ENERGY FOR THE BREWERY / Page 18 direct process Information for Power and Process Technology, April 2013 INTELLIGENCE FOR VALVE ACTUATORS / Page 08 DECENTRALIZED AUTOMATION GENERATES STRUCTURE / Page 12 2 NEW SWITCHING SYSTEMS PROVIDE A SECURE SUPPLY IN THE LONG TERM Page 04 TELECONTROLLER AS ECO VERSION Page 06 THAT CERTAIN EX-TRA IN EX-I: NEW INTRINSICALLY SAFE MODULES FOR THE WAGO-I/O-SYSTEM Page 07 INTELLIGENCE FOR VALVE ACTUATORS Page 08 DECENTRALIZED AUTOMATION GENERATES STRUCTURE Page 12 PUMPING STATION Page 15 ENERGY FOR THE BREWERY Page 18 WATER MANAGEMENT IN THE INTERNET Page 22 IMPRINT Page 24 CONTENTS NEW SWITCHING SYSTEMS PROVIDE A SECURE SUPPLY IN THE LONG TERM / Page 04 3 direct process Dear Readers, Modular automation concepts, in the sense of the “F3 Factory” EU research project, were the focal point of our last WAGOdirect process. The modularization of machines, systems or entire facilities remains relevant, and it fits hand in glove with an increasing decentralization: Intelligent control moves from a high automation level down to the field level and thus ever closer to the process. The hardware used there must primarily fulfill two prerequisites: On the one hand, it has to be powerful enough that all auto- mation technological demands can be met. On the other, it should be independent of manufac- turer and protocol, so that it can be seamlessly integrated into a modular system. Both of these factors were decisive, when Zauner Automation decided to use the WAGO- I/O-SYSTEM 750. The specialists in automated valves and position actuators used it to develop a standardized electrohydraulic control unit that is used, among other places, for 24-inch valve automation on natural gas platforms. Another application, in which decentralized automa- tion plays a decisive role, is the wastewater treatment facility in Rinteln. Among other tasks, the WAGO-I/O-SYSTEM forms the interface between various systems and measurement concepts in the process technology. You will find these and other successfully completed projects from recent months in your current issue of our WAGOdirect process. Enjoy the articles! Best regards, Wolfgang Laufmann Market Management Industry & Process Chemistry CONTENTS EDITORIAL 4 ■ To ensure the power supply at Volkswagen’s Wolfsburg facility, between 2005 and 2015, VW Kraftwerk GmbH will be modern- izing the 110 kV, 20kV, and 6kV power networks. During this process, the switching systems will be replaced one after another. As part of the system renovation, VW Kraftwerk decided to use maintenance-free spring-clamp terminal blocks rather than screw- clamp terminal blocks. VW Kraftwerk GmbH is a 100% subsidiary of Volkswagen AG. It is a service provider for the Volkswagen group, as well as for communities, industry, and commerce in the areas of power sup- ply, trading, power plant planning, and facility management. Both the north/south and west heating plants, operated by Volk- swagen AG at its Wolfsburg location, supply power and heat to Volkswagen AG’s headquarters (Wolfsburg plant). They also supply the city of Wolfsburg with heat. Some of VW Kraftwerk’s equipment was more than 45 years old. During the moderniza- tion, the company focused on ensuring that the replacement and retrofitting were associated with cost advantages as well as ac- tively contributing to environmental protection in the interest of sustainability. In relation to the switching systems, the moderniza- tion of the electrical network in 2010 was the largest part of the renovation. By the end of 2015, VW Kraftwerk GmbH will have replaced a total of 23 switching systems. After completing all of the work, 90% of the electrical connections will have been con- verted to maintenance-free spring-clamp terminal blocks. ■ Spring-Clamp Terminal Blocks Win Over Planners The first project began in 2005 with the rebuilding of a 6.3 kV in-house switching system at the power plant. Criteria such as technical safety and return on investment played a large role in the selection of the new terminal blocks. WAGO’s disconnect terminal blocks are constructed so that there can be no improper operation by the user. Every conductor makes contact via its own clamping point. Furthermore, they are touch-proof, easy to han- dle, and maintenance-free. Aside from system-dictated contact terminal blocks, only WAGO terminal blocks were used for this project. NEW SWITCHING SYSTEMS PROVIDE A SECURE SUPPLY IN THE LONG TERM 5 direct process ■ Many Types of Rail-Mounted Terminal Blocks The responsible department was especially interested in WAGO’s 280 and 282 Series disconnect terminal blocks for test and measurement. The 282 Series disconnect terminal blocks make contact regardless of the user, which prevents misuse.“ Accurate handling is very important to us, especially for work on current transformer terminal blocks that does not occur on a daily basis,” confirms Wolf. Only one switch lever must be manually shifted to create the desired electrical connection to the adja- cent terminal blocks, in order to short current transformers, for example. Integrated insulated test sockets also facilitate the direct connection of a measuring device. Large variety of spring-clamp terminal blocks, including TOBJOB ® S Safe and maintenance-free connection technology 8-level terminal blocks for matrix patch- ing facilitate rewiring and measuring of individual signals. 6 For through connections, both TOPJOB ® S rail-mounted terminal blocks and 285 Series high-current rail-mounted terminal blocks are used. TOPJOB ® S rail-mounted terminal blocks are equipped with CAGE CLAMP ® S Spring Pressure Connection Technology, providing push-in termination of solid or ferruled conductors. The terminal blocks accommodate conductors ranging from 0.25 mm 2 (AWG 22) to 16 mm 2 (AWG 6). For larger cross- sections, both engineering department and suppliers selected WAGO’s 285 Series high-current through terminal blocks. They accommodate conductor sizes ranging from 6 to 95 mm 2 (AWG 10–4/0) A locking tab holds the clamping unit open for terminal blocks with POWER CAGE CLAMP connection. In this way, the user has both hands free to position the conductor end properly. An additional patchboard level is located between the field and automation level. 727 Series 8-level terminal blocks for matrix patching replace the soldering strips from the earlier system. The terminal blocks for matrix patching facilitate rewiring and measur- ing of individual signals. As neutral transfer points, they increase the flexibility of the system. The allocation of the signal lines can be quickly determined via terminal block markers. Text: Renate Klebe-Klingemann, WAGO Photo: VW Kraftwerk GmbH, WAGO ■ Economical alternative: WAGO’s 750-880/025-002 ECO Tele- controller offers unlimited application potential in a limited number of modules Unlike the regular 750-880-025-001 Telecontroller: The new 750-880/025-002 ECO version is limited to a maximum number of four modules (without end module), and is therefore around one- third less expensive. This is a cost-saving alternative for customers with smaller applications (e.g., transformer station or local network station monitoring, EEG plant power reduction, virtual power plant control). Functionally, the ECO Telecontroller is in no way inferior: all 400+ modules from the WAGO-I/O-SYSTEM 750 can be used without limitation. The 750-880/025-002 can be programmed using the standard CODESYS environment according to IEC 61131. Furthermore, both configuration and diagnostics can be performed via Internet and in- tranet access to the integrated Web server. The telecontroller also sup- ports the IEC 60870-5-101/-104, IEC 61850 and IEC 61400-25 protocols for wireless (GPRS) or wired (ETHERNET, ISDN, analog) connection to the I&C system. In case of a connection interruption, all relevant data is stored and transmitted at a later time to the con- trol system. TELECONTROLLER AS ECO VERSION Cost-saving alternative for smaller applications: The 750-880/025-002 ECO Telecontroller connects up to four modules from the WAGO-I/O- SYSTEM 750. 7 direct process ■ The Ex i portfolio for the WAGO-I/O-SYSTEM is constantly grow- ing. In addition to an I/O module, which is both functional and in- trinsically safe, there is an 8-channel NAMUR digital input module and a 2-channel relay output module for switching intrinsically safe circuits. ■ Safety Meets Ex i – 750-663 4-Channel Digital Input Module Just 24 mm wide but with guaranteed safety: The 750-663 for PROFIsafe applications is used when safety of personnel is called for in hazardous Zones 0 and 1. The four intrinsically safe inputs with functional safety can be used for safety functions up to “SIL 3” and “Cat. 4 PLe.” Despite the combined features, the requirements for us- ers during commissioning remain the same: The safety interface for the new 4-channel digital input module is identical to that for a pure safety I/O module from WAGO. ■ Higher Integration Density – 750-439 8-Channel Digital Input Module Likewise just 24 mm wide, the 750-439 8-Channel Digital Input Module records NAMUR binary signals from sensors operating in hazardous environments. Besides NAMUR sensors and optocou- plers, mechanical contacts and other actuating elements can also be connected via intrinsically safe devices. Short circuits and wire breaks can be evaluated separately, either optically (LED), or based on the process data (process image). When monitoring contacts, er- ror LEDs can be switched off via control byte. Each sensor is supplied with a short-circuit-protected 8.2 V supply. THAT CERTAIN EX-TRA FOR EX-I: NEW INTRINSICALLY SAFE MODULES FOR THE WAGO-I/O-SYSTEM ■ Switching Intrinsically Safe Circuits – 750-538 2-Channel Relay Output Module In addition, the 750-538 2-Channel Relay Output Module features two changeover contacts and switches intrinsically safe circuits (e.g., relays, magnetic valves, contactors, optical/ acoustic signal generators). The 750-538 Module’s switching voltage/current is rated at 125 VAC/0.5 A and 30 VDC/1 A; the maximum permissible limits depend on the respective oper- ating site and the necessary device groups (I, IIA, IIB, or IIC). The switched status is shown by a LED. ■ The WAGO-I/O-SYSTEM – Comprehensive Automation in Hazardous Areas The WAGO-I/O-SYSTEM is designed for installation in non- hazardous areas or in Zone 2/22. The system integrates sen- sors and actuators via intrinsically safe Ex i modules in Zones 0/20 and 1/21, without additional devices(e.g., zener barri- ers or isolating amps). This allows Ex i applications to be safely and economically combined with standard automation appli- cations. 8 Decentralized automation introduces flexibility into electrohydraulic controls INTELLIGENCE FOR VALVE ACTUATORS ■ While decentralization has been well established in industrial au- tomation, the topic has only recently gained entry into process tech- nology. Zauner Automation GmbH, a specialist in automated valves and position actuators, can now offer, thanks to WAGO’s decen- tralized automation technology, intelligent, efficient, and compact electrohydraulic control units, fabricated at their location in Landau. Zauner places an emphasis on high flexibility during their planning and commissioning phases. Pneumatic and hydraulic valves are used in the most varied of sectors, in the oil and gas industries, chemical and petrochemical facilities, refineries, desalination plants, power stations, and water treatment systems. Over the past twenty years, Zauner Automa- tion GmbH has specialized in controlling and monitoring valves, or “valve automation.” The company plans, develops, and manu- factures complete units tailored to customer specifications. The sys- tems are ambitious – the typical duration of a project is around two years. 9 direct process Decentralized automation introduces flexibility into electrohydraulic controls INTELLIGENCE FOR VALVE ACTUATORS 10 ■ Serving Global Demands Like many German companies, Zauner Automation has a strong international orientation. However, their proportion of exports is extremely high: 95 % of sales are to foreign companies. “Our cus- tomers come from all over the world and not only have different mindsets, philosophies, and local regulations, but they also present different technical requirements,” explains Kai Kroll, Project Man- ager for Electrohydraulic Controllers at Zauner Automation. “This relates, for example, to preferences regarding fieldbus systems and extends up to their interpretations of electrical signals.” Traditionally, the electrical controller for an electrohydraulic system is located in a separate control cabinet. Relay technology is also currently used; however, it is subject to failure and offers only lim- ited functionality. In this context, Zauner Automation set a goal of developing a compact and intelligent electrical controller, which would allow for a high degree of flexibility to enable them to better and more quickly fulfill their customers’ requests. “Since the market demands increasingly more data from the field, it was clear to us that the trend was going in the direction of decentralization,” he explains, and as the manager responsible for in-house product de- velopment, he is in a position to know. ■ WAGO-I/O-SYSTEM 750 – Modular and Universal With the aid of the WAGO-I/O-SYSTEM 750, Zauner Automation developed a standardized electrohydraulic controller, which the company can now use as the basis for providing fast and flexible individualized solutions for their customers. The system constitutes a compact, autonomous unit, in which the control cabinet is visibly reduced in size, and the electrical components could be merged with the hydraulic system. It is suitable for direct use in areas with explosion hazards and is designed for extreme environmental tem- peratures. Zauner Automation can use this to cover applications from a quick-action controller using relay units up to a linear or 90° position actuator with torque ranges up to 600,000 Nm. Just recently, the company from Landau implemented a sophisti- cated project in Mexico. This involved the transportation of natural gas. Two natural gas platforms are connected by a pipeline that is approximately 1000 km long. There are 24 inch valves at the outlet and inlet regions of the two platforms, and Zauner technol- ogy is now monitoring and regulating them. Both platforms are unmanned. That means that the systems have to run completely au- tonomously and be 100% reliable. Since the energy supply to the platforms is not guaranteed, and bottle necks can occur, depending on production status, the electrohydraulic controllers are supplied completely by solar energy. They can manage for up to five days without sunlight. ■ Optimized Control, Monitoring, and Maintenance The drives are double-acting position actuators with a torque of 55,000 Nm. A WAGO 750-880 ETHERNET Fieldbus Controller is used in each case. “We monitor pipeline pressure and specify thresholds for underrun and overrun, so that the valve actuators can be switched into the fail safe mode in case of problems. This safety provision is also initiated in case of electrical failure,” states Kroll. The WAGO-I/O-SYSTEM 750 thereby takes over controlling the motors and valve automation as well as detecting analog and digi- tal signals for pressure, temperature, opening and closing cycles, end position, and through flow amounts. The electrical controller is located in an independent system, in a completely pressure-encap- A current project in Mexico demands complete energy supply of the elec- trohydraulic controllers using solar power; the system can hold out for up to five days without sunlight. The electrical controller for the electrohydraulic unit, which is based on the WAGO-I/O-SYSTEM, is located as an autonomous system in a completely encapsulated housing, which is designed for hazardous areas, Zone 1. Zauner Automation developed a standardized electrohydraulic control- ler, which enables them to cover applications from quick action controller units through regulation devices up to linear or 90° position actuators with torque ranges up to 600,000 Nm. [...]... ■ Reducing Energy Costs Following the retrofit of the 20 kV protection technology, the personnel in the control center were able to monitor the brewery s medium voltage network, and also keep an eye on the outputs on the low voltage side at the individual stations Monitoring the energy supply from the control center has enabled the operators to implement load management This means that they can avoid... electricity from the municipal power station during peak loads Which in turn allows them to significantly reduce energy costs Measuring the consumption values on the low voltage side has enabled further optimizations At several stations, for example, a transformer can be switched off when the energy requirements can be covered by the remaining transformers The more expensive energy becomes, the more conservation... 20 mA At these and many other points, a glance from on high shows that the I/O system consistently forms the interface between various systems and the measuring concept for the process technology Instead of “operating and observing” the wastewater treatment processes via a central server as in the past, Lübbing Elektrotechnik GmbH uses the visualization already present in the controllers for the I/O... constructed SCADA system, which informs the employees in the control center about the status of all systems on large monitors, replaced the old analog mimic diagram over the course of the conversion work The large bundles of cables for transmitting analog signals, which used to run from all points in the brewery to the control center, are likewise a thing of the past The new optical fiber ring transmits... commissioned from the ground up The system runs on the Web server for the WAGO 750-880 Controller In Ponte Capriasca, the water utility is distributed across several locations When the community wanted to modernize the system, they found their way to Mathias Hofmann, who runs his engineering office there He describes the initial situation, “Normally, a water utility just works If there are problems, then people... voltage, which is then fed into the facility’s own medium high voltage network The steam, which still has a pressure of 3.5 bar downstream of the turbine, is then available for the brewing process “In this way, we can generate on average 45% of our electrical energy ourselves,” states Peter Baltes, who is responsible for electronics technology in the Production and Energy Departments at the brewery A 20 ... replaced the old protection relays on the medium high voltage side Manuel Müller, the power station construction manager at Imtech responsible for the project, states one of the goals in modernizing: “In relation to the retrofitting process, we wanted to convert the conventional data transmission in the control center into modern bus technology.” 20 The personnel in the brewery s control center monitor the. .. the Low Voltage Side Over the course of planning, the desire was expressed to be able to integrate power measurements on the low voltage side into the control system Current transducers, located downstream of the transformers, detect the actual currents in the individual strands Prior to the retrofit, these measured values could only be read on site using analog measuring devices In order to make the. .. Real Time For example, by using the PLC, which is freely programmable in the standardized languages of IEC 61131-3, the frequency converters for the pumps are controlled and the link to operators and observers on site is established on a touch panel An additional central task for the I/O system lies in constant communication with the control center through a VPN tunnel via Ethernet TCP/IP For Lars Laubenthal,... levels and water use in real time The system is modularly programmed The PLC program uses the same elements as in a control system, such as pumps, valves, or UV sterilization The software also checks information from the sensors against each other If, for example, one basin is being filled and therefore a throughflow is measured; however, the water level remains unchanged in the basin, a warning is sounded . of electrical energy. In the Karlsberg brewery in Homburg, they have connected the generation of process heat in the form of steam to the generation. uses the visualization already present in the con- trollers for the I/O system. The divided Web browser-based vi- sualization has another advantage: If the