ACCESS ALL AREAS – I/O SYSTEM SUITS BOTH EX AND NON-EX


Industrial processes often involve huge batches of ingredients that can be time and temperature sensitive. In the plastics industry, for example, a delay in the process prior to moulding can result in huge wastage costs. Similarly, in the pharmaceutical


industry, the production of medicinal products requires the critical control of large batches of ingredients. With the value of a single batch often running into £millions, the control of all parameters throughout the process is vital. High-speed, continuous


throughput requires a process system that is not only fast and efficient but can also offer fail-safe, uninterrupted, operation. To satisfy this demand, system builders and end customers use a universal I/O system from Turck Banner that is suitable for Ex area protection, but whose benefits extend to many non-ex applications. The Excom I/O family offers an I/O system


with versions to satisfy all application ranges including: Non- ex; Intrinsically safe circuits and installation in the non-ex area/zone 2; Intrinsically safe circuits and installation in zone 1. Customers benefit from component


optimisation for particular zones and also from a standard configuration concept for periphery and field instrumentation. Common programming, regardless of application area, simplifies commissioning. Distinct terminal connection colours and clear labelling positively identify Ex and non-ex circuitry. Rationalisation across all zones brings cost saving through reduced inventory as well as uniform installation. Module racks for 8, 12 and 24


modules allow high packing density and flexibility. In terms of continuous


operation, a key feature of the


Excom system is the ability to hot swap power supplies and I/O modules, eliminating the need for a “Hot Work Permit”. Hot swapping is also an advantage in non-ex areas where continuous operation is required. The system can be serviced and changed at any time. The I/O modules, and the power supply modules, can be plugged and unplugged during ongoing operation, even in zone 1, without interrupting the field communication. The system allows a fully redundant set-up of the power supply, as well as communication interfacing. www.turckbanner.co.uk


FULLY AUTOMATIC, IN-LINE PH MONITORING


HORIBA has launched the UP-100, a micro- volume in-line pH monitor for use in applications and sectors such as bio reactors, food and drink processing, pharmaceutical, chemical manufacturing and the semiconductor industry. The unit is programmable, fully automatic, self-calibrates and can provide continuous operation without user intervention for up to six months. When connected to a storage vessel


containing - or a pipe conveying - a liquid for which the pH level must be monitored, the UP-100 is able to take a small sample (only 0.5ml), as frequently as once per minute, determine its pH level and then dispose of the tested sample to waste; thus removing any risk of contaminating the product. Stuart Knight, director of HORIBA UK, said:


“Many industrial processes require continuous pH monitoring. Even if a reading can be taken in just 10 minutes, that equates to about 60 hours when extrapolated over the course of a year, assuming only one sample per day. The UP-100 is therefore a cost-effective aid to any


process that requires frequent pH monitoring for data acquisition and/or control purposes.” The UP-100 covers the pH range of 0 to 14


and comprises two parts; a sensor unit and a controller. The controller displays the pH level of the most recent sample (or the electrode’s voltage if preferred) and its temperature in ˚C. It also has an RS-485 connector for data I/O and enables the UP-100 to be programmed remotely. In addition, there is an analogue output (4 to 20mA) proportional to the most recent pH reading, allowing the UP-100 to connect directly to a PLC or alarm. www.horiba.com/uk/up-100


ASK THE EXPERT: THE BENEFITS OF USING S88 FOR BATCH AUTOMATION


ISA-88 batch control standard, commonly known as S88, is a standard addressing batch process control applications. It is a design philosophy for describing equipment and procedures for batch applications. We take a look at what the benefits are and why you should look at using it.


Many processes involve batch operations where you mix or react some raw materials in a vessel to create a product. If it is only ever going to be a standalone piece of equipment with little requirement to make changes, get information out of the system, or integrate with other equipment, then S88 may not be very important to you. However, with today’s focus on efficiency, fast new product introduction, integrated manufacturing plants, and global manufacturing operations, S88 can offer some significant flexibility benefits. Whether you are specifying your requirements to an


equipment supplier, instructing a Systems Integrator, or developing a specification to integrate with your MES, the standard can help. S88 defines models and terminology to describe a batch process so everyone uses a common language. A key point is that it separates the recipes from the physical equipment, which enables reuse and increases flexibility since it’s not necessary to re-program the control system to make recipe changes. As the structure is standardised, it makes it easier to develop reporting systems and exchange information with MES and ERP systems. This can save significant time and money compared to developing multiple bespoke interfaces. A common question we hear goes something like


this: “I am only building a small system at the moment, can I worry about S88 later?” The short answer, in our opinion, is no. If you don’t follow a structured approach to your small batch application, then when you come to expand it or integrate other technologies, you will run into problems. Fortunately, S88 tools are no longer the preserve of large and expensive systems. Control systems such as the Allen-Bradley Logix range have the S88 structure for phases and sequences built-in. These can be used in a small system and then be developed to be part of a large integrated system at a later date. The standard can appear quite complex at first


glance. But don’t let this put you off looking into how it could benefit your processes. Find a supplier who can help you apply it correctly for your particular needs and it will help you to build a better plant in the long term. Rockwell Automation www.rockwellautomation.com/en_uk/


/ PROCESS&CONTROL


PROCESS & CONTROL | JULY/AUGUST 2017


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