iaa sept 07

Intelligent Motor Control

Going Modular

Wireless Sensors & Networks

Smarter Environment

Plant Analytics & Intelligence: Seamless Data integration

WIRELESS SENSORS & NETWORKS

EnvironmentSmarter

ü

September 2007

MICA(P) 012/12/2006 | ISSN 0219/5615 | PPS 1561/7/2008 (000553) www.iaasiaonline.com

Unlocking The Hidden Capacity of

On The MoveWarehousing

INTELLIGENT MOTOR CONTROL

Going ModularWIRELESS SENSORS & NETWORKS

EnvironmentSmarter

Process Plants

Industria

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• Inte

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LISTEN.THINK.SOLVE.

A L L E N - B R A D L E Y • R O C K W E L L S O F T W A R E

INTEGRATED ARCHITECTURE

The Rockwell Automation Integrated Architecture improves your productivity and reduces total cost of ownership by providing unparalleled functionality, flexibility and scalability.

The Integrated Architecture also addresses plant or enterprise performance and information needs including quality and compliance, production management and asset management. By emphasizing third party connectivity, interoperability and use of open industry standards, the Integrated Architecture provides seamless information integration with the rest of the site or enterprise.

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• Reuse engineering designs and practices to reduce development time and cost

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Rockwell Automation Southeast Asia Pte Ltd

Singapore Tel: 65 6356 9077 Fax: 65 6356 9011

Indonesia Tel: 62 21 573 5680 Fax: 62 21 573 5679

Malaysia Tel: 603 8996 1688 Fax: 603 8996 1699

Philippines Tel: 632 893 9712 Fax: 632 810 4397

Thailand Tel: 662 936 1500 Fax: 662 936 1510

ENQUIRY NO. 678

Scalable…Multidisciplined…Information-Enabled

ASEAN CC-LINK PROMOTION CENTRE307 Alexandra Road #05-01/02 Mitsubishi Electric Building Singapore 159943Tel: (65) 6473 2308 • Fax: (65) 6476 7439 • Did: (65) 6470 2480 • E-mail: [email protected] • http://www.cc-link.org

ENQUIRY NO. 648

CC-Link Safety... meets the need of production sites for saving wiring costs while at the same time ensuring safety. This safety field network inherits high-speed communication from CC-Link and makes it possible to both meet safety requirements for production lines and provides the benefit of wire-reduction.

All You Need For Safety Field Bus Network

CONTENTS

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]

SUBSCRIPTION RATES:IAA is available to readers on subscription in Singapore at S$60.00 per annum. Subscription by airmail to readers in Malaysia is also at S$60.00 per annum; and Asia Pacific, America, Europe and other regions at S$100. Refer to the subscription card in each issue for further details.

FOR MORE SUBSCRIPTION INFORMATION Fax: (65) 6379 2806 • Email: [email protected]. Eastern Trade Media Pte Ltd. All rights reserved. No portion of this publication covered by the copyright herein may be reproduced in any form or means – graphic, electronic, mechanical, photocopying, recording, taping, etc – without the written consent of the publisher. Opinions expressed by contributors and advertisers are not necessarily those of the publisher and editor.

SEPTEMBER 2007

ISSUES & INSIGHTS20 Seamless Data Integration

Much has been made of the benefits of open and interoperable fieldbuses, but not enough attention is paid to open and interoperable data structures. By David Marschall and Tieng Ling

24 Alarm ManagementThe implementation of an effective alarm management program involves creating a comprehensive and consistent alarm philosophy for documenting, collecting and analysing alarm data. By Frost & Sullivan

CONTROL POINT30 Intelligent Motor Control:

Going ModularThe pursuit of lower cost, higher availability, optimised maintenance and safety heralds the arrival of intelligent motor control systems that are modular, scalable and configurable. By Gunnar Zank

20Much has been made of the benefits of open and interoperable fieldbuses, but not enough attention is paid to open and interoperable data structures.

24ALARM

MANAGEMENT

INTELLIGENT MOTOR CONTROL: GOING MODULAR30

SEAMLESS DATA INTEGRATION

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CONTENTS

42 Real-Time Identification & TrackingGeo-location and identification technologies enhance visibility in asset tracking and ensure greater security on the plant floor. By Honeywell

INSTRUMENTATION & MEASUREMENT44 Going With The Flow

Built-in flow sensors improve machine efficiency, reduce downtime, and cut costs. By Christian Boehm

SECTOR SPOTLIGHT47 Warehouse Management:

On The MoveSeamless integration of warehouse management and control systems, and process optimisation through enabling technologies increases visibility in the supply chain. By Augustine Quek

IN BUSINESS50 Systems Integration:

Integrating Demand ResponseIntegrating demand response in control strategies allows users to leverage on both the demand and supply side of the equation. By Peter Kelly-Detwiler

SOFTWARE & NETWORKS34 Serving Up OPC

OPC offers a standard interface for accessing device data. By Marius Wotschik and Nadine Haid

38 Wireless Sensors & Networks: The Smart EnvironmentThe deployment of wireless sensor motes in physical environments, aided by self-organising network architectures, are quietly bringing about a sensing revolution. By Prasanna Ballal and Prof Frank Lewis

24ALARM MANAGEMENT

44GOING WITH

THE FLOW

SEPTEMBER 2007

pRefer to for Advertiser Enquiry Numbers 60a

REGULARS 8 News

14 CAN in Automation

16 Profibus Association S E Asia

17 Fieldbus Foundation

18 EtherCAT Technology Group

52 Automation Sources & Services

57 Calendar of Events

58 Advertising Index / Ad Sales Office

60A Product Enquiry Card

Cover picture: Emerson Process Management

Process uptime.Lowest cost of ownership. Proven safety leadership.Process uptime.Lowest cost of ownership. Proven safety leadership.

©2006 Invensys Systems Inc. All rights reserved. Invensys and Triconex are trademarks and registered trademarks of Invensys plc. All other trademarks noted herein are owned by their respective companies.

There are other important numbers besides a SIL rating.

No Purchase Necessary. Sweepstakes ends 08/31/06. To enter, register at www.triconex.com/sweepstakes. Sweepstakes open to legal residents of the (50) United States, the District of Columbia, the Commonwealth of PuertoRico, Canada (excluding the province of Quebec), Austria, Denmark, Germany, The United Kingdom of Great Britain and Northern Ireland, Ireland, Finland and Italy, who are 21 years of age or older and employed as a professionalindustrial, information or automation engineer. Promotion is void where prohibited. See Official Rules at www.triconex.com/10. The Sony name, logo and Sony Dream are registered trademarks of Sony. All rights reserved. Sonyis not a sponsor of nor associated with this promotion.

The fact is, SIL ratings on their own fall short of processfunctional safety. That’s because SIL ratings only measurethe “fail safe” capability of a system. Fail Safe alone can have unintended consequences and higher risk factors associated withunplanned shutdowns. In the processindustry, there are other safety-criticalnumbers that equate to uptime andoptimal asset availability. There is only onevendor that can put up big numbers inuptime, Triconex, the process safety leader.

Only Triconex Triple Modular Redundancy technology can trulydeliver the lowest lifecyle cost—by preventing unplanned

shutdowns 99.999% of the time. Avoid high costs and highrisk. Don’t entrust the safety of your plant tolightweights whose sole idea of performance is a SILnumber. Rely on Triconex, the experienced safetyleader who delivers safety, uptime and the bottomline. Visit us online at triconex.com/sweepstakes by August 31, 2006, and you could win a FREE

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ENQU

IRY

NO.

677

EDITOR’S PAGE

6 industrial automation asia | September 2007

Published by:

EASTERN TRADE MEDIA PTE LTD(A fully owned subsidiary of Eastern Holdings Ltd)

MANAGING DIRECTOR Kenneth Tan

MANAGING EDITOR Eileen Chan

[email protected]

EDITOR Goh Tz’en Long

[email protected]

TECHNICAL EDITOR Lim Wee Hing

[email protected]

EDITORIAL ASSISTANT Sharifah Zainon

[email protected]

SENIOR ART DIRECTOR/STUDIO MANAGER Lawrence Lee

[email protected]

GRAPHIC DESIGNER Katherine Ching

[email protected]

SALES & MARKETING MANAGER Caroline Yee

[email protected]

ASSISTANT CIRCULATION MANAGER Foo Boon How

[email protected]

CIRCULATION EXECUTIVE Agnis Lim

[email protected]

CONTRIBUTORS Prof Frank Lewis, Prasanna Ballal, David Marschall,

Peter Kelly-Detwiler, Gunnar Zank, Christian Boehm, Christian Dressler, Tieng Ling, Nadine Haid, Marius

Wotschik, Augustine Quek

EDITORIAL CONSULTANTS Jim Pinto

Industry Analyst

Alastair Ross Director, Codexx Associates Ltd

SUPPORTED BY:

EASTERN HOLDINGS LTDEXECUTIVE BOARD

CHAIRMANStephen Tay

EXECUTIVE DIRECTORKenneth Tan

FINANCIAL CONTROLLERBoris Chan

etm EasternTrade Media Pte Ltd

an Eastern Holdings Ltd company

Head Office & Mailing Address: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]

MICA (P) No. 012/12/2006ISSN 0219/5615

PPS 1561/7/2008 (000553)Co Reg No. 199908196C

Colour Separation: Pica Digital Pte LtdPrinter: Fabulous Printers Pte Ltd

Educational institutions impart

the foundations upon which the

individual can pursue lifelong

learning.

Learning is so multi-faceted these days. There are so many ways to learn – one of the easiest is to simply google the subject matter – and a long list of possible information sources is immediately available. On top of that, there are webinars, wikis, and professional blogs, amongst others.

It is true that structured learning is necessary to instil the traits of logical enquiry and critical thinking as they will serve students of the sciences well in their future careers. Educational institutions impart the foundations upon which the individual can pursue lifelong learning.

But how to produce a world class workforce? Is our educational system still relevant in the face of changing technology? What is the role of educators in light of such rapid technological developments? What

skills are our engineers equipped with and what knowledge will be relevant when they graduate?

I s i t bet ter to cram future engineers with all the knowledge they can absorb within a four year period, or is it better to significantly reduce the time it takes them to get qualified as engineers? They can be out in the field much earlier, but with serious options and systems in place to pursue lifelong learning.

How many biomedical engineering, aerospace, machining, chemical, electronics or mechanical engineers do we need four years from now, when the current cohort graduates? Are they primed to ride the next technology wave – or will they be limited by their choices? What is the next technology wave? Do grades matter if the subject matter doesn’t?

It is heartening to note that there is an increase in collaboration between educational institutes – not just universities but polytechnics, and vocational training institutes as well. The recent ABB technology fair at sprawling futuristic ITE Simei campus, in Singapore, shows that future specialists are being exposed to industry relevant, state of the art technology, early in their careers. This bodes well for the future development of the industry and the individual.

Goh Tz’en Long

Learning @Warp Speed

ENQUIRY NO. 686

VEGAPULS 67 VEGAPULS 68

Measuring range Up to 15m Up to 70m

Temperature – 40...+80°C – 40...+200°C

Pressure Vacuum up to max. 2 bar Vacuum up to max. 40 bar

Antennas Plastic-encapsulated antenna Parabolic antenna

Horn antenna

Swivelling mechanism Via mounting strap Via mounting flange

Air purging connection No Yes

Flange sizes DN 80 ... DN 150 From DN 50

Approvals ATEX II 1⁄2 D IP6X T ATEX II 1G, 1/2G, 2G EEx ia IIC T5

ATEX II 1⁄2 D IP6X T

Pluggable electronics 4...20mA/Hart two wire 4...20mA/Hart two wire

4...20mA/Hart four wire 4...20mA/Hart four wire

Profibus PA Profibus PA

Foundation Fieldbus Foundation Fieldbus

VEGAPULS 67 VEGAPULS 68 Guided microwave Ultrasonic Capacitive

Contactless measurement ■ ■ ■

Two-wire technology ■ ■ ■ ■

Measurement during filling ■ ■ ■ ■

Unaffected by dust generation ■ ■ ■ ■

Unaffected by air currents ■ ■ ■ ■

Unaffected by noise generation ■ ■ ■ ■

Free of mechanical loads ■ ■ ■

Independent of product characteristics ■ ■ ■ ■

Reliable in narrow silos ■ ■ ■ ■

Application in high pressures Up to 2 bar Up to 40 bar ■ ■

High measuring range Up to 15 m Up to 70 m ■

Application in high temperatures Up to 80°C Up to 200°C ■ ■

Maintenance-free ■ ■ ■

A complete line of radar instruments

Radar is our worldVEGA Grieshaber KG is a worldwide leading company in level, pressure and switching instrumentation. In 1997 VEGA introduced the first two-wire radar instrument to the world. Two years later, VEGA advanced to international market leader in level measurement with radar. As far as liquids are concerned, radar has become accepted meanwhile as the standard technology – and with the radar instruments of ERA II, VEGA has set a new standard for continuous measurement of bulk solids.

Radar – ideal for bulk solids measurement

VEGA radar technology covers virtually all areas of application with bulk solids. Thanks to non-contact measurement, both instruments are absolutely wear and maintenance-free. The wide dynamic range of the sensor ensures reliable measuring results, absolutely free of influence from strong dust generation. Even under the difficult conditions of pneumatic filling and the associated noise there is no signal degradation.

The instruments are Dust Ex and Gas Ex approved.

VEGAPULS in comparison with other measuring techniques

Technical Data

Universal and cost-effective

VEGAPULS 67 was developed for applications in which ultrasonic technology was primarily used until now. VEGAPULS 67 offers superior measurement reliability at very low cost The performance of VEGAPULS 67 is unaffected by air turbulence and noise as they commonly occur during pneumatic filling. Even strong dust generation and temperature fluctuations do not influence the measuring results.

VEGAPULS 67 operates contactlessly and is therefore also suitable for applications in chemically corrosive products. VEGAPULS 67 is thus applicable in virtually all areas of production and represents more than just an alternative to ultrasonic technology due to its price-performance ratio.

VEGAPULS 68:VEGAPULS 67:

For the most demanding application conditions

VEGAPULS 68 delivers reliable level data even in high temperatures, such as e.g. in steel production.

The dusty conditions in the coal processing facilities of power plants or in building materials storehouses do not bother VEGAPULS 68 in the least. The wide dynamic range of the sensor also opens up new possibilities in applications with powders and granulates in the food and chemical industries.

Through optimized radar technology, the sensor can process signals up to a thousand times smaller than those normally handled by conventional radar instruments. This high sensitivity enables measuring ranges up to 70 m even in products with poor reflective properties.

VEGA INSTRUMENTS (SEA) PTE LTD 25 International Business Park #04-52 German Centre Singapore 609916 Phone: +65 6564 0531• Fax: +65 6567 5213 • Email: [email protected] • Website: www.vega.com

8 industrial automation asia | September 2007 www.iaasiaonline.com

ENQUIRY NO. 6001

igus Singapore Pte Ltd.Phone +65-6487 1411Fax +65-6487 [email protected]

Over 750 special Chainflex® cables for dynamicsystems available, no cutting charges.

Control cables, data transmission cables, fibre optic cables, servomotorcables, power cables ... special cables

Chainflex®.Tested!

ENQU

IRY

NO.

684

MARKETS

INDUSTRY N E W S

US: In a recent ARC study entitled ‘Distributed Control Systems Worldwide Outlook,’ ABB takes the leading world-wide market position in this core automation market. The study reveals that total worldwide market for DCS increased by 14 percent between 2005 and 2006, with total revenues of US$13.4 billion, and forecasts that the compound annual growth rate for this market through 2011 will be 9.9 percent.

The ARC report states that the DCS market is a leading indicator of the overall health of the process automation business; overall growth in 2006 exceeded expectations. Factors contributing to this upward trend include high energy prices and the growing worldwide demand for energy, as well as the continued need by manufacturers to improve their plant operations, meet increasing regulatory requirements, and modernise the aging installed base. ARC estimates the total installed base of DCS systems worldwide to be over US$65 billion.

“The rapid growth of the DCS market, and the battle for the installed base, make it no easy task for the market leader, but ABB still retains its leading position in the worldwide market for 2006. The company continues to enjoy the largest installed base of any supplier, and is making key strides in evolving its installed base forward to its System 800xA platform,” says Larry O’Brien, Research

DCS Market Up 14 Percent

Director for Process Industries, ARC. “ABB is also the market share leader in key global verticals including Oil & Gas, Electric Power, Cement and Glass, and Pulp and Paper and the regional leader for Europe/Mid East/Asia (EMEA).”

Oil & Gas Leads MarketsThe Oil & Gas, Refining and Power industries superseded the Pharmaceutical and Food & Beverage industries as the fastest growing DCS markets in 2006, providing new areas of opportunity across all geographies. ARC forecasts that Oil & Gas will see more growth in the DCS market than any other industry area over the next five years; this growth will be driven by increasing investments in oil exploration and production.

Asian PowerhouseAccording to ARC, Asia is still a powerhouse and opportunities continue to abound in the Middle East, Eastern Europe, and Latin America, but the developed markets such as North America and Western Europe are beginning to show signs of sluggishness. ARC expects the current growth phase of the global market for automation to last through the next several years. While the overall market remains strong and will continue to grow, odds are that there will not be the stellar growth in the automation marketplace that was present between 2005 and 2006.

From a macroeconomic perspective, both China and India are poised for significant long-term growth. Both countries are increasing their focus on manufacturing for export, in addition to developing infrastructure, investing in basic industries, and in training personnel to operate automation plants. China is still the primary catalyst for global growth in the automation industry. As a result, ARC expects that China will be the single biggest geographical market for automation products and services in 20 years.

www.iaasiaonline.com September 2007 | industrial automation asia 9

ENQUIRY NO. 6002

Singapore: The Asia Customer Application Center (CAC) in Singapore, launched in July 2006, primarily targets the power generation, oil and gas, petrochemical, pulp and paper, wastewater plant and steel industries.

The 15,000 sq ft facility provides in-depth product demonstrations, case studies and simulations to enable customers to see how GE’s products and services can help improve plant productivity. GE’s latest investments into the facility are the Mark VIe control system for turbines and the OC4000 distributed control systems for plant performance improvement.

Knowledge InnovationsIt has also recently introduced new optimisation and control innovations that include:

• The Knowledge3 (KN3) neural net technology for complex optimisation typically applied in the power generation industry;

• Anomaly detection, an application of the KN3 technology, that analyses sizeable amounts of data to identify patterns of behaviour and warns of deviations, and;

• Wireless Condition Monitoring solu-tions for distributed assets based on the innovative mesh network and power harvesting technologies.

GE Energy: CAC 1st Anniversary

INDUSTRY NEWS

ENQU

IRY

NO.

683

According to Hitesh Shah, Regional Leader for GE Energy's Optimisation and Control business in Asia, the CAC has served more than 200 customers in various industry segments across all of Asia in the last year since it was established.

Most recently, the centre hosted cus-tomers who attended the specialised seminars on Advanced Reciprocating Compressor Diagnostic in April and Performance Monitoring and Optimi-sation in June.


ENQUIRY NO. 6003

ENQU

IRY

NO.

668

Phoenix, US: OneWireless is a universal industrial wireless mesh network solution that helps improve plant safety, reliability and efficiency. The scalable wireless infrastructure that supports wireless-enabled devices in strategic locations throughout a facility.

The universal network supports multiple industrial protocols and applications simultaneously, providing a single wireless network that is simple to manage and efficient to operate.

“The significance of OneWireless goes beyond the prohibitive cost

of wiring. The break-t h r o u g h value lies in the ability to turn more information into knowl-edge across the plant, leading to o p t i m i s e d

productivity and improved safety, compliance and asset reliability,” says Au Yeong Pak Kwan, Regional General Manager, Southeast Asia, Honeywell Process Solutions.

Scalable to 30,000 devices, One-Wireless supports existing Honeywell XYR 5000 wireless transmitters and XYR 6000 transmitters, which includes corrosion, gauge pressure, differential pressure, high-level analogue input and temperature transmitters.

The solution also supports wired transmitters, mobile worker devices such as IntelaTrac* PKS and Mobile Sta-tion, and standard Wi-Fi and Ethernet clients. The open, standards-based infrastructure allows manufacturers to take advantage of new applications as they become available.

Honeywell has implemented field trials of OneWireless at multiple sites, including Nucor Steel Tuscaloosa Inc in Alabama where the OneWireless network is configured with wireless temperature and pressure sensors

Honeywell: One Wireless Network

CEJN Products Far East Pte Ltd70 Bendemeer Road #03-03 Luzerne (Hiap Huat House) Singapore 339940

Tel: +65 6748 6434 Fax: +65 6747 0375Website: www.cejn.com Email: [email protected]

CEJN is a world leader in designing and manufacturing quick connect couplings that provide reliable connections in breathing air, gas, fluid, pneumatic, hydraulic and high pressure hydraulic applications. We offer diverse accesory products including adapters, fitting, hose, hose reels, air preparation units and blowguns.

You Know You Get Quality When It Say’s CEJN!

The Global Quick Connect Specialist

to improve the efficiency of several steel-manufacturing processes. The pressure sensors, for example, enable operators to measure air filtration system performance and schedule maintenance only as needed. This leads to more efficient maintenance and less downtime.

Au Yeong Pak Kwan

XYR 6000 transmitters

ENQUIRY NO. 6004

Belden: Account Manager, Thailand

Thailand: Nichapa Gludpiboon has been appointed Account Manager – Industrial for the Thailand market. Prior to joining Belden, Nichapa spent more than 4½ years with Kerpen (Thailand) as Assistant Sales Manager in charge of cable products. She has over six years of

sales experience, including project and channel sales. Nichapa has helped Kerpen Thailand to triple the sales volume in her assigned territory. In this newly created position, Ms Gludpiboon will be focusing on developing the Thai industrial market. Her duties include assisting in business development, sales planning and execution.

INDUSTRY N E W S


HIGHEST SWITCHINGDISTANCE & FACTOR 1Perfect solutions for your applications!

• Highest switching distance: the new sensors from TURCK offer Factor 1 and the highest switching distance.

• Highest efficiency in system construction through comprehensive standardisation: a single replaces many “conventional” sensor types.

• Highest operational reliability right from the start due to simple and safe installation.

• Highest flexibility based on a wide choice of housing styles for application-optimised solutions.

www.turck.com

TURCK Singapore Pte. Ltd.25 International Business Park, #03-22/23 German CentreSingapore 609916 Phone (+65) 65628716, Fax (+65) 65628719E-Mail [email protected]

S0133_80x240_uprox_GB_Singapore.1 1 18.01.2007 08:30:33

Yokogawa Wins Major Thai Petrochem Contract

ENQU

IRY

NO.

682

Thailand: Yokogawa (Thailand) has received a contract to supply control systems, field sensors, and other devices for a petrochemical plant complex construction project of Map Ta Phut Olefins Co, Ltd, a petrochemical company of the Siam Cement Group..

It will participate in the project from an early stage as a main automation contractor (MAC) together with engineering, procurement, and construction (EPC) contractors. This will enable the company to contribute to the standardisation of control device specifications, improvement of engineering quality, and reduction of costs and delivery times. This is the first time Yokogawa has won an MAC contract in Thailand.

This plant complex will be constructed at the Map Ta Phut Industrial Estate, which is located in Rayong, southeast of Bangkok. A key part of the complex will be a naphtha cracker plant with an annual production capacity of 1.7 million tons (900,000 tons of ethylene and 800,000 tons of propylene). This plant complex will also produce downstream products and have an annual production capacity of 400,000 tons for both high-density polyethylene (HDPE) and polypropylene.

For higher propylene output, an olefins conversion technology (OCT) will be used that converts butene and ethylene to propylene using a catalyst. The plant will also employ the latest technology to enable the use of such materials as naphtha as well as light condensate obtained from the natural gas extraction and generation process.

Under the contract, Yokogawa will deliver to the plant complex a Centum CS 3000

Integrated Production Control System and ProSafe-RS Safety Instrumented System, as well as approximately 60 GC1000 Mark II process gas chromatographs and 5,000 field sensors, such as pressure transmitters and flowmeters.

ENQUIRY NO. 6005

INDUSTRY NEWS


ENQ

UIRY

NO.

664

ENQUIRY NO. 6006

Citect: Always In Control

�S5-TCP/IP 100

�X5 / X7 CPU

Link S5 controllers to Industrial Ethernet to visualize process data, for example.

turns your S5

into an S7!

INAT GmbHOstendstr. 50A

90482 Nuremberg • GermanyTel.: +49 (0)911 / 544 27-0

Fax: +49 (0)911 / 544 [email protected] • www.inat.de

Are you still using Simatic® S5?

�

�

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10/100 Mbps Ethernet CP4-port switchintegratednetwork agentProtocols:TCP/IP, RFC1006, ISO (H1), S5-AP, Modbus on TCP, Send/Receive

High-performanceCPU for the S5 with TCP/IP interface

compatible with CPU 416 and CPU 945programmable in Step® 5 and Step® 7Integration of S5 controllers in S7 projectsMixed operation: S5 and S7 pro-grams run parallel2-port Switch

�

�

�

�

�

Step® and Simatic® are registered trademarks of the Siemens AG.

Turbo-Ethernetfor

PLC oldies

LonMark Sessions Impact Asia

The Tech Update roadshows held in the capital cities of Malaysia, Philippines, Thailand and Singapore were well received and attracted a turnout averaging 80 delegates per session. Commencing in the last week of June, users across South East Asia gained valuable insights into future solutions, and opportunities to network with industry experts.

At the Tech Update held in Kuala Lumpur, Malaysia, Scott Druery, MD, Asia shared his views on strategy for the region, retaining quality employees and global support. At the Manila, Philippines roadshow, VIP attendees included the President of the Philippines Instrumentation and Control Society. The society celebrated its 30th anniversary this year. Citect customer, Global Steel Phils Inc, specially flew in to give a case study.

At the Singapore event, the Australian Trade Commissioner delivered the opening keynote speech.

US: The recently concluded LonMark Sessions 2007 tour was well received and enjoyed strong participation from hundreds of attendees. The series of one-day seminars discussed benefits of LON based, open building control solutions. It travelled through Australia, China, India, Japan, Korea, and Singapore visiting a total of 12 Asian cities.

The seminar topics included the following: • Energy savings• Improving efficiencies through

system integration• Maintenance, operating, and

training cost reductions• Leveraging IT infrastructure• Successful projects and market

trends• Professional certification

Attendees ranged from end users, property owners, institutional organisations, integrators, product vendors, IT professionals, and HVAC installers. Topics discussed included ROI models, increased operating efficiency, and green building solutions.

ENQUIRY NO. 6007

INDUSTRY N E W S

(L) Scott Druery, MD CitectAsia, mingles with guests in Manila


ENQUIRY NO. 6008

NI: Real-Time Multicore Support & Statechart DesignTexas, US: National Instruments has released the latest version of the graphical system design platform for test, control and embedded system development. LabVIEW 8.5 extends the embedded platform to program multicore, real-time processors.

The latest version combines the familiar graphical programming environment of the software with commercial multicore hardware to achieve significant performance gains. Additionally, LabVIEW 8.5 introduces the LabVIEW Statechart Module for higher-level designs to run on targets including FPGAs, real-time systems, PDAs, touch panels and a variety of microprocessors.

With the inherent parallel nature of the graphical code, embedded developers can enhance applications ranging from design validation sys-tems such as hardware-in-the-loop

simulators to complex control systems such as high-speed particle accelerators. To achieve real-time symmetric multiprocessing (SMP), NI developed a real-time load balancing scheduler to automati-cally assign tasks to dif-ferent processor cores, providing performance improvements without sacrificing determinism or requiring user code changes.

The Statechart Module gives engineers an alternative to designing systems with a high-level diagram based on the Unified Modelling Language (UML) standard. Statecharts are commonly used to design state machines that model the behavior of

real-time and embedded systems to depict event occurrences and responses for designing digital communication protocols, machine controllers and system-protection applications.

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INDUSTRY NEWS


Typical application fields for safety-related communication include:

off-road vehicles, industrial machin-ery, cranes, medical equipment, or fire-protection doors. Devices such as emergency stop switches have to communicate in a safe way.

The residual error probability of the transmission of a CAN data frame using standard hardware is about: ρ = 4.7 x 10-11 error rate in a network consisting of 10 nodes. With every 1000th frame being erroneous, the probability calculates to ρ = 4.7 x 10-14. That means an undetected error occurs in a network under average conditions about every 2000 years.

As the details of the internal structure of microcontroller units cannot be readily verified, a different way is needed to get CAN hardware certified. A concept has to be created, which ensures reliability of communication independently from the used hardware and its properties. One of the safety mechanisms which can be verified by standards bodies is the use of a safety-related protocol.

Safety-Related ProtocolAn appropriate protocol is fundamental for safety-related devices. Such a protocol is specified in CiA 304 for example. It is based on CANopen and considers bit errors, loss or delay of frames, wrong receiving order of frames, and un-wanted extra frames.

This is achieved by the use of SR-DOs (safety-related data object), SCT (safeguard cycle time) and the SRVT

The seventh part of this series looks at the requirements of safety-related communication. By Christian Dressler

(safety-related validation time). The protocol also provides a so-called GFC (global failsafe command). These terms are introduced as follows.

An SRDO is comparable to a PDO, with the dif-ference, that the data is sent twice: two CAN frames with different identifiers (at least two bits have to be different) are sent consecutively. They contain the same data, but the second frame stores the data bit-wise inverted. This concept is called serial redundancy. The receiving device verifies, if both frames of an SRDO have the same content.

SRDOs are transmitted periodically. When SCT expires and no SRDO has been received yet, the device switches into safe state.

The SRVT defines the maximum

Safety-Related Communication

time, which may elapse between the both frames of an SRDO. If they are not received within SRVT the device switches to safe state.

The both timing parameters are illustrated in Figure 1.

The network can be used for both, conventional services and SRDOs at the same time by all devices. Consequently, traffic could increase and frames with lower priority may be delayed.

The GFC is used to reduce the reaction time when a device wants the other devices to go into the safe state. It is a single CAN frame with high priority and no data content. The message will be received by all means, because a GFC is always followed by an appropriate SRDO. The number of SRDOs in a network is limited to 64.

Newsdesk

Figure 1: The CANopen safety timing restrictions

SRDO1 SRDO1 SRDO1

refresh-time refresh-time

SCTSCT

SCT

SCT expired

time

SRDO1 SRDO1

SRVTexpired

SRVTSRVTtime

SRVT

SRDO1

CAN Basics: Part 7 of 8


Hardware CertificationFour safety integrity levels (SIL) are defined, with SIL4 being the most dependable and SIL1 being the least.

Nowadays, more and more safety related applications migrate from wired connections to a serial bus system. The devices can be certified for use in functional safety applications according to IEC 61508, giving evidence that the application, including device, is compliant.

The SIL requirements for hardware safety integrity are based on a probabilistic analysis of the device. To achieve a given SIL, the device must have less than the specified probability of dangerous failure and have greater than the specified safe failure fraction.

The international standard IEC 61508 defines SIL using requirements grouped into two broad categories: hardware safety integrity and systemat-ic safety integrity. A device or system must meet the requirements for both categories to achieve a given SIL.

To get a μC certified according to safety standards does afford more than just implementing a safety protocol. For example, when an actor may be connected to the safety hardware, a ENQUIRY NO. 6010

watchdog or a similar mechanism has additionally to monitor the μC.

Also, peripheral devices (eg: power supply) or programming modules, have to be monitored. A consortium formed by CiA has developed hardware that is certified according to SIL 3, with safety-protocol pre-programmed. The structure can be seen in Figure 2.

The MCU uses two CAN controllers, which are used for redundancy reasons. The CAN frames are received by both controllers and verified. When a CAN frame is sent, the used controllers alternate.

Using Safety HardwareWorking with a safety-related node in a network does not mean that the whole network is safety-compliant. Every part of a network has to be checked for safety until the whole system is certified.

With CAN and the CANopen safety protocol it is possible to interconnect the safety-related devices in a network directly. No PLC is needed, eg: an emergency switch taking effect on a safety relay. The logical linking of devices is similar to traditional wired connections.

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News Updates

ENQUIRY NO. 6020

Roundup Of Regional Events

Seminar HighlightsSafety Fieldbus: This workshop will explore the benefits of using Profisafe SIL3 Safety Fieldbus technology. Safety Fieldbus allows for more flexible safety system architectures, higher availability and also direct connection to field devices supporting Profisafe. This is installed using fault tolerant PA ring and reduces the need for expensive safety system I/O. Applications such as partial stroke testing of shutdown valves can be greatly simplified using the technology.

Asset Management: Information is contained in three different files:• GSD files specify the communication between the

master and slave devices • FDT/DTM is a standardised Profibus interface

specification that allows the integration of intelligent devices into, for example, asset management and process control systems

• EDDL is the IEC based integration of intelligent devices and information displays

This workshop will go through the entire process of network configuration.

Audio Paper: Why use a fieldbus?An audio white paper in MP3, as well as in pdf form can be downloaded from the international website. It explains the arguments for the use of the fieldbus system and associated advantages.

Coming into the final quarter of 2007, an events roundup indicates that the regional Profibus association had an activity filled first three quarters in 2007. Response from the roadshows was generally positive, attracting many industry players interested in becoming members or sponsors.

The association participated in major trade events such as IMAC in Bangkok, Thailand; OGA 2007 and Industrial Automation 2007 in Kuala Lumpur, Malaysia. Upcoming events for the remaining part of the year include the Regional Industry Networking Conference (RINC) held at the Singapore Polytechnic (November 1–2, 2007) and CIA 2007 (November 27–30, 2007).

WorkshopsWorkshops were also conducted in Singapore, Thailand, Malaysia and Indonesia, concurrently with some of the roadshows. The association is currently gearing up for an upcoming roadshow/workshop in Vietnam.

Vietnam Roadshow ScheduleHanoi: September 19–20, 2007

Ho Chi Minh City: September 26–27, 2007

The Philippines roadshow has been postponed to January 2008, and actual dates will be informed at a later stage. Registration for the Vietnam roadshows can now be made online at the Profibus website: www.profibus.com.

Malaysia

Thailand

http://www.profibus.com


ENQUIRY NO. 6030

The Singapore End User Council (EUC) recently met to discuss the latest progress in Foundation technology and to share fieldbus application experiences. Chung Ock Jin, Acting President of the Singapore EUC, spoke on the proliferation of intelligent devices in process automation. President and CEO, Rich Timoney, gave a presentation titled ‘Changing the Playing Field’. Mr Timoney said that the scope the technology makes it a process automation infrastructure – one of the most advanced and scalable solutions available. It is supplier-neutral and standards-based, providing end users with a common framework to implement and manage strategies for operational excellence

and continuous improvement in process manufacturing.

Jonas Berge, Chairman of the Fieldbus Foundation’s Singapore Marketing Society, presented on the topic of ‘Keeping Fieldbus Systems And Communicators Up-To-Date Using EDDL.’ The role of EDDL in the overall scheme of things was explained. According to Mr Berge, recent enhancements to the IEC 68104-3 EDDL technology add significant value for diagnostics, setup, and calibration. They allow device manufacturers to neatly organise device information on tabs and in frames. Images illustrating wiring, block diagrams, gauges, bar graphs, and strip-charts can also be included.

The HTML-like characteristics of EDDL technology makes it desirable as a long term solution, since it is not affected by upgrades or changes in operating systems. Enhanced EDDL is also more secure and robust, since it is not executable and does not involve procedure calls between applications from different vendors. There is much greater emphasis being placed on device management software and administration.

End User Council

Foundation Celebrates 10th Anniversary

A short address was delivered by Jonas Berge, President of the Singapore marketing committee. He noted how ‘mega-projects’ in the Asia-Pacific region are increasingly adopting the technology on ever larger scales.

A fieldbus expert panel consisting of Mok Wing Kee, ExxonMobil; Leong Gim Heng, Shell; Dr Joachim Zobel, Novartis; Stephen Weng, Yokogawa; Alvin Wong, Emerson Process Management; and Rich Timoney and Hisashi Sasajima, Fieldbus Foundation, fielded questions form attendees.

Several interesting discussions resulted. For example, it became clear that to fully benefit from digital architectures, bus alone is not sufficient. The software that unleashes predictive diagnostics information must also be in place to complete the infrastructure.

In addition, the discussion gave Mr Timoney the opportunity to explain the latest developments to better support intelligent device management as per the NAMUR NE 107 recommendation. He also provided an update on the FF-SIF technology verification and the parallel development of engineering and operations best practices for safety bus.

Following the formal presentations, Mr Sasajima, VP, Asia-Pacific operations toasted the foundation’s continued success. The evening ended on a high note with food and drinks, as well as casual networking among industry associates.

The Fieldbus Foundation celebrated its 10th anniversary in the Asia-Pacific, at the National University of Singapore Students Union (NUSSU) Guildhouse on July 19, 2007. The event drew a large crowd of automation suppliers, endusers and leading industry figures.

Guest of honour, President and CEO, Rich Timoney delivered a keynote address describing the dream of a group of visionaries that became a reality – first, an industry-standard fieldbus technology, and then an automation infrastructure for operational excellence. He singled out the contributions of those people who helped make Foundation fieldbus the ‘technology of choice’ for process automation in Asia and around the world.

Asia NewsUpdates

ENQUIRY NO. 6040

Fifty-five Japanese representatives attended the Tokyo member meeting. Among the participating companies were well-known names such as Amada, Brother, Epson, Fuji Electric, Hitachi, Muratec, Okuma, Panasonic, Proface, Sanyo Denki, Sumitomo, and Toyota TDC. Altera, Beckhoff, Hilscher and Xilinx presented hardware and software for EtherCAT slave device interfaces, and Hitachi, Muratec and Okuma gave an update on their projects. There is a strong following in Japan where several vendors are currently implementing EtherCAT devices. ■

Japan Member Meeting

Kenichi Karigane, Hitachi IES presents at the Member Meeting in Tokyo

The Safety over EtherCAT protocol has been certified by TÜV for transferring process data between devices, up to SIL 3, according to the IEC 61508 Standard.

It uses EtherCAT as a com-munication system for the safety protocol, although in principle any transmission link can be used, including fieldbus systems, Ethernet, as well as optical fibre cables, copper cables, or radio links.

There are no restrictions or requirements for bus couplers or other devices located along the transfer route. The transport medium is regarded as a ‘black

channel’ and not included in safety considerations. A safety frame containing the safe process data and the required data guard is included in the EtherCAT process data. This ‘container’ is safely analysed in the devices at the application level.

Through suitable measures, the protocol reliably handles all error as-sumptions that are relevant in the con-text of transferring safe information via a communication system (corruption, repetition, interchang-ing, loss, delay, inser-tion, masquerading, and invalid addressing of messages). Based on suitable procedures the frame is designed such that a minimum container length of 6 bytes is sufficient for transferring all error detection and cor-rection information, including one byte of safe process data.

The protocol does not impose any limits regarding the length of safe process data. With appro-priate selection of the error detection and correction informa-tion, the transfer rate has no influence on residual error probability for the Safety over EtherCAT protocol. ■

Embedding of the Safety over EtherCAT frame process data

Safe Real-Time Communication

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Much has been made of the benefits of open and interoperable fieldbuses, but not enough attention has been paid to data structures. By David Marschall (L) and Tieng Ling (R), Senior Principal (MES) Project Execution Engineers, Emerson Process Management

Seamless Data Integration:

Unlocking The Hidden Capacity Of Process Plants

I n an ideal world, all communication and record keeping in a plant, from production floor to boardroom,

would be seamless, immediate and error-free. A good start towards this end is embodied in ISA-95 (formerly known as SP95), the international standard for the integration of enterprise and control systems, although, this has not yet spread to all companies or solved all problems.

ISA-95 divides plant activities into four levels (five, if you include Level 0, the physical production equipment itself). Starting at the highest (enterprise) level, these are:• Level 4 — This is the ERP level.

It is concerned with business logistics management, including plant production scheduling, shipping, receiving, inventory and so on. The interface between Level 4 and Level 3 is handled by the business process information network. Information exchanged includes production capability information, product definition information, productions schedul-ing and production performance.

• Level 3 — This is the MES level. It is concerned with manufacturing

Level 1-4: Device to Enterprise

operations management: dis-patching, detailed production scheduling, production tracking and so on. Major activities at this level include maintenance operations, inventory operations, production operations, quality operations, management of documentation, management of security, management of con-figuration, and management of compliance. Equipment status maintained/validated by MES also includes other systems such as LIMS, WMS and CMMS. Level 3 connects to Level 2 via the operations information network.

• Level 2 — This level is concerned with the actual manufacturing process, be it batch control, continuous process or discrete control, and in some ways can

be considered as two levels. The upper part includes equipment managed/monitored/controlled by HMI, SCADA and batch systems, which connect via the automation networks to the equipment below it that provides operational control: PLCs, DCSs and packaged systems. Level 2 interfaces to the level below it via a number of discrete and process device communication networks.

• Level 1 — This level consists of the physical interfaces between the control equipment and the physical machinery. Equipment includes I/O, actuators and sensors.

With such an orderly arrangement, and with the appropriate networks in place, one would think that information would flow smoothly from level to level. At levels 1 and 2 much of it does, or plants would not be able to operate at all, but there are still significant difficulties, particularly between levels 2 and 3, and even within level 3. Each requires information from a separate source – typically in a different form. Some information is found in databases, some in paper records. The databases tend to be disparate, and paper

Emerson


ISSUES & INSIGHTS

records are notoriously subject to human errors and omissions. This is a long way from the goal of tying together process control and equipment management, and then integrating that into manufacturing operations, like recipe execution, materials management, asset manage-ment, and so on.

Linking DatabasesThere have been attempts to link individual systems, like LIMS with batch systems, by simply doing database queries. Unfortunately this method always poses a great challenge as the individual system does not necessarily provide information like the context of a batch, and even when the link is successfully developed and working such one-off, site-specific solutions are not transportable from one company to another or even from one site to another, within the same company.

One example was a pharmaceutical plant that had built up about 250 different spreadsheets, databases and other software tools to meet their record keeping needs. As one can imagine, trying to maintain 250 different applications, connect them together and ensure that the batch record context was consistent was

a major headache. It simply didn’t work.

PaperlessOne of the biggest steps forward would be to get away from paper. The paper system fosters missing data, errors, inaccuracies and wasted time. Even the physical amount of paper can be a problem. A recent conference on MES issues included a presentation from a company that produces pharmaceutics based on the genetic makeup of each individual patient. The company tracks each person and the drugs made for that particular person through its manufacturing process.

The analysis has to flow

Paperless record keeping

through the system as the drugs are manufactured in order to prove efficacy and comply with multiple regulations, but in doing so the company creates about 1.5 to 2 ft of paper per person per product – all of which must be managed. The company hopes to grow to the point that it processes drugs for perhaps 1000 people every two weeks. It would have to go paperless, if for no other reason than that it will not be able to buy enough warehouse space just to manage the paper.

While not every company is faced with 1.5 ft of paper per production lot, it still generates a great deal of paper involving materials management, laboratory information, training records that have to be checked or maintained, equipment logs, process control system logs and things of that nature. The systems that generate them are typically provided by different vendors because nobody really has an integrated or total solution. Any realistic solution must somehow encompass all those disparate systems or islands of automation.

One of the issues, particularly in regulated industries, is the time required for a review of paper batch records. It can exceed the manufacturing process time by two, three or more times. A 14-day manufacturing process might require two months to review the paper batch record before the product can be released. Meanwhile the product sits in a warehouse unsold while the clock on expiration starts ticking.

Error RateAnother major problem with paper records is the error rate. It has been estimated that around 95 percent of paper records have errors of some kind before being reviewed and corrected by the manufacturing people and moving on to the quality department. We did a study in which we found that a large percentage – 60 percent or more, probably – of these errors were omissions and transpositions.

All companies have processes in

Linking databases can be a challenge


ISSUES & INSIGHTS

place to catch errors, so when the product goes out the door all of those things have been addressed, but such correction takes supervisor time and operator time – anywhere from four hours to a day or more – that could be spent better on producing output. A right-first-time rate in the single digits is unacceptable.

If the errors cannot be corrected, or the missing data cannot be found, the product must be dumped, although no company is likely to reveal how often that happens.

Value Of Real-TimeThe best answer would be to have all needed data in real time, and to be able to verify things proactively using electronic work instructions that prevent human error and streamline production. This is to avoid problems instead of reacting once they’ve happened.

An example is verification of training. Before an operator in a regulated industry can carry out a process, that person has to be trained on it; if not, then technically there is a deviation.

Yet today, because of the overhead and manual effort involved those checks are often treated as a deviation or an audit after the fact, and it is assumed that those records are maintained and that all needed training has been done. With modern paperless systems it is possible to check those in real time before the action is taken, before the activity is performed. That is seldom feasible in a paper world.

Applying the same methods to a LIMS, the automation system should take over management in real time, handling the submission of requests, tracking which ones are still outstanding, and incorporating the results into the record so that everything is available for the review process with no missing information and no missing reports.

Unlocking Hidden CapacityAs an example of the timesavings possible with proper information handling, we are familiar with a

company that uses a fermentation process to produce an intermediate material that is considered as internal or mini inventory and must be analysed before being used.

Currently this takes one or two weeks, but the company plans to go to zero review time. The automation process will allow the company to take the risk and do the review process after release. If there is a problem they will catch it later on, but the odds of that happening are so low that they don’t expect it to be an issue. They’re saving one to two weeks per production cycle in the manufacturing process.

As a general rule, comparing normal cycle time to best-case cycle time, consider a product that, under normal conditions, takes 120 days to go from receipt of order to delivery. Given a sufficiently urgent rush order, that time might be cut to perhaps 35 or 40 days. By adopting paperless methods it should be possible to bring the average cycle time down close to the rush-job cycle time; in general it means at least a 50 percent improvement in release cycle time.

On the manufacturing side there may be a 15 or 20 percent reduction in work effort, simply by the reduction in the cost of quality. And similar savings occur in maintenance.

Because of the way the automation systems can track productivity or equipment utilisation it’s often possible to extend maintenance times to close to the theoretical maximum; for example, if equipment calibrations are good for one year, the ability to track and monitor makes it possible to move from the usual six-month or nine-month cycle to close to the one-year.

Single SourceWhen going for such improvements it is a good idea to stick to integrated systems provided by one vendor instead of many vendors and trying to integrate them together. This will minimise the number of interfaces to maintain and the change control needed as those different solutions migrate or upgrade.

Working with different vendors requires significant time and effort to resolve conflicts, overlaps and holes. Choosing a single source makes it possible to put all that burden on the vendor, which lowers your risk, makes it easier for you to operate, and lets you focus on the things that you care about – how your plant runs versus how well your systems talk to each other.

Unlocking the hidden capacity in the plant

ENQUIRY NO. 6100


ISSUES & INSIGHTS

ENQUIRY NO. 6900

P epperl+Fuchs is developing WirelessHART, an industrial field communication protocol,

and the products will be available in mid-2008. For process automation, products ranging from simple analog isolators via remote I/O systems to complete field bus infrastructures have been designed.

These process measurement and control applications require wire connections: costly, time-consuming wiring. But this will soon change.

WirelessHART offers huge benefits, bringing high-speed connectivity to its field devices and enabling data sharing between them ‘over-the-air’, without using a 4-20mA loop. The objective is to produce a wireless communication standard for process measurement and control applications.

To bridge the distances in widespread facilities, a flat mesh network is utilised, with each device acting as a signal source and a repeater. Information is routed through the whole network until it reaches the base station as the final recipient.

It is for setting parameters of field devices, supervising uncritical measurements and environmental values, managing and optimising assets, supporting preventive main-tenance, monitoring performance, and managing energy.

These applications are a good introduction to wireless technologies since they do not demand hard requirements for latency and trans-mission security. Utilisating a mesh network in non-critical applications is practical.

The time delay caused by repeating the message is negligible,

so the next step would be simple, open loop controls. Existing devices can be upgraded to enable wireless communication. In future, all these devices could be wireless.

Another product, the WirelessHART Gateway, acts as a message coordinator for communication between the maintenance workstation PC and the devices. It also acts as a multiplexer on the DCS side to ensure integration in existing DCS. The communication with the field devices takes place via radio.

To upgrade the available field devices, WirelessHART Adapter will

be developed. This device is put into the 4-20 mA loop for extracting the signal and sending it over the air.

Depending on the application, Pepperl+Fuchs would also offer the following options:

• A loop-powered adapter -- this allows simple integration to the existing control loop, allowing transmission through the adapter. The existing wiring will be used for conventional signal transmission.

• A battery-powered adapter – this

supplies the field device from a battery powered option. According to the selected duty cycle, the field device is powered up. The measurement value is read and transmitted, and the field device is powered down again. This enables independent measurements.

To be released in the third quarter of 2007, WirelessHART will be the first wireless standard widely used in process automation. By Gerrit Lohmann, Product Manager, division of process automation

WirelessHARTThe Future of

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ISSUES & INSIGHTS

O n March 23, 2005, 1:20 pm, an explosion at the third-largest oil refinery in the United States,

the BP Texas City Refinery, leaves 15 people killed and 180 injured. When a distillation tower was unknowingly overfilled, extreme pressure resulted in the release of flammable hydrocarbon which then caused the massive explosion.

Critical LapsesSeveral factors contributed to this disaster which resulted in a financial loss of US$1.5 billion. However, the Final Investigation Report of the incident, released in March 2007 by the US Chemical Safety and Hazard Investigation Board, highlighted lapses in alarm management that were critical:• “The tower’s high level alarm

set-point was exceeded 65 times during the last 19 startups, with more than 50 hours of operating time with the high level alarm activated”.

• “The redundant high level alarm (for the distillation tower) did not activate. When the...tower was filled beyond the set points of both alarms...in the early morning

on March 23, 2005, only one alarm was activated. The high level alarm was triggered at 3:09 am. The redundant hardwired high level alarm never sounded”.

• “The (redundant high level) alarm’s set-point was not known to operations personnel or provided in the procedure, control data, or training materials”.

• “A functionality check of all alarms and instruments was also required prior to startup, but these checks were not completed”.

• “Tower pressure alarm set-points were frequently exceeded, yet the procedure did not address all the reasons this might happen and the steps operators should take in response”.

Companies the world over are looking at these findings to understand not only how best to prevent such disasters from happening on their watch, but also to reassess their entire safety and risk management approach and specifically revisit their alarm management approach and practices.

Intrinsic To SafetyAlarm systems have been an intrinsic part of plant safety management for a long time. They play a critical role in alerting operators to a change in operations at a process plant, inform operators about the nature of the change and guide operators to implement corrective action.

Poor alarm management results in:• Increased downtime. This trans-

lates into lost production as well as increased operator costs through overtime, and higher lifecycle cost of equipment through increased maintenance costs

• Reduced plant productivity. When operators do not read early the signs of a developing problem, their response to alarm floods (large numbers of alarms annunciated at the time of process upset) typically takes the form of stabilising the process through reducing the rate of throughput

• Reduced quality (when alarm systems fail to alert operators


ISSUES & INSIGHTS

The implementation of an effective alarm management program involves creating a comprehensive and consistent alarm

philosophy for documenting, collecting and analysing alarm data. By Frost & Sullivan

Christian Lagereek

Increasing Alarm Management:

Improving Relevance,

Usability

to corrective action at the right time, off-spec product has to be contended with)

• Reduced operator effectiveness, higher operator stress levels and increased operator staffing costs

• In the worst-case scenario, alarm-related confusion can result in or aggravate serious industrial accidents

• Increased insurance premiums on plant equipment or fines incurred by not meeting regulatory requirements

Too Much However, despite their obvious significance, alarms have become yet another case of having ‘too much of a good thing’, making less functional what was once an effective safety and productivity improvement system.

When control systems became mainstream, they also brought down the cost of alarms; thus increasing the proliferation of such alarms. After all, engineers did not have a strong cost disincentive to configuring excessive numbers of alarms.

With this excess came reduced visibility of urgent and underlying problems, increased clutter that operators had to deal with, and longer response time to undertaking appropriate corrective action.

Systematic Approach To help organisations move away from the ad hoc approach of the past and adopt a more systematic and rational approach to alarm management, in 1999 the Engineering Equipment and Materials Users Association (EEMUA) released 191, ‘Alarm Systems: A Guide to Design, Management and Procurement’. This guide has rightly become the global reference point for alarm management. Its second edition – available from June 2007 – significantly updates and builds on the first edition.

Designers and operators have much to gain from using EEMUA 191 when undertaking improvement of their existing alarm systems or launching into a new alarm management program.

The EssentialsTo understand how best to improve an existing alarm system or introduce a new alarm management program, it is useful to approach the task using the steps outlined in the well-known Six Sigma sequence.

exercise, the task – by virtue of its scale – can be quite daunting.

This is where certain plant historians (central data repositories that gather, historise, archive and distribute plant data) can simplify the task. For example, CitectSCADA Reports, the plant-wide reporting solution from Citect, is capable of accurately recording all alarm data and tag values at high speed. Such a tool can help engineers and operators gather and organise alarm data from across the entire site.

AnalyseIf gathering data from thousands of alarms appears daunting, then analysing such data to derive useful insight can be even more formidable an undertaking.

Some plant historians provide assistance with this by helping engineers and operators with the following:• Event analysis: Pulling up all

alarms that occurred at a given point in time, be they basic process alarms or aggregated alarms or even critical safety-related alarms.

• Alarm and event archiving: Historising all alarms and events for long term analysis.

• Alarm analysis, which includes: – Identifying consequential/source

alarms around which other alarms are triggered

– Identifying nuisance alarms such as stale alarms (that remain present for – extended periods of time), chattering alarms (that go in and out of alarm mode in a short span of time), or duplicate alarms (that persistently occur within a short period of time of another alarm). Pareto analysis can help rank nuisance alarms by frequency; to help detect the so-called ‘bad actors’

– Identifying shelved alarms (temporarily suppressed) or permanently suppressed alarms (that are prevented from appearing on the opera-tor’s screen)

Successful alarm management is based on a comprehensive and con-sistent alarm philosophy document that defines:

• Business objectives to be met• Needs and requirements of the

users of the alarm system• Alarm system design principles• Compliance parameters• Roles and responsibilities• Criteria for alarm generation,

setting, prioritisation and pre-sentation

• Management of Change (MOC) (for example, tracking authorised and unauthorised changes to alarm settings or alarm suppression or shelving)

• T r a i n i n g / m a i n t e n a n c e parameters

• Escalation guidelines (moving from normal status mode where operators are trying to keep the process within the ‘safe envelope’ to emergency/ disaster management)

MeasureTypically, with thousands of alarms per site, a ‘stock take’ of the existing process, alarms and trends is critical before any changes are implemented. But while engineers and designers appreciate the benefits of such an


ISSUES & INSIGHTS

• Alarm setting analysis by the state/mode of operation of the plant

The fruits of such analysis are many:

Cutting through the clutter: EEMUA 191 suggests that 150 alarms per day (one every 10 min) presented to an operator is ‘very likely to be acceptable’ and 300 alarms per day (an alarm every 5 min) is considered ‘manageable’. In reality it is not unusual to record tens of thousands of alarms per operator per day, which makes such a system self-defeating. Identifying nuisance alarms helps to eliminate unnecessary or ineffective alarms, thus bringing the number of alarms per operator to a more manageable ratio.

To do this, clear justification for each alarm is required. An alarm’s reason for being should be related to a specific problem or abnormal situation and also to a specific and defined operator response. If there is no problem or if the alarm is not intended to elicit specific operator action, then its legitimacy should be questioned. A process indicator or alert does not automatically equate to an alarm.

Under the carpet: Analysing shelved alarms can help highlight potential reductions in alarm numbers there as well. More importantly, by looking at how long important alarms have been

shelved or permanently suppressed, operator practices can be corrected (having shelved an alarm, there is no guarantee that the operator remembers to go back to reactivate it).

The heart of the matter: Identifying root alarms or consequential alarms helps ensure that in an alarm flood, prioritisation models have been configured such that the consequential alarm does not get lost or remain unnoticed.

For consequential alarm and event analysis, most historians would compare one set of alarm data with another set of alarm data (depending on the query placed). However, what is even more useful is to be able to compare alarm data with plant/

process trend data. This is significant because alarms

– being reactive in function – cannot anticipate by themselves any process drift towards an abnormality which could eventually lead to breakdown or process failure. Co-relating alarm data with trend information can help throw up such insight.

Fine-TuningIt can also help in fine-tuning alarm settings and in linking alarm spikes to specific process conditions (startups, shutdowns, change in process set points such as tank levels, pressure, temperature levels etc), changes in instrumentation or new or changed control system configurations. In addition, it is by analysing operator response to alarms (and not simply focusing only on alarm data) that poor alarm system design is identified.

CitectSCADA Reports offers such an option, since it historises both alarms and plant process trends. This way, alarm and event data can be co-related to trend data from the plant to throw up anomalies or areas for alarm rationalisation or even assist in incident reviews.

ImproveThe analysis stage seeks to assess each alarm from the standpoint of the alarm philosophy of the organisation and typically leads to certain specific

Average Alarm Rate

Very likely acceptable < 1 per 10 min

Manageable < 2 per 10 min

Likely over-demanding > 5 per 10 min

Very likely unacceptable > 10 per 10 min

Peak Alarm Rate

Should be manageable < 10 per 10 min

Hard to Cope 20 to 100 per 10 min

Definitely Excessive < 100 per 10 min

Source: EEMUA 191

Alarm Analysis:• Identifying consequential

/ source alarms• Identifying nuisance

alarms• Identifying shelved or

permanently suppressed alarms

• Alarm setting analysis

Alarm-to-Trend Analysis:• Event analysis• Identifying process drift

towards anomalies

Plant / Process Trend Data

Alarm Data


ISSUES & INSIGHTS

ENQUIRY NO. 6101

improvements:• Reduction in needless alarms• Recalibration of alarm parameters

where necessary (such as action, set point, detection time etc)

• Bringing in consistency in alarm settings where desirable

• Prioritisation of alarms where re-quired

• Reorganisation of the presenta-tion of alarms if needed (to ensure relevance to operator, visibility etc)

This process of alarm rationali-sation and system improvement is clearly a laborious, expensive and disruptive effort, but the support of robust alarm analysis can help simplify this step.

While implementing this step, the temptation is to focus only on the ‘bad actors’ ie: the low-hanging fruit. This, as an initial focus, is appropriate – given that it provides immediate relief to an overloaded system. However, alarm floods (which involve many more alarms presenting than just the top five or 10 most frequent alarms) can be minimised only by undertaking a total rationalisation exercise of all alarms in the system.

ControlSuccessful alarm management rests on what tools are used to ensure that the KPIs set out are achieved so that

gains are sustained. This also involves creation of appropriate training material for new personnel who get involved, procedures and manuals for management of change (MOC) and ongoing review of analysis findings from the historian. The operative word here is ‘ongoing’. This is because new nuisance alarms have the habit of appearing surreptitiously (pro-bably the result of instrumentation fail-ure, changesto plant

equipment and process conditions, lack of adherence to MOC procedures, or inadequate justification for new alarm additions).

SynergiseIn a ‘learning organisation’, the fruit of analysis of the alarm system is shared with other stakeholders who are not necessarily on the plant floor. This is also helpful when plant engineers need to keep senior management informed of progress in alarm system improvements and to justify future investments in the alarm system to senior management.

With CitectSCADA Reports v4 and above, which uses an embedded Microsoft SQL Server 2005, operators, engineers and management will be dealing with an industry-standard data storage and exchange tool. Reports can be delivered in a variety of formats (such as pdfs for regulatory reports, Excel spread sheets that allow any user to immediately extract data for further analysis or web pages that can be integrated with other business systems in the organisation).

The Next LevelTo ascertain clearly what is the extent of improvement required in an alarm system (gap analysis) or to measure improvements after a new alarm management program has been initiated, it is useful to compare the

system with industry best practice. To undertake this, benchmarking tools can prove useful. Citect’s Meta enables comparison of KPIs across plants, divisions and countries; both within an organisation or across an industry peer group.

Some alarm KPIs that could probably form the basis for such benchmarking include:• Average number of alarms per hour• Maximum number of alarms per

hour• Percentage of hours where there

were > 30 alarms per hour• Operator response time

The ‘Human’ DimensionIn the final analysis, successful alarm management is not about the equipment or the alarm, but about people who impact and are impacted by the alarm system – operators, process and control engineers, maintenance personnel, shift super-visors, instrument and control system technicians, designers, safety officers, training staff and senior management.

To implement a successful alarm management programme requires factor-ing in the different expectations and priorities as well as the differing levels of awareness and understanding among these diverse groups of stakeholders.

Tools that can help to effectively share alarm analytics and the resulting insight across these stakeholders in a simple, relevant, meaningful and easy-to-understand format will help ensure that alarm management is fed back to the multi-level and multi-disciplinary input it requires to validate it and keep it relevant to the business objectives and the alarm philosophy of the organisation. Tools that can take alarm KPIs and benchmark them against industry best practice, could take alarm management to the next level and provide the organisation alarm report cards that can directly result in improved productivity, profitability and safety.

EEMUA recommendation on split of total alarms by priority assignment levels

<1% Critical

5% High Priority

15% Medium Priority

80% Low Priority Source: EEMUA 191


ISSUES & INSIGHTS

ENQUIRY NO. 6102

A ustralian national cement supplier, Adelaide Brighton Cement (ABC), employs over

1,300 staff, with major sites at Birkenhead, Angaston, Cockburn Cement, Swan Cement and Independent Cement and Lime. The Angaston site has 92 employees who manage the manufacture of lime, cement and clinker.

The plant has a manufacturing capacity of 250,000 tonnes but faced restrictions in maximising its quota due to outdated technology and processes. ABC recognised the need to upgrade its technology and improve the quality and efficiency of its manufacturing operations at Angaston.

Plant PerformanceIn 2001, ABC adopted a management style that focused on continual process improvement for its plant and operators. This led to the development of initiatives such as Six Sigma process improvement teams, standardisation teams and operational performance managers. The drive to continuously improve operations has helped to identify unscheduled system downtime as a significant contributor to an increase in production costs against raw material output.

The Planning and Plant Perfor-mance team gathered downtime

data using a number of sources such as control room log sheets, Microsoft Access databases, Excel spreadsheets, SPC control charts and CitectSCADA reports. This information was then analysed and reported during weekly performance meetings.

Using Pareto analysis of this data, ABC was able to define the root cause of the top ten plant stoppages. Although this information was carefully collated each week, it was always analysed some time after the event, which often delayed an immediate response.

In addition, the effort required to collect the data was in itself affecting plant performance as the process engineers could spend up to three days per month simply generating reporting data. ABC needed a more efficient method to measure, in real time, the overall equipment efficiency (OEE), taking into account the availability, quality and performance of each asset.

Requirements• ABC approached Citect to help

develop a downtime reporting system that:

• Is easy-to-use so that any operator could monitor downtime occurrences during any shift

• Provides access to data remotely

as networked computers were not readily available in all areas of the plant

• Enables automatic, real-time col-lection of stoppage data

• Is able to replace the multiple downtime reporting systems with one overall system

• Is quick to implement from design to active utilisation

Minimising DowntimeCitect implemented its customisable Ampla Downtime reporting system that measures asset utilisation, stoppage information and trend data. The system also measures Pareto data (count and duration) by shift, asset, equipment and cause so that operators have a more detailed picture of what may be causing each stoppage and how easily it can be solved. In many cases, the operator can resolve the stoppage with minimal disruption to production.

The plant operators enter their interpretation of the situation using customised pick lists, or by entering the cause, during each shift. This data is analysed by management on a daily and weekly basis to help identify trends and abnormal occurrences for prioritised action.

The entire development from design to implementation took less than two months with operators able to access the system and report data almost immediately.

Stoppage ReductionAs a result of implementing the Ampla Downtime reporting system, ABC Angaston has already reported a 50 percent reduction in plant stoppages. Kiln Three achieved a 50 percent reduction in stoppages just one month after implementation. This in turn created increased output from each asset and a decrease in cost per tonne of production.

Ampla has reduced reporting and analysis time from three days to just one hour per month allowing operators to concentrate more time on production and process improvement.

Customisable downtime reporting allows production to be optimised at a cement plant. By Citect

Cement ProductionMaximising


ISSUES & INSIGHTS

www.iaasiaonline.com30 industrial automation asia | September 2007

CONTROL POINT

Product Aspects Past Situation Current Trends

Starter module Huge numbers of different application and modules

Highly standardised yet flexible configuration

Intelligent functions Optional Embedded and Integrated by design yet independently accessible

DCS Communication

Single master and dedicated interface

Scalable with multiple masters and meaningful integration

Configuration possibility

Point to point Multiple combinations yet highly optimised, possible to enhance at any stage of project life cycle

Information Too much and not in context

Pertinent and specific to operator needs

Table 1: Motor control centre product features

Going Modular

The pursuit of lower cost, higher availability, optimised maintenance and safety heralds the arrival of intelligent motor control systems. By Gunnar Zank, Regional Support Manager, ABB Low Voltage Systems

L ow voltage motor control centres and switchgears are a vital part of an industrial plant.

Whether oil refinery, pharmaceutical plant or paper mill, reliable motor control is a mandatory part of a successful plant operation. Electric motors were once considered connected when the electrical parts in switchgear were tested and the drive shaft was correctly attached. Motor starters were considered only to be means of starting and stopping the motor by a push button station

and also provide a general thermal overload protection. Control and protection philosophies were based on conventional methods.

The introduction of micro-processor technology into motor starters two decades ago was a significant development, improving the motor protection functions, monitoring and allowing digital control. Following the emergence of open fieldbus technology more than a decade ago, the intelligent motor control system (IMCS) has rapidly gained acceptance from users.

Real TimeAlready considered mature in certain industrial applications, an IMCS provides extended information and process data. Communication protocols like Profibus or Modbus permit serial process control application. Robustness and response time suitability make this technology reliable for real-time applications. Intelligent motor controllers are becoming an integral part of a plant control and management system.

The ongoing pursuit of lower cost, greater availability, optimised maintenance and higher safety levels has leveraged a platform for flexible engineering that provides shorter

Intelligent Motor Control


CONTROL POINT

commissioning times, advanced information, better diagnosis and simplified troubleshooting, all leading to less downtime.

Plant managers are seeking further productivity gains through better overall plant uptime and coordination of operations and maintenance. The key in achieving this is delivery of the right information to the right people at the right time. This would not be possible without the appropriate connectivity of an IMCS. New system architecture and communication configurations are adapting to better meet this demand.

Scalable ApproachThe demand for higher-level informa-tion, flexible communication and data processing is different for different industries. Although with a common target of highly optimised plant operation and availability, the approach and expectation varies with the customer. Leading technologies are adopting a scalable approach. An IMCS does not need to be complicated. Simplicity and scalability is the key

factor for such requirements. The possibility to build a MCC in certain levels, packages and upgrade facilities at any stage of a project or plant life cycle is taken into consideration.

Work place safety has become a priority when considering IMCS. There is a growing demand from separating different voltages. An independent access to electrical components and cables as well and independent control and protection part allows the personnel to work in its dedicated areas safely and conveniently. Interferences, either personally or electrically are eliminated. The power side of the IMCS is interlocked behind closed doors enabling a control technician to work on the IMCS control part in complete safety without the need to shutdown the switchboard.

Configuration VariabilityIMCS applications for process industries require various different system configurations to meet different customer plant operation philosophies or site-dependent de-

mands on information flow. Multiple motor starters can be accessed via a central communication unit: This approach allows simultaneous access from several control locations on different communication interfaces. Further, certain tasks like adding motor starters for plant extension or modifying configurations are supported through higher system flexibility.

Motor starters are fully standardised modules yet allowing a flexible use through programming facilities. Complicated starter control functions, conventionally built with relays are a thing of the past. A high number of different starter types, control schemes and spare parts are no longer a headache for plant maintenance. Off the shelf starter modules, easily available and interchangeable between plant locations, withdrawable technology with inbuilt wiring reduces the time for repair.

The high level of integration in a plant operation environment and the need of access to motor controller by control system personnel, independently of the electrical part are reflected in the IMCS. Motor controllers are conveniently located outside the motor starter yet connected through inbuilt wiring technologies. To access them there is (theoretically) no need of coordination between different plant maintenance sections anymore as electrical parts remains untouched.

The integration of the IMCS into the plant asset management system allows an optimised maintenance process. Failure analysis, main-tenance trigger and spare part handling are the keys to higher operational performance of the plant. Maintenance data of the IMCS and motor are helping to optimise maintenance allowing optimal plant up time.

ReliabilityThe IMCS monitors at any point of time the correct location of every motor controller and its starter module. It also ensures that the correct control

Going Modular

(R) Gunnar Zank in front of the MNS iS LV switchgear system

www.iaasiaonline.com32 industrial automation asia | September 2007

CONTROL POINT

and protection function is applied. Mixing modules or inserting wrong type of modules does not lead to mal operation of motors anymore.

Communication integrity with predictable behaviour in case of a failure is mandatory to ensure motor availability under different circumstances. The operational safety of a motor is ensured against breakdown in communication through continuous monitoring of the communication integrity from the motor starter to the process control system (DCS: Distributed Control System) at all times. And, should communication break down, the motor is led to a pre-defined safe state.

Furthermore, the possibility of control access from a different location is safeguarded by a user access rights mechanism. At any point of time it is clear which location can or even has operated a motor.

Communication CapabilitiesA standard fieldbus does not exist today; adoption varies between customers and control systems. Preference is given to Modbus and Profibus with the emergence of Ethernet-based Modbus TCP and Profinet.

Besides serving as a fieldbus communication interface to process control systems, the IMCS provides far more data than needed in a process controller. Delivering that information to the right location faces limitations imposed by fieldbus capabilities and a huge engineering effort of the DCS. Advanced IMCS eliminates such situations by providing multiple data access through central communication units or a data concentrator.

Minimises EffortThe use of standard fieldbus com-munication is reduced to basic functions to transfer process control related data, minimising the engineering effort to its base. Advanced information is available through Ethernet based interfaces. Today it is all about information flow to the right operator at the right time. OPC is a standardised way of handling additional information that is not mission critical, but nevertheless important for successful plant operation and asset maintenance.

Using OPC, customers can connect to operator stations, maintenance systems and other applications, directly without having to program a process controller. By using OPC Servers provided within the scope of IMCS, additional information for operators can be added to the faceplates without further engineering and configuration effort in both the DCS and the IMCS.

Alarm and event handling is totally automated so operator stations obtain motor relevant alarms and time-tagged events directly from the motor controller. The maintenance relevant information can be taken directly via OPC to the electrical maintenance system or SCADA package. With this approach the information required can be presented as and where it is needed.

DCS Process Control SCADA Asset Management

OPC ServerParameteringand Setup

Fieldbus

Switchgear Control Network (Ethernet based)

Communication I/F Web Server OPC Data Provider

Local ControlPanel

Communication I/FWeb ServerOPC Data Provider

Motor or Feeder Module



Control &Protection

Control &Protection

Control &Protection

SwitchgearBus

SwitchgearBus

Control &Protection

Control &Protection

Control &Protection

Motor or FeederModule



Remote Control Panel

Each motor starter or feeder uses its own withdrawable and control unit

Schematic of switchgear control network

ENQUIRY NO. 6300


CONTROL POINT

Compact SolutionABB is offering an IMCS solution with MNS iS (iS stands for integrated Solution) as part of their proven Low Voltage Switchgear System technology MNS.

MNS iS is a compact IMCS integrating LV Distribution and motor control centre technology in one single switchgear application. Each motor starter or feeder uses its own withdrawable unit and a control unit. All control units (MControl) are located in a separate compartment, offering access independently and safely whilst fully separated from power parts, starter and feeder module (MStart and MFeed) in the switchgear.

Data AnalysisElectrical starter and feeder modules are widely standardised in order to reduce the numbers of different components for easier maintenance and spare parts handling.

Advanced data are collected and analysed to provide high information value for optimal asset management. Maintenance data are extended to cover both electrical and mechanical aspects. Local and web server based control and monitoring extends the solution to for plantwide monitoring.

Communication between the MNS iS control modules to DCS or SCADA systems takes place via standard fieldbus protocols such as Profibus and Modbus, and also Ethernet protocols such as Modbus TCP. A real-time Ethernet based communication internally ensures data availability and consistency between the control unit and the communication interfaces.

As an open interface to any SCADA or DCS integration, MNS iS provides an integrated and configuration free OPC Server application, which allows seamless integration into the plant operation and asset management system and application. Standardised interface components based on COTS products allow easy maintenance and upgrades.

ENQU

IRY

NO.

654

© 2007 National Instruments Corporation. All rights reserved. CompactRIO, LabVIEW, National Instruments, NI, and ni.com are trademarks of National Instruments.Other product and company names listed are trademarks or trade names of their�

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A utomation technology produces large amounts of data. These are usually physical variables such as temperature, current, pressure or other production

data such as number of units, time of error, number of errors, and so on. They are supplied by a wide variety of different devices such as controllers, level measuring devices, weighing machines, scanners, and so on. Information is required for a wide variety of different software applications.

Certain information may be stored in databases while other data may be needed for a table calculation or by visualisation software. Information from devices supplied by different manufacturers must be provided to different applications from various vendors.

OPC offers a standard interface for accessing device data. By Marius Wotschik (L) and Nadine Haid (R), INAT

Serving Up OPCIn earlier years – up until 1996, before OPC, that is – a

special driver had to be written for every application to which the I/O device was to be connected. There was one driver for Controller X for the link to software application A, one driver for the link to application B, one driver for the link to application C, and so on. Data had to be supplied several times by the same source – once at the request of application A, once at the request of application B, once at the request of application C, and so on. And naturally the same applied to controller Y. One driver for each application was also required here. In addition the number of drivers kept increasing with the different communication protocols and bus systems.

The arrival of OPC changed this. OPC DA (Data


SOFTWARE & NETWORKS


Access) interface offers a uniform solution with which different software applications can access a wide variety of data sources. Today’s hardware manufacturers now only develop one single driver – the OPC server. Software manufacturers on the other side supply only one OPC client interface.

As is usually the case with client-server architectures, the client utilises the services of the server. The OPC server accesses the process data of the hardware and makes these data available. OPC clients can read these ‘served up’ data or write commands to the server. The server then passes the control data along to the hardware. Thanks to OPC, only one driver – the OPC server – is now required per device. All applications – the OPC clients – access these servers. Automation without OPC is unthinkable today. The OPC interface is supported by almost all SCADA, visualisation, and process control systems.

How Does OPC DA Work?OPC is based on DCOM/COM. The component-object model is an object-based programming model developed by Microsoft. Software is divided into smaller, independent units – the objects (components). An object can execute certain actions (ie: supply certain methods). While the available methods are visible from the outside, the inner life of the object remains hidden. For this reason objects are enclosed and one or more interface(s) are defined for the outside. The interface contains the description of which functions are available and how these are to be used. The functions are called with the help of so-called virtual function tables (VTBL). These tables consist of a number of pointers which point to different functions.

Standard InterfaceOPC simplifies the link to applications by providing a standard interface which is not dependent on individual applications. This allows the customer to choose freely between products of different software and hardware vendors. Both OPC servers and clients are COM objects. It makes no difference who developed these objects, when they were developed, or in what programming

language and on what Windows operating system they were written. As COM objects they can all communicate with each another.

Network capability was added to COM with DCOM (Distributed COM). In other words not only the services of the OPC servers on the same computer are available but also those of all servers which can be accessed within the network. And the client does not even notice whether the server is a local server or a remote server.

Cooking Up A RecipeProcess visualisation is the main application area of OPC today. That is not surprising since it was primarily the visualisation manufacturers who demanded standardised

Serving Up OPC


SOFTWARE & NETWORKS

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ENQU

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685

Process data acquisition with OPCProcess data acquisition without OPC

SOFTWARE & NETWORKS

www.iaasiaonline.com

Application Aeg: visualisation

Application Beg: spreadsheet

Application Ceg: database

Application Aeg: visualisation

Application Beg: spreadsheet

Application Ceg: database

ENQUIRY NO. 6203

access to the different controllers. Process visualisation is used to dynamically represent data which are supplied – whether in the form of text or graphics. This gives users an overview of their processes together with the opportunity to intervene via buttons or touchscreens. It must also be said that not all tasks require costly visualisation.

The pointer or object-oriented approach of COM offers users capabilities which far exceed the ‘simple’ connection of finished OPC servers and clients. COM objects can be implemented in a wide variety of different applications. It is possible to program a separate client which utilises the methods of an existing OPC server provided that the programming language is object or pointer-oriented (eg: C, C++, Delphi, .Net or VB6). The OPC client accesses the server via its interface. There are two types: the custom interface and the automation interface. While function-oriented languages such as C++ use the custom interface, communication with the automation interface can be effected using script languages such as Visual Basic.

Ease Of CustomisationThe advantage of client programming is that it allows the application to be customised to specific require-ments. INAT has handled numerous implementations in this connection. For example, a recipe editor was developed for a customer so that recipes can be written to or read from the PLC just by pressing a button.

Recipes are collections of process parameter values such as, for example, temperature, pressure, etc. A recipe usually forms the basis for a certain product or product type to be manufactured. The recipes are located in a database. Hardware (PLC) to be addressed is selected from a pull-down menu while data transmission can be initiated with a button. The program which is currently being executed can be called, indicated and stored in the database at all times.

Sending & ReceivingSince the recipe editor must com-municate with controllers of different manufacturers, an all-in-one OPC server is required. For example, the INAT OPC server can handle all the primary Ethernet-based industrial protocols – it can be used for a wide variety of different systems. In addition to the Siemens protocols S7 and S5 via TCP/IP and H1 it can handle the Modbus on TCP protocol which is used to communicate with the Ethernet interfaces of Beckhoff, Phoenix Contact, Schneider Electric, Wago, and so on. Send/receive communication can be used to transmit data to devices which do not support any of the protocols mentioned.

Not only can the recipes be read from the controller to a database, when necessary the reverse is also possible – for a product change, for instance. Data transmission is started with a button and the recipe is loaded to the controller. A test bit is also scanned prior to the data transmission. Depending on whether this bit is set or not, the data transmission is allowed or prohibited.

Up till now, recipe parameters had to be explicitly transferred as part of a recipe data block using a programmer, for example. The recipe editor has now eliminated the need for this complicated transfer at the controller level. The transfer is handled by OPC

and the controller is free to concentrate on data processing.

Object Oriented ProgrammingProgramming an OPC client is easier than most would believe. That raises the question of whether an expensive client is actually needed for a specific application. Why not use Microsoft Excel as an OPC client? VBA, the object-oriented programming lang-uage for MS Office applications, makes it possible. Excel offers many excellent ways to present information: columns, bars, lines, circles, networks, tracking diagrams and more, depict the interrelationships and trends particularly clearly. Numerous control elements are also available. And if that is not enough, graphics can also be imported.

With its comprehensive calculat-ing capabilities, Excel is especially suitable for open loop and closed loop control. Almost any formula-based link can be implemented. Numerous possibilities are available: Cyclic data acquisition, reports, data analyses, trends and so forth. A decisive advantage is that almost everyone can be familiar with the program. From service personnel to sales engineers to management – most people already know how to use Excel and don’t have to learn a new tool first.

An OPC client can also be programmed in Excel


SOFTWARE & NETWORKSSOFTWARE & NETWORKS


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SOFTWARE & NETWORKS

I magine a physical world that is invisibly interwoven with sensors, actuators, and computational

elements, embedded in everyday objects of our lives, and connected through a continuous wired or unwired network. Smart environments represent the next evolutionary development step in building, utilities, industrial, home, shipboard, medical, and transportation systems automation. In these environments, wireless sensor networks (WSN) have played a key role in sensing, collecting, and disseminating information about environmental phenomena.

WSN generally consist of a data acquisition network and a data distribution network (which may be the same), monitored and controlled by a management centre (Figure 1). The plethora of available technologies makes even the selection of components difficult, let alone the design of a consistent, reliable, robust overall system. The study of wireless sensor networks is challenging in that it requires an enormous breadth of knowledge from an enormous variety of disciplines.

Wireless Sensor ModelA wireless sensing unit consists of four main components; namely a sensing unit, a processing unit, a transceiver unit and a power unit (Figure 2). The sensing unit consists of a sensor and an analogue to digital converter (ADC). The digital signal from the ADC is sent to the processing

Wireless Sensors & Networks:

The Smart Environment

unit for data processing which is then sent to the transceiver.

The transceiver connects the sensor node to the network. The power unit is the most important unit in the sensor node. If the sensor node is used in a small environment, replaceable batteries can be used. But

in cases where the sensor nodes are deployed in remote, difficult-to-reach locations, rechargeable batteries (eg: solar cells) have to be used.

ModulesDepending on applications they might have additional units such

The deployment of wireless sensor motes in physical environments, aided by self-organising network architectures, are quietly bringing about a sensing revolution. By Prasanna Ballal (L), Research Associate, and Prof Frank Lewis (R), Moncrief-O’Donnell Chair, University of Texas At Arlington, USA.

Figure 2: A Wireless Sensor Unit

Machine Monitoring

WirelessSensor

Animal Monitoring

Ship Monitoring BST

Vehicle Monitoring

Medical Monitoring

Wireless Sensor

BSC(Base Station

Controller, Preprocessing)

Wireless Data Collection

Networks

Management Center (Database large storage,

analysis)Data Acquisition

Network

Data Distribution Network Roving

Human monitor

PDA

Any where, any time to access

NotebookCellular Phone PC

Wireless (Wi-Fi 802.11 2.4GHz

BlueTooth Cellular Network, -

CDMA, GSM)

Wireland (Ethernet WLAN,

Optical)

Online monitoring

Printertransmitter

Server

Figure 1: Wireless Sensor Network

Location Finding System

Power UnitPower

Generator

Mobiliser

ProcessorStorage

Processing Unit

TransceiverSensor ADC

Sensing Unit


SOFTWARE & NETWORKS

as a localisation module, a power generator, and a mobiliser. The localisation module is used for finding the location of the sensor node in the environment. There are cases where nodes are attached to mobile platforms. The mobiliser unit connects the sensor nodes to the mobile platform.

There are different design constraints that have to be taken care of while designing a wireless sensor. These constraints are fault tolerance, scalability, production costs, hardware constraints, topology, transmission media, environment and power consumption. To make matters even worse, all these factors have to be designed for a matchbox size sensor unit.

Architecture & TopologiesProtocol architecture for WSN has to be designed carefully. Different applications require different protocols. The commonly used WSN protocol architecture is loosely based on the 7-layer Open Systems Interconnections (OSI) model developed by ISO in 1977. In this model, a networking system is divided into layers. Within each layer, one or more entities implement its functionality.

Each entity interacts directly only with the layer immediately beneath it, and provides facilities for use by the layer above it. Protocols enable an entity in one host to interact with a corresponding entity at the same layer in a remote host. The OSI model is shown in Figure 3.

The OSI model has seven layers, namely, the Physical layer, the Data Link layer, the Network layer, the Transport layer, the Session layer,

the Presentation layer and the Application layer. WSN does not necessarily utilise all the layers.

DLL & MAC LayersIn addition to these layers, WSN has three more layers namely the task management layer, the mobility management layer and the power management layer. In WSN, the Medium Access Control (MAC) layer lies above the Physical Layer. According to the OSI model, it is the part of Data Link layer (DLL), but in the case of WSN, there is a separation between DLL and MAC.

Topologies remain an important part of network design theory. A communication network is composed of nodes, each of which has computing power and can transmit and receive messages over communication links, wireless or cabled. The basic network topologies are shown in Figure 4 and include fully connected, mesh, star, ring, tree, bus. A single network may consist of several interconnected subnets of different topologies.

In October 2003, IEEE finalised the IEEE 802.15.4 standard for WSN. This standard covers the physical layer and MAC layer (topologies) for low rate wireless personal area network (WPAN). The ZigBee standard (December 2004) provides low cost and low power connectivity for equipment that needs battery life as long as several months to several years but does not require

data transfer rates as high as those enabled by Bluetooth. In addition, ZigBee can be implemented in larger mesh networks.

Energy ConservationOver the years, sensors have gone from macro scale to micro scale and the most substantial challenge for WSN designers is the need of significant reduction in energy consumption. Small-sized wireless sensor units imply smaller power supplies which means shorter lifetime for application usage. Most of the wireless sensors these days are event driven. Even for event driven applications, energy consumed during sensing, transmission and reception of data is quite high.

Energy inefficiency in WSN is observed in sensor electronics, transceiver electronics, network protocol, network topology and programming methods. An energy aware design methodology emphasises on appropriate scalability of energy consumption which stresses on factors such as available resources, event frequencies and the quality of service.

Scalable ConsumptionThe framework for an energy efficient WSN design highlights the collaboration between software for sensor programming and hardware with scalable energy consumption. The best way for achieving energy efficiency is by using low duty

Figure 4: Basic Network Topologies

Figure 3: OSI for WSN

Application Layer

Presentation Layer

Sessions Layer

Transport Layer

Network Layer

Data Link Layer

Physical Layer

Pow

er Managem

ent Plane

Mob

ility Managem

ent Plane

Task Managem

ent Plane

Star Bus

MeshFully connectedTree

Ring


SOFTWARE & NETWORKS

cycle protocols and event driven programming. Also, the use of multihop topology over single hop in certain applications has helped achieve energy efficiency.

Current research also focuses on designing small MEMS (microelectro-mechanical systems) RF components for transceivers, including capacitors, inductors, etc (Figure 5). The limiting factor now is in fabricating micro-sized inductors. Another thrust is in design-ing MEMS power generators using technologies including solar, vibration (electromagnetic and electrostatic), thermal, etc.

Spatial RelationshipsWireless sensors are coupled to the actual physical environment; hence their spatial relationship to other objects in the environment is very important. Localisation refers to the collection of techniques and mechanisms that measure these spatial relationships. A sensor data with its spatial information increases the network capability substantially. Most of the networks are static by nature, and hence it becomes difficult to find the location of the nodes in such situations.

One method of localisation is recording the location while installing the network, which is not feasible in applications involving random deployment. There are many factors that affect localisation of nodes such as energy constraints and node limitations. Also, the environment plays an important role; for example, GPS does not work indoors while RSSI based localisation are prone to distortion due to fading.

Self-OrganisationRelative localisation requires inter-node communications, and a TDMA message header frame that has both communications and localisation fields is shown in Figure 6. There are various means for a node to measure distance to its neighbours, mostly based on RF time-of-flight information.

In air, the propagation speed is known, so time differences can

be converted to distances. An approach based on robot kinematic transformations provides a straight-forward iterative technique for adding new nodes to a network. Figure 7 shows how to start a self-organising algorithm for relative positioning location.

Platforms, OS & InterfacesThere is a need for high performance but inexpensive wireless sensor platforms for testing various research concepts. Crossbow motes (Figure 8) may be the most versatile

wireless sensor network devices in the market for prototyping purposes. It makes three mote processor radio module families– MICA [MPR300] (first generation), MICA2 [MPR400] and MICA2-DOT [MPR500] (second generation).

Tiny MotesNodes come with five sensors installed: Temperature, Light, Acoustic (Microphone), Acceleration/Seismic, and Magnetic. These are especially suitable for surveillance

Figure 6:TDMA frame for communication protocols and localisation

y

x2d121O

a. two nodes - define x & y

y

x2d121O

y3

x3

θx23θ213

d3 d23

3

b. 3 node closed kinematic chain-compute (x3, y3)

T frame

StartupNodeID nr

Neighborinfo

Dist.toNeigh-bors

(x,y)coords.andOriginNode ID

Hier.routingnr

NetEntry-inviteresponsepointer

comm link mesh info Position grid info

I extraR P repeat nextTDMA frame

Figure 7: Integrating new nodes into a relative positioning grid

Figure 5: MEMS power generator using vibration and electromagnetic method

Permanentmagnet

Vibrating bodywith the coil

MEMS Chip

Non-ferromagnetic

materialFerromagnetic material

ENQUIRY NO. 6201


SOFTWARE & NETWORKS

networks for personnel and vehicles. Low power and small physical size enable placement virtually anywhere. The operating frequency is ISM band, either 916 MHz or 433 MHz, with a data rate of 40 Kbits/sec. and a range of 30 ft to 100 ft. Each node has a low power microcontroller processor with speed of 4 MHz, a flash memory with 128 Kbytes, and SRAM and EEPROM of 4K bytes each. The operating system is TinyOS, a tiny micro-threading distributed operating system developed by UC Berkeley, with a NESC (Network Embedded Systems C) source code language.

TinyOS/ NESC is an event-based programming method. This operating system supports concurrent execution of several processes

Figure 8: Crossbow sensors

Figure 10: LabVIEW Interface for WSN

and communication between these processes. In WSN, sensors send data only when an event is triggered. Such events occur at a low rate than other wireless systems. Hence, the programming used in wireless systems when applied to WSN, would cause considerable power consumption. Figure 9 shows the architecture for event-based programming.

Intelligent interfacesMany software products are available to provide advanced DSP, intelligent user interfaces, decision assistance, and alarm functions. Among the most popular, powerful, and easy to use is National Instruments LabVIEW. What makes LabVIEW good for WSN? It’s because LabVIEW has a unique style called data controlled execution, not sequential execution as in most of the other programs.

It has built-in drivers for many applications. It is easy to interface a sensor to a program developed in LabVIEW. Figure 10 shows a LabVIEW user interface for monitoring machinery conditions over the Internet for automated maintenance scheduling functions. Included are displays of sensor signals that can be selected and tailored by the user. The user can prescribe bands of normal operation, excursions outside of which generate alarms of various sorts and severity.

Crossbow Transceiver

Berkeley Crossbow

Sensor

Figure 9: Event-based Programming

Sensor Event

Sensor Event Handler

Processor Radio Event Handler

Radio Event

racking assets has received con-siderable interest in the recent years, thanks in part to Wal-Mart’s

Radio Frequency Identification (RFID) inventory tracking programme. This interest has resulted in the development and improvement of various tracking technologies which can be used for different applications. In the process industries, companies need solutions that can help track critical assets and also locate personnel during emergency situations.

The geo-location of an asset becomes a new variable that can be used to reduce operating costs, and improve safety and emergency response time. Honeywell Instant Location System (HILS) seamlessly integrates best-in class location and identification technologies to meet process industry requirements and track physical objects.

Today the geo-location technology is mainly used within the supply man-agement chain. In the process industry, these technologies can be used also for warehouse management as well as improving safety and work processes.

Improved Security: HILS is designed to work with a diversity of security offerings, including access cards, digital video and biometrics.

Increased Mustering Accuracy: Real-time mustering reports can be generated within a few seconds, providing accurate location of missing or injured personnel. This is made possible by radio frequency based tags worn by all personnel.

Safer Operating Procedures: Geo- location information can be used during plant operations to improve safety. HILS allows sites to incor-porate the location of staff into their procedures in order to ensure that procedures are executed only when authorised personnel are in the perimeter. The combination of HILS

and Procedural Operations solutions takes plant safety to the next level.

Workflow Optimisation: Inventory and valuable assets moving

inside and outside the plant can be quickly located and tracked.

Time spent looking for assets can be significantly

reduced. The system also allows operational workflow

to be optimised by analysing the time spent completing various

activities and taking corrective measures for process improvement.

Technology OverviewWith the variety of identification and location technologies available, choos-ing the appropriate technology can be confusing. Considering these factors will help select the best positioning system for a particular application.

• Infrastructure requirements• Detection range• Detection position• Reliability• Asset and personnel tags battery

life (not applicable to passive RFID)• Update rate• Cost

The following chart illustrates the detection range and accuracy of each technology.

Ultra-Wide Band: Ultra-Wide Band (UWB) positioning system is the best solution for applications that require precise location in harsh multipath outdoor or indoor environments such as chemical or manufacturing plants.

Geo-location and identification technologies enhance visibility in asset tracking and ensure greater security on the plant floor. By Honeywell

Real-Time &Identification

Tracking

Figure 1: This detection accuracy and area coverage for each identification and location technology.

Battery Life

Active RFID

UWB

Passive RFID

100 m

10 m

1 m

10 cm

1 cm

Det

ectio

n A

ccur

acy

>10000 km 100 m 10 m 1 m

Detection Range

Wi-FiGPSAGPS

<1 day 1 year >3 years


SOFTWARE & NETWORKS

UWB positioning infrastructure is composed of multi-year battery-powered tags and 24 VDC-powered receivers.

The active RFID tags emit pulsed signals at high frequencies that are captured by UWB receivers. A minimum of three receivers is required to provide an accurate location of an asset (up to one-foot accuracy) using triangulation principles.

The system can also provide proximity data if less than three receivers are available. The detection range can reach up to 200 meters (650 feet) line of sight in an outdoor environment. UWB technology can also provide two- and three-dimensional geo-location information.

Wi-Fi: Wi-Fi positioning system is the best solution for applications that require approximate location information in outdoor and indoor environments. Wi-Fi positioning infra-structure is composed of battery-powered tags and off-the-shelf Wi-Fi access points. The solution is best for facilities with an existing Wi-Fi network.

Wi-Fi detection range can reach up to 200 m line of sight in an outdoor environment and 60 m in an indoor environment. The Wi-Fi signals emitted by the tags are captured by the Wi-Fi access points. Using triangulation principles, the system calculates the position of the assets. Wi-Fi positioning system provides up to 15 feet detection accuracy which is less than UWB and works best in a non multi-path environment.

Active RFID: Active RFID systems are composed of active RFID tags emitting signals at various frequencies. The emitted signals are received by active RFID readers which will provide proximity location information. Active RFID systems have limited detection range of 35 m line of sight. The main advantage of the active RFID is cost. The active RFID tags and readers are less expensive than UWB and Wi-Fi receivers and have multi-year battery life.

Global Positioning System: Global Positioning Systems (GPS) have been available for many years. The advantage of GPS is that it does not require any infrastructure. The system consists of GPS receivers that calculate their positions by measuring the distance between themselves and three or more GPS satellites.

Measuring the time delay between transmission and reception of each GPS radio signal gives the distance to each satellite since the signal travels at a known speed. The signals also carry information about the satellites’ location. By determining the position of, and distance to at least three satellites, the receiver can compute its position using trilateration. GPS devices have a short battery life (few hours) and are expensive for tracking hundreds or thousands of assets. GPS accuracy varies from 3-5 m.

Locate & IdentifyHoneywell has harnessed proven identification and location technologies within one easy-to-use solution to help locate and monitor equipment and people, in real time. HILS converts geo-positions into data which is used to improve safety, security, workflow and asset utilisation. The solution integrates

four of the most positioning technologies: GPS, UWB, Wi-Fi and active RFID. The geo-location data provided advanced by these various positioning systems is managed by the HILS management application.

HILS is integrated with Honeywell’s Experion Process Knowledge System (PKS) allowing users to view alarms or alert notifications on the Experion Station and use geolocation data in their control strategies.

The HTML-based interface allows users to:

• View the position of assets on two- or three-dimensional maps

• Associate active RFID tags or GPS devices with equipment or personnel

• Create business rules that trigger automatic notifications

• Search assets using attributes• Create queries and view

reports ENQUIRY NO. 6202

ActiveRFID

GPSUWBWi-Fi

HILS Manager

TPS/Experion/EBI

Figure 2: HILS Overview


SOFTWARE & NETWORKS

C ompressed air is second only to electricity in importance as an industrial energy source,

and there is hardly a factory that functions without it. For many industrial applications pneumatics is the preferred drive technology, thanks to advantages such as overload resistance, long life, economy, ease of assembly, reliability, and safety.

Because pneumatic equipment generally operates trouble-free, users tend to take it for granted and typically do not look for problems or inefficiencies. This may be why air leaks are often not taken seriously. After all, wasting compressed air is usually harmless to the environment.

The uncomfortable truth is compressed air is the most expensive energy available in production

Built-in flow sensors improve machine efficiency, reduce downtime, and cut costs. By Christian Boehm, Manager, Technical Engineering Center, Festo.

System MonitoringA common way to prevent waste is to regularly search for compressed-air leaks. Formal leak-detection programs usually involve complete, manual inspections of all airlines several times per year. Regular inspections find new leaks and also confirm that tagged leaks from past inspections have been repaired. Technicians typically diagnose pneumatic leaks by listening for hissing air, periodically inspecting tubes, and tightening fittings.

One disadvantage of leak-detection programs is that depending on inspection frequency, leaks can go undetected for a long time. Also, inspections are usually time consuming and may be problematic in noisy industrial environments. Inspectors often miss small leaks, which prevent repairs in the early stages before leakage becomes a major problem.

Many experts now recommend installing a network of flow sensors to continuously track compressed-air use. It is more efficient and cost effective than manual inspections and detects costly increases in air consumption caused by malfunctions and leaks.

Modern SensorsFlow sensors, properly sized and installed at important locations within an air-distribution system, highlight deviations, send messages, and activate alarms when flow exceeds

Studies show that 79% of the costs for compressed-air systems are for electrical energy, with 6% for maintenance and 15% for capital investment. Therefore, it makes sense to pay attention to the proper use of compressed air.

Operating costs for compressed-air systems

79%

6%15%

Maintenance costs

Electrical-energy costs Capital Investment

FlowGoing With The

facilities. Therefore, it makes sense to pay attention to the proper use of compressed air. One technique gaining ground is to monitor air consumption, as it is a good indicator of the health of pneumatic systems.


INSTRUMENTATION & MEASUREMENT

tolerance thresholds. Technicians can easily pinpoint leaks, failures, and other problems, and take immediate action to fix them. In addition, flow sensors in production facilities can track air consumption of pneumatic systems – even down to specific components – and help calculate true operating costs.

Advances in sensor technology have only recently made all this possible. Until now, most flow sensors only provided real-time flow data over a relatively narrow operating range. There were also a lot of restrictions on where they could be installed. Flow measurement is, unlike pressure measurement, rather

The latest flow sensors measure and record air consumption, which is helpful in environments where flow varies over a period of time. This graphical representation based on digital outputs shows all four areas are the same size.

Digital output impulse

Flow signal

100

90

80

70

60

50

40

30

20

10

0

Flo

w, l

pm

Cumulative flow

Time

MS6-SFE has a measurement range of 200 to 5,000 lpm. Large, backlit LCDs show flow information and transmit data via digital or analogue outputs.

How Anemometers Work

complex. Normally, sensors are quite sensitive to upstream flow conditions, so installation plays a critical role in measurement accuracy. Units often had to be located in laminar-flow regions – for instance, away from tees and elbows – and this made widespread use on industrial equipment impractical.

In contrast, newer sensors contain features such as special inlet tubes or filter cartridges that stabilise flow. Thus, users do not face installation restrictions or require specific knowledge about the incoming flow. And a bypass-measurement system gives accurate readings over a wider flow range than was previously

The cross section of a Festo MS6 flow sensor shows the sensing element is housed away from the main flow channel.

Anemometer flow sensors contain a heating element

held at a constant temperature in the fluid medium. Gas or liquid flow cools the heating element due to convective heat loss, but a regulator keeps heater temperature constant. When there is heat loss, the device requires more power to hold the heating-element temperature constant. Thus, power consumption is a useful indicator of fluid velocity.

The latest flow sensors do not place the anemometer in the main flow channel but, rather, in a bypass channel within the housing. The main channel is shaped to create a Venturi effect that generates a pressure differential and forces a well-defined proportion of flow through the bypass. This helps protect the sensor element and ensure long, trouble-free life. Readings are independent of pressure, which makes this technique ideal for a variety of tasks – even measuring rather small flows. Thus, anemometry-type flow sensors are suited for many different applications, from measuring air consumption on a single pneumatic drive to monitoring large production areas.

Sensor element

Connector plate

Housing

SocketInlet tube

Inside an anemometer



possible. The sensors quickly install most anywhere and even temporary setups are now practical.

System SetupFlow sensors can be used throughout an entire air system, though the number of sensors and exact location depend on customer requirements. Typically, some sensors should be integrated at important points of the air-distribution system. These monitor flow to groups of machines. Any increase in air consumption would at least indicate a problem exists and note the general area of concern.

Other users are more interested in monitoring flow to a single machine or individual subsystem. In these cases, sensors quickly narrow the source of any increase in air consumption.

Finally, a single actuator is sometimes crucial to the manu-facturing process or operating an entire assembly line. In such cases, it

or controller. And while currently hardwired, wireless data transmission can be expected within the next few years. Determining acceptable deviations in normal operations and where to set alarm thresholds strongly depends on the application and the user’s experience. But customer-selected thresholds are not only for alarms. Trigger signals are often used to start and control manufacturing processes. And on retrofits, feedback signals can lead to higher machine speeds. Sensor data can also be used in predictive-maintenance programs. Early recognition of an increase in air consumption is a useful indicator that repairs are needed or equipment must be replaced.

Some manufacturers have started to mount flow sensors at critical locations within their plants and display the data on a central terminal in the maintenance department. For example, one OEM displays air

consumption in different plant sections and high-lights areas of higher air consumption in red. Armed with this knowledge, the maintenance staff quickly responds when and where it is needed.

Determining Flow RangeBefore adding flow sensors to a line, engineers must determine the required measuring range. Choosing sensors for normal pneu-

matic applications is usually straightforward. But selection gets more complicated in low-flow applications. In such cases, it helps to calculate the required flow-measurement range. One way to estimate the flow range is from the orifice-flow equation:

C = 0.154d2 ⁄ P

where d = orifice diameter, mm2; P = pressure differential across the orifice, bar; and C = flow, litre/s. The equation is a simplified approximation for supercritical conditions and is valid for small differential pressures

and orifices.As an example, an automotive

supplier needs compressed air to clean a crankshaft borehole and possibly use airflow to also gage hole size. The goal is to ensure the crankshaft borehole diameter d = 4 ± 0.3 mm. Selecting pressure is the first step. A one-bar pressure differential is a good compromise between ensuring sufficient flow to clean the hole and, at the same time, minimising air consumption.

This results in the following C values based on the above equation:

C = 147.8 lpm at d = 4.0 mm C = 170.8 lpm at d = 4.3 mm C = 126.5 lpm at d = 3.7 mm

Results show significant differences in airflow, so the manufacturer can use flow sensors to determine borehole diameter and monitor consumption. In this example, an appropriate sensor should have a measuring range up to about 200 lpm.

Continuously evaluating airflow and consumption provides useful diagnostic information and helps determine whether a pneumatic system or subsystem operates efficiently. Flow sensors can highlight problem areas and quickly detect malfunctions. Users who want to reduce production costs and system downtime should consider using flow sensors as an efficient and inexpensive diagnostic tool. They are a much better alternative than a futile search for leaks or adding compressors.

ENQUIRY NO. 6400

is a good idea to mount a sensor that will closely monitor just that component.

A general rule of thumb is to install at least one flow sensor in the main supply line on every machine with an average-size pneumatic system. It tracks air consumption over the long term and easily identifies sudden increases in demand.

Trigger PointsThe sensors deliver analogue or digital signals to any standard PLC

Sensors are typically integrated at important points of the air-distribution system.



The SFE1 sensor measures flows from 0.5 to 200 lpm.

oveMoveM

C ompanies have tradit ionally concentrated on the inputs and outputs of the supply network

processes, with little concern for its internal management, and workings of individual components.

However, organisations today in-creasingly find that they must rely on effective supply chains, or networks, to successfully compete in the global market and networked economy. The purpose of supply chain management is to improve trust and collaboration among supply chain partners, thus improving inventory visibility and

velocity. The choice of technologies for internal management controls is now able to impact a company’s supply chain efficiency and performance.

A major component of inventory visibility lies in a well-organised ware-house, with an up-to-date warehouse management system (WMS) in place. Warehouse management systems provide the backbone that runs the overall distribution operation. It organises work and aligns resources and labour to satisfy customer requirements, and optimises fulfil-

ment and distribution processes to ensure that products are delivered on time and to order. The WMS manages the order processing, receiving, put-away, and shipping functions through a cohesive integrated methodology.

However, the WMS does not optimise and direct material flow in conveying/sorting operations, determine the ideal location to store an item within an automated storage system, nor does it manage the precise details of light- and voice-directed order fulfilment. To get the most performance out of these

Seamless integration of warehouse management and control systems, and process optimisation. By Augustine Quek

Warehouse Management: On The

Dematic


SECTOR SPOTLIGHT

automated subsystems, a warehouse control system (WCS) is required.

In ControlWCS i s a sof tware solut ion that manage s and prov ide s s t rategic cont r o l o f automate d mate r ia l handling technology, such as light- and voice-directed order fulfilment, sor tat ion, conveying, automated storage/staging, etc.

The WCS optimises the control and performance of an automated system by maximising material flow, executing efficient storage strategies, and providing accuracy in order fulfilment and sorting.

A typical WCS would have a host interface for communication between the WCS and WMS, MES, or ERP software, as well as several standard modules, including order fulfilment, material flow and storage, sortation management, visualisation control and information management.

Peak PerformanceAn example of high performance results from implementing a WMS/WCS can be seen in Gruppo Coin’s automated warehouse management and control system. Gruppo Coin’s sys tem at a 9,500 sq m garment handling distribution centre in Rome, Italy was provided by Intelligent Distributed Controls Ltd (IDC).

The system employs 330 intelligent bar code readers, PLCs and a central server in a package that handles 11-12 million garments annually, yet requires only two

or three operators per shift, even though at peak turnover times, over 300,00 garments are being handled over a two shift period.

The WMCS system is based around an overhead conveyor system supplied by Moving ITS, which provides the speed, flexibility and versatility to move trolleys freely and silently around the four-storey warehouse. The Trolley Guidance Supervisory Control System is based upon IDC’s intelligent bar code readers, which are fitted at trolley divert points to control the route of each trolley. Readers recognise and react to each of the 13,000 trolleys in the warehouse, communicating data and instructions via a gateway PLC to the RAID Level 5 Server, running on a Windows NT software platform.

This communicates to the ware-house management system via a TCP/IP network, enabling route selection of each trolley to be designated and the monitoring of goods in real time. To ensure response times for messaging between the WMS, WCS and the PLC network are independent of server database size, an Oracle 8 relational database software is employed.

In addition to its role in passing routing instructions to the readers and confirming trolley arrivals, IDC’s server also controls the flow of empty trolleys to ensure that they are returned to a buffer; and provides

an operator interface (MMI) and diagnostic tool for such occurrences as trolley jams.

Integrated IntelligenceT h e h i g h l e v e l o f i n t e g r a t i o n and intelligence provided by the intel l igent reader s dramat ica l ly reduce s sys tem hardware cos t s , especially in comparison to systems using separate barcode reader s with standard PLC’s and separate communication networks.

In relation to WMS, several technologies serve as key enablers. The first is the use of radio frequency identification (RFID). The method most commonly used stores data that identifies an object on a microchip attached to an antenna (an RFID tag). The antenna transmits the identification information to a reader, which converts the radio waves reflected back from the RFID tag into digital information passed on to computers that can make use of it.

RFID technology automates the process of moving goods from the manufacturer, to a warehouse, to a store and finally to the home or business. An RFID reader captures the tagged goods’ information when loaded onto a staging area and communicates the details immediately to the backend system. It can be customised to trigger warehouse

Strategic control of material handling technology

Siem

ens

Siemens

RFID based asset management


SECTOR SPOTLIGHT

updating, customer notification, and other related operations.

Active RFIDFor example, APL, NOL’s logistics and container transportation subsidiary, has introduced active RFID technology to it s Southern California marine terminal to speed up cargo container proces sing. By int roducing real -time locating system technology at its Global Gateway South terminal, APL can reduce by 12 hours or more the amount of time taken to track a container in the yard and prepare it for transport.

Passively TaggedRecent in-flight tests on a Boeing-FedEx MD-10 freightliner, also demon-strates the capability of RFID’s in tracking efficiencies. Various parts of the aircraft were tagged with passive UHF RFID tags and read by readers for 90 days in 2004 in Memphis, Tennessee.

Information stored on the RFID tag enhances part traceability and reduce cycle time to solve in-service problems by improving the accuracy of information exchanged between customers and suppliers. Now, Boeing not only has 1700–2000 mission-critical parts to track using RFID, it is even working together

with Airbus to issue the same RFID requirements to their suppliers.

The growing popularity of RFID has even seen a push towards regional harmonisation of band frequency at the Asia Pacific level. Singapore has rallied ASEAN to agree in-principle to harmonise RFID spectrum allocations in the 860 MHz to 960 MHz range. Such interoperability of RFID would allow cross-border tracking of the movement of goods, similar in concept to the Boeing tests, but one level higher.

Voice ActivatedAnother component in the modern supply cha in i s voice - act ivated technology. The key feature of voice technology is the user interface. It is based upon speech synthesis and recognition and operates through a voice terminal, worn by the user on a belt, which communicates with a host control system, typically a warehouse management system (WMS), via radio frequency (RF) links.

Voice activated technology is gaining greater prominence in the warehousing industry. It is seen by some as the source of a new generation of operational improvements in the warehouse, especially for activities like picking.

The benefits of voice-directed w a r e h o u s i n g management are threefold. Firstly, productivity im-proves through significantly re-ducing the work-steps required for the picking proc-ess. Instructions can be issued and validation checks carried out whilst the user continues to pick. This time saving translates into considerable i m p r o v e m e n t s in productivity over the course of a shift, unlike manual picking,

which requires picking up a hand-held terminal, reading the instruction from the screen, possibly pressing a few keys and then scanning a bar code. It also reduces the number of trips the picker makes to the ware-house office to get the next pick list to work on. The administrative task of confirming a picked list back to the host system can also be eliminated.

Secondly, there is greater accuracy in the ‘hands free, eyes free’ operation that is inherent in speech-controlled picking systems. It allows the real-time validation of the operation as it proceeds. Any errors in product picking can be detected and corrected immediately at this stage before proceeding. Lastly, there are indirect benefits such as ease of use by operators, fewer product damage and less physical strain, all attributable to the ‘hands-free, eyes-free’ ergonomics of voice-activated technology.

Mature & RobustIts robustness and maturity has been proven in numerous installat ions a round t he wor ld. For example Dematic, has over 80 pick-by-voice installations worldwide. The largest pick-by-voice system delivered by Dematic in Europe with 960 order pickers in one warehouse is in used in a Finnish retail chain.

As supply chains have become much more fragmented and global, companies will have a harder time putting together the right process controls and visibility in place. This is true not only from a supply and logistics visibility standpoint, but also a security standpoint to make sure nothing dangerous is slipped into a container.

It is also good for consumer confidence, to make sure the correct raw materials are being used in products – to prevent a supply chain disruption, which recently happened with the recent toy recall by Fisher-Price. Thus, technological solutions will be increasingly sought, not just by companies manufacturing products, also by services that provide them.

ENQUIRY NO. 6500Dematic


SECTOR SPOTLIGHT


IN BUSINESS

I n today’s business environment, companies are thinking about energy as a strategic asset that is important to every aspect of their business. The scenario is all

too familiar. CEOs are under pressure from shareholders and board members to green-up and cut greenhouse gas emissions, reduce energy consumption, and shrink their carbon footprint.

CFOs are looking for increasingly more creative ways to trim costs and gain a return on investments, and facilities managers are tasked with the challenge of keeping a wide range of systems operating efficiently and effectively under a myriad of conditions, including a volatile energy market and a steady increase in capacity costs. Is the decision to fire up the generators the right one when ISO calls for a curtailment on the hottest, or coldest, day of the year or is there a more sophisticated approach for today’s fiscally and environmentally minded CEO?

One PlatformLON systems integrators already utilise one comprehensive platform to manage the lighting, HVAC and building systems within a facility. Integrating demand response into this platform brings the supply side of the picture into perspective, further leveraging their customers’ ability to control the internal environment not only with regards to creature comfort, but also energy consumption.

The result is a smarter and more energy responsive building that is positioned to react flexibly to curtailment

demands from the ISO system and changes in the energy market as well.

Demand & SupplySystems integrators who are able to combine a demand response programme are well positioned to help customers leverage both the demand and the supply side of the equation.

Load management and energy efficiency strategies are most effective when all elements of the energy chain are linked together for the customer. Integrating a LON based system, ideally with LonMark certified products, makes this possible.

Systems integrators who are able to bring the supply and demand side expertise to the table have a competitive edge when assisting end users with managing energy in their facility. This expertise can be brought to bear in three primary ways:

• Shaping load via control system upgrades and retrofitting.

• Reducing load via advanced demand limiting and peak shaving applications.

• Smoothing bandwidth via optimising control strategies.

Integrating demand response in control strategies allows users to leverage on both the demand and supply side of the equation. By Peter Kelly-Detwiler, Senior Director, Constellation NewEnergy

Quantum Automation

Demand response chart

Systems Integration: Integrating Demand

Response

IN BUSINESS

Quantum Automation

Typical DR Load Curve

2 Reduce kW via advanced BAS demand limiting and

peak shaving applications

3 Smooth bandwidth via optimising control strategies Improve Bandwidth to 10% or Better +/-5

Peak ReductionSystems Integrators Can Affect Load 3 Ways:

Constellation Demand Response Partner Program

1 Reduce kWH via control system upgrade and

retro-commissioning5 to 10%Efficiency

www.iaasiaonline.com September | industrial automation asia 51

IN BUSINESS

Enhancing the elasticity of a company’s facilities is fundamental to reducing energy needs in the future and taking unnecessary stress off the grid during peak demand. There are a multitude of opportunities to leverage on – lighting, primary air handling and pumping equipment, central plant operations and HVAC systems.

Real-Time SavingsFurther savings can be realised from access to meter and price information systems, which allow up-to-the-minute views of energy usage and costs and the ability to employ this information to better shape and control usage patterns. Real-time energy information and the ability to shape energy load will put a business in the driver’s seat when responding to a demand for curtailment from the ISO and when navigating a volatile energy market.

Demand response can be integrated into energy efficiency upgrades to older, existing facilities or incorporated into the design and construction of new buildings. This successful bridging of energy supply with actual on-site demand addresses everyone’s needs from the corner office to the control room. For example, Constellation NewEnergy has worked with New York’s Syracuse University since 1995 on multiple projects involving more than 40 buildings.

Energy ManagementAmong the upgrades is a new energy management system which controls all HVAC systems using the LON platform in 44 buildings. VAV conversions were made in more than 12 buildings, including more than 185 lab fume hoods and VSDs placed on more than 50 individual pumping and air-handling systems ranging in size from 7.5-100 Hp. Constellation NewEnergy worked with the incumbent systems integrators to help design and install the controls upgrades.

The investment has resulted in annual cost savings of US$1.9 million and reduced energy costs by more than 10 percent over a five-year period. New electric metering, measuring and monitoring systems provide necessary information for the university to comprehensively evaluate, assess and shape its energy load going forward.

The BenefitsDemand response provides measurable benefits to customers that go well beyond the financial. Among these are contributing to the effort to prevent regional blackouts without resorting to on-site generation.

While other demand response providers typically use generators as their main load reduction product, leading companies believe in leveraging building automation systems and applying advanced control strategies for true load shaping. This method helps to prevent brownouts, rolling blackouts and high cost peaking plants from coming online during ISO emergency curtailment events, thus a demand response programme is more akin to a “virtual” peaking plant.

Shaving Off EnergyShaving off-peak usage results in additional kilowatts becoming available where they are most needed on the grid without the need to fire up older gas, oil or coal plants to meet regional demand. This puts companies in a position to contribute to the larger effort of preventing regional blackouts, without resorting to on-site generation and the associated issues of run-time and air emissions that accompany them.

During demand response events, customers who are set up with the technology and metering applications to curtail at least 100 kilowatts of electricity consumption during peak demand hours are able to reap year-round financial benefits.

The result is a reduction in energy costs through regular monthly payments for committing to participation in the ISO curtailment program as well as the savings earned during actual curtailment events. And finally, integrating demand response into existing platforms positions customers to fully take advantage of an ever evolving and increasingly more sophisticated energy market.

ENQUIRY NO. 6600

Qua

ntum

Aut

omat

ion

Enhancing the elasticity of a company’s facilities is fundamental to reducing energy needs in the future


AUTOMATION SOURCES & SERVICES Latest products and software available in the market

Adlink: Portable PXI ChassisPXIS-2690P is a 14-Slot, 3U portable PXI chassis fully compliant with the PXI specification, rev 2.2. The PXIS-2690P is designed for

military, aero-defense, field testing, and in-vehicle testing

applications by providing a touch panel 15” LCD display, keyboard, touchpad, DVD combo drive, and 500W power supply in an aluminium alloy frame.

Designed for ruggedness and stabi l i ty, the PXIS-2960P has been fully tested for a variety of shock and vibration situations – such as those experienced in outdoor applications. Three onboard 120 mm x 120 mm x 25 mm fans deliver an airflow rate of 223.5 CFM to help ensure proper operation even in high temperature environments.

The 13 peripheral slots of the PXIS-2690P support a variety of 3U PXI/CompactPCI modules such as digitisers, waveform generators, multimeters, data acquisition cards, analogue output cards, and digital I/O cards.

Enquiry no. 6701

Belden: Wireless EdgeThe Wireless Switch/AP Edge Solution, offers a unique channel blanket topology, giving users a secure, zero latency, interference-free WLAN. It has been designed to help its users achieve a predictable rate of connection and service.

It is easy to install and maintain – plus it delivers high end performance with features which include no co-channel interference, seamless mobility with no roaming latency, robust client connections that do not drop, no edge-users or client bunching and no mixed-mode b/g performance issues.

The wireless solution ensures that security concerns are fully addressed. It complies with IEEE 802.11i, (also known as WPA2), for authentication as well as encryption. And, it includes rogue access point detection.

Enquiry no. 6702

Comitronic: Non-Contact Safety SwitchThe Supermagnet range of safety switches are sealed to IP65 standards, ensuring reliability in hostile environments. The non-contacting design ensures less wear and higher tolerance to door misalignment. It provides zero activation radius, unlike a key interlocking system for which the minimum distance is often 250 mm.

There are two versions of electromagnets, namely power off locking with a holding force of 30 DaN and power on locking with 50 DaN latching force that is the equivalent of 30 kg and 50 kg of latching power.

Models in dual-function latching & switching are also available. A coded non-contact safety switch with an Acotom2 process is integrated inside, ensuring tamper resistance and satisfies EN954 safety category 4 when used alone with the safety module AWAX, safety category 3 when wired in series. The built-in LED display indicates the status of auxiliary contact.

Enquiry no. 6703

ESI: Composite Parts SimulationPAM-RTM software for CATIA V5 establishes a direct link between the numerical simulation of manufacturing liquid composite moulding processes and CATIA V5 Composites Part Design (CPD). It will help engineers reuse information generated during design to quickly create injection/infusion models.

ESI Group has developed PAM-RTM for CATIA V5 – an application to simulate composite parts manufacturing, which is based on liquid composite moulding processes, such as RTM or VARTM (Vacuum Assisted RTM). The 3D modelling included in the software now makes the study of thick parts possible and thermal management can, therefore, be optimised.

PAM-RTM for CATIA V5 can be used to design and develop new tooling and processes for composite materials. It fine-tunes the mould design and the process parameters in order to make sure that the parts are injected correctly first time.

Enquiry no. 6704


AUTOMATION SOURCES & SERVICES

Harting: Ethernet SwitchesThe eCon and mCon 9000 family extends the spectrum of managed and unmanaged Ethernet switches. Up to 10 Ethernet clients can be connected via RJ45 or M12 sockets (D-coding) at the front of the device. The product

family is suitable for use in industrial applications and supports both Ethernet (10MBit/s) and

Fast Ethernet (100MBit/s). Line- and star-topology networks as well as mixed forms are supported.

The por t s o f the Ethernet switches are fitted with integrated LEDs, which enable easy and fast network diagnosis. In addition to these optical indicators, all switches have a potential-

free relay contact, which can be connected via the DIN cable connector.

The eCon 9000 comes with standard plug-and-play features while the

mCon 9000 series switch can be managed over an SNMP and web interface.

Enquiry no. 6705

Hirschmann: Fast Ethernet SwitchThe Fast-Ethernet-Switch RS 20 Basic can be mounted on DIN rails, is compatible with both Profinet and EtherNET/IP and is offered as standard with four or eight twisted-pair ports (RJ 45). Two of these connections can be configured optionally as Fibre-Uplink-Ports (FX-SC).

With the basic software package which supplements the previous OpenRail versions Professional and Enhanced at the bottom end of the range, the RS 20 offers a low-cost solution for automation networks in which no extensive management functions are necessary.

The operating state of the switches can be detected locally by a signal contact. Detailed information can be displayed via standard web browsers. A further central management function is offered by the integrated SNMP interface which enables the use of a network management software. The devices have several status displays for local diagnostics. The switches are designed for an operation temperature of 0 to +60 degrees Celsius and comply with common industrial standards.

Enquiry no. 6706

Siemens: Optical Link ModuleVersion 4.0 of the Profibus optical link modules (OLMs) has been equipped with additional functions. New features include improved electromagnetic compatibility achieved in part by the new stainless steel housing, LEDs for indicating the fibre optic line quality with channel monitoring, and meets standards such as Atex ExZone 2 and UL-HazLoc.

T h e l i n e q u a l i t y v a l u e s c a n n o w b e t r a n s f e r r e d v i a m e a s u r i n g t e r m i n a l t o t h e analogue input module of the controller and analysed there. The OLMs are available in five versions: for all commonly used fibre optic cables and an extended temperature range to minus 25 degrees Celsius.

Optical Profibus networks can be established in linear bus, star and redundant ring topologies using the OLMs. The data transfer rate of a fibre optic line up to 15 km is independent of distance and can be up to 12 Mbit/s.

Enquiry no. 6707

Turck: Magnetic Field Sensors BIM-UNT magnetic field sensors are designed for the detection of pistons on pneumatic cylinders. Namur versions are available for application in explosion hazardous areas, as well as versions with direct M8/M12 connectors at the housing and a pair-set with two sensors on one M12 connector.

The BIM-UNT-AP7X. The BIM-UNT is wear-free and shock resistant. A maximum operating current of 50 mA is sufficient for most applications. With a total length of only 28 mm, the BIM-UNT has a compact size. The active faces are located directly at the sensor end and thus enable a safe detection of the piston rod up to the end postion at the compact short-stroke cylinder.

The vibration-resistant fixation of the screw near the cable routing prevents an uplift of the sensor when pulling the cable. A useful support for adjustment and operation is the local and clearly visible LED, by which the switching status of the sensor is displayed at any time.

Enquiry no. 6708


EVENT PREVIEW

ore than 350 exhibiting companies from over 30 countries, including eight

national groups from Austria, China, France, Germany, Italy, Taiwan, United Kingdom and the US will make their presence felt. The trade fairs will serve as a platform to introduce, in many cases for the first time to Southeast Asia, tools and solutions with the potential to give industry players a competitive edge in their business.

Tech GaloreAugust Neuhoff Traxit International, the global supplier of dry drawing lubricants, coatings and carriers serving solely the wire industry, will be introducing its latest boron-free coatings.

AccuScan 5000 diameter gauges from Beta Lasermike offers more than twice the usual measurement rate at 2,400 measurements per second, thereby providing high accuracy, single-scan measurement data. Another product is the DataPro 5000 Process Controller, which uses the latest in software PLC and fieldbus technologies providing advanced functionality, flexibility and expandability.

Debuting at wire Southeast ASIA is the LPSNH3 from CERSA MCI for 3-axes, very high frequency diameter measurement for the cable and plastic industries. Parameters measured are diameter and lump and neck detection at the accuracy of the diameter.

Nailing It RightEnkotec A/S will demonstrate their latest nail machine, the NI01, which produces high-quality nails of diameter 2.4 – 3.84 x 50 – 90 mm at 1,500 nails per minute. Featured at Machinenfabrik Niehoff’s stand will be the NPS SV400 type spooler developed mainly for high-speed production of automotive wires.

India’s Gandhi Special Tubes brings

to Tube Southeast ASIA its range of cold drawn and bright annealed seamless steel tubes for hydraulics, cold drawn seamless tubes for high pressure diesel fuel injection, and small diameter (below 12.7 mm OD) welded steel tubes (plain/inside & outside copper plated/outside electro galvanised) for automobile fuel lines and refrigerator condensers.

Winding DrivesISA Technology will introduce the Uhing RGK3-15 and RGK3-20 Rolling Ring Traverse winding drives. For a shaft diameter of 15/20 mm, the winding drives feature continuous pitch adjustment, automatic reversal, a release lever for moving the traverse freely, maintenance-free design and maximum corrosion protection.

The ability of Thermatool to vary the welding frequency at the operator’s console in 1 kHz increments from 150 to 400 kHz has revolutionised the high frequency (HF) tube welding process. Thermatool has now extended the capabilities of variable frequency HF welding to its HAZ Control Technology.

The international wire, cable, tube & pipe trade fairs for Southeast Asia will be held October 16–18, at BITEC, Thailand. A diversity of cutting-edge technologies, products and solutions will be introduced at the events.

Beyond Tubes & Wires

ENQUIRY NO. 6801


EVENT PREVIEW

This year, Global Entrepolis @ Singapore 2007 (GES 2007) will see stronger collaboration and

cooperation between participants and exhibitors in the technology field. Many new innovations are expected to be launched and showcased at The Enterprise Exchange, a technology-focused exhibition at GES 2007 where a large number of delegates from ASEAN, India, and China are expected to gather and interact.

To date, 80 percent of exhibition floor space at The Enterprise Exchange has been booked, based around this year’s theme of Global Gathering, Growth Opportunities, and Green Initiatives. The event is jointly presented by the Singapore Business Federation and the Singapore Economic Development Board, and organised by Zenith Events Management.

Inventive StepsThis year, Neublick, a provider of sunlight readable LCD solutions for outdoor TV, and Murata, a manu-facturer of electronics components

and modules, are both showcasing exciting new innovations; a bicycle-riding robot and an interactive sandwich-board man respectively. Such inventions are an indication that robots with the ability of making their own independent decisions could soon be part of everyday life, taking over jobs that are too dangerous for humans, or serving as helpers and companions for the physically challenged.

The ‘Green’ theme at GES 2007 is illustrated by the participation of Agro Genesis, an agricultural nanotechnology solutions provider. The company plans to launch its Agro-Silica range of products which will offer multiple benefits, including yielding stronger and healthier plants, increasing crop yield and quality, increasing plant resistance, optimising soil pH, and reducing the need for pesticides.

Among other confirmed exhibitors are Fujinon, an optical instrument manufacturer; BIG Interactive, a creator and provider of interactive digital media; Island Optical Systems, an optical system integrator; and

Phion Technology, a company delivering next generation fashion electronics.

Talks That MatterAs part of the agenda at GES 2007, participants will have an opportunity to attend a series of conferences that focus on topics that matter most to businesses today. Among these is the E-Government Summit 2007, which will cover a range of issues facing both citizens and governments around e-government services. Participants of the E-Government Summit 2007 will include decisions-makers from government agencies around the world.

Through GES 2007, technology companies will also be able to network with potential customers, partners, and investors. The event will act as a melting pot where CXOs, venture capitalists and entrepreneurs work synergistically to explore and exploit ideas and innovations to facilitate growth and business opportunities globally.

Spotlight On Technopreneurs

Next-generation robotics among innovations slated for launch at The Enterprise Exchange. GES 2007 will be held November 12–15 at Suntec Singapore.

GES 2007:


EVENT PREVIEW

ENQUIRY NO. 6802


EVENT PREVIEW

ControlsAsia2007 & Instrument-Asia2007 covers solutions and products for measuring and

testing, and include actuators and drives, bus systems, field devices, and software on plant asset management, QA and test systems, ERP and supply chain management, and more.

AnaLabAsia2007 will showcase solutions in assays and testing, chromatography, diagnostics, lab automation, microscopy, optical and image analysis, spectroscopy, filtration and separation technology, and other analytical science solutions.

According to event organiser Singapore Exhibition Services, over 669 exhibiting companies from 38 countries are expected to participate in the show this year, including six country group pavilions from China, France, Germany, Singapore, Spain and the UK.

Asia’s premier event in process engineering, instrumentation and scientific equipment once again makes a return to Suntec Singapore from the November 29 to December 2.

“CIA2007 provides industry players with a fantastic opportunity to stay ahead of the game, network, and open business opportunities,” says Tee Boon Teong, Project Director, Singapore Exhibition Services. “The event boasts a 26 year track record, and is the most established event of its kind for the Asia Pacific market. We expect this year’s show to surpass the last, and attendees are fully encouraged to take advantage of the unique business opportunities that are on offer at the event.”

Supplementing the exhibition

is an ICS New Technology Forum where industry experts present the latest innovations, applications and solutions in instrumentation, process control/engineering and technology migration.

Alongside CIA2007 are two associated events at the same venue: EnviroAsia2007 – a leading trade show for the regional environmental and water industries, and Energex 2007, the 12th international energy conference and exhibition.

&Analysis

Controls,Instrumentation

ENQUIRY NO. 6803

industrial automation asia 57

Of

SEPTEMBER

12 – 14 Elcomp India 2007 Pragati Maidan, New Delhi Exhibitions India Pvt LtdTel: 91 11 4279 5000Fax: 91 11 4279 5098/99Web: www.elcompindia.com

17 – 20 SCM Logistics World Suntec City, SingaporeTerrapinn B2B MediaTel: 6322 2737Fax: 6226 3264Web: www.terrapinn.com

20 – 22 India Electricity 2007 Pragati Maidan, New DelhiFederation of Indian Chambers of Commerce & IndustryTel: 91 11 2373 8760 70Fax: 91 11 2335 9734Web: www.ficci.com

24 – 27 National Manufacturing Week

Illinois, USDonald E Stephens Convention CenterCanon Communications LLC Tel: 310 445 4200Fax: 310 996 9499Web: www.devicelink.com

26 – 29 Manufacturing Technology World 2007

Metro Manila, PhilippinesGlobal-Link Marketing & Management Services IncTel: 632 750 8588Fax: 632 750 8585Web: www.globallinkph.com

OCTOBER

3 – 5 SMART Automation Austria 2007

Linz, AustriaReed Messe Salzburg GmbHTel: 43 0662 4477-0Fax: 43 0662 4477-161Web: [email protected]

9 – 12 Scanautomatic 2007 Götheborg, SwedenThe Swedish Exhibition CentreTel: 46 31 708 80 00Fax: 46 31 16 03 30Email: [email protected]

9 – 13 Korea Electronics Show 2007 Gyeonggi, S KoreaMinistry of Commerce, Industry & EnergyTel: 82 2553 0941Web: www.kes.org

13 – 16 electronicAsia 2007 Wanchai, Hong KongHKTDC/Messe Muenchen GmbHTel: 49 89 949 20-320Fax: 49 89 949 9720-320Web: www.global-electronics.net

17 – 18 Mocon-Hydromech 2007 Brussels, BelgiumEasyFairs SA/NVTel: 32 02 740 10 70Fax: 32 02 740 10 75Web: www.easyfairs.com

18 – 21 Linkage Vietnam 2007 Saigon, VietnamChan Chao Int’l Co LtdTel: 8862 2659 6000Fax: 8862 2659 7000Web: www.linkage-vn.com

NOVEMBER

6 – 8 Vision 2007 Stuttgart, GermanyLandesmesse Stuttgart GmbHTel: 49 711 / 25 89-0Fax: 49 711 / 25 89 440Web: www.messe-stuttgart.de

6 – 10 Industrial Automation Show Shanghai, ChinaHannover Fairs China Ltd - ShanghaiTel: 86 21 5045 6700 307/203/259/207 Fax: 86 21 6886 2355 5045 9355Web: www.factory-automation-asia.com

13 – 16 Productronica 2007 Messe Muenchen GmbHMunich, GermanyTel: 49 89 949 20318Fax: 49 89 949 20339Web: www.productronica.com

Calendar 2007Events13 – 16 SCS Automation & Control 2007

Lyon, FranceSCS Automation & ControlTel: 33 01 49 68 52 86Fax: 33 01 49 64 54 66Web: www.scs-automation.com

15 – 18 Metalex 2007 Bangkok, ThailandReed Tradex CompanyTel: 66 2686 7299 Fax: 66 2686 7288Web: www.metalex.co.th

27 – 29 SPS/IPC/DRIVES 2007 Nuremberg, GermanyMesago Messemanagement GmbHTel: 49 711 61946-60Fax: 49 711 61946-92Web: www.mesago.de

27 – 30 CiA 2007 Suntec City, SingaporeSingapore Exhibition ServicesTel: 65 6738 6776 Fax: 65 6732 6776Web: www.cia-asia.com

DECEMBER

4 – 7 Industrial Automation India 2007

Bangalore, IndiaDeutsche Messe AGTel: 49 5111 8931116Fax: 49 511 8939681Web: www.hannovermesseworldwide.com

5 – 8 Automation Technology Indonesia

Jakarta, Indonesia PT Pamerindo Buana AbadiTel: 62 21 3162001 Fax: 62 21 3161981Web: www.pamerindo.com

12 – 15 Machine Tools & Automation Pakistan 2007

Karachi, PakistanPegasus Consultancy (Pvt) LtdTel: 92 21 111 734 266Fax: 92 21 241 0723Web: www.pagasus.com.pk


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Greater opportunity requires a unique vantage point across your entire enterprise.

Honeywell is more than an industry leader in process automation, we also offer cutting-edge

technology and the services you need to oversee and optimize your plant’s operation. Our

applications go beyond the control system, allowing you to view your plant data in context

as well as integrate other relevant intelligence. Our offerings in cyber and physical security, wireless solutions,

and advanced applications like simulation technology, and planning and scheduling, better optimize your

facility while keeping your people safe. At Honeywell, we can help you see the information you need to

make better decisions faster for increased reliability, productivity and greater profit.

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