Boilers, Coal, O&M


Issue 6 and Volume 120.

A123 Backup Battery System

A123’s new 26650 cylindrical cell is the next generation that brings greater power and energy density and lower impedance. This versatile lithium-ion cell is suitable for a wide variety of applications and systems designs.

Proven performance in the toughest conditions, combining durability, reliability, and safety, the 26650 cylindrical cell offers an excellent combination of price-performance.

The cylindrical cell’s primary applications are for use as portable, high-power devices and as stationary battery backup systems.

A123 Systems
Info RS#: 400

Data Acquisition System

Endress+Hauser releases the Memograph M RSG45 Data Manager, a compact device that can serve as a data acquisition system for small process control applications. The RSG45 acquires up to 14 discrete and 20 universal/HART analog inputs from process sensors, displays sensor data on its 7-inch multicolor TFT screen, records the data internally, performs math calculations and alarm checks, and transmits the data to a PC or any control system via Ethernet, RS232/485, Modbus, Profibus DP or PROFINET digital communication links. Data can also be stored to a device plugged into the USB or the SD port.

Inputs to the RSG45 include 4-20mA, 4-20mA with HART, voltage, RTD, thermocouple, pulse, frequency and current. The base unit can accommodate up to 14 discrete inputs, 2 analog outputs and 12 relay outputs. Up to five I/O cards can be added to the base unit, allowing up to 20 universal/HART analog inputs. Data is stored in tamper-proof internal memory, on an SD card or on a USB stick-all of which fulfill the security requirements of FDA 21 CFR part 11. An integrated web server allows browser-based access to the unit via laptops, PCs, smartphones, tablets, handheld maintenance devices and remote systems.

Batch management software allows users to reliably record and visualize process data. User-definable or externally controlled analysis intervals can be configured for up to four batches simultaneously. Batches are assigned batch-specific values and the measured data, start, end and duration of every batch, along with the current batch status, are displayed on the device. At the end of the batch, a batch print-out is automatically sent to the device’s USB or network printer, or can be printed out on a connected PC.

The energy package allows users to calculate the mass and energy flow in water and steam applications on the basis of the flow, pressure, temperature or temperature difference input variables. Other energy calculations are also possible for glycol-based refrigerant media.

Info RS#: 401

Combustion Gas and Emissions Analyzer

E Instruments introduces its E6000 hand-held industrial combustion gas and emissions analyzer.

The E6000 analyzer can measure up to six gases simultaneously: O2, CO, NO, NO2, SO2, CxHy (HC) and H2S. It also includes a dilution pump for CO auto-range measurements up to 50,000 ppm. The analyzer has a built-in printer, full color graphic display, and temperature and pressure measurements. The internal data memory can save up to 2,000 tests automatically. The software package comes with a USB and Bluetooth.

E Instruments
Info RS#: 402

Electrical Housing Enclosures

The HWHK Series from Hammond Manufacturing is a family of easy to open, yet secure, wall mount enclosures designed to house electrical and/or electronic equipment in harsh industrial environments. Available as standard in 30 sizes in six heights from 24 to 60 inches, five widths from 16 to 36 inches and five depths from 6 to 16 inches, the range is specifically engineered for use in heavy industrial plants, utility, outdoor municipal or other locations where the enclosure sits in harsh conditions and is frequently opened for internal equipment access.

Access is via a durable zinc die-cast handle with padlock provision, which operates a smooth action three-point roller latch locking system that gives excellent sealing with minimum effort in opening and closing the door. The rugged full height stainless steel piano hinge enables 180° door opening, and the removable hinge pin allows the door to be demounted if required.

Manufactured from 14-gauge mild steel, finished with a recoatable smooth ANSI 61 gray powder coating to both the interior and exterior, the HWHK features ground smooth continuously welded seams, a formed lip to exclude flowing liquids and contaminants and a seamless poured-in place gasket. It meets the requirements of UL 508 Type 3R, 4 and 12, CSA Type 3R, 4 and 12, NEMA 3R, 4, 12 and 13 and IP66 to IEC 60529.

Hammond Manufacturing
Info RS#: 403

Gigabit Managed Switches

Antaira Technologies is proud to announce its expansion in the industrial networking infrastructure family with the LMP-0800G series.

Antaira Technologies’ LMP-0800G series is a cost effective 8-port industrial gigabit PoE+ managed Ethernet switch line with a 48~55VDC power input. Each unit is designed with eight 10/100/1000Tx gigabit ports that are IEEE 802.3at/af compliant (PoE+/PoE) with a PoE power output up to 30W per port. With a 16 Gigabit backplane speed, the LMP-0800G supports Jumbo Frames and wide bandwidth for huge Ethernet data packet transmission for edge level connectivity solutions. The product series provides high EFT, surge (2,000VDC) and ESD (6,000VDC) protection; and built with dual power input design with reverse polarity protection. There is also a built-in relay warning function to alert maintainers when power failures occur. This makes it ideal for applications requiring high reliability and distance extension.

This product series is pre-loaded with “Layer 2” network management software that supports an ease of use Web Console or Telnet through the serial console by CLI configuration. All Antaira managed switches provide the ring network redundancy function with STP/RSTP/MSTP and the ITU-T G.8032 (ERPS – Ethernet Ring Protection Switch) protocol which supports a <50ms network recovery time, eliminating the compatibility issue for any existing network concerns. The advanced network filtering and security functions, IGMP, VLAN, QoS, SNMP, Port lock, RMON, Modbus TCP and 802.1X/HTTPS/SSH/SSL increase determinism and improve network management for remote SCADA systems or control networks. Plus, the advanced PoE ping alarm software function allows users to recycle power on any remote powered device (PD) through PoE ports. The external USB2.0 port allows users to export and save all the configuration settings. Lastly, the flexible “custom label” feature allows networking planners to name each connection port. By naming each port, the networking planners can easily manage remote field devices.

Antaira Technologies
Info RS#: 404

Hydro Network Modeling

Power Costs Inc. has updated its optimization algorithms to include sophisticated hydro network modeling. Optimizing thermal generation, hydro generation and/or pumping resources, reservoirs, and fuel constraints, ancillary services simultaneously is a highly complex process. Adding cascading hydro network, elevation and head-dependent efficiency parameters to the problem is even more challenging. The latest version of PCI GenTrader is deploying the most advanced algorithms to solve these challenges and is taking hydro-thermal and network optimization to the next level. Four key model elements distinguish PCI GenTrader’s enhanced hydro network model:

Complex Topology Users may define a complex hydrological network with reservoirs and ponds and then connect them through waterways. Multiple hydro-electric generators can be fed by reservoirs via penstocks. Pumps can be configured to move water between two reservoirs. Each water path can be constrained with minimum and maximum flow rates expressed in cubic feet per second (cfs). Local inflows (e.g., rainfall) and outflows (leakage and evaporation) can be specified as well. Water level, flow rates, and even spillways can be controlled to achieve desired water management objectives.

Water Measurement

Reservoir elevation is expressed in feet, storage in acre-feet and flows in cubic feet per second. During the optimization process, PCI GenTrader performs the necessary internal conversions as described in the next section.

Non-linear Conversions

A key to incorporating detailed hydro characteristics in any optimization is the inclusion of non-linear conversion curves that define the relationship of water to electrical energy. GenTrader uses such curves for:

Tailrace Representation

In order to accurately capture the efficiency effects of varying head levels, GenTrader explicitly calculates upper reservoir level and tailrace level. Since tailrace elevation can vary significantly with discharge rate, GenTrader includes this calculation to obtain a precise head level.

Info RS#: 405


Alliance Sensors Group is offering a system for drop-in mounting their PGHD series LVDTs for use on GE steam turbines that currently utilize GE’s inductive valve position sensors. These mounting kits utilize the same hole spacing and produce the same center height as the existing GE sensors. They are available for mounting a either a single PGHD LVDT or a dual-redundant stacked pair of PGHD LVDTs. These kits make it unnecessary to design new mounting schemes or to fabricate new hardware when replacing the old GE sensors. The picture below shows how the GEDS kit makes mounting a pair of PGHD LVDTs for dual redundant operation a simple undertaking.

Features of the Alliance sensors PG LVDTs and mounting hardware:

1. Mounting hardware meets the same hole spacing as the GE mounting blocks and produces the same center height

2. Mounting hardware is available in single and dual redundant configurations

3. Dual kit includes tie bar assembly

Alliance Sensors Group
Info RS#: 406

Linear Position Sensors

LVDT Linear Position Sensors can be repackaged with modern materials to address conditions associated with thorium-based nuclear power and high sulfidation processes associated with heavy oil, process control and bio-chemicals.

Macro Sensors’ HSAR Hermetically Sealed Sensors are constructed entirely of stainless steel along with coil windings sealed against hostile environments to IEC standard IP-68. The conduit exit of these AC-operated sensors ensures a hermetic seal from the operating environment.

For harsher environments, the HLR 750 Series LVDT Linear Position Sensors for Hazardous Locations meet UL and ATEX requirements for Class I Division 1 & 2, Zones 1 & 2. Macro Sensors offers Teflon-free, half bridge versions of these AC-operated linear position sensors that are popular in steam turbine applications in radiation environments.

As passive sensors, the HSTAR, HSAR and HLR sensors can operate in more robust applications, offering a high mean time between failures. LVDT electronics that power these sensors, like Macro Sensors’ EAZY-CAL LVC-4000 LVDT Signal Conditioner, can be partitioned from harsh environments, enabling the Nuclear LVDT sensors to operate under more extreme conditions than is viable with DC-operated sensors having internal electronics.

Macro Sensors
Info RS#: 407

Proportional Valve Module

WAGO Corp.’s new Proportional Valve Module significantly simplifies the connection of hydraulic or pneumatic valves to the WAGO-I/O-SYSTEM 750. Just 12 mm wide, the compact 750-632 Proportional Valve Module offers a high-performance solution with flexible valve control operation modes.

Two single-coil valves or one dual-coil valve can be controlled either uni- or bi-directionally. For each channel or coil, the output current is 2A in 1-channel operation and 1.6A in 2-channel operation. In connection with a lower set point/actual value deviation, both small and large valves can be controlled reliably and with high repeatability.

The 750-632 features two current-controlled pulse-width modulation outputs (24V) with adjustable dither. Discrete dither frequency setting minimizes the motion, which is adjusted to the valve around the rest position, allowing the set point to be defined without considering static friction. This also prevents the valve from being stuck due to medium residues. Set point definition can be adjusted to the application via both scaling and configurable up/down ramps.

The Proportional Valve Module can operate via any popular fieldbus (e.g., MODBUS TCP, EtherNet I/P, CAN or PROFIBUS) and offers reliable CAGE CLAMP connection technology. Ideal for heavy equipment that uses high-pressure pneumatic or hydraulic valves, the 750-632 can be utilized across a variety of industries, including mining, oil and gas, heavy mobile equipment and metal forming.

WAGO Corp.
Info RS#: 408

Siemens Industrial Notebooks

Siemens has equipped the latest generation of its rugged, ready-to-run industrial notebooks with a multitude of practical functions for mobile engineering. The Simatic Field PG m5 programming device has been designed with pre-installed Simatic TIA Portal (Totally Integrated Automation) engineering software for fast and efficient configuration, commissioning, service and maintenance, as well as for engineering work in technical bureaus. There are two versions of the new notebook with robust hardware for mobile use in industrial plants: The Comfort version is equipped with an Intel Core i5 processor, the Advanced version with a more powerful Intel Core i7 processor. The Advanced device can also be configured with the interfaces of the previous Simatic S5 controller generation.

Simatic memory cards can be programmed directly on the industrial notebook through the Simatic Card Reader interface. The Simatic Field PG m5 is delivered ready-to-run with pre-installed Simatic engineering software. It has also been optimized for engineering with the TIA Portal – for the current and previous generations of Simatic controllers and HMI (Human Machine Interface) devices.

The Simatic Field PG m5 is equipped with a fast DDR4 work memory of up to 32 GB and an impact-resistant, fast, exchangeable, solid-state technology mass storage device of up to 1 terabyte. The space-saving, three-pole power supply unit is supplemented by a powerful accumulator with sophisticated accumulator management and a smartphone charging concept: In off-mode, the Field PG can be used as a power bank. Integrated TPM (Trusted Platform Module) data security functions and WoL (Wake on LAN) and iAMT (Intel’s Active Management Technology) increase the level of security when using the hard disk and simplify remote administration in the company network.

Info RS#: 409

Signal Conditioners

Alliance Sensors Group’s S1A and SC-100 DIN-rail-mounted, push-button-calibrated LVDT signal conditioners were developed by listening to customers and LVDT manufacturers’ comments and wish list. This has allowed Alliance Sensors Group to design and build signal conditioners that work with all different types of LVDTs, LVRTs, GE “buck-boost” LVDTs for gas turbines, half-bridge pencil gaging probes, and RVDTs, rather than only satisfying markets where they are strong and not addressing the concerns of LVDT users with other applications.

Solution: S1A and SC-100 LVDT Signal Conditioners offer smart and fast LVDT setup with built-in null indication and simple front panel pushbuttons to set zero and full scale. Calibration time is now reduced from at least 20 minutes per channel to just a minute or two.

The S1A and SC-100 each offer the user:

• Power inputs from 15-30 V DC or ±15 V DC.

• Choice of 4 LVDT excitation frequencies

• Choice of 6 voltage and 2 current loop analog DC outputs

• Unique auto-mastering for master/slave operation – even if a master were to fail, the S1A and SC-100 can eliminate beat frequency effects in remaining units

• RS-485 digital communications link with an available GUI and hot swapability

• Built-in diagnostics for LVDT winding failures or cable disconnection.

Alliance Sensors Group
Info RS#: 410