

• Bangladesh

• Middle East Countries

As a regional headquarter, Hitachi Asia Ltd (HAS) markets electric motors, air compressors and digitalized inverters. It is also responsible for the marketing of various industrial products such as programmable logic controllers, ink jet printers, hoists, vortex blowers, contactors and circuit breakers.

Hitachi Variable Frequency Drives

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Metso Signs Letter Of Order With MCC Meili Helsinki, Finland: Metso and the Chinese MCC Meili Paper Industry have signed a letter of order for the delivery of a lightweight-coated papermaking line to the customer’s mill in Zhongwei city, Ningxia autonomous region in China. The start-up of the production line is scheduled for the first quarter of 2011. The total value of the order is approximately €90 million (US$128 million). The deal is still subject to the parties coming to the final agreement of the project within a few months.

The letter of order covers a complete paper machine from headbox to reel with related stock preparation and air systems as well as finishing systems.

Delcam Launches Online TV ChannelBirmingham, UK: Delcam has launched its own online TV channel, Delcam TV, on www.delcam.tv.

Customer testimonials are featured covering design, manufacturing and inspection across a range of industries such as aerospace, automotive, orthotics, dental, robotics, sculpting, jewellery, coin-making and signmaking.

Existing Delcam users can benefit from product videos showing the latest

developments in the software and highlighting tips and tricks to further improve their productivity. Content can be viewed online or downloaded to be played on a range of media players.

Viewers can share videos with friends and colleagues directly from Delcam TV. Delcam TV also supports mobile phone platforms, ensuring content is easily accessible for users on the move.

Japan Member Meeting

The ETG member meeting in Japan was well received as 123 representatives from Japanese member companies joined the event. In a joint presentation Murata Machinery (Muratec) and Applied Materials (AMAT) introduced an EtherCAT based semi-conductor fab automation project.

ETG executive director Martin Rostan gave an update on EtherCAT technology news and the global ETG status, emphasising the outstanding adoption rate among vendors and users alike.

So far over 40 servo drive vendors, over 30 I/O device vendors support EtherCAT in their products. Over 60 companies offer EtherCAT masters. With respect to Japan, the 100 member mark has now been reached. Last year alone, ETG membership in Japan grew by 77 percent.

In line with this growth, supported by several other members, Omron has taken up the task to

Asian Test Centre Opened

The EtherCAT Test Centre (ETC) at the Advanced Software Technology & Mechatronics Research Institute (ASTEM RI) of Kyoto, Japan was opened with a ceremony on July 9.

This conformance testing facility is the second one worldwide, following the first test centre located in Nuremberg, Germany.

Having hosted the former

ODVA test lab in Japan, ASTEM has a long lasting experience with performing conformance tests. This experience is also fed back into the EtherCAT conformance testing process as such, since ASTEM contributes to the further advancement of the tools, documentation and test specifications.

ETG representative, Japan, Takeshi Kameda expressed his content: “By establishing the first test centre outside Europe in Japan, ETG clearly honours both the rapid growth of the organisa-tion in this country as well as its strong automation device vendor community, which is adopting EtherCAT at a fast pace.”

Besides the test services as such, ASTEM will also offer techni-cal support for the Japanese and the Asian EtherCAT community.

From left: Takeshi Kameda, ASTEM president Prof Dr Yukihiro Nakamura, ETG executive director Martin Rostan, Eiji Ikeno

translate the entire EtherCAT specification into Japanese language, together with an equal number of supporting documentation.


Asia

ENQUIRY NO. 5121

ENQUIRY NO. 5122

ENQUIRY NO. 5123

Fieldbus Foundation’s Agreement With Prolist

The Fieldbus Foundation today announced it has signed a copyright agreement with Prolist International. The agreement allows Prolist to publish Foundation fieldbus parameter names and definitions in its standardised process control device/system specifications and database.

Prolist International seeks reduced engineering and transaction costs for procurement and sales in the area of process control technology. This includes integration of the workflows of all parties involved in plant lifecycle management. The basis for this effort has been created in the form of machine-readable descriptions of the properties of process automation components that are relevant for engineering purposes.

The working results of Prolist are published as LOPs in the NAMUR Recommendation NE 100

‘Use of Lists of Properties in Process Control Engineering Workflows’, which provides a method for standardising the descriptions of process control and instrumentation equipment. As such, it supports data exchange between systems in a customer-supplier relationship.

“The Fieldbus Foundation is pleased to take part in Prolist through this copyright agreement,” said Fieldbus Foundation president and CEO Rich Timoney. “We support the long-term goal of Prolist, which is to optimise processes throughout the entire plant lifecycle at every point where information systems exchange data on process control devices. This endeavour will help companies reduce transaction costs by an electronic data exchange format which vendors, owner/operators and EPC firms can use for communications.”

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ENQUIRY NO. 5124

CAN in Automation (CiA) has scheduled a CANopen seminar series in the EU for 2009. The one-day seminars provide an overview about the CANopen higher-layer protocol. The English-spoken seminars will take place in Nuremberg (September 22), Tampere (September 29), Katowice (October 8), Amsterdam (October 21), Brussels (October 22), Zurich (November 10), Prague (November 12) and Stockholm (November 19).

The information provided in the Seminar will enable development engineers and system integrators to judge if CANopen is suitable for their application.

Attendees will receive a comprehensive insight

‘CANopen’ and ‘CiA’ are now word-marked in Europe for the organisation. CiA gives to all of its members and those companies, to whom the organisation has assigned a CANopen vendor-ID,

‘CANopen’ & ‘CiA’ Word-Marked

the right to use the word-marks for their products and services. All other companies are not allowed to use the word-marked terms for products and services.

The word-mark registration will increase the quality of products claiming to be CANopen devices, because the organisation has now the possibility to forbid

using the CANopen naming, if the products doesn’t fulfill the related specifications. “The word-marks protects those c o m p a n i e s i m p l e m e n t i n g properly CANopen and other CiA specifications,” explained Holger Zeltwanger, CiA MD.

Content Date Time Location Language

CAN 21 September 2009 1:00pm – 5:00pm Nuremberg (DE) English

CANopen 22 September 2009 9:00am – 5:00pm Nuremberg (DE) English

CANopen 29 September 2009 9:00am – 5:00pm Tampere (FI) English

CANopen 08 October 2009 9:00am – 5:00pm Katowice (PL) English

CANopen 21 October 2009 9:00am – 5:00pm Amsterdam (NL) English

CANopen 22 October 2009 9:00am – 5:00pm Brussels (BE) English

CANopen 10 November 2009 9:00am – 5:00pm Zurich (CH) English

CANopen 12 November 2009 9:00am – 5:00pm Prague (CZ) English

CANopen 19 November 2009 9:00am – 5:00pm Stockholm (SE) English

CANopen Seminar Series In The EUinto the technical opportunities of CANopen basic and additional CANopen functionality will be discussed (eg CANopen manager, layer setting services, CANopen safety).

Important aspects of system design will be demonstrated. The CiA trainer will also explain the CANopen device and application profiles that enable to manufacture devices with a high degree of ‘plug-and-play’ capability.

Furthermore, multi-level networking is considered. Well-specified applications such as CANopen-to-CANopen-routers, TCP/IP-to-CANopen-gateways and CANopen-to-AS-interface-gateways are discussed.

ENQUIRY NO. 5125

Newsdesk

18 industrial automation asia | May 2009

Newsdesk


Industry Updates

ENQUIRY NO. 5128ENQUIRY NO. 5127

Profinet Basic Information

entire industrial automation field, are discussed.

To supplement the system description, PI has published ‘Profinet Technology – The Easy Way to Profinet’. This informational brochure shows the options for integrating Profinet into products. It also provides an overview of the available services, from basic consultation to complete development.

Both documents are available for download free of charge on the PI website in both English and German.

FDI Project Team Achieves Development Milestones

The Steering Committee of the Electronic Device Description Language (EDDL) Cooperation Team (ECT) has achieved important milestones as it develops a common solution for field device integration (FDI).

The FDI project team worked the past 18 months to identify use cases encompassing all facets of plant operations: from start up and commissioning; to ongoing maintenance activities and plant operations. A key outcome of the team is a draft architecture that migrates Field Device Tool (FDT) and EDDL technologies to a common device integration standard.

Along with the draft architecture, the technical team performed a complete inventory of use cases and wrote a draft functional specification. The solution is a client/server structure based on the OPC Unified Architecture (OPC UA). The FDI solution contains two elements: a ‘device package’ provided by the device supplier containing EDDL components and an optional programmed application for customised user interfaces. This design permits complete flexibility for users to develop customised user interfaces to meet individual needs.

The next milestone of the project is the development of detailed specifications of the FDI solution. The specifications will then be validated by each of the member organisations which will begin during the second quarter of 2009.

Details of the exact FDI architecture and associated device interface will be unveiled with the release of the final functional specification, currently planned for the summer of 2010.

ENQUIRY NO. 5126

PI (Profibus & Profinet International) is publishing a new version of the Profinet system description, as well as an informational brochure on the base technology. These two publications provide important basic information that describe the current level of Profinet technology and its efficient implementation in products.

The concentrated presentation of the fundamentals in the ‘Profinet’ system description provides the reader with a quick overview of the full scope of functions, from network installation and scalable communication to web-based diagnostics.

Following an initial overview, a host of topics that make Profinet a universal and comprehensive Ethernet-based automation technology, that can be used by the

PI Publishes White Paper

PI is publishing a white paper demonstrating the versatility of Profinet in a wide variety of applications. The publication demonstrates the strength of Profinet as a universal Ethernet-based communication system.

The white paper names a host of applications in which Profinet has been proven and established. The white paper also describes the factors for success responsible for Profinet’s rapid growth. The most important include scalable real-time capability, standardised integration of fieldbuses, the use of wireless communication and the availability of profiles, especially Profisafe and Profidrive.

These features, combined with the flexibility of the Ethernet and IT standards, are the driving force behind Profinet’s success. Profinet is being given another boost thanks to current efforts by manufacturing companies to both reduce energy costs and increase competitiveness through more efficient automation solutions. These activities will result in the energy saving profile ‘Profienergy’.



issues & insights

M ost plants already have a large installed base of intelligent devices. The intelligent device can make hundreds of different parameters

available to the operator, technician, inspector and engineer or plant manager. This data about the process or instrumentation are valuable, but only if the information reaches the right person in time to be useful.

Plants realise efficiency by providing timely and easily useable data for operations and maintenance personnel. Effective integration of engineering, configuration, maintenance, and operational displays into the operations and maintenance work stations of a plant’s digital control centre make it easier to use the power of field intelligence to improve plant performance.

systems must in turn continuously monitor the status from the self-diagnostics. This is where many older systems fail - as device diagnostics simply do not get delivered.

In some systems this is because the I/O cards use proprietary device communication protocols. In others there is no device communication at all. Although the devices in these plants generally communicate in standard HART protocol, the proprietary systems can’t access their intelligence. The diagnostics are ‘stranded’ in the devices.

Most modern control systems support open communication protocols like HART or Foundation fieldbus. They must also have device management software installed to enable the diagnostic intelligence to reach those that can act on it.

EDDL allows seamless integration of devices into a digital plant architecture that uses diagnostic intelligence for predictive asset management solutions. By Jonas Berge, director of PlantWeb Consulting, Emerson Process Management

Plant Asset Management:

EDDLSpeaking

Electronic Device Description Language (EDDL) with enhancements is the key technology for seamless integration of devices into a digital plant architecture that uses their diagnostic intelligence for predictive asset management solutions. EDDL now makes it easier than ever before to use intelligent devices.

Stumbling BlocksPlants want to benefit from the diagnostics available in intelligent devices, but may in the past have struggled to achieve use of it by their personnel for several reasons.

Devices do their part by continuously monitoring their own health using internal self-diagnostics. However, the digital automation and asset management

Furthermore, if diagnostics are only displayed on a maintenance console, it may not be seen in a timely manner since maintenance technicians are often in the field rather than in front of the computer. For this reason, the operator must be able to open an integrated detail device screen to access diagnostics of devices from any operations and maintenance/engineering workstation. Operators are in front of their consoles and will see the device alerts.

A third possible stumbling block in the past could be devices that were too difficult to use, and device management software that was not user friendly.

Integrated Device ManagementFor effective device management the control system


should be capable of commissioning, setup, and maintaining all devices. This function should be integrated into the control system and available from workstations.

• ConnectTo interoperate with the field devices that plants use, the system must have HART I/O cards or Foundation fieldbus interface cards which in turn pass device communication through to the intelligent device management software. This is available with most modern control architectures.

If the plant has a traditional Distributed Control System (DCS) that does not support HART communication, the only solution available until now has been to connect a HART multiplexer in parallel with the DCS I/O cards to tap into device communication and pass it through to the intelligent device management software.

Fortunately there is now an easier way to integrate diagnostics of intelligent devices connected to traditional DCS’s into device management software. For this purpose, a WirelessHART adaptor is screwed into an unused conduit entry on the existing HART device and connected to its terminals. As a result, all device intelligence including setup and diagnostics is now accessible wirelessly.

With this wireless approach, adapters on the existing devices form a wireless mesh network communicating digital data to a WirelessHART gateway. This wireless solution is significantly easier to deploy than earlier wired HART multiplexer approach, making WirelessHART a good way out of the strangle hold of proprietary device protocols of traditional DCS.

Having establ ished this WirelessHART infrastructure, the plant can deploy WirelessHART transmitters for pressure, level, flow, temperature, valve position feedback, pH, and vibration etc.

• IntegrateA device problem, if not acted upon, will eventually lead to a process problem. It could take minutes or hours. Device diagnostics are an early warning that gives operators advance notice to take evasive action before their process is affected.

Depending on the device fault, they may put the loop in manual or send somebody to hand operate the

valve. Once the process is taken care of, they can alert maintenance technicians to fix the device. However, for operators to make use of the device diagnostics this way requires easy and convenient to access.

In the case of a device failure the operator shall be advised via an alert, able to launch a more detailed analysis via device management software. That is, it shall be possible to open a detail device diagnostics screen integrated in the operator console; this ability to get to diagnostics in two clicks, and actionable help in another two clicks, saves time as compared to having to search in a separate maintenance station.

The device diagnostics must at the time of system engineering be prioritised based on the criticality of the device to the process and the severity of the fault such that only the critical alerts, that have an effect on the process, are routed to the operators. This ensures operators are not flooded with irrelevant alarms. Moreover, the operator station shall only be able to see device diagnostics, not change device configuration or perform calibration.

All device alerts, including less urgent predictive alerts for failures which have not yet occurred, are logged in the maintenance station. That is, condition-based maintenance functions should be carried out from dedicated workstation or be integrated into the engineering station. However, the operator shall have the ability to launch device management software directly from the operator console.

Critical device diagnostics serves as an early warning to process operators. In this example, broken glass on a pH meter is noted and the cause along with troubleshooting guidance is delivered so the problem can be quickly corrected

By upgrading to new enhanced eddL rather than driver-Based technoLogy, pLants make using inteLLigent devices easier


issues & insights

HigH-KVA ToucHsAfe conTAcTsIntegration of device diagnostics into the operator

console can be achieved using EDDL which is an integral part of HART, Foundation fieldbus, Profibus, and WirelessHART. Because EDDL device integration is based on compressed text files, not software drivers, the solution is robust and can be integrated on the control system itself. Other device integration

solutions are not suitable for integration on operator consoles.

Similarly, for simplicity, display of commissioning and maintenance screens shall be possible from the engineering workstation. For example, it is convenient to configure the devices from the same console as the system database. Therefore, only one engineering workstation shall be necessary to perform system database and Foundation fieldbus device configuration and editing.

However, maintenance technicians should not disturb operators at their consoles. Therefore a system can provide for a separate maintenance workstation to allow for device diagnostics and configuration separate from operating functions.

That is, the system shall have flexibility for both integrated and separate device diagnostics. However, a dedicated maintenance station may not replace commis-sioning and maintenance function integrated into the control system.

It is only the control system operator clients and intelligent device management software clients which are integrated. The servers are kept separated. For security reasons, the maintenance station and functions shall be maintained on a separate server with access only from a controlled area.

This will prevent changes from being made to the network, thus affecting the entire control system, without proper control and management of change procedures in place.

• SimplifyAnother intrinsic benefit of EDDL is that all devices are displayed consistently. The device manufacturer creates an EDDL file for their device in which they define how they want the system to display their device.

This includes the definition of the menu structure, graphical display of advanced diagnostics and complex setup functions, step-by-step wizards to make calibration and other complex tasks easy, as well as help text and images to guide the user. This makes sense because the manufacturer knows the device best.

Since the content and structure of the display is controlled by the device manufacturer, not the system manufacturer, full interoperability and access to all device functionality is achieved. Yet at the same time the system controls the look and feel of the display.

For example, the device manufacturer may define that the machinery health transmitter shall have a display including a vibration spectrum in the form of a graph with frequency along the x-axis and acceleration along the y-axis. But the system defines the toolbox that goes along with the graph, including the ability to zoom in on a particular area. As a result, all graphs

Thanks to EDDL graph and chart tools pan and zoom the same way for any device

Machinery Health Transmitter

Temperature Transmitter

guided Wave Radar Level Transmitter

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issues & insights

function the same way which makes working with a mix of devices and learning new devices intuitive.

As another example, a valve signature graph for a positioner is zoomed in exactly the same way even if this device comes from another manufacturer and uses another protocol. The same goes for the setup of an echo curve in a radar level transmitter. The same toolbox is again used in all trend charts, so the technician pans backwards and forwards in time the same way for any device type.

Such consistency cannot be enforced by device drivers, and provides unparalleled ease of use for EDDL. Likewise, device problems are flagged the exact same way for all devices eliminating ambiguity.

attention, and avoid unnecessary removal, tear-down, rebuild, and installation of valves that do not need maintenance yet.

An electromagnetic flow meter detects grounding fault if flow tube grounding is lost over time for instance due to corrosion. This enables the problem to be corrected rather than letting a poor quality measurement negatively affect the process.

A machinery health transmitter detects imbalance and other problems in motor-pump trains. It is used on critical pumps to detect problems to schedule maintenance before they fail.

Some pH analysers have sophisticated diagnostics that continuously measure the impedance of the pH glass electrode and the reference electrode to detect sensor failure or degradation online, for instance if the junction is plugged or if the filling solution or gel is depleted (dry). A cracked glass electrode which would produce erroneous pH readings is also detected so it can be replaced to ensure process is not affected or regulations are not broken.

A simple pressure transmitter will detect sensor failure such as corroded diaphragms. A more advanced pressure transmitter use Statistical Process Monitoring (SPM) to detect process and installation problems like plugged impulse line, entrained air, compressor or pump problems, and loss of agitation etc which enables abnormal situations to be prevented, rather than managed after they have already occurred.

Deployment & AdministrationMost plants today rely on the traditional DD technology to work with their intelligent devices. By upgrading to new enhanced EDDL rather than driver-based technology, plants make using intelligent devices easier.

EDDL meets all the requirements of NAMUR NE 105, for instance investment protection in view of new operating system versions, easy loading of EDDL files for integration of new device types and update of new device versions saves you time, there are no license keys for devices, and interoperability testing is done by an independent third-party. Moreover, EDDL as a single technology can be used in intelligent device management software, DCS, and handheld field communicators.

By integrating device diagnostics into the operator consoles using intelligent device management software based on EDDL, device failures are alerted to those that can act on it, before the process is affected. Once integrated, using device diagnostics becomes a natural part of the daily job which is the essence of a successful predictive maintenance programme. ENQUIRY NO. 1701ENQUIRY NO. 1701ENQUIRY NO. 5201

Applying Device DiagnosticsA simple temperature transmitter will detect sensor failure or broken sensor wires giving operators minutes or hours to take action before the process is affected. A more advanced temperature transmitter will detect sensor drift by comparing two sensors or will detect thermocouple degradation by also monitoring its resistance giving technicians days or weeks to schedule maintenance at an opportunity with minimum impact on the process.

A control valve has many moving mechanical parts subject to wear and tear. A valve positioner counts the number of travel direction reversals and tracks the total accumulated travel. These numbers are good indicators of how ‘hard’ the valve is working, far more accurate in estimating wear of the stem packing than is calendar days.

Alerts can be configured in the positioner, for instance to notify maintenance technicians when the cycle count one million valve reversals is reached if this is what the valve/actuator package manufacturer recommends for replacement of moving parts.

This and other valve diagnostics allows technicians to spend their time and resources on valves that need

A pH analyser diagnostics and user guidance

ENQUIRY NO. 036

M YC K

While every effort has been taken to carry out instruction to customers satisfaction NO RESPONSIBILITY liablilty will be accepted for errors CUSTOMERS ARE THEREFORE URGED TO CHECK THOROUGHLY BEFORE AUTHORISING PRINT RUNS DALIM

11 2 3 4 5 6 7 8 9 10 OK LCL McCann CN DVD: CN246CN255792 Dalim-HC3 12.05.2009 150#

ESS0001829 IAA June 2009205Wmm x 275Hmm 150# Epson + CD-rom(PDF)


control point

unit in a process plant consists of fluidics/mechanics (plant components/apparatuses/machines) together with the sensors, actuators

and associated automation software, which is often needed in this combination of components (Figure 1).

As a ‘type’, the unit serves as a model for producing several instances which can be differently parameterised. The term ‘unit’ should not be rigidly applied to a particular level of the system hierarchy, but should be understood as a plant component in terms of the Namur recommendation NE 91.

Plant components such as apparatuses, containers, machines, pipes and devices are divided there into various basic types.

APC methods improve the plant performance in terms of productivity, cost-effectiveness, product quality, operability, availability, usability, safety and environmental protection. By Dr Otmar Lorenz and Dr Bernd-Markus Pfeiffer, Siemens

Templatefor

Performance

In process engineering today, there are already so-called package units, for example, vacuum systems and packaging machines. The manufacturer of the mechanical/industrial apparatus has included automation functionality that is specially tailored for this apparatus and which is located on special local hardware. The package unit is integrated as a whole into a process control system. No detailed knowledge of the automation of the package units is required for configuring the DCS (distributed control system).

However in process plants, in addition to these package units, there is a large number of other apparatuses that can be assigned to specific classes, which always occur in a similar form.

Now, the basic idea of ‘unit-oriented automation’ is to harmonise the total automation solution for units in the form of templates and to deliver them as prefabricated solution templates in order to considerably reduce the engineering costs for concrete application to the instance of a unit: ‘Parameterisation instead of programming’.

Figure 1: The unit concept, exemplified here by a reactor, harmonises the entire automation solution in the form of templates and is delivered as a prefabricated solution so that the engineering costs and the expertise requirements for the concrete application on the instances of the units are considerably reduced


Figure 3: System configuration of CRK Series using a driver with built-in controller features

Within the scope of the solutions, the expertise of the system supplier can be passed on to the customer and the expertise needed to develop the application can be reduced.

For this reason, there is particular interest in unit-oriented solution templates for Advanced Process Control (APC). An advanced control solution must be adapted to the automation environment.

Therefore, a holistic automation approach is followed. At a minimum, a template for a unit encompasses the facets of basic automation, advanced control and human machine interface. It can also include asset management, performance monitoring and alarm management, if applicable. Of course, there can also be solution templates for units that do not have a need for APC functions.

Advanced Control Solution TemplatesA solution template in a process control system such as Simatic PCS7 encompasses all of the functions required to automate a plant component: CFCs (continuous function charts, instances of process tag types), SFCs (sequential function charts), and OS screens (operator screens on the operator station).

They are combined in a hierarchy container of the technological view of the ‘Simatic Manager’ engineering tool. Instances (entities) of a solution template can be automatically generated with the aid of an import/export file.

Although the capability of creating solution templates in the PCS7 engineering system has existed for many years, this capability has rarely been used until now. The template for distillation columns that is presented here is therefore taking on a pioneering role.

The Simatic PCS7 Advanced Control Library V7.0 SP1 makes process tag types for advanced control functions available for the first time as a standard product, eg for model-based predictive control.

The MPC function block is a lean multi-variable controller that is seamlessly integrated into the DCS (‘embedded MPC’).

This MPC function block controls up to four interconnected manipulated variables and controlled variables and one measurable disturbance variable. Such an embedded MPC has the following advantages:• TheMPCblockcorrespondstotheconventional

PID controller in terms of its availability. Therefore no backup strategies or functionalities for monitoring the communication with external PCs are required. The capabilities of redundant AS systems can be fully utilised

• Within the scope of the engineering system,the MPC block can easily be linked, just like a

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• Speed Highest application rate: Typical read-write time 0.5 ms per byte

• Flexibility Modular mounting 2, 4, 6 or 8 channel interfaces and read-write heads with different application optimised housings

• Universal applicability Durable FRAM data carriers – also for special applications like direct mounting on metal, in auto- claves or with temperatures up to 210 ºC

• Integration Interfaces for PROFIBUS-DP, DeviceNet™, Ethernet Modbus-TCP, PROFINET IO, EtherNet/IP™, Programmable gateway

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conventional PID controller, by using prefabricated process tag types (templates for signal flow charts in the CFC)

• Operating andmonitoring theMPCblock arepossible using a standard faceplate

• Becauselookandfeelarebasedasmuchaspossibleon a conventional PID controller, familiarisation and implementation costs are reduced

• Theneed tobring inexternal serviceprovidersas experts for special MPC software packages is completely eliminated

• InsummaryitcanbestatedthatembeddedMPCis comparable to advanced PID applications with respect to investment cost for acquisition, design, engineering and maintenance while at the same time, it provides more powerful features. This means a lot of ‘smaller’ applications which could not be realised using ‘full-blown MPC’ because of cost reasons, now can be realised in a profitable way using ‘lean MPC’

Solution TemplateDistillation is the most important separating process in the chemical-pharmaceutical industry. It is a thermal separating process used on a liquid mixture for separating different substances soluble in each other by means of their different relative evaporation and different boiling points.

Some typical applications for distillation are the production of alcohol and the distilling of crude oil inarefinery.Basically,adistinctionismadebetweenbatch distillation and continuous distillation (eg rectification, extractive or reactive distillation).

During rectification (counter flow distillation), a multi-component mixture is separated into at least two streams. The tops (low boiler) are drawn off at the top of the rectification column and the bottoms (high boiler) are drawn off at the bottom.

There are at least five different variants for controlling distillation columns via a single temperature, because using conventional means the product quality (temperature) can be controlled either at the top or at the bottom of the column, but not both due to the strong thermodynamic interactions in the distillation column.

Through the routine use of a multi-variable controller that has two controlled variables and two manipulated variables, almost all of the columns that were previously operated according to one of the five conventional control patterns can now, for the first time, be equipped with the same standardised automation structure, which includes a complete quality control: Control of the top and bottom temperature via the reflux ratio and the amount of heating steam.

In an individual case, the user can specify which controlled variable is particularly important to him by prioritising the optimisation criteria of the predictive controller. Figure 2 shows the piping and instrumentation diagram in the graphic format which the plant operator sees. The presented solution template covers the following facets of automation of the plant component ‘distillation column’:• Basicautomation,includingPIlevelcontrolinthe

bottom of the column and in the collecting vessel for the reflux, PI pressure control at the top of the column, PI flow control of the raw material feed, the amount of heating steam and the reflux.

• APCapplicationqualitycontrol:Whenthecolumnis designed by the engineers, an S-shaped, vertical temperature profile is determined inside the column, which leads to the desired concentration profile and the desired purity of the product.

In addition, two temperature measuring points that are representative of the control are positioned in the intensification and output part of the column. The model-predictive multi-variable controller handles the correlation between these two temperatures and the two important control actions at the top and the bottom, namely the amount of reflux (setpoint value of the corresponding flow controller) and the amount of evaporation (setpoint value of the corresponding flow controller).

As an important measurable disturbance variable, the flow of feed is taken into consideration for the prediction, in order to be able to react to variations in the feed flow in advance by adjusting the amount of reflux and steam without causing

Figure 2: The operator station screen for a distillation column subsystem, generated from the solution template, shows the piping and instrumentation diagram for the harmonised automation structure


the product quality to deviate significantly from the setpoint value.

• Performancemonitoring: the keyperformanceindicators (KPIs) production quantity (tops and bottoms), reflux ratio, relative energy consumption and pressure loss inside column are calculated or measured and monitored for limits.

In addition, unit-specific alarm and warning messages and maintenance messages are pre-configured, as is the suppression of superfluous alarms:• Whenthecolumnispoweredup,mostalarmsare

deactivated. • If the feed flow exceeds a specific limit, the

message ‘column under threat of flooding’ appears. The message ‘column flooded’ only appears if the level in the bottom actually exceeds the upper alarm limit.

• Because the reflux ratio is explicitly calculatedand monitored, separate monitoring of the absolute vales of the reflux is not required. The corresponding messages are deactivated.

• If the control error in the first channel of thepredictive controller becomes too negative, the following message appears: Quality distillate – ‘Concentration of low boiler very low’. If the control error in the second channel of the multi-variable controller becomes too great, the following message appears: Quality bottoms – ‘Concentration of low boiler very high’.

• Themulti-variablecharacterof the process is taken into consideration as much as possible in the control performance monitoring: If one of the two temperature control loops is not in the stationary state, control performance alarms are suppressed in the other temperature control loop and also in the two level control loops.

• Theslavecontrollersofcascadeconnections,inthis case FIC Reflux and FIC Vapor, dispense with control performance monitoring, because their variance greatly depends on the variance of the setpoint values, where the setpoint values are set by the master controller. If no high requirements are made on the control performance of the two level controllers, control performance monitoring can be dispensed with in this case too.

• Ifthepressurelossviathecolumnbecomestoo

great, an AssetMon block triggers a maintenance alarm. (The asset monitor is a universal function block for monitoring mechanical/industrial assets which are not registered on the fieldbus as field devices.)

• Periodicmaintenancerequestsarealsoautomatedvia the AssetMon depending on the number of operating hours.

Column Proxy BlockTypically, several distillation columns are displayed on the overview picture of a process plant. A special column proxy block is available to be able to display the most important performance characteristics of a column in a compact form on the overview screens. It summarises the required actual values from the individual measuring points (process tags) and supplies the assigned process picture symbol and faceplate (Figure 3).

Quality (deviation of the controlled temperatures from their setpoint values) and the quantity of tops and bottoms are displayed on the picture symbol. The green A means that all of the control loops of the column are in automatic mode (AND operation).

In the standard view of the column faceplate, the actual values are displayed as numbers and horizontal bars:

• Quality(controldeviation)oftops• Quality(controldeviation)ofbottoms• Quantity(outflow)oftops• Quantity(outflow)ofbottoms• Refluxratio• Relativeenergyconsumption• Pressureloss

In a second ‘parameter’ view, the vertical temperature profile can be displayed at points along the column. This only makes sense if other temperature measuring points exist on the column in addition to the two control temperatures.

Figure 3: Screenshot from a plant overview screen with an entity of the column proxy, process picture symbol on the left, two views of the opened faceplate on the right

ENQUIRY NO. 5301


control point

OptimalTrade-offs<<

Achieving energy efficiency and environmental compliance is not a problem thanks to advanced process control. By Eduardo Gallestey, Greg Cairns, Konrad S Stadler and Jan Poland, ABB

<<


Figure 3: System configuration of CRK Series using a driver with built-in controller features

M odern industry works hard to achieve efficient production. However, this can often

be quite difficult because many companies are bound by complex contractual and environmental conditions. This in turn increases the complexity of operations for both the operators driving the process and the plant managers setting the production goals, requiring them to make trade-offs between the amount and type of production, the availability of energy and the volatility of its costs.

Process industries can now virtually‚ be all things to all market conditions’. With leading-edge products, customers have the tools

Cement clinker production unit: Gas flow is indicated with the red arrows and meal flow with the blue arrows

needed to stabilise and control a process and to effectively manage the complexity arising from new market conditions.

Moreover, state-of-the-art mathematical algorithms have been packaged to easily tackle the optimisation and control problems that were intractable just a few years ago.

Constant DevelopmentWith ever -changing market conditions, companies cannot afford to sit back and survive from the rewards of past successes. Indeed, according to Akira Mori, one of Japan’s most successful businessmen: “Past success stories are generally not applicable to new situations. We must continually reinvent ourselves, responding to changing times with innovative new business models.”

As well as business models, innovative products, processes and services are necessary if companies and their customers are to survive what can only be called truly testing times.

Rather than waiting for change to come, companies should be looking for changes in the market

that may be a developing trend. Determining if this trend is likely to impact the long-term success of a business enables the best solution to be found.

Kiln Control A standard application for APC is kiln control in the cement clinker production process. The clinker minerals are formed at about 1,400 deg C within the rotary kiln.

This process requires a lot of thermal energy, which is p ro v i d e d b y f o s s i l f u e l s supplemented to a substantial degree by alternative fuels (tires, plastic, etc).

To make the process more energy efficient the hot exhaust gas travels further up the kiln and into the preheater tower. The raw meal travels in the opposite direction and picks up energy from the gas on its way down through the preheater tower and into the rotary kiln.

As it heats up, the meal undergoes chemical reactions, such as calcining, which pre-treat it before it enters the mineral-forming phase in the last third of the rotary kiln.


control point

A cooler forces ambient air through the clinker bed, thereby guaranteeing ef f icient heat exchange and rapid cooling of the clinker. This in turn ensures that the formed minerals remain in their required form.

The clinker production process is highly interconnected in that changing one of the main actuators (raw meal feed rate, exhaust gas flow rate, fuel input, rotary kiln speed) affects all the main process indicators (burning zone temperature, cyclone stage-two temperature, oxygen level in the kiln).

Moreover, stabilisation of the process depends strongly on the composition of raw meal as the energy requirements at various phases of the process are influenced by the different meal components.

To reduce the amount spent on fossil fuels, up to 70 percent of the fuels used can be alternative, such as waste. This in turn introduces highly variable heat input from the fuel combustion.

It is important to know how the reaction conditions in each phase of the process are affected as the quality of the clinker depends on it. In other words, if the system cannot compensate quickly as the cold meal travels along it the chemical reactions needed to form clinker cannot take place.

The process is divided into compartments or zones, with each zone influencing the one beside it. This allows predictions to be made regarding the evolution of the energy within a zone and therefore on the temperature profile along the whole production process.

In the past fuzzy-logic-based controllers were used in some implementations to control the process, but this has now been replaced by a model based predictive control (MPC) approach.

Predicting the feed and gas temperature profiles provides

Performance of an MPC kiln controller

Temperature profile for feed (meal) and gas (air) with the main characteristic zones of the clinker production process

valuable information when it comes to stabilising the process to ensure the desired clinker quality and production rate.

The problem is the temperature profiles have to be derived from a restricted number of measure-ments taken at a few points along the process. By reformulating the optimisation problem to look backwards in time, as in MPC, rather than forwards an accurate temperature profile can be estimated.

This estimation enables the MPC algorithm to derive the best sequence to change the manipulated variables so that the process targets are optimally reached.

The controller performance where the temperature of the sintering zone is kept close to its target while at the same time maintaining the temperature in the pre-heater tower to within range.

T h e t r a d e - o f f b e t w e e n maximising production and keeping the critical process variables within acceptable ranges is resolved using MPC.

Typical ly, the control ler adjusts the fuel input. However, whenever the process temperatures indicate that the system will rapidly cool down, the controller reduces the feed rate to support a faster recovery.


ENQUIRY NO. 5302

ABB:

Process oPtimisation suite

Pulp & Paper Plant SchedulingPulp and paper plants are ideal environments in which to demonstrate the power of nonlinear MPC. The process used in these plants is challenging in that the right mix of chemical additives must be applied at the right moment and under the right conditions in order to meet stringent quality requirements.

A nonlinear MPC schema allows a mill to be better utilised by continuously monitoring its current state and giving decision support in real time, aiming for maximum profit at minimal cost.

A Modelica model inside the Expert Optimizer run-time tool

The tool optimises mill operations by balancing supply and demand between subsystems. Every subsystem or buffer has to be fed material and sufficient supply must be available for the subsystem to produce as required.

The relationships become nonlinear because they must cover a large operat-ing range of plant

set-points. In many cases proper schedul ing necess i tates a variety of models to describe, for example, the sodium and sulfur chemistry as well as the fiber balance. Very often more detailed models for fiber lines are developed to describe, for instance, kappa number and brightness .

With a modern non-linear MPC schema, customers can typically expect the following functionality: • Onlineproductionplanning• A stop planning tool (stops

and limits capacity at certain process sections)

The cpmPlus Expert Optimizer is the process

optimisation suite developed by ABB as part of its Collab- orative Production Manage- ment portfolio. It is designed to address the need for managing the complexity of today’s operations.

The cpmPlus Expert Optimizer supplements process control with optimisation of industrial processes in closed loop mode. It achieves results by ENQUIRY NO. 5303

• Softsensorfunctionality• Diagnostics formeasurement

points• Bottleneckanalysis

Using the nonlinear models and real-time data from the plant floor, as well as taking into consideration events such as t h e m a i n t e n a n c e o f k e y equipment, advanced process control can predict all key variables, which may be valid for several days.

Typically, these models are large, consisting of dozens, if not hundreds, of dynamic states, and manipulated and controlled variables.

In addition, they are tailored to predict the process variables that cannot be measured directly.

These ‘control applications’ are related more to economic process optimisation rather than to regulator control. In other words, they try to exploit degrees of freedom in order to increase the plant financial performance.

ensuring that the best possible actions are applied accurately, tirelessly and consistently at all times.

The cpmPlus Exper t Optimizer has the following characteristics:• It delivers all advanced

process control techniques, such as model predictive control, fuzzy logic and neural networks

• Itisflexibleandcanhandlethe process requirements

of different industries with different business objectives

• Itisuserfriendly,shieldingmathematical complexity from the process engineer,

thereby allowing its use by non mathematicians

• It reduces deploymenttime via modularity, re-usability and scalability



control point

n the past, many companies underestimated the cost and complexity of implementing and

maintaining real-time optimisation systems. Traditionally, companies involved in optimisation projects adopted a ‘top down’ approach using detailed non-linear steady-state process models.

H o w e v e r, u n l e s s p l a n t personnel were committed to understanding and maintaining such systems, most of these real-time optimisation systems went out of service within the first year.

A large portion of the optimisation problems in the process industries today can be addressed more directly with more leverage of plant data and less extensive, targeted modeling that focuses on key units that exhibit significant non-linearity.

Even so, detailed process modeling has proven invaluable to operating companies as a tool

for process design, operator training, and operations planning, monitoring and optimisation. Detailed modeling is essential for performing tests which are not feasible on the real plant.

In many cases, a less extensive modeling approach may be used for on-line optimisation because process measurements are available to correct for model inaccuracies on an ongoing basis.

The challenge for the process industries is to provide a level of optimisation which realises the best return on investment (ROI) for the customer. This ROI includes not only the cost of implementing a project and the expected optimisation benefits, but also the cost of maintaining the system with the customer’s available resources.

To meet this challenge, a layered approach to optimisation is necessary. A company positioned to provide the level of optimisation needed for a particular application, from robust multivariable control and dynamic optimisation to detailed first-principles modeling and non-linear optimisation, is necessary.

In addition, process and optimisation consultants that can analyse the process to determine which technology is most appropriate.

Layered Optimisation SolutionAs shown in the Figure 1, advanced control and optimisation are dependent on other enabling technologies such as advanced

A layered optimisation solution is low risk, requires low lifecycle maintenance costs and sustains benefits in the long term. By Donald Morrison, senior product marketing manager, Honeywell

Layered

Strategy

A


regulatory control and inferential modeling tools. In addition, optimisation occurs at a number of layers in the control and optimisation hierarchy, from unit control and optimisation to multi-unit optimisation to plant-wide optimisation. These layers represent increasing optimisation scope.

The layered optimisation ap-proach also consists of different optimisation technology layers, from linear dynamic optimisation, to non-linear steady-state opti-misation, to non-linear dynamic optimisation.

Optimisation technology can be divided into four categories:

The goal in selecting the appropriate optimisation tech-nology is to maximise the ROI and achieve an optimisation solution that has sustained benefits over the long term with minimised lifecycle costs. Accounting for both the magnitude of potential benefits, as well as a customer’s ability to maintain the solution, ensure that the benefits are sustainable.

Optimisation Solution ComponentsBriefly, a layered optimisation solution includes the following technology components:

calculated at each iteration as part of the optimisation process. PVO is illustrated in Figure 2.

Multi-Unit Dynamic Optimisation The second level of optimisation in the control and optimisation structure consists of multi-unit dynamic optimisat ion based on distributed quadratic programming. When process units interact with other units, it is important to consider the dynamics of their interactions and shared constraints when formulating the optimisation problem.

Unit Optimisation The first level of optimisation used with APC is the Product Value Optimisation (PVO) component built directly into the multivariable control application. The PVO opt ion provides economic optimisation for a process unit (or sub-unit) based on a quadratic (QP) objective function.

The user specifies product values and associated production costs, which are then used to maximise the most valuable products , subject to un i t constraints. The optimiser uses the controller’s dynamic process models and is fully integrated with the controller to provide dynamic optimisation.

Therefore, both the optimum steady-state solution and the best path to that optimum are

For example, one may want to maximise feed rate to an upstream unit but be limited by the production capacity of a downstream unit. Multiple unit optimisation considers multiple process units, their multivariable controllers and any dynamic interactions between these units.

Companies should of fer mult iple unit opt imisat ion with the distributed quadratic programming opt imisat ion component. The advantages of this include reliability, dynamic optimisation, ability to work with controllers, its capability to leverage control investments, and high return on investment.

Dynamic optimisation is an extension of the lower-level optimisation technology found in most commercial model-based,

• Linearmodel-basedpredictivecontrol

• Non - l inear model -basedpredictive control

• Dynamicoptimisation• Steady-stateoptimisation

Optimisation TechnologiesOptimisat ion technolog ies are often used in combination with APC technologies. These advanced control technologies also contain embedded optimi-sation to enable optimisation and control to be performed simultaneously.

The advantage of a layered optimisation strategy is that the appropriate combination of technologies can be selected to solve specific customers’ problems, rather than using the same technology for each problem.

Figure 1: Advanced control and optimisation layers

Integrated & Scaleable Optimisation Solutions

Non-Linear Control& Plant-wide Optimisation

Model Predictive Control & Unit Optimisation

Soft Sensor Technology

Advanced Regulatory Control

Figure 2: Product Value Optimisation within the controller

ProcessControllerPredictions PVsOPs

DynamicsModels

Optimization(PVO)

Predicts futuretrajectory of all

Controlled Variables

Determines most cost effective steady state

operating pointUses dynamic model to

determine optimal adjustments to MVs to bring CVs to

setpoints or inside ranges


control point

predictive controllers (MPC + PVO); however, multi-unit dynamic optimisation combines the QP objective functions from two or more PVO applications and offers a coordination layer for the dynamic constraints among the various applications.

This type of technology can be quickly configured and implemented on top of existing controller-based applications. By using existing MVC models and a set of sensible graphical user interface (GUI) tools, large-scale optimisation is feasible in a much shorter time and at a significantly lower cost than compared to traditional steady-state RTO solutions.

Non-Linear Dynamic Optimisation The next layer of the complete optimisation adds the non-linear control and optimisation aspect in the heirarchy via a set of dynamic gain extraction and gain mapping (DGEM) software.

By updating the linear models embedded in the base control and optimisation applications with information from user-supplied non-l inear process models, DGEM technology represents a high performance alternative to large-scale, rigorous optimisation systems.

Generally speaking, DGEM software is capable of automatically detecting the onset of process nonlinearities, extracting gain information from non-linear models and regularly updating the control and optimisation models to reflect this information.

The result is improved control and optimisation benefits, since varying conditions that affect the optimum, such as changing feeds, economics and environmental factors, can be accounted for automatically.

DGEM software integrates non-linear process models with

controller-based and/or multi-unit dynamic optimisation applications to deliver enhanced control and optimisation benefits. The software automatically extracts gain information from these models and updates the linear models with the information.

This gain-updating feature provides superior control and optimisation capability since the control and optimisation models are constantly updated to reflect the current operating conditions.

DGEM software employs existing process models developed for off-line use in process design and analysis, thus leveraging the investment made to create these models, and ensuring consistent models for both off-line and on-line use. The software is not limited to

a specific type of process model; it can be easily configured to use models provided by most modeling systems or it can use custom user-written models within dynamic flowsheet simulation packages.

An Unconstrained OptimumTypically, most units operate in a constrained mode where there are few available degrees of freedom.

However, in some cases there is the potential for an unconstrained optimum, such as in FCC operation, where the optimal Riser Outlet Temperature (ROT) is chosen to maximise production of a specific component, such as naphtha.

The use of DGEM software for gain updating of multivariable control applications is ideally suited for such an application and enables convergence of the solution to an unconstrained optimum. An LPsolutionwithstaticgainswillalways reside at the intersection of constraint limits.

When an unconstra ined optimum is encountered using gain updating, the solutions of subsequent optimisation runs will switch from one constraint intersection (ie corner) to another,

and the multivariable control application will move the process to the solution subject to the configured optimisation speed.

By using the concept of MV soft limits (essentially a more restrictive set of limits honored only by the optimiser) to define MV step sizes, the distance between subsequent optimisation solutions can be reduced by

Figure 3: Comparison of dynamic and steady-state optimisation

DetaileD moDeling is essential for performing tests which are not feasible on the real plant

DynamicOptimization

OptimumOperation

CurrentOperation

Wait for Steady State

Profit Additional $ Benefits

Steady-StateOptimization

Time


ENQUIRY NO. 5304

limiting the search space that the control application has for its optimisation calculations at each optimisation interval.

Somemulti-variable controlapplications have the unique ability to separate the control horizon (time over which constraints are met) from the optimisation horizon (time over which the optimisation targets are reached) and ensures that the controller does not oscillate when an unconstrained optimum is reached.

Though minor oscillations occur as the solution switches between soft limits, these fluctuations are normally not observable and are close to the magnitude of the noise of the measurements.

Non-Linear Steady-State Optimisation The next level of optimisation includes a non-linear steady-state optimisation (often mistakenly re ferred to as Rea l Time Optimisation [RTO]) solution. Th is technology i s typically used where multiple local optima or significant non-linear behaviour is observed.

In addition to on-line optimi-sation, this technology can be used for predictive simulation, process moni tor ing and troubleshooting, engineering studies, development of regressed models for control , planning and scheduling, and operator training. Certain non-linear steady state technologies can be run in on-line or off-line modes with varying levels of practical difficulty.

Additionally, non-linear steady-state optimisation should integrate with simulation software to determine optimum steady-state targets that can be downloaded to the APC application. This allows the application the flexibility to

carry out the steps required for ‘traditional RTO’ such as data validation, steady-state detection, data reconciliation and parameter estimation, optimisation, etc.

Dynamic Non-Linear Control & Optimisation Dynamic non-linear control and optimisat ion (DNLCO)technologies allow the plant to carry out both control and optimisation simultaneously, primarily for polymer applications. Delivering robust control and optimisation, such technology is designed to control nonlinear processes in both process gains and process dynamics.

The use of a rigorous process model that describes process equipment geometry and chemical kinetics removes the need for step testing the plant. This model also combines the advantages of reliable multivariable control and optimisation of on-line process and dynamic off-line simulation

for example: new product grades in polymer applications.

Each of these optimisation technologies have merit depending on the application, and as a result, each of these technologies form part of the layered optimisation solution.

Recommended Approach & BenefitsIn general, the recommended RTO solution is to use controller-

based optimisation for single unit optimisation, distributed dynamic optimisation in conjunction with controller-based optimisation for multi-unit optimisation, and then add DGEM software as necessary to account for significant non-linearities that could result in an unconstrained optimisation solution.

This solution approach is the most practical optimisation solution available and results in significant, sustainable benefits with low maintenance costs. Extensive experience with this technology reveals significant benefits comparable to traditional RTO, but with less maintenance requirements and higher on-line time (>95 percent).

Project implementation times of 3-6 months for this recommended approach is significantly less than traditional RTO (typically 6-12 months), and training time is low for engineers and operators because the solution leverages

existing advanced control technology and user interface(s) without the need for another level of end-user complexity.

In some cases, traditional RTO is still necessary and therefore traditional steady-state non-linear solutions are appropriate. Also, traditional RTO has some additional features such as the ability to do process monitoring, however the

drawback is that the large models are often difficult to maintain for control engineers.

Dynamic non-linear control and optimisation (DNLCO) isrecommended for those cases where step testing is difficult (or prohibited), significant non-linearities exist in the process and there are frequent changes due to product specification changes.

Figure 4: Multiple unit optimisation with dynamic optimiser

Dynamic OptimiserDistributed Dynamic Optimiation

Model-Based Controller



Product ValueOptimisation

Model-Based Algorithm

When integrated with RFID and vehicle-mounted computers, forklifts become mobile data hubs

software & Networks


ost current supply chain RFID operations involve tracking pallets, containers

and cases. Much of this activity is driven by compliance with customer initiatives, which has made it difficult for manufacturers and their distribution wings to get a positive financial return on their RFID investments.

RFID has been proven time and again to provide strong ROI when it is combined with improved business processes that reduce labour and prevent errors.

Forklift RFID systems are a flexible and cost-effective way to support RFID operations. By Jack Tay, senior marketing manager, Asia, Intermec Technologies (S)

WithReady

RFID

Operationally

A combination of mobile and fixed-position RFID readers supports these operations and helps deliver these benefits. Adding mobility to RFID systems with forklift-mounted readers adds value to compliance, shipping, receiving and other RFID implementations. They are

an emerging resource for improving supply chain visibility and reducing capital expenditure and labour costs.

Mobile systems can be implemented for a fraction of the cost of many traditional

RFID infrastructure configurations, while supporting more uses. Forklifts can be much more than vehicles for moving goods.

When integrated with RFID and vehicle-mounted computers, forklifts become mobile data hubs that deliver strong return-on-investment from lower imple-mentation costs, more operations flexibility, and a more complete, real-time view of inventory.

Four Ways Forklift RFID Helps ROIIntegrating RFID and forklift operations improves ROI in four primary ways:1) Reducing the capital expen-

diture required for a RFID deployment

2) Increasing asset utilisation3) Providing scalability4) Supporting labour-saving

processes


1. Reduced Capital ExpendituresWhether used for basic ‘slap-and-ship’ compliance or more extensive applications, forklift and other mobile RFID systems can save significant implementation costs compared to traditional configurations.

Organisations that need to ship or receive RFID tagged cases and pallets have typically installed fixed-position RFID readers at dock doors to record tagged shipments. The alternative is to install readers at a portion of dock doors and have a manager spend a significant amount of time scheduling and coordinating pickups and deliveries so tagged shipments are processed at RFID-enabled locations.

The second option greatly complicates yard management and transportation planning and requires managerial time, while the first option requires RFID hardware and networking at each dock door, even if only a fraction of shipments need RFID processing.

Compare this to how forklifts are al located in factories, warehouses and distribution centres, where it is common to have a ratio of approximately one forklift for every four dock doors. By integrating RFID read/write capability with the forklift, not the dock door, businesses can efficiently handle their dock-door RFID operations with the same 1:4 equipment ratio.

Forklift configurations make it is possible to reduce RFID hardware costs by 75 percent. Asset utili-sation for the RFID equipment improves because forklift readers will sit idle far less than dock door portals.

2. Increased Asset UtilisationAsset utilisation and return on investment improve even more when RFID applications move from the dock. RFID enabled forklifts can process tagged cartons and pallets

wherever goods are handled, such as at picking and putaway locations, staging areas, packaging lines, and even within trailers or in the yard. Mobile readers can be used multiple ways throughout a facility, which provides superior asset utilisation to application- or location-specific readers.

RTLS can also enhance picking and putaway operations and help reduce losses by automatically recording items in unmarked locations.

3. ScalabilityBecause mobile RFID systems for dock door applications can also be used throughout the facility, new RFID readers may not have to be purchased every time new applications are added or operations are expanded.

RFID processes for picking, re p l e n i s h m e n t , s h i p m e n t verification, inventory transfers can be completed with the same mobile equipment used at the dock door.

The inherent scalabi l i ty of mobile systems takes much of the incremental cost out of expanded RFID operations, making it practical to introduce a d d i t i o n a l l a b o u r - s a v i n g applications that leverage the initial investment and improve overall ROI.

4. Labour Savings & Process Improvement

The scalability, asset utilisation and capital expenditure benefits of forklift RFID systems all help keep costs down. The process improvements that mobi le RFID equipment creates bring productivity up. RFID makes it possible and practical to track goods in locations and environments where barcode scanning or manual data entry is too labour intensive or physically impossible.

Increased tracking improves visibility, which can help prevent shortages, over stocking, shipping errors, reduce shrink and provide numerous other benefits. RFID-supported distribution centre processes are proven to reduce costly inventory handling and shipping errors and reduce associated costs.

The computer should support advanced capabilities like speech recognition to give real-time feedback

Intermec RFID forklift systems have optional real time location service (RTLS) features to further enhance asset utilisation. A module on the forklift works with the wireless LAN in the facility to provide real-time location data. Software applications can use the data to provide real-time feedback and recommendations or for longer-term asset utilisation, productivity and trend reporting. Forklift RTLS applications include:• asset locating and management• dynamic routing• maintenance management• security• dwell time monitoring• productivity reporting• route/layout analysis


softwAre & Networks

Possible ApplicationsWhen a reader is integrated with the forklift, every movement of RFID-tagged cases and pallets can create data that can be used to enhance existing business process applications.

Combining read data with location information provided by the wireless LAN and/or a forklift location tracking application provides total, real-time visibility, creates accurate putaway location records, and builds an audit trail. Here’s how RFID-enabled forklifts can improve three common operations: receiving, picking and shipping.

• ReceivingReceiving errors were responsible for 58 percent of all shipment shortages and overages in a seven-month analysis of receiving operations and the potential impact of RFID processes conducted by EPCglobal, an RFID standards organisation.

A typical receiving error is miscounting or failing to identify materials received, which leads to inaccurate inventory records. More than half the discrepancies could be prevented by automated receiving with more accurate RFID identification.

The resulting improvement in inventory accuracy would reduce out-of-stocks and thus potentially increase sales.

Identifying goods received with RFID-enabled forklifts instead of dock door readers requires less RFID hardware and improves utilisation. Other benefits include operational flexibility – with mobile systems, RFID shipments can be cross docked or even processed in the yard if all dock doors are unavailable or if goods will be stored outside.

R F I D - e n a b l e d f o r k l i f t s with wireless access to host applications can also quickly verify incoming shipment contents

against purchase orders, which can catch shortages and overages before they create inventory accuracy problems. As with fixed-position readers, mobile RFID processes also save receiving and putaway time compared to manual recording and barcode scanning practices.

• Picking&ShippingVerifying orders prior to shipping eliminates shortages and overages that lead to costly adjustments and inventory inaccuracies. Case picking is where most errors occur (typically between two and four percent of total case

shipment volume), resulting in undocumented overshipments (shrink), mispicks (which are typically left at the retailer for their disposition rather than returned), or picking incorrect quantities (resulting in out-of-stocks).

RFID can improve picking accuracy and automate the labour-intensive shipment verification process with minimal disruption to legacy processes.

Mobi le RFID operat ions can prevent picking errors by automatically reading items picked and recording the unique case identification. Using a wireless LAN connection between

RFID antennae are typically mounted on the forklift load backrest

the forklift-mounted computer and host system, the tag data is used to confirm the picked item belongs with the order. This enables problems to be identified and prevented as they occur, rather than corrected later at an inspection station, or worse yet, at the dock door.

Utilising Serialised Shipping Container Code (SSCC) labeling and tags, shipping units can be uniquely identif ied and associated for a specific customer and truck.

Staging areas can also be tagged for proper pallet/container placement verification. Finally, both the dock door and trailer can be tagged to verify that the load is going on the proper vehicle.

These applications not only reduce write-offs for inventory shrink, but also increase ‘perfect orders’ and reduce costs associated with penalties, invoice/shipment dispute investigation and invoice adjustments, which cost hundreds of dollars per occurrence.

Topping it off with EDI, using Advance Shipment Notices, ensures that the receiving party is informed and prepared for a fast, limited audit receiving goods, while keeping your delivery personnel on-time for their next stop.

Mobilising vs OptimisingThe RFID system should be designed specifically for forklift operator needs and usage environments to ensure safety, c o n v e n i e n c e a n d re l i a b l e operation. Each component must be rugged enough to withstand the shock, vibration, bumps and cleaning that go with forklifts, without impairing the operator’s vision or access to controls.

Besides providing reliable, RFID read/write capabilities, forklift-mounted systems should integrate tightly with the mobile computer used on the vehicle and

the load backrest, along with the enterprise wireless network and security protocols. The following considerations are specific for each component to provide safe, reliable performance in forklift-mounted RFID operations.

• AntennaRFID antennae are typically mounted on the forklift load backrest so they will be very close to tags on pallets, cases or rack locations. Ideally, the antenna will fit within the profile of the backrest so it doesn’t obstruct the operator’s view or protrude outside the protective housing, where it is more susceptible to damage.

The antenna should offer flexible placement options so read/write operations can be optimised for the specific usage environment. Antenna cables should be secured to prevent tangling and potential damage.

• ControlsThe forklift operator should be able to easily reach and use RFID controls without having to leave the seat or take his or her eyes off the task at hand. If gloves are commonly worn, consider whether controls can be worked easily by gloved operators. LED indicators and audible tones for alerts and confirmations should be clear and suitable for noisy forklift environments.

• Mobile ComputersThe mobile computer used with

the RFID system has all the same requirements as traditional forklift computers: vibration, shock and dirt resistance; an easy to read screen that can be mounted conveniently; resistance to temperature changes and condensation if used for cold

storage or highly hot, humid operations; support for enterprise wireless LAN and security protocols; interface ports, including Bluetooth if desired (Bluetooth and RFID wireless communication can be used concurrently); ruggedness and reliability; etc.

The computer should also minimise obstruction of the user’s view and should support advanced capabilities like speech recognition to give real-time feedback, even while the user is off the forklift picking cases.

Enabling ReturnsForklift RFID systems are a flexible and cost-effective way to support RFID operations. Provided the RFID equipment is purpose-built for forklift operations, it will provide long-term reliable performance and scalability to support increased volume and new applications.

A f o r k l i f t - b a s e d R F I D infrastructure helps return on investment by holding down implementation expenses and provides a scalable, cost-effective migration path to meet expanded needs. Best of all, it will improve productivity and accuracy while reducing labour costs.


ENQUIRY NO. 5401

Mobile systeMs can be iMpleMented for a fraction of the cost of Many traditional rfid infrastructure configurations, while supporting More uses


softwAre & Networks

ENQUIRY NO. 5402

Collaborative Production Management For Process Industries Defies Recession

The Collaborative Production Management Market for Process Manufacturing (CPM-P) is expected to exceed US$4 billion by 2013.

The global economic slowdown has adversely affected nearly all of the process industries along with the suppliers of process automation technology. Despite the recession, however, the CPM-P market continues to grow albeit at a very modest pace.

Even during times of cutbacks and cost cutt ing , process manufacturers continue to invest in CPM-P projects that have a quick ROI and focus on improving efficiency, reducing costs, consolidating operations, complying with regulations, and standardising on applications across their enterprise.

CPM has three main areas of functionality that include plan, operate, and inform. The ‘plan’ segment consists of functions such as short-term production planning, plant simulation and modeling, and scheduling. The plan functions determine what products to make, when to make them, and what equipment to use.

This segment emanates from the need to continuously find new and better ways to control process equipment and operate plants more efficiently. The purpose of the inform category is to gather,

store, organise, and communicate data and information. It includes data collection, performance analysis, reporting, and role-based KPI visibility.

Manufacturers Need CPMThe economic slowdown is forcing companies to re-evaluate their bottom line and return to the basics of reducing costs and improving margins while maintaining quality.

Succeed ing in the new economy requires operational e x c e l l e n c e a l o n g s e v e r a l dimensions such as cost efficient o p e r a t i o n s , s u p p l y c h a i n synchronisation, and dynamic value creation, all of which are facilitated by CPM systems.

Dynamic Value Creation Today, the value of a given product or service changes quickly because alternatives can quickly enter the marketplace. To be successful, manufacturers must enhance their ability to innovate and adapt their products and services to changing conditions.

Innovation can focus on products, production processes, or business processes — or any combination of these. Product innovation relies on developing new products and quickly moving them into production.

M a n u f a c t u r i n g p ro c e s s

innovation increases profitability o r c re a t e s n e w b u s i n e s s opportunities based on better serving the customer. And business innovation takes many forms as the emerging needs of customers, suppliers, engineers, business managers, and partners are addressed.

All forms of innovation benefit from enhanced collaboration between the plant floor and other areas. A CPM system provides the visibility to uncover opportunities for innovation. It captures and automates business processes so that they can be easily modified when needs change.

A CPM system also synchronises new manufacturing requirements with the supply chain, engineering, and business systems to improve operations.

The CPM-P market continues to grow despite the recession. By Tom Fiske, senior analyst, Arc Advisory Group

Market Report

Collaborative Production Mgmt. Business for Process Industries

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ENQUIRY NO. 5403

Integration & Innovation Key Factors Fuelling Growth In The Asia Pacific RFID Readers Market

The Asia Pacific radio-frequency identification (RFID) readers market has been growing steadily despite the current economic scenario, which has slowed down ongoing implementations, as well as making it unlikely for new commissioned projects as companies exercise caution in spending and investment.

This is mainly due to the opportunities offered by expanding appl icat ion segments and increased government support.

Manufacturers too are striving to improve reader efficiency cost-effectively to optimise on opportunities. Estimates reveal that China is the largest RFID readers market in Asia Pacific while Indonesia is the most nascent.

The market earned revenues of US$134.3 million in 2008 and estimates this to reach US$503.9 million in 2015.

Integrating RFIDWith the advantages provided by RFID, end users are exploring ways to put the technology to better use. Integration of RFID with other technologies will enhance market prospects during the short to medium term as software companies are successfully integrating RFID into the current infrastructure.

Previously, RFID readers’ market growth had been driven by traditional applications such as toll collection and security and access control. At present, there is demand for RFID readers in supply chain management for varied applications that range from livestock, healthcare, sports timing, and transportation to document tracking.

Technological AdvancementsAs the spectrum of applications widens, RFID readers enable value optimisation, providing a surefire method to increase return on investment. The cost of RFID readers is reducing while the technology is seeing advancements at a steady pace.

Improvements have been made to overcome limitations, such as read range, which had been an issue that had earlier dogged the technology. Multi-port readers are deployed to extend the read range between the readers and tags with multiple antennas connected to these readers.

Overall, cost and accuracy are vital factors spearheading growth in the market. Companies are going the extra mile to provide features on readers, keeping costs at a minimum to obtain a clear edge over competition. Users have

displayed a preference for readers that support multi application functions, offer high security, and cost efficiency.

Role Of The GovernmentCountries that had established strong trade ties with the United States and other industrial nations are likely to experience a slackening of output growth for now. The corporate segment will slow down considerably, but the government segment will be minimally affected. National ID and e-passports, sea ports, airports, and infrastructure security will keep the market outlook upbeat during 2009.

Government projects will generally be awarded to bigger vendors. Hence, it is important for smaller integrators to form new alliances, affiliations, and forms of distribution.

Governments in the region have played active roles in promoting RFID technology by providing direct funding for vendor initiatives and subsidies for end users intending to leverage on the technology. Continuous education will help achieve better outreach and prove that RFID brings real value to business enterprises.

Boosted by expanding application segments and increased government support, the Asia Pacific RFID market has been growing steadily. By Parul Oswal, industry analyst, Frost and Sullivan

Market Report


sector spotlight

ater is a precious commodity all over the world, one which humanity needs to be even more careful in using as consumption levels

rise. Industrial automation of potable water and wastewater treatment plants ensures customers have access to this high quality resource, whenever it is needed.

Pneumatics presents a valuable and extremely reliable alternative to electrical automation systems, especially when it comes to meeting the requirements of water and wastewater treatment. Pneumatics, one of the indispensable core technologies for automation, has the additional advantages of robustness and cost-effective system solutions.

Automation In Water Treatment PlantsA pneumatic automation system reduces the costs of investment, installation and operation compared with conventional electrical installations. Many system planners favour pneumatic drives for opening and closing gate and process valves because of their durability, long service life and safety under overload conditions.

Compressed air provides a high degree of safety, since it performs opening and closing movements without any need for electrical power. This means that in practice the system is easy to operate and not prone to failure, resulting in excellent system availability.

If one or more process valves are required for dosing a flow of material into the system, the pneumatic actuators are also capable of advancing the process valves to intermediate positions. So-called position dependent actuators are used to this end.

In addition to the actuator itself, actuator systems of this sort also include the following function and modules (Figure 1): • Electro-pneumatic positioning controller• Displacement encoder for actual position• Limit switch for sensing the drive’s end-position• Tubings and fittings• Complete air preparation unit with pressure

sensors

Figure 1: System automation solution

Water & Wastewater:

PneumaticThe

Advantage

Compressed air supply

Process control system

Valve terminal

Process regulator

Process valves

Fieldbus/Ethernet

Pneumatics presents a reliable alternative to electrical automation systems in meeting the requirements of water and wastewater treatment. By Armin Muller, process application management, segment manager water/wastewater, Asia Pacific, Festo


valve terminals may be fitted in a modular structure, depending on the number of valves.

This system solution has just one clearly defined and standardised interface between the control system (PCS) and the valve terminal – the fieldbus.

Pneumatic ActuatorsPneumatic actuators require little or no maintenance throughout

their entire service life. With a service life in excess of a million operating cycles, pneumatic actuators outlive any device. Since the butterfly valves in a water treatment plant are only operated occasionally, their safety under overload conditions is of great importance.

This is because sediments or incrustated material can result in a steep increase in breakaway torque. Pneumatic actuators are ‘overloadable’, while electric actuators trigger the torque limiter when torque or the need for power increases.

With pneumatic actuators (Figure 4), increasing the operating pressure and forces and thus torque is a simple matter. Since most devices in water systems are operated in open/closed mode or are designed as manual controls, compressed air systems offer significant potential for rationalisation.

In particular for economical and technical reasons, compressed air should only be purified to the extent necessary for the respective application. Preparation must be executed such that long service life and error-free operation of the pneumatic control components are not impaired.

In each individual case, the manufacturer’s specifications regarding compressed air quality must

Figure 2: System solution in control cabinet

Figure 3: Open sandfilter during backwash Figure 4: Actuators for closed rapid sandfilter (valves up to DN800)

• Modular valve terminal solution with fieldbus connection or complete control cabinet solutions (Figure 2)

The most important components of a water treatment plant are the filters. They’re used to treat and filter raw water, thus processing it into drinking water. Regardless of whether closed or open filters, or ultra-filtration systems are used, the processes are automated (Figure 3).

The butterfly valves are equipped with pneumatic actuators to this end, and are controlled by the valve terminal. The filter’s fill-level, differential pressure and flow rate are defined by its current status.

These measured values are also acquired at the valve terminal. If a filter needs to be backwashed, the PLC controls the valve terminal, and thus the order in which the butterfly valves are actuated, in accordance with the backwashing programme.

After the back-washing programme has been completed, normal filter operation is once again initialised. The valve terminal is configured in accordance with the number of pneumatic actuators, limit switches and measuring instruments. The


sector spotlight

be adhered to for the operation of pneumatic control components. This is the only way to assure error-free operation, and to assure long service life for the utilised components.

Diagnostic ConceptWith regard to total cost of ownership (TCO), reliable system operation is more important than the initial investment, ie system construction up to the point in time of commissioning. Just how successfully the system concept has been implemented does not become apparent until it is placed into operation.

With the help of a consistent, well functioning diagnostics concept, users are able to reduce unscheduled downtime for the production process. Possible diagnostics concepts can be subdivided into various stages in this respect:

Stage 1: Simple monitoring functions (detection of malfunctions)

Stage 2: System diagnostics (localisation of faults within the system)

Stage 3: Subsystem diagnostics (error identification)

By incorporating just a few pressure and flow sensors into the pneumatic control loop in a manner which is suitable for the respective requirements, and by taking advantage of existing electrical control signals, conclusions can be drawn regarding the status of the system by simply comparing setpoints and actual values (stage 1).

Stage 2 involves the evaluation and automated interpretation of process parameters from stage 1. A diagnostics controller which can be utilised in a decentralised fashion, as well as model-based software solutions, evaluate and interpret the data.

Trends involving the change of process parameters can be recognised early by comparing targeted and actual values. On the basis of this knowledge, maintenance measures can be implemented before failure occurs. The foundation for preventive maintenance is thus laid.

Stage 3 is above all advisable for especially critical process functions. Additional sensors monitor critical drives and detect, for example, misadjusted flow control valves, worn seals and pinched supply lines. Evaluated diagnostic information can be visualised at master control systems. Required action can then be implemented in a targeted fashion and carried out effectively.

Different methods for condition monitoring in the field of process automation:

Counting:• Switchingcycles

• Hoursofoperation

Monitoring of parameters:• AirPressuresupply,actuatoroperatingpressure

• Runtime-/positioning-monitoring

• Temperaturemeasurement(devices)

• Valveseat(endpositions)

• Driftofcontrolcharacteristic,thresholddeviation

• Electronics(powersupply,voltageswing)

Diagnostic of components:• Breakawaytorque,torquereserve

• Leckageofactuator/valve

• Friction(compressiongland,spindle)

• Mechanicalbreaks(spring-returnactuator)

Pneumatic Open-Loop ControlThe typical open-loop control in a pneumatic system consists of the air supply (air preparation with filter and pressure control), the solenoid valves/ valve terminals as control element, the exhaust throttles to control the actuation velocity and the actuators (linear cylinder or quarter-turn actuator).

As signals normally the control or limit switch signals are available. For process sensitive actuators the position-indication sensors, pressure or volume flow sensors are applied. With this open-loop control, several faults can be classified.

The pneumatics itself are very rarely the cause of a system failure, errors in the process, communication errors or sensor failures are more frequently. Errors in the process are often becoming evident in the system behaviour of the pneumatic system, so the pneumatic actuator is applied as a sensor for the process diagnostics, whereas failures in the pneumatic system are manifested in leckages or changing actuation velocity.

A pneumAtic AutomAtion system reduces the costs of investment, instAllAtion And operAtion compAred with conventionAl electricAl instAllAtions.


The difference between the pressure profile during the movement and the maximum pressure difference is a degree of the torque reserve of the actuator and can be used for diagnostics. (trend monitoring or defintion of a minimal torque reserve).

In addition to that the pressure profile is an indicator of the closing time of the process valve. And as a final result the the position of the process valve is indirectly determined with the pressure/volume flow signal and helps to identify leckages within the actuators.

Crux Of The MatterValves and drives have mechanical parts which are subject to wear, and must be serviced or readjusted at regular intervals for this reason.

Preventive maintenance functions ‘remind’ the operator of the respective maintenance intervals in a timely fashion or are transmitting warnings via e-mail or SMS.

A consecutive switching cycle counter is normally integrated into the electronic module for each solenoid coil to this end, which generates a message when the selected setpoint has been reached. An integrated diagnostics memory saves these messages along with a time-stamp.

Further integrated features for preventive maintenance include diagnostics trace with error memory, as well as continuous monitoring of solenoid valve coil currents and voltages.

Any increase in the occurrence of sporadic errors can thus be detected without delay. In the past, this usually wasn’t detected until the individual components failed.

Offsite DiagnosticsState-of the-art systems can be monitored from

the office, and configured and diagnosed via the Internet using the established direct Ethernet interface for the communication between automation and information technology.

The integrated direct communication not only makes it possible to network automation components amongst one another, it also makes all common IT services accessible to system operators:

This allows the operator to keep an eye on their systems from anywhere via remote maintenance, and to change configurations by means of online access.

ENQUIRY NO. 5501

Examples for failures and causes are shown in the following table:

System/ • DisturbanceofoperationalairMedia Air/ pressure(compressor,network),Air Preparation increasingairconsumptiondueto

systemleckage

• Reducedairquality,egcontentof water,lubricatedair,dustparticles

• Blockedairfilters

Cylinders/ • Damagedpistonrodorpistonsealing,Actuators/ increasingfrictionValves • Breakofthevalveshaft

Solenoid valve • Delayedswitchingofthemainorpilot valveduetoleckage

• Wearandtearofthesealing, contaminatedsilencer

• Faultsintheelectronics(short-circuit, breakdownofpowersupply)

Tubing And • Untightfittings,squeezingorAccessories crackingoftubing,contaminated

silencer,icing

The analysis of the monitoring of a Scotch-Yoke-Actuator shows the diagnostic concept. For the diagnostics the pressure difference of both pressure chambers is evaluated.

When the actuator has reached the end position, one chamber is exhausted, in the other chamber supply pressure is determined, so that the maximum pressure difference can be measured. If the actuator is moved, depending on the required force, a characteristic pressure profile is monitored (Figure 5) (dependent on the valve type and the pressure/volume flows).

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0 0,5 1,5 2 2,5 31

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Figure 5: Trend monitoring of pneumatic actuator


energy

nvironmental issues are now one of the most pressing problems facing humanity

today. These issues have not gone unnoticed in the manufacturing industry. In fact, manufacturing companies have been quick to adapt to market trends, with lean manufacturing, six sigma quality practices, and lately, flexible and smart automation.

Although these practices were meant to reduce production costs and improve quality, they had the indirect effect of reducing waste. Waste reduction is thus not only good for the environment; it also reduces financial costs and ultimately improves the bottom line.

Resource OptimisationMinimising the amount of waste produced by manufacturers almost always involve optimising their use of raw materials. One popular method used currently by almost all manufacturers is nesting.

This optimises the usage of the flat raw material by arranging the parts in such a way that minimal area is left unused. Common features in most nesting software optimisation algorithms include true shape nesting and edge gap fitting.

True shape nesting is the consideration of actual geometric details of the part without approximation to another shape, such as a rectangle or any other simpler shapes. True shape nesting enables interlocking of parts, recognition of arbitrary shaped sheet and part geometries, and holes present in the sheet.

Edge gap fitting allows for even closer nesting where parts have multiple passes with different tooling. Many companies now offer CAM software with in-built nesting capabilities, such as Jetcam Expert, Geometric NestLib and Alphacam Nesting.

Another way is by designing products that not only uses fewer

resources to manufacture, but consume less resource over the entire product lifecycle.

For example, BMW is using a single digital software environment for the design of all BMW engines. Using CATIA software, a type of Computer Aided Design (CAD), BMW can design smaller engines, increase piston and cylinder performance for better ignition and fuel performance.

A related area of immense interest is digital prototyping, which allows for design verification and testing on screen, speeding time-to-market and decreasing costs. With digital prototypes, no

Not only good for the environment, waste reduction also reduces production costs. By Augustine Quek

Waste Reduction:ABusiness

Decision

As humanity has become more environmentally aware, waste reduction is one method used to curb the harm done to it

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actual physical prototypes need to be built, saving material and energy costs, time and money.

One example is the develop-ment and manufacture of Honda’s F1 Racing Team 2008 Formula One car. Using Dassault Systemes' CATIA and Enovia VPLM, the complete vehicle was realised in a virtual environment.

Process Monitoring There are several waste reduction strategies that can be implemented during the manufacturing process. In general, improve visibility of the production processes such as accurate measurement of raw material usage, monitoring of process parameters, and frequency of inspection all contribute to reduced wastage.

The use of digital automation like manufacturing execution systems (MES), supervisory control and data acquisition (SCADA), and energy management systems (EMS) can help to reduce waste and costs while improving production.

One example is Rockwell’s Pavilion8 Control Applications, which can provide a computa-tionally efficient multivariable m o d e l p re d i c t i v e c o n t ro l (MPC) technology for both nonlinear and linear applications.

Another example is the use of predictive intelligence technology software to anticipate what needs to be done to maintain optimal operations. A biopharmaceutical plant in Singapore will use this technology. Switzerland-based Lonza Group selected Emerson’s PlantWeb technologies for the plant.

Once the plant is in operation, field device monitoring and predictive maintenance will be managed from a designated central location via AMS Suite predictive maintenance software. The AMS Suite software will be configured to monitor and access data online from some 4,500 field devices.

Another area where automation has helped to reduce waste is the use of robots in manufacturing. Robots increase efficiency in material and energy use, reduce defects and improve overall production efficiency by making processes more precise and efficient.

Singapore-based First Engi-neering has introduced a six-axis ABB robot to produce ultra-precision moulds and plastic parts for use in high-tech products. This move increased its output by 75

percent, from 170,000 to 300,000 parts

per month. Operators

can reduce

unproductive high-energy phases by optimising processes and reduce setup, heating and start-up phases. For example, industries could change from hydraulic-powered injection moulding machines to electric machines and drives.

Energy efficiency can also involve the use of lighter materials like magnesium, plastic composite and glass fibre to make parts. Such materials demand a controlled means of moving the parts between several different processes, a task that is easily achievable with precision robots.

One particular technology from ABB, called Machine Sync is a precision robot synchronising system. This system increases the output of robot production by overlapping the workflow of the robot and machine. By synchronising the robots with the operations of the machine, Machine Sync reduces root wear and helps avoid collisions. Another ABB product, the RobotStudio software tool, can simulate the actions of a robot before it goes live, allowing lean manufacturers to optimise operations without producing trial and error waste.

A recent innovation in the automation of quality control and waste minimisation is machine vision inspection. Machine vision can be used as a diagnostic tool to detect potential problems with products as they are manufactured.

Waste can be limited when the vision system can detect defects such as too high/low fill levels, crooked labels, illegible ink

markings instead of characters or even remove non-saleable products from a supply chain through a robot.

Scrap Material ReuseTechniques or processes

can also be introduced that enable production scrap to be

Digital prototyping allows for design verification and testing on screen

SolidWorks


energy

ENQUIRY NO. 5601

immediately re-incorporated at the beginning of the manufacturing line so that they do not become a waste product. Many industries routinely do this; for example, paper mills return any damaged rolls to the beginning of the production line, and in the manufacture of plastic items, off-cuts and scrap are re-incorporated into new products.

In this respect, Siemens VAI has developed a highly efficient sludge recycling process for wet dedusting systems. Following initial sedimentation in a settling pond, the sludge is filtered to reduce the total water content to about 30 percent by weight.

The resulting filter cake is then thoroughly mixed with burnt lime. This reduces the water content, saves energy in the downstream thermal drying step and also serves as a binding agent for the subsequent granulation step.

The final oven-dried product is pellets with a water content of less than 5 percent – strong enough to be stored, handled and charged into the converter together with scrap. Producers are therefore able to recover ferrous components from the sludge and reduce their disposal costs.

Waste Exchanges Waste can be further reduced even after it has left the facility, where the waste product of one becomes the raw material for another. Waste exchanges represent another way of reducing waste disposal volumes for waste that cannot be eliminated. The exchanges are primarily information services, linking suppliers with buyers.

The listings usually include materials wanted and materials avai lable , subdivided into

categories (like batteries). The sales and transportation are worked out by the companies involved without the exchange's involvement.

Wa s t e e x c h a n g e a s a n environmental consideration began in Europe in the early 1970s. The boom in computer technology has driven waste exchanges online, with many appearing all over the

world. Online waste exchanges have gone further than before, with online meetings, discussions and forums.

The Resource Ef f iciency Knowledge Transfer Network (KTN), launched in March 2006, is a DTI business support solution delivered through the technology programme, which aims to stimulate innovation in the UK's key technology sectors by promoting collaboration, best practice and knowledge sharing.

The network is managed by C-Tech Innovation, a private t e c h n o l o g y d e v e l o p m e n t consultancy based in Capenhurst near Chester. The exchange aims to help UK firms, of all sizes and from any industrial sector, reduce their waste in three main ways.

First, by demonstrating to

businesses how they can make better use of materials and energy. Second, by using industrial wastes as a source of new products which other companies can make use of. And third, by companies processing recovered material into value-added resource. The key to all these objectives is networking and transferring knowledge between different industries, companies

and individuals within these companies.

Waste exchanges, t h e r e f o r e , u t i l i s e knowledge transfer mechanisms to allow companies to implement innovative technologies to minimise waste and gain a competit ive advantages.

Current concerns over rising energy costs and environmental issues, have forced many companies, particularly manufacturing firms, to look for ways of reducing their resource bills, either by making better overall use of materials

and energy or by harnessing new technologies that help reduce these rising resource costs.

Perfect SenseThe incorporation of automation into manufacturing allows for companies to improve process visibility, reduce and reuse scrap. Information solutions, such as waste exchanges help achieve manufacturers ' energy and sustainability goals.

The goa l o f increas ing productivity therefore directly supports environmental goals, by consuming less energy and raw materials; enforcing regulatory compliance through emissions monitoring and environmental reporting, and reducing operating costs by eliminating waste.

Robots increase efficiency in material and energy use, reduce defects and improve overall production efficiency

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energy

ind power relies on turbines to convert wind energy into electricity. Compared

to traditional energy sources like fossil fuels, it does not emit harmful greenhouse gases, making it a very environmental friendly proposition. In addition, it is readily available.

The winds of change are clearly evident as the US govern-ment has announced its intention to increase the portion of wind-generated power from its current level of 1 percent to over 20 percent of the power used in the US by 2030, according to Samsung Heavy Industries.

This form of power generation does not require investments

other than the initial installation costs. As its power generation costs are just 20 percent those of solar power generation and are lower than those of natural gas and oil, it is expected that wind power will fulfil 12 percent of the global energy demand in 2020, and that its power generator market will grow to US$74 billion.

With growth expected in this industry, Bosch Rexroth has expanded the capacity of its wind-power operations. Investments in the gearbox plant will total �180 million (US$251 million) come 2013. In roll-out year 2009, the plant will manufacture some 300 large gearboxes for the latest generation of multi-megawatt turbines.

Generating PowerA power train transfers the rotational force of the rotor to the generator. Gearboxes are required to increase the rpm in generators that produce electrical energy. They act as a ‘step up’ mechanism as the propeller moves slowly while the generator moves a lot faster. Without this effect, the tip of a rotor will have to move at a great speed.

Gearboxes in this case work in an opposite manner compared to a typical gearbox in a car. In wind power generation, they convert slow rotating, high torque power, which you get from the turbine rotor and high-speed, low torque power, which you use for the generator.

Opportunities The market for wind energy is on the rise as countries and companies alike warm up to its potential. By Joson Ng

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installed capacity of 10,242.3 MW. In terms of wind power installed capacity, the country is ranked fifth in the world.

In an estimate by the Indian Wind Energy Association, based on the current level of technology, the ‘on-shore’ potential for utilisation of wind energy for electricity generation is in the order of 65,000 MW.

In North America, the US became the country to install the highest number of new wind- ENQUIRY NO. 5603

power output in 2008, and has now surpassed Germany as the leading country for wind-power ut i l isat ion. Encouraged by comprehensive incentive schemes, the US market will continue to grow rapidly. Back in Asia, both China and India are making great efforts to expand wind power, and are catching up rapidly. The Global Wind Energy Council forecasts that installed power output will triple by 2013.

ENQUIRY NO. 5602

Techno UpdaTe

The WindBoost control system upgrade by GE Energy enables the turbine blades to spin faster and increase the turbine output by 100 kW, from 1.5

to 1.6 MW. By generating more power from the same unit, turbine operators can increase their profitability.

The control system is designed for both new and existing 60 hz GE 1.5 sle wind turbines with plans to apply the technology to additional 1.5 MW models. It is capable of delivering up to four percent increment in annual energy output. It is also possible to turn the control system on and off remotely at the turbine level.

According to the Danish Wind Industry Association, a single gear ratio dictates the conversion of power between the rotation of the rotor and the generator. For a 600 or 750 kW machine, the gear ratio is typically 1 to 50.

The gears are generally made from aluminium alloys, stainless steel and cast iron. Metalworking process like grinding is used to produce spur, helical gears and also to cut or grind the teeth on a customer supplied blank. As far as wind energy goes, metrology equipment makers can get in on the act as well. The axle bores on transmission case used in wind turbine has a tolerance range of about 50 microns. This is where a CMM can be used to check the part.

Winds Of ChangeIn Asia, wind turbines are spouting up. Vestas has sold 58 V52-850 kW wind turbines for the Zhaqi phase one wind farm, located in Tongliao, Inner Mongolian autonomous region. Across the border in India, the wind energy sector has an

Wind Farms:

noT YoUr average Kind of farm

A cluster of wind turbines in an area makes up a wind farm. These farms harness wind energy and convert them to electrical power. Size of a farm varies from

a few dozen to about 100 individual wind turbines. They generally cover a large area spanning up to hundreds of square kilometres. These wind farms may also exist offshore where strong winds blow.

There are wind farms located all over Asia Pacific and with more in the pipeline, there are opportunities for the metalworking industry especially in gearbox manufacturing.

In Japan, the Nunobiki Plateau wind farm is located at an altitude of 1,080 m. Generating enough power for approximately 35,000 houses, it is said to be the largest wind generating station in Japan. Lake Bonney wind farm, in South Australia, consists a total of 99 turbines with a rated capacity ranging between 1.75 to 3 MW. With combined capacity of 239.5 MW, it was the biggest wind farm in Australia at the time of completion.

ENQUIRY NO. 5604

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features

ENQUIRY NO. 5702

aving built up an extensive network of local subsidiaries throughout Asia in the last

few years, such as the setting up of a plant in Zhuhai in China three years ago, Harting’s influence now covers the whole of Asia, reaching from India to Japan, with subsidiaries in countries including Singapore, South Korea and Taiwan.

Moving ForwardIn order to further establish themselves in Southeast Asia, reveals Harting Singapore MD Sören Montag, the company, which positions themselves as an innovator for connectivity and

industrial network technology and customised system and product solutions, has identified certain

d irect ions where the company wants to increase its focus and sales approach to successfully implement growth strategies.This includes amongst

others the automation and m a c h i n e r y b u s i n e s s , especially in Singapore, Indonesia, Thailand and

Malaysia, the expansion of the Southeast Asia distributor network eg in

Indonesia and Thailand and therefore in areas where they

are not locally present and the implementation of business models that are classified as VAB (value added business), according to Mr Montag.

In Southeast Asia currently approximately 60 percent of the business is related to the electronics side and device connectivity business, which includes Telecommunication, Outdoor Telecom Applications and Embedded Computing.

Harting’s Connectivity & Networks division is grouped into three product divisions; comprising

Employing a strategy of diversification, Harting has emerged from being a components supplier to a solutions provider. By Derek Rodriguez

By DiversificationProgression


o f t h e w e l l k n o w n industrial connectors Han, classified as Installation Technology, the Electronic connector division under Device Connectivity and the Automation IT, which offers industrial Ethernet s w i t c h e s , E t h e r n e t connectors and system cables.

Broadening StrategyThis diversification of product groups and therefore markets has enabled Harting to buffer the adverse effects of the worldwide economic slowdown. Explains Mr Montag: “We can offset a certain industry that is currently heavily impacted like machinery for example, and I think this kind of broadening or diversified strategy is definitely an approach that is healthy to Harting.”

To add to this, new markets are being identified as part of the plan to move the organisation forward. Mr Montag elaborates: “There are markets we have not really captured yet in Southeast Asia. We have the products and solutions but have never really entered and penetrated these markets. Going forward we will change this by broadening our sales and go-to-market focus in the region”

He continues: “For example take Ethernet, the whole fieldbus, the whole machinery approach; by talking to local machinery makers for instance in Malaysia, Thailand or Vietnam and offering them our support by providing either single components or value added business where we come up with complete harnessing or other customised electrical and electronic products.”

“We want to provide a complete solution, be it cable, connectors, or networks where you have the active components together with the passive components. We want to try to move towards a solution

selling and provide customers more to become an integral part of the value-add process.”

Technology DrivenDespite its strong standing in the industry, the company is not resting on its laurels as its research and development teams continue churning out the latest in technological advancements. One example is Fast Track Switching technology, which received a nomination for the Hannover Messe Hermes Award technology prize and was placed in the top five.

Harting:

Fast track switching technologyFully compatible with standard Ethernet, the Fast Track Switches guarantee deterministic data transmission at the field level. This makes it possible to meet high real-time requirements in automation without changing the standard Ethernet.

All the benefits, such as flexibility, many degrees of freedom, large portfolio of globally available devices and established technology, can be fully exploited.

No special hardware is required in the terminal units. The switches guarantee on-time data transport. This works for various automation profiles, such as Profinet RT, Ethernet/IP, ModbusTCP and all other standard-unchanged Ethernet protocols that can be identified in their headers. These are given priority, identified and sent using cut-through methods. The central point is that they can pass other protocols.

The first products will be the demonstrated FTS 3100 10-port switches in protection class IP 30. They will go into production in December of this year and will be joined in the 2nd quarter of 2010 by further models, such as the FTS 3060 6-port switch.

Declares Mr Montag: “The Fast Track Switching is a forward development when it comes to real time and determinism.”

Products l ike Fast Track Switching not only provide customers with the most cutting edge products, but also, says Mr Montag, allows Harting to show their customers, system integrators and the general industry that the company is innovative and coming up with technology that other known Ethernet companies do not have in their portfolio.

We can offset a certain industry that is heavily impacted like machinery for example, and i think this kind of broadening or diversified strategy is definitely an approach that is healthy to harting

ENQUIRY NO. 5701

ENQUIRY NO. 5702


feAtures

ENQUIRY NO. 5703

O rg a n i s e d b y E m e r s o n P ro c e s s M a n a g e m e n t , the Performance Without

Compromise seminar was held at the Crowne Plaza Mutiara Hotel in Kuala Lumpur, Malaysia on July 2 of this year. The one-day event was attended and officiated by YB Datuk Liew Vui Keong, Deputy Minister in the Prime Minister’s Department.

Over 300 customers from around the region gathered at the event which served as a platform not only for Emerson to provide useful presentations and showcase their products and services offerings but also for participants of the event to have an opportunity to network amongst themselves.

Global PresenceKhairil Affandi Akhiruddin, GM, Emerson Process Management Malaysia gave a breakdown of the company’s 2008 sales by geography: Although the largest piece of the pie is still the US with 32 percent, Europe, Asia and the rest of the world are close behind

Innovation and Safety, Health and Enviroment were issues discussed at the Performance Without Compromise Seminar

with 24 percent, 21 percent and 23 percent respectively.

Mr Akhiruddin also stressed the importance the company placed on its presence in Malaysia. Other figures highlighted were the US$728 million spent on engineering and development in 2008 and the 8,500 engineering and development personnel worldwide, emphasising the company’s commitment towards innovation.

Topics Of InterestTwo key development areas were identified by Shaun Taylor, VP, Rosemount Asia Pacific: smart wireless technology and human centred design. One area Emerson is investing heavily in is operator graphics, where effectiveness in terms of safety and ease of use are the main objectives.

Hakan Erdamar, VP, customer services talked about Safety, Health and Environment (SHE). He discussed the global trends in this area for the process industry and offered some solutions in

preventing SHE incidents from occurring in the plant.

Director of customer services and marketing Neo Chow Yang’s speech on the services provided by Emerson shed light on the importance of a maintenance blueprint and a maintenance priority index.

Technology ShowcaseThe second half of the event was a technology exhibition with live, hands-on demonstrations of Emerson solutions. Visitors at the smart wireless corner benefited from the live presentation showing the effectiveness of a wireless plant in predictive maintenance.

At another corner of the hall was a demonstration of smart SIS (safety instrumented systems), which showed how the company’s solution is able to increase the reliability of a plant.

July 2, 2009Crowne Plaza Mutiara HotelKuala Lumpur, Malaysia

Emerson’s Performance Without Compromise Seminar


ENQUIRY NO. 5704

Creating Jobs, Improving Government Citizen Services & Stabilising The Economy Are The Top Priorities Of APEJ Governments

According to the IDC Government Insights study, Economic Stimulus and Expansionary Budgets: Tabulating the Government’s Response to the Economic Downturn in Asia/Pacific, US$767 billion worth of initiatives have been unveiled by governments in Asia/Pacific (excluding Japan) or APEJ between August 2008 – April 2009. The initiatives range from economic stimulus packages and expansionary budgets to the advancement of planned spending and projects.

Most new government budgets do not single out IT spending but incorporates it as an element of a new and urgent government initiative. Despite this, it is still welcoming news for both govern-ment technology officers and information technology vendors.

Based on the init iatives announced by governments across the APEJ region, IDC Government Insights analysts have identified the fol lowing key areas of investments, the implications of these priorities on ICT spending, as well as potential opportunities for businesses. These investments will begin in late 2009 and continue through 2014.

Infrastructure ProjectsInfrastructure projects not only

create jobs immediately but also boost citizen services as it provides an opportunity for government agencies to redress aging issues and problems with congested transportation systems, or upgrade healthcare and educational facilities for the benefit of their citizens.

The spike in infrastructure projects would likely boost ICT investments in areas such as remote monitoring for building maintenance, automated adherence to stricter safety standards and environmental compliance such as industry emissions-monitoring technologies.

Healthcare ReformsHealthcare is a key investment area for governments as it is related to job creation, skills development, citizen-services enhancement, and digital inclusion. Healthcare investments provide a clear boost to public-sector ICT investments. For example, to accelerate the move towards digital patient information, investments will have to be made on the existing ICT infrastructures of hospitals.

Green Technologies The current financial crisis provides a window of opportunity

to restart the economic engine with a focus on long-term solutions that are economically, socially, and ecologically sustainable. In this context, national stimulus packages, to varying degrees, are seeking to not only revive but also green their national economies.

Furthermore, green tech-nologies also help government agencies meet cost-cutting and budget optimisation goals through a focus on energy efficiency. Investments to strengthen green infrastructures across

APEJ countries have clear implications for technology spending in areas such as intelligent grid technologies, energy efficiency technologies, environmentally sound tech-nologies (ESTs) that generate low or zero waste, etc.

While current economic stimulus priorities will have a dominant impact on the short-term investment behavior of APEJ governments, it is worth noting that ongoing strategic concerns such as the rising threat of transnational terrorism should be continually addressed in order to ensure economic stability over the long run.

APEJ governments have unveiled US$767 billion worth of initiatives to jump-start their sluggish economies. By IDC Government Insights

Market Report


products & services

Advantech: digital input card

Basler: one Megapixel camera

Based on Kodak’s KAI-1050 CCD sensor with a resolution of 1024 x 1024 pixels, the Basler aviator camera series pushes the speed barrier to 120 frames per second. Progressive scan readout and global shutter technology combined with a Camera Link data interface make the aviator camera well suited for various application areas such as semiconductor and electronics manufacturing, metrology, or medical imaging.

As a result of Basler’s extensive Camera Link interface and Kodak sensor experience, the Basler aviator offers excellent imaging results in terms of dynamic range and noise level, factors that will be measured and documented for each camera by automated EMVA 1288 sensitivity testing during production.

Enquiry no. 5804

Enquiry no. 5802

Enquiry no. 5803

Enquiry no. 5801

Ametek: Alloys For engineered shapes

The combination of strength, formability, non-sparking and anti-galling characteristics of Ametek’s Pfinodal alloys make them a choice for a range of land-based or off-shore oil and gas applications, especially as a suitable replacement for beryllium copper components.

The alloy consists of copper, nickel (15 percent) and tin (8 percent), are made using powder metallurgy technology. The homogeneous single-phase structure of the alloy achieves uniformity, formability and strength and ensures reproducible properties.

In addition, they have low permeability, good lubricity, machinability and anti-seizing characteristics. They are available in a variety of forms, including rod/bar, plate, tube and as custom engineered shapes and finished parts.

Baumer: ultrasonic sensors

Baumer’s Series 09 ultrasonic sensors are capable of measuring into wells with as little as 3.3 mm opening diameter, providing a 0.1 mm resolution. This performance converted to a type 384 microplate results in a resolution of 1.09 microliters.

Thus, the loss of liquid can be kept within very tight limits. Additionally, the measurement allows the detection of flaws at an early stage of the analysing process, which keeps the general process quality at a high level. Efficiency concerning scanning speed is a further highlight of the Series 09 sensors. Thanks to a housing width of less than 9 mm, eight sensors arranged in-line are capable of scanning a type 96 microwell plate in one single cycle.

The Advantech PCM-3761I is a form C type eight channel relay and eight channel isolated digital input PCI-104 card for machine and production automation. The PCM-3761I’s relay allows operators to retain output values even in the event of an unexpected system reboot. The input channels support 2,500 VDC and a wide input range of 5 ~ 30V, allowing it to be resistant from surge or noise interference.

Moreover, the PCM-3761I provides a newer variation on the PC/104 standard, PCI-104, which is designed for embedded computing environments. PCI-104 is replacing the ISA bus, which is being phased out in the industry due to speed and compatibility issues with newer processors. PCI-104 is stackable and fast providing reliable anti-vibration functionality.


products & services

Enquiry no. 5808

Enquiry no. 5806

Enquiry no. 5807

Enquiry no. 5805

cognex: id reader

Cognex DataMan 200 ID reader adds Ethernet connectivity and liquid lens technology to the fixed-mount reader.

Ethernet connectivity gives DataMan 200 users the advantage of real-time data and image transfer, and easier integration with plant controllers and information networks. With liquid lens technology, autofocus is achieved with a single software command. The lens also provides exceptional depth of field and field of view range, and, the system is extremely rugged and resistant to shock, vibration and wear.

Setup is simplified with the use of two laser aimers. The laser targets are easily seen through the entire depth of field, enabling operators to quickly position the code to the reader.

contec: Multifunction Module

Contec’s GAIO-163202FX-USB is a multifunction module that provides analogue input / output signals through a computer’s USB port. This unit features high-precision 16bit analogue input (32 channels), analogue output (2 channels), digital I/O (LVTTL level 8 channels each), and counter (32bit binary, LVTTL level 2 channels).

This module includes an event controller that integrates management control signals via hardware and buffer memory (128K data) making it ideal for use in various high-performance PC-based measurement and control systems.

The GAIO-163202FX-USB is compatible with both the PCI (ADA16-32/2(PCI)F) and PCI Express versions (AIO-163202F-PE) allowing for easy to migration from an existing system.

Flow technology: turbine Flowmeter system

Flow Technology’s FT/DF (Diesel Fue l ) t u rb ine f l owmete r system, provides accurate measurements of diesel fuel consumption in a wide range of industrial applications.

Pairing Flow Technology’s FT Series turbine meter with the LinearLink Temperature Compensated Interface (TCI), the FT/DF system can accurate measure diesel fuel at temperatures as low as -50 deg F. The turbine flowmeter incorporates a ‘fail open’ technology, meaning that in the event of a malfunction, fuel continues to be fed to the generator, ensuring there is no interruption of power to the industrial operation.

Because of its versatility, the FT meter is suitable for a wide variety of liquid and gas flow sensing applications.

digi: vpN connector

Digi International’s Digi TransPort VC7400 is an enterprise-class virtual private network (VPN) concentrator that provides connectivity to large installations of remote cellular or wired devices. It is ideal for retail, financial/ATM, lottery and telemetry applications.

The Digi TransPort VC7400 is ideal for connecting thousands of remote devices using Digi Connect WAN, ConnectPort WAN and Digi TransPort cellular routers. The Digi TransPort VC7400 supports up to 3,000 simultaneous clients and features a 1 Gb/S Ethernet port, a 4-port 10/100Mb/s Ethernet switch (plus 1 DMZ port) and a front panel color LCD screen for displaying statistical and performance data.


products & services

Enquiry no. 5812

Enquiry no. 5810

Enquiry no. 5811

Enquiry no. 5809

HMs industrial Networks: GsM/Gprs Web Gateway

HMS Industrial Networks’ Anybus RemoteCom is an industrial GSM/GPRS based device for remote monitoring and control, alarm management and data logging.

Anybus RemoteCom is an easy-to-use web gateway which acts as a Modbus bridge as well as providing remote access and control of serial devices over Ethernet, Internet, LANs, GSM, GPRS and telephone modems. The product has a built-in powerful web server to provide web-based access from a remote location, alarm management, data logging and trend graphs of field equipment data. The integrated alarm and status handler automatically notifies remote supervisors by email, SMS, SNMP and Modbus TCP if pre-defined limits are exceeded.

igus: twistable optical Fibre cable

Igus has developed a twistable fibre optic cable for all 3D movements in energy chains, to keep bus systems working reliably. The twistable TPE fibre optic cable ‘Chainflex CF Robot-LWL’ makes high data rates possible and can be routed directly alongside high-capacity electrical power cables. The design uses twist-optimised compensating elements, and the mechanically strong fibre optic cable is absolutely robust even with rotary angles of +180° eg on a robot arm.

The fibre optic cable has a 2-fibre optic core, is resistant to oil, bio-oil and UV light and remains flexible in the cold.

sanyo denki: cooling Fan

Sanyo Denki’s San Ace 40 - GA type, 40 x 40 x 28 mm cooling fan, achieves 30 percent energy savings and a sound pressure level that is reduced by 6dB(A), compared to a conventional Sanyo Denki fan.

It also has the PWM (Pulse Width Modulator) speed control function for external fan rotation speed control. San Ace 40 GA type features four models. In the low speed rotation version, it offers flow ranges of 0.13 m3/min and 0.16 m3/min, static pressures of 20 Pa and 33 Pa, power consumption from 0.48W to 0.60W and sound pressure level from 17 to 22 dB(A).

In the high speed rotation version, it offers flow ranges from 0.46 m3/min to 0.67 m3/min, static pressures from 258 Pa to 535 Pa, power consumption from 2.52 W to 5.88 W and sound pressure level from 47 to 54 dB(A).

Fluke: Milliamp clamp MetersT h e Fluke 772 and 773 Milliamp Clamp Meters join the Fluke 771 to deliver a range of test and

measurement capabilities. These precision tools are designed for

instrumentation technicians, contractors and process vendors who install and

commission instruments, process and automation technicians, commercial electricians and auto repair technicians who do mA loop troubleshooting on process control c ircuits, instruments

and automotive systems.The F luke 771, 772 and

773 Milliamp Clamp Meters are engineered to measure the minute amounts of current (4 to 20 mA signals) that flow through control system circuits, without having to shut down the system, break the circui t and inser t a tes t

instrument.


products & servicesproducts & servicesproducts & services

Witte: sandwich plates

Wonderware: custom interface toolkit

sensortechnics: capacitive sensor

S e n s o r t e c h n i c s ’ C L C se r i e s uses a contact-free capacitive sensor technology to continuously measure the fill level of liquids as well as granular or pulverised materials.

The miniature sensor can be easily mounted to the outside of a container or vessel and is able to

measure through almost any non-metallic wall material. The level sensing range of the standard device is up

to 10 cm which can be enlarged in special multi-sensor configurations.

The CLC series achieves a high accuracy and reliability due to an additional reference electrode which compensates for all changes in ambient environmental conditions such as temperature and humidity.

Sandwich plates are often used as a base for measuring fixtures and structures. However they are increasingly being used as a means of transport between measuring centre and assembly area. Witte Far East has a roller driven sandwich plate.

This Multi Direction Drive (MDD) sandwich plate is easy to move and steer. The special character of the rollers enables simple movement and positioning, which is remote controlled with the help of a joystick. The controls automatically align the rollers to the desired turning direction. Then it is easy to rotate the sandwich plates on the spot or drive sideways. The rollers have a special outer surface, which ensures careful treatment of the floor.

Wonderware DAServer Toolkit 3.0 gives customers and partners the capability to create, test and deliver custom interfaces to equipment.

The toolkit enables users to develop customised connectivity solutions for Wonderware System Platform for instances where there is not a pre-existing protocol interface. The toolkit is typically used by system providers that need to connect to proprietary devices when integrating solutions with System Platform.

Fully integrated with Microsoft Visual Studio 2008, the DAServer Toolkit 3.0 also offers wizards for creating new Ethernet protocol drivers, serial protocol drivers and an install utility that enables these components to be easily delivered and implemented where needed.

Enquiry no. 5816

Enquiry no. 5814

Enquiry no. 5815

Enquiry no. 5813

turck: Fdt/dtM software

To simplify device setup and installation time, Turck’s interface module (IM) family may now be programmed via a PC or integrated push buttons using FDT/DTM software, along with PACTware. This software allows multiple parameters to be set and saved in a matter of seconds. The ease of use and structure of this system allows asset management ability with trending and data logging of values.

Turck’s IM models may be used to monitor the speed of motors, shafts and conveyors, the temperature of RTD’s and thermocouples, and to control or monitor analogue signals for linear movement, temperature, pressure, level control or any other device using 4 to 20 mA signals.


EVENT rEViEw

It was business as usual a t BroadcastAs ia2009 and CommunicAsia2009 as 54,354 attendees congregated at the media and infocomm trade event. Of the total number of attendees, 49 per cent came from outside of Singapore, hailing from about 100 countries and regions across Asia Pacific, Europe, US and the Middle East.

Spanning 58,000 sq m, the exhibit ions featured 1 ,923 exhibiting companies from 60 countries and regions. The shows saw a total of 34 group pavilions, with countries like Belgium, Brunei Darussalam and Vietnam participating for the very first time.

T h e s p o t l i g h t w a s o n the S ingapore Pavi l ion at BroadcastAsia. With more than 20 local companies taking part for the first time, interactive digital media was one of the main features. One such project is ‘Wish Singapore’ developed by PGK media. Making its debut at this year’s National Day, the gigantic floating LED cylindrical display will feature Singaporeans’ well wishes at Marina Bay.

2009

CommunicAsia

s u c c e s s f u l e - g o v e r n m e n t programmes.

Singapore's Senior Minister Goh Chok Tong shared about good governance in his 45 years' experience in government at the opening of the iGov Global Exchange. Urging the public sector to open up e-government platforms to the private sector, he said that government agencies should take the role of facilitator and enabler, and evolve from “being the sole provider of services to being a provider of a platform”.

Speakers from the industry and various government agencies shared their experience on implementing e-government initiatives in countries including Canada, France, Hong Kong, Italy, Philippines, Saudi Arabia, Singapore, the UAE and the United States. In addition, the programme for delegates included visiting the iGov exhibition at CommunicAsia and site visits to some of the government infocomm projects in Singapore.

June 16 – 19, 2009Singapore ExpoSingapore

Discussing Business StrategiesThe CommunicAsia2009 Summit attracted 700 delegates and saw a line-up of up-to-date topics in the infocomm industry. The speakers provided delegates with insights to addressing the most current issues faced in today’s global marketplace.

At the CEO Perspectives which kicked off the summit, telecommunications bigwigs shared about the need to invest in their networks, go all-IP and embrace their competition in matters like infrastructure sharing. Dato’ Zam Isa, group CEO of Telekom Malaysia asserts that the business model for telcos is not about voice anymore. “You have to change your mindset and move up the value chain and become an enabler of any-to-any services,” he said.

e-Government InitiativesThe inaugural iGov Global Exchange drew 600 leading e-government experts from 27 countries to discuss opportunities and challenges in developing ENQUIRY NO. 5901


ENQUIRY NO. 5902

Metaltech 2009 made its fifteenth presentation from May 6-10, 2009 at the Putra World Trade Centre, Kuala Lumpur, attracting over 17,371 trade visitors from 53 countries. Amidst the economic recession, exhibitors expressed that sales activities had exceeded their expectations at the show.

Albert Lai, MD of Trade-Link Exhibition Services, and organiser of MetalTech 2009 said: “In view of the pessimistic market economy, many exhibitors were planning to use MetalTech 2009 as a platform to network with their business contacts and promote confidence level in their business. However, at the conclusion of MetalTech 2009, exhibitors were making unexpected substantial amount of sales with a number of serious buyers visiting the exhibition from around the region.”

Covering 25,000 sq m of exhibition space, MetalTech 2009 drew the participation of over 900 exhibiting companies including six national groups from Singapore,

China, Taiwan, South Korea, Austria, and Germany.

High TechnologyThe Deputy Minister of International Trade & Industry, Dato’ Mukhriz bin Tun Dr Mahathir who officiated the opening ceremony

of MetalTech 2009 commented: “The Machinery & Equipment industry does indeed play a vital role in the overall Malaysian economy as it also provides a strong level of support to the small and medium enterprises (SMEs) which forms the backbone of our market economy.

It is for this very reason that the entrepreneurs in this M&E Industry must persevere and invest the required resources to enhance their presence in the marketplace in the hope of catching the next wave as, or rather when the global economy finally recovers.”

With increasing competition from lower cost producing countries, Malaysia’s Machinery and Equipment (M&E) industry has moved away from the manufacture of low-end and low-technology M&E towards high technology and high value added M&E such as standard M&E for niche market and custom made M&E.

MetalTech 2010 will return from May 5–10, 2010 as an event for manufacturers and metal industry players from around the world to showcase and source for metal work, machine tools, CAD/CAM, metrology, mould and die, surface and heat treatment, s u b - c o n t r a c t i n g , f o u n d r y, industrial automation, robotics, precision engineering and welding technology and products.

May 6 – 10, 2009Putra World Trade CentreKuala Lumpur, Malaysia


EVENT rEViEwEVENT rEViEw

Water Prize increased in size and quality.

Water NeedsAbout 1,500 people attended the opening ceremony, where Senior Minister Prof S Jayakumar communicated the theme of ‘Sustainable Cities-Infrastructure and Technologies for Water’, in his opening speech. It was clear that the world would become more highly urbanised in the near future, with more intense use of water. Many cities would lack behind in infrastructure for the capturing, storage, treatment and delivery of water to meet the needs of the people.

Governments must therefore step up efforts to address these needs through infrastructural changes now. The global financial crisis provides a good opportunity to do so before such changes becomes too expensive to make in the future.

Business OpportunitiesDue to popular demand, two new forums, the North America business forum and a finance forum were introduced, increasing the number of business forums from seven to nine. The Middle East forum was also expanded to include North Africa. The finance forum titled ‘Financing for Water Infrastructure & Technologies’ was held to address pertinent questions on how the credit crisis has affected the financing of water projects and what business opportunities could emerge from the changing financial landscape. In all, deals worth a total of S$2.2 billion were sealed, nearly six times the amount achieved last year.

The Water Convention, held in conjunction with the International Water Association’s Leading Edge Technologies Conference (LET), also saw more than 200 oral and poster presentations. The convention focused on four key themes; Water Technology Solutions for Today’s Applications, Managing Water Infrastructure, Water and Health, and Planning for Sustainable Water Solutions.

This year’s SIWW attracted more than 10,000 participants from over 85 countries, surpassing last year’s 8,500. By Augustine Quek

The myriad of events, from ministers’ conferences to water sport activities, packed the week of June 22–26, 2009 with activities at the Singapore Internat ional Water Week. Major events unique to this year’s Water Week included the opening of one of the largest water reclamation facility in the world at Changi and the release of new water design guidelines to provide greener waterways and cleaner waters.

The key staples from last years inaugural Water Week, such as the Water Leaders Summit, Water Convention, Water Expo, Business Forums and the Lee Kuan Yew

Singapore International Water Week 2009


ENQUIRY NO. 5903

Water Expo also expanded its exhibition area from 8,000 to 12,000 sq m, which was booked by over 400 participating companies from 26 countries. This included more than 140 direct exhibiting companies f rom about 20 countries.

The S ingapore Pav i l ion showcased the capabilities of over 50 local and Singapore-based water companies, and expanded

four-fold from 200 sq m in 2008 to 800 sq m this year. About half of the companies within the Singapore Pavilion are first-time participants.

Prof Tommy Koh summed up the lessons learnt during his closing remarks at Water Leaders Summit: “For most parts of Asia, the water problem was not due to an absolute shortage of water but to poor governance. The

problem could be solved with good governance and better management practices. If you wish to make a fundamental progress in the field of water, you should invest in all the four links of the value chain, namely, people, asset, innovation and management.”

June 22 – 26, 2009SuntecSingapore

Dow Water & Process Solutions: Membranes

D o w W a t e r & P r o c e s s Solutions, a division of The Dow Chemical Company, has two variants of their FilmTec elements for brackish water t rea tmen t . T he F i lmTec element BW30XFR-400/34I reduces the cleaning frequency of Reverse Osmosis ( RO ) systems while offering superior removal of contaminants while the BWHR30-440i improves permeate water quality and

RO system productivity by setting a new standard for the rejection of solutes.

ITT: Predictive Condition Monitoring

T he I T T P ro Smar t Predictive Condition Monitoring system is a predict ive, online mach ine cond i t i on monitor ing system. I t uses inputs from m u l t i p l e s e n s o r s , such as v ib ra t ion ,

temperature, oil level, pressure and speed, with patented algorithms, to create alarms to notify operators through various means like cell phone, email and browsers.

The total cost of ownership is low as the ProSmart system was designed from the ground up, with low cost sensors and simple installations.

Siemens: Electrodeionisation Module

For water hardness reduction, Siemens Water Technologies has introduced the VNX-HH electrodeionisation (EDI) module. The EDI is a chemical-free process for deionising water using a combination of selective ion exchange membranes, conductive resins and electricity to remove ions from water.

The VNX-HH modules can operate in water hardness up to 2 parts per million (ppm), which four times the industry standard of 0.5 ppm.

Water SolutionsInnovations&The Water Expo saw the worldwide launch of twenty-nine new products and technologies. Sixteen of these were launched at its Innovation Corner.

Singapore International Water Week 2009


EVENT PREVIEW

ENQUIRY NO. 5904

The second annual JEC Asia Show will be held in Singapore at the Suntec Centre from October 14 – 16, 2009. This Show reflects the growth potential of the composite industry in the Middle East, Asia Pacific, and Australia and New Zealand. It brings new solutions and ideas in the composite field to emerge from the current economic crisis.

This year’s theme will highlight the automation of manufacturing processes: how to produce more and optimise prices, quality, safety and environment impact? Where to buy new materials? To whom? How to adopt new technologies? Who are the best suppliers for machines and equipment? How to find the best partners?

Asian GrowthSays JEC president and CEO Frédérique Mutel: “In 2000, Asia represented 25 percent of the global composites consumption. Now it represents 42 percent with a value of €18 billion (US$25 billion). It could reach 50 percent in 2013. With major growth markets in China and India, along with interesting growth in Middle-East, Malaysia, Vietnam, Indonesia, without forgetting the stable consumption in Australia, Japan and South Korea, the outlook for the composites industry in the Asia Pacific is quite bright.”

A l ready seven nat iona l pavilions have been confirmed for the 2009 session, including

Australia, Taiwan, India, Japan, China, South Korea and France.

Connecting Science, Technology & BusinessThere will be three exhibition halls (an increase of one compared to 2008) for industrial players to showcase composite solutions and services, business meetings to facilitate business connections between exhibitors and visitors, end-user forums devoted to main composite markets of aeronautics, automotive/mass transportation, wind energy, construction/building/civil engineering.

JEC Asia 2009

There will also be an innovation programme to award current innovations which use composites in the different application fields, technical lectures on the latest advances in materials and processes and an innovation showcase, displaying composites products and solutions chosen for their technical and economical performances.

October 14 – 16, 2009SuntecSingapore

Of

august

5 – 8 2009 Taipei International Industrial Automation & Robot Joint Exhibition

Taipei World Trade CenterTaipei, TaiwanTaiwan Society of Manufacture Engineering and Automation TechnologyEmail: [email protected]: www.tsmea.org.tw

11 – 14 Propak Malaysia 2009 Kuala Lumpur Convention Centre Kuala Lumpur, MalaysiaMalaysian Exhibition ServicesEmail: [email protected]: www.propak.com.my

13 – 16 TADTE 2009 Taipei World Trade CenterTaipei, TaiwanTaiwan External Trade Development CouncilEmail: [email protected]: www.tadte.com.tw

september

16 – 18 Industrial Automation Vietnam 2009

Saigon Exhibition & Convention CentreVietnamHong Kong Exhibition ServicesEmail: [email protected]: www.iavietnam.com

16 – 18 Clean Energy Expo Asia Suntec SingaporeKoelnmesseEmail: [email protected]: www.cleanenergyexpoasia.com

october

5 – 8 SCM Logistics World 2009 Raffles City Convention CentreSingaporeTerrapinnEmail: [email protected]: www.terrapinn.com

7 – 10 Manufacturing Technology World

SMX Convention CenterPasay City, PhilippinesGlobal-Link MPEmail: [email protected]: www.globallinkph.com

7 – 11 Bangkok RHVAC 2009 Impact Arena Exhibition & Convention Centre Muang Thong ThaniThailandRoyal Thai Government Office of Trade Fair ActivitiesEmail: [email protected]: www.bangkok-rhvac.com

13 – 15 Wire Southeast Asia BITECBangkok, ThailandMesse Düsseldorf AsiaEmail: [email protected]: www.wire-southeastasia.com

14 – 16 JEC Show Asia 2009 Suntec SingaporeJEC CompositesEmail: [email protected]: www.jeccomposites.com

22 – 25 Metal Technology Show 2009

Putra World Trade CentreKuala Lumpur, MalaysiaFairs & Events ManagementEmail: [email protected]: www.femsb.com/MTS2009

26 – 27 Carbon Forum Asia Raffles City Convention CentreSingaporeInternational Emissions Trading Association (IETA) and KoelnmesseEmail: [email protected]: www.carbonforumasia.com

26 – 29 CeMAT Asia Shanghai New Int’l Expo CentreShanghai, ChinaDeutsche MesseEmail: [email protected]: www.cemat-asia.com

27 – 31 Korea Metal Week 2009 Korea International Exhibition CenterSeoul, South KoreaKorea Trade FairsEmail: [email protected]: korea-metal.com/english

Calendar 2009Events

november

18 – 20 Clean Energy Expo Asia Shangri-La HotelSingaporeKoelnmesseEmail: [email protected]: www.cleanenergyexpoasia.com

18 – 20 NDE Tokyo 2009 Tokyo Big SightTokyo, JapanJapan Management Association (JMA)Email: [email protected]: www.jma.or.jp/nde/en

19 – 22 Metalex 2009 BITECBangkok, ThailandReed TradexEmail: [email protected]: www.metalex.co.th

December

1 – 4 CIA 2009 Suntec SingaporeSingapore Exhibition ServicesEmail: [email protected]: www.cia-asia.com

2 – 4 Semicon Japan 2009 Makuhari MesseChiba, JapanSemiEmail: [email protected]: www.semiconjapan.org


To be considered for inclusion in the Calendar of Events, send details of event (name, date, venue, organiser contact) to:

The Assistant Editor IAA.Eastern Trade Media Pte Ltd.1100 Lower Delta Road, EPL Building#04-02, Singapore 169206Tel: (65) 6379 2888Fax: (65) 6379 2805Email: [email protected]

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