november 2016 newsletter-(2) · 1 the winery engineering association proudly acknowledges the...
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TheWineryEngineeringAssociationproudlyacknowledgesthesupportofits
PatronSponsor & FoundingSponsor
Timehasflownonceagainandwearealllookingdownthebarrelatthatincomingdeadline,notChristmas,butVintage.BynowIhopeallmembershaveallthepre-vintageworksunderwayoratleastplanned,andforthosewhoaresuperorganised,complete.Projectsarewellunderwaywiththescrambletosecuretradespersons,techniciansandmaterialstocompletetheworks.Generallyspeaking,itseemsevidentthattheindustryismorebuoyantthanintherecentpastandwiththatwelookoptimisticallytowardsthefuture.FromthistheWEAwillbecomeevenmorerelevantwithrespecttonetworking,providingopportunitiesforbothsuppliersandwineries,andalsoincreasingthefellowshipwithintheindustry,andwiththatincreasemembershipandparticipationwithintheWEA(anditsnewsletter).Onthatnote,IwishallourmembersandreadersasafeandhappyChristmasperiod,getwhatrestyoucan,andcomebackrechargedfortheonslaughtofvintage.
www.wea.org.au
WineLines November 2016 Issue
Newsletter of the Winery Engineering Association
President
Ben McDonald Treasury Wine Estates
Treasurer
Peter Stone Best Bottlers
Secretary Ray Pender
Australian Vintage Limited [email protected]
Postal Address
PO Box 433 BURONGA NSW 2739
Phone
03 5022 5100
Facsimile 03 5022 5135
Conference Organizer Trevor Leighton
PO Box 432 Buronga
NSW 2739 Ph. 03 5024 8611 Fx. 03 5024 8925 Mb. 0417 597 956
Speaker Coordinator & WineLines Editor
David Clark Ph. 03 5358 2059 Mb. 0412 518 685 [email protected]
InThisIssue• PresidentsReport–BenMcDonald• WEA2016McLarenValeConferenceReview• WEAMembership• AFullProfessionalRepaintatNoUpfrontCost–ProgrammedProperty
ServicesArticle• NotallVariableSpeedDrive(VSD)CompressorsareCreatedEqual–Atlas
CopcoNZArticle• WhentheWaterisasGoodastheWine–ContinentalWaterArticle• MajorEnergySavingswithClimateWizardSupercool–SeeleyInternational
ProductPromotion• MakeSmartSoftwareYourSecretWeapon–RockwellAutomationArticle
WEAPresidentsReport
2TheWEAislookingforwardto2017andwhatwecandoforourmembers.Watchthisspaceformoreinfoonupcomingevents,conferenceandgeneraltechnicalinformation.Finally,Iwouldliketothankallcommitteemembers,new,continuingandrecentlyretiredfortheirsupportoverthepast12months.MerryChristmas,andasalways,Cheers,Ben.BenMcDonald–WEAPresident
WineEng 2016 TheNationalConferenceandExhibitionoftheWEA
InnovationforSmarterSolutionsSeptember2016sawtherunningofyetanothersuccessfulWineryEngineeringAssociationNationalConferenceandExhibitionthatranovertwodaysandwasheldattheSerafinowineryinMcLarenVale. Pre-ConferenceEventAhalfdaypre-conferenceworkshopwasheldattheSerafinowineryduringtheafternoonofTuesday6thSeptemberbeingthedaypriortothe2016WEAMcLarenValeconference.InthisworkshopAlexFarrenFounderandCEOofCalifornianbasedcompanyBlueMorphpresentedindetailtheprocessandequipmentthathiscompanyalongwithassociateTomBeardEngineeringhavedevelopedinrecentyearstoenabletheUVCsanitisationofwinerytanksofallsizes.AlexexplainedanddemonstratedviaanalyticalresultsofsuchtrialscarriedbyanindependentcertifiedauthorityhowthistechnologyhasgonethroughexhaustivefieldtestingintheUSAwithincredibleresultsbeingachieved
-2016McLarenValeConferenceReview-ZealandConference-
3whenbeingdirectlycomparedwithtraditionaltankcleaningmethodsandthattheuseofthistechnologyinthewineindustryhasthepotentialtosavewineriesofallsizessignificantcostsassociatedwithcurrentwater,chemicalandenergyuseplusreducedloadingonexistingwastewatertreatmentsystems.
The workshop concluded with ademonstrationofaBlueMorphunitbeingplacedintoatanktoshowtheeaseofusingtheequipment.
Althoughparticipantnumberswerelimitedtherewasagooddealofinteractivediscussionthattookplaceandthoseinattendancefoundtheworkshopcontentextremelyinformativeandenlighteningtothepointwheretrialsarebeingplannedbyacoupleofthewinecompaniesbeingrepresentedattheworkshop.
UVCDemoin9KLTank UVCDemonstrationUnit
ConferenceThisyear’sAustralianWEAConferenceandExhibitionranoverWednesday7th&Thursday8thSeptemberandinturnwasattendedbydelegatesrepresentingallareasofwinemakingproduction.Withthethemetitleofthisyear’sconferencebeingtitled‘InnovationforSmarterSolutions’delegateswereabletoattendacomprehensiveprogramoftechnicalpapersoverthetwodaysoftheconferencewhichcommencedwithawelcomeaddressbyWEApresidentBenMcDonaldandkeynoteaddressfromMr.JohnIde–WineryOperationsManagerforYalumbaFamilyVignerons,inhisaddressJohnfocusedonhowinnovationandinventionhasshapedthewineindustryinAustraliafromitsverybeginning,theinformativeaddressgivenbyJohnincludedareviewofpastandpresenttechnologies,theireffectonboththequalityandproductionefficiencyaspectsofwinemaking,andwhatwecanseeforthefuture.Hethenposedthequestionisthereanydifference
betweeninnovationandinvention?anddoesthisreallymattertousanyway?Theaddressthenconcludedwithlookingathowwecanfosterinnovationandinventioninourdailylivestolookatproblemsandopportunitieswithacreativeaswellaslogicalapproachandarriveat“outofthebox”solutionstoaddvaluethroughthesupplychain.JohnIdepresentingthe2016keynoteaddressThekeynoteaddressfromJohnsetthescenefortheconferenceandwasfollowedbyanumberoftechnicalpresentationsdeliveredondayoneoftheconference
coveringtheapplicationofGeographicInformationSystems(GIS)inboththeVineyard&Winery,
4InnovationinViticulturalMachineryandGrapeSorting,UVTankSanitisation,TitaniumFiltrationandBarrelStorageCoolingviaEvaporativeAirConditioning.
DaveGerner–TWE–GISPresentation AlexFarren–BlueMorph–UVPresentationProceedingsfordayonethenconcludedwithaneducationaltastingconductedbyMattHoldstock–SeniorOenologistwiththeAWRIlookingatShirazwineproducedinthevariousgrapegrowingareasofAustraliawiththeobjectiveofthetastingbeingtogivetheparticipantsanunderstandingofthedifferentcharacteristicsthateachregionimpartsintothisgrapevarietyduetodifferingterroir.Thiseducationaltastingwaswellattendedwithallparticipantsappreciatingtheopportunitytobeabletobroadentheirknowledgeregardingthispopularvariety.
MattHoldstock–AWRIconductingtheShirazeducationaltasting
DaytwooftheconferencecomprisedoftenpresentationswiththemorningsessioncoveringSolarPowerProcurementStrategiesforWineries,SmartSolutionsforOptimisingPowerQuality&PowerFactor
5Correction,InnovativeIoTMonitoringforPredictiveFaultFinding,Innovation,TrendsandthefutureofSynthetic&NaturalRefrigerants.FollowinglunchtheafternoonsessionscommencedwiththefirstcomprisingofthreepresentationsfromtheAWRIcoveringRapidExtractionTechniquesforRedWineProduction,UsingIn-LineSensorstoMonitorSugarLevelsDuringFermentation,Closures–OurChangingUnderstanding.ThefinalsessionoftheconferencealsocomprisedofthreepresentationscoveringMassSerialisationThroughthe“InternetofThings”(IoT),MachineSafetyMaturingintheTechnologyAge,Real,ResilientLeadership,allofthesepresentationsdrewahighdegreeofinterestfromthedelegatesandinturnwereafittingwaytoconcludetheconferenceproceedingsforanotheryear.ExhibitionAllexhibitorboothsweretakenupbyabroadrangeofsuppliersfrombothAustraliaandoverseaswhichinturngaveexhibitorsanddelegatesagreatopportunitytodiscussnewproductsandservices,developmentplansandassociatedequipmentrequirementsforthefutureaswellasgeneralnetworking.Allexhibitswerewellattendedduringtheteaandlunchbreaksaswellasbeforeandaftertheconferenceproceedingseachday.
RockwellAutomationStand JMAEngineeringStandConferenceDinnerAsalways,theconferencedinnerwaswellattendedandenjoyedbyoneandallwithgreatfoodandwinebeingtheorderoftheday.FormalitieswerekeptshortfortheeveningandfollowingashortaddressbyWEAPresidentBenMcDonaldashortandinterestingpresentationwasgivenbyMr.RossCurtis,DonorRelationsManageroftheRoyalFlyingDoctorService(RFDS)CentralOperationsinwhichhetalkedabouttheworkoftheRFDSwhohavebeenbeneficiariesofourconferencedinnerraffleproceedsforagoodnumberofyears.Entertainmentforthenightwasconductedbyanextremelyaccomplishedhypnotistwhogatheredseveralvolunteersfromtheaudiencewhointurnbecamestaractsmuchtotheamusementofallinattendance.TheRFDSpresentationwasextremelyrelevanttothenight’sproceedingsasthenextitemonthenight’sagendawasthetraditionalWEAdinnerrafflewhichhasbeenconductedeachyearsince2003,thetotalproceedsofwhichgototheRoyalFlyingDoctorService.Thisyearanearrecordamountof$6,640wasraisedwhichnowbringsthetotalamountraisedanddonatedtotheRFDSbytheWEAsince2003to$57,789.AllraffleprizesovertheyearshavebeengenerouslydonatedbyexhibitorsandsupportersoftheWEAforwhichweareextremelygratefulaswithoutsuchsupportwewouldbeunabletoassisttheRFDSinprovidingtheirgreatservicetotheoutbackandbeyond.Finally,wearemuchindebtedtothetwoMC’sforthenightbeingJoMarshallfromProgrammedPropertyServicesandGregSchultzfromRockwellAutomationbothofwhomdidanoutstandingjobincludingJo’stirelesseffortinmakingtherafflesuchasuccessasshehasdoneforanumberofyears.
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AnotherSuccessfulWEAConferenceDinner
JustareminderforthoseofyouwhohavenotrenewedyourWEAmembershipthatrenewalfallsdueeachyearonApril1st.Membershiprenewalsarenowalsohandledseparatelyfromtheconferenceregistrations.ThischangewillensurethatyourmembershipdoesnotlapseandthatinturnyouarekeptfullyinformedofallWEAeventswellinadvanceofthemtakingplace.AsaWEAmember,youwillalsohaveaccesstothemembersonlysectionofourwebsitethereforeallowingyoutoaccesspresentationmaterialsfrompreviousWEAconferences.IfyouknowofanycolleagueswhoyoubelievewouldbenefitbybecomingamemberoftheWEA,applicationformembershipcanbemadebyeithergoingtoourwebsitewww.wea.org.auorcontactingTrevorLeightonon0417597956/trevorleighton@wea.org.auTheannualcostofbeingamemberiscurrentlyonly$65whichnotonlyentitlesmemberstoreceivethenewsletterandotherupdatesbutalsoentitlesthemtoreducedregistrationfeestoourconferenceswhichinitselfcanresultinsavingsofaround$45/year
ProgrammedPropertyServicesArticle
-WEAMembership-
-FullProfessionalRepaintatNoUpfrontCosts–YesYouCan-
7On-goingpaintingmaintenancekeepsyourfacilitylookingwell-presented.Costandaffordability,however,canpreventthisfrombeingimplemented.Yet,thereareverygoodfundingandmaintenanceoptionsavailabletohelpyouavoidupfrontcosts,evenwhengettingspecialiststoprofessionallypaintyourbuilding.Whenconsideringarepaint,bethisinteriororexterior,lookforalong-termpaintingmaintenancesolutionthatletsyoucompleteasmuchworkyou’dlikeupfront,whileallowingyoutoamortisethecostoftheseworksovertheagreedmaintenanceperiodsoyoudon’tincurimmediatecosts.
Instead,youtailorrepaymentstosuityourbudget,buildingthistoalignwithanon-goingpreventativemaintenancecomponent.Themaintenanceservicewillensureyourbuildingstayswell-presented,andbecauseyouareabletohavecostsforboththerepaintandmaintenancebrokendownintosmallerpaymentsovertime,you’llbettermanageyourbudgetandcashflow.Thisisusefulwhenyouhavemultiplemaintenancerequirementstocommittosimultaneously,andalsoletsyousustainmaintenanceforlongerperiods.Plus,nolongerdoyouneedtoputoffimportantmaintenancetasks.Surfacepreparation,buildingrepairworksaswell
asfixingbrokendownpaintonwindowsanddoorsareallpartandparcelofgoodpaintingmaintenance.Thisdeliverslasting,qualityresultsabletoextendassetlifespanandstaveoffexpensivereplacementcosts.
Inthisway,yourbuildingconsistentlylooksgood,andyoudon’thavetowaituntilcracked,peelingpaintworkpromptsyoutoact.Often,delayingrepairsuntilsuchastagecouldendupmorecostly.Remedyingtheappearanceofabuildinguntilafteritstartstodeterioratewillquitelikelyincurextensivepreparationandcostlysubstratereplacementcostspriortorepainting.
Thisisparticularlytruewherethecostofrepairandreplacementincreasesovertime,andwhentheoverallcostofaproactivemaintenanceprogrammepresentsacomparativelycheaperoption.Especiallyifyoutakeintoconsiderationtheabilitytoreduceancillaryintangiblecostssuchasextendeddowntimeandlossoffacilityuseduetomajorreactiveworks,orlossofgoodwillandimageduetoalacklusterappearance.
ExampleofthebenefitsofongoingMaintenancePaintingvs.AdHocbasedonlevelofappearanceover6years.
Meanwhile,toretainthat‘asnew’look,annualpressurewashingaspartoftheserviceremovesdirtandgrime.Wheresurfacesaresoiledbytimeandweather,thesewillberepainted.
8EngagingspecialistsinpaintingandmaintenancelikeProgrammedalsogivesyouaccesstouniqueexpertise,suchasabseilpaintingteamswhocanpainthigh,difficulttoaccessareassafely.Youwon’thavetohideyourbuilding’sfaçade’sbehindscaffoldsduringarepaint.Allassociatedrisksarealsomanagedonyourbehalf.
Don’twaituntilyouhaveafadedanddatedbuilding.SpeaktotheexpertsatProgrammedtodayandseehowamaintenanceprogrammecanbetailoredtomoderniseyourproperty’sappearanceandkeepitingoodcondition–withouttheupfrontcost
-Programmed’sDiversityJourney– ArticleprovidedbyMartinCrabb–SeniorBusinessDevelopmentManager–ProgrammedPropertyServices
NoUpfrontCosts–YesYouCan-
-NotallVariableSpeedDrive(VSD)CompressorsareCreated-Equal-
9AtlasCopcoArticleHowdoVSDcompressorswork?VSDcompressorsaredesignedtoeliminatethetimethatacompressorspendsinanunloadedor“idle”statewhendemanddrops.Incontrasttoafixedspeedcompressorthatwillloadandunload,aVSDcompressorwillcontinuouslymeasureoutletpressureandregulateitsspeedtomatchyourdemand.Typically,afixedspeedcompressorwillunloadwhentheupperpressurelimitisreached,duringthisprocess-theinletvalvecloseswhilstthemotorcontinuestoturn,hencestoppingtheproductionofcompressedair.Theselossescanbegintomountasthedemandvariesinthefactory,theresultisalargepowerbillthatservicesunproductivetimeonyourcompressor.WithaVSDcompressor,thisissueiseliminatedasthecompressedairoutputisregulated-insteadofhavingtounload,aVSDcompressorcanslowdowntypicallytowithin12-13%ofmaximumoutput(AtlasCopcoVSD+range).CriticalfactorstolookforwhenchoosingaVSDcompressorNotallVSDcompressorsarecreatedequally.ThereareanumberoffactorsthatshouldbeconsideredwhenlookingtopurchaseaVSDcompressorforyourplant-priceisnottheonlyfactor.VSDcompressorsaresophisticatedpiecesofequipmentwhichcombinethelatestmechanicalandelectronictechnologiestoachieveoptimalperformanceandthusenergysavings.Themotoristheheartofacompressor,VSDratedmotorsshouldbeusedtoachievethehighestlevelofperformance.
• Itisimportanttonotethatafixedspeed
compressorcannotbecomeaVSDcompressorbysimplyattachingafrequencyconvertertotheunittovaryspeed.Thiswillworktosomeextent,howevertherewillbegreatlimitations.
• AsmotorRPMisreduced,motorcoolingbecomescritical,afixedspeedcompressoristypicallycooledbyafanattachedtothemotorshaft,andthiswillinturncauseissueswhentheRPMdropsandcoolingcapacityisreduced.
• CheckforminimumFADoutputfigures,thelowertheminimumFADforanequivalentmotorsize,
thebettertheperformance.
• Doesthecompressorunload?“Real”VSDratedmotorscanstartupundersystempressureanddonotrequireadepressurisedsystemtostartthemotorafterstopping.
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• Howisthemotorcooled?Isthemotorcooledbyafancoupledtothemotorshaft,ordoesithaveanindependentcoolingsystemthatoptimisesthecoolingloaddependingonmotorRPM?
• Whatmechanismisusedforthecompressors’drivetrain?Lossescanbeminimisedbyusingeitherdirectdriveorgeardrivesystems,beltdriveisnotrecommendedforVSDcompressors.Maintenancerequirementsarealsokepttoaminimumasdirectandgeardriveunitsaretypicallymaintenancefree.
BearinmindbeforesigningonthedottedlineCompressorsaretheproducersofoneofyourmostvitalutilitiesinthefactory.Thereareavarietyofoptions,configurationsandbrandstochoosefrom.Buyinganewcompressorshouldbeaprocesswherelongtermrunningcostsoutweightheoutrightinvestment.Buildquality,advancementintechnology,andcompatibilityoftechnologiesshouldallbeconsidered.WhatshouldIdobeforeIdecide?
• Consultyourlocalsalesengineer• Performacompressedairenergyauditonyoursystemtomeasurecurrentcompressedairand
energyconsumption• RequestasimulationoftheVSDcompressortopredictenergysavings• Compareoptionsandlookforvalueaddingfeatures• Makeaninformeddecisionbasedonfactspresented
-WEA Membership-
-WhentheWaterisasGoodastheWine-
11ContinentalWaterArticle
ADrinkingWaterSystemforLevantineHillEstateWhenKrongoldConstructionswereengagedtoconstructanewCellarDoorandRestaurantfacilityforLevantineHillEstate,intheColdstreamHills,oneoftheconsiderationswastheprovisionofwaterfordrinkingandotherassociatedpurposeswhichmatchedthequalityoffoodandwineonofferintherestaurantwhichwouldoperateunderthehighlyesteemedEzardBannerasE@LevantineHill.Thewatershouldbeclear,colourless,odourlessandtasteless,befreefromtoxicsubstances,pathogensandexcessiveamountsofsubstancesinsolutionnotnormallydetectablebytheunaidedsenses.ItshouldcomplywiththerequirementsoftheVictorianDepartmentofHealthGuidelinesforPrivateDrinkingWaterSuppliesatCommercial&CommunityFacilities(2009)andtherecommendationoftheAustralianDrinkingWaterGuidelines(ADWG).Ineffect,itshouldbetheverybestdrinkingwateravailable.LevantineHillhasarainwaterharvestingsysteminplacehoweverthisisusedforirrigationoftheextensivegroundsandsupplyofthefirefightingsystem.Theonlyotherreliablesourceofwaterwasadamonthepropertyfedbyrainwater,surfacerun-offandtoppedfromthenearbyYarraRiverwhenrequired.ContinentalWaterSystemswereaskedtolookattheproblemandprovideasolution.Ananalysisofthewaterfromthedamshowedthat,inadditiontothenormallyexpectedcontaminantswhichincludedmicro-organisms,sedimentsandorganicmatter,whichwoulddiscolourthewater,ironandmanganese,werepresentinrelativelyhighquantitiesandthiswouldneedtobeaddressedasapriority.SteveJeffs,fromContinentalWaterinMelbourne,proposedasystemcenteredona20,000litresperdayUltrafiltrationsystemwhichwouldbehousedinacontainersitednearthedam.
12Inthefinalsystem,waterwaspumpedfromthedamandpassedthroughapretreatmentfiltrationsystem,whichremovediron,manganeseandsediment,andthenthroughtheUltrafiltrationprocesswhichremovessuspendedparticlesdownto0.2micron.Fromtherethewaterundergoesasanitisationprocess,toremoveanybacteria,andispumpeduptothe280,000litreholdingtankintheCellarDoorcarpark.Fromtheholdingtank,beforethewaterreachesitsendusepoint,itisthenpassedthroughultravioletlightsanitisationand,finally,throughacarbonfiltertoremoveanyminortasteorodourthatmaystillbeevident.
TheacclaimedE@LevantineHillSallyanneBartlett,DirectorandScientistatWaterQPlusPtyLtdinMaidenGully,wasengagedtoassessthesystematcommissioningstage.Sheundertookareviewofdatafromacomprehensivesuiteofbothsourcewatersamplesandsamplescollectedatvariouslocationsthroughoutthewatertreatmentplant,includingthefinaltreatedwater.Sallyannefoundthatthecapabilityandperformanceoftheplantwasmorethanadequatetomanage/controlthewaterqualityrisksposedandtoconfidentlyproduceareliable,safedrinkingwaterproduct.Toensurethisqualityismaintained,aDrinkingWaterQualityManagementPlanhasbeenimplementedandaseriesofmonitoringdevices–includinganORPmonitorontheozonesanitisationsystem,anintensitymonitorontheUltravioletsanitisationsystemandpressuremonitoringoftheUltrafiltrationsystemarealllinkedtoeitheraudibleorvisualalarmslocatedinhightrafficareasthroughoutthefacility.Theresultingwaterissweet,pureandfullycompliantwiththeAustralianDrinkingWaterGuidelines.
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SeeleyInternationalProductPromotionWithinstalledsystemsalreadyreducingwineenergycoolingcostsbyupto80%comparedtorefrigeratedsystems,ClimateWizard’sSupercoolIndirect/DirectEvaporativeCooling(IDEC)configuration,isclearlyworking.Energy-mindedwineriesintheBarossa,AdelaideHillsandMcLarenValehaveinstalledClimateWizardwithexceptionalbenefits.Fromapuredollarcost,ClimateWizardsIDECtechnologyhaslowerpowerrequirementsandlowoperatingcosts,fromamodestcapitalinvestment.Asastand-alonesystem,oradaptedintoexistingbarrelandtankstoragecooling,ClimateWizardSupercooladdsasmallamountofmoisturesotheamountofangels’shareisminimisedplus,theneedforextrahumidificationequipmentisnegated,with100%fresh,outsideaircoolingthespaceandwine.Withagrowingproliferationoforganicandeco-sustainablewineries,theneedforconsistent,costeffectiveandlowimpactenergysupplyfor‘offthegrid’vineyardsiscritical.Indeed,energyconsistencyisimportant,especiallyforwinerieswhohaveexpandedinremotelocations.Thefurtherenergyneedstotravelregionally,themoreunpredictablethepowersupply,sothebenefitsofferedbyClimateWizard’snewcoolingsystemisturningwinemakingheadswhoneedtoutiliseplantandequipmentwhichdrawsminimalpower.AnindirectcorewithanevaporativeprocessafterwardsgivesSupercooltheedge.ClimateWizardsuppliesamuchlowertemperaturethandirectevaporativecooling,whilegivingsustainablewineries,vitaltemperatureandhumiditycontrol.AboutIndirectEvaporativeCooling:Indirectevaporativecoolingreducesthetemperatureoffreshairthroughaheatexchangesurface,that’simpervioustowater.Ononesideofthesurface,evaporationproducescooltemperaturesinwaterandair,allowingheatexchangetotheincomingairontheothersidesurface.So,primaryairiscooledwithoutchangingitsmoisturecontent.InClimateWizardsystem,someairisheatexchangedtoalowertemperature,returningalongthewetchannel.Evaporationonthewetsurfacesofthewetchannelwillproducelowertemperatures.
SupercoolInstallationExamples
PeterLehmannWines BarossaValleyEstates
-MajorEnergySavingsforPremiumWinerieswithClimateWizardSupercool-
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RockwellAutomationArticleSmartsoftwaresolutionsleverageincreasedconnectivitytoanalyseanddeliveroperationalandbusinessinformationforimprovedproductivityandprofitabilityAttheheartofanycontrolandautomationsystem,isasoftwaresolutionthatwhendesignedcorrectly,providesvaluableinsightintoaplant’soperationalandbusinessobjectives.However,withsomanyvariablestoconsider,asignificantnumberofcompanieshavedifficultyidentifyingtherightsolutionfortheirparticularapplication.AccordingtoJeffPhoon,engineeringteamleaderatGlobalSolutions,RockwellAutomation,“Whilethereareanumberoffactorstoconsiderwhendesigninganewsoftwaresolutionorupdatinganexistingsystemtomeetchangingrequirements,asolutioncanbedevelopedthatwillmeetacustomer’soperationalandbusinessobjectivesbyfollowingasystematicprocess.”DevelopingasoftwaresolutionThefirststepindevelopinganeffectivesoftwaresolutionistodevelopaUserRequirementsSpecificationtoidentifyspecificcustomerrequirements.“ThisiswhereITandautomationcrossbecausetraditionallythisstepisperformedbybusinessanalystsintheITworld,butnowourengineersalsoprovidethisexpertise,”saidPhoon.
MakeSmartSoftwareYourSecretWeapon
15Thenextstageindevelopingasoftwaresolutionisdeterminingthefunctionalrequirementsofthesystem.Thisinvolvesidentifyingandanalysingthecapabilitiesthatthesystemneedstoprovide.Byadoptingacollaborativemethodology,theengineertogetherwiththeendcustomerworktogethertoidentifytheserequirements.“Intheearlystagesofsoftwaredesign,it’sdifficultforthecustomertohaveacompleteunderstandingofalltheirsystemrequirements.Byadoptingourcollaborativemethodology,wecanleverageourdomainexperiencetodeliveradetailedanalysisofthefunctionalrequirementsforaparticularapplication,”explainedPhoon.“WecanalsoconductaFIT-GAPanalysiswherewelookatthestandardfeaturesofasoftwareplatforminrelationtotherequirementsofaspecificapplicationanddetermineifanythinghastobedonetoextendthefeaturestomeetthecustomerspecification.Sometimeseventhemostcomplete‘offtheshelf’softwarepackagerequiressomelevelofcustomisation,”headded.OncetheUserRequirementsSpecificationandfunctionalrequirementshavebeendeterminedthesoftwaresolutionmovesintotheimplementationstage.Thisinvolvesdetaileddesignanddevelopingthesolutionfortesting.TheUserAcceptanceTestingphaseprovidestheopportunityfortheendusertoverifythatthesolutionmeetsthefunctionalrequirements.Oncecomplete,operatortrainingcanbeconductedandthenthesoftwaresolutioncan‘golive’.Adoptingbestpracticeinthesoftwaredevelopmentlifecyclereducesriskandallowsenduserstogetabetterhandleonprojectcosts.Phoonemphasisesthat,“Poorplanningestimatescanleadtoprojectfailurebutwithproperplanningandexecution,softwaresolutionscanbedevelopedeffectivelyontimeandwithinbudget.”AvoiddrowningindataInthebigdataera,accesstoinformationismoreimportantthaneverasglobalcompetitivepressuresmount.Asaresultofadvancesinconnectivityandaccesstooperationalinformationfromcontrolsystems,theamountofdatathatiseasilyaccessiblehasincreasedexponentially.However,theassumptionthatmoredataisbetterdataisnotnecessarilycorrect,makingidentifyingtheimportantdataakeyprioritytoprovideoperationalinsightandvalue.“Oncewehaveaclearunderstandingoftheimportantdatapoints,thenextstepiscontextualisingthisinformationsothatoperatorscanseeinformationthatisimportantfortheirrole,”explainedPhoon.“Forexample,aproductionmanagermaybeinterestedinanoverallproductionsummarydashboardwhereasaplantfloorsupervisorwouldneedmoredetailintermsofadailysummaryreportsotheycandelvealittledeeperastothereasonswhyamachinemayhaveshutdown.Wehavethetechnologyandapplicationknowledgetopresentthedatabasedonwhoislookingatitandwhattheirrolesare,”hesaid.Theultimategoalistogettherightdatatotherightpeopleinasclosetorealtimeaspossiblesotheycanmakeinformeddecisionstooptimiseproductionandimproveproductivity.MakingitmobileSmartmobiledeviceshavebecomeanessentialpartofeverydaylife.Wenowhavethetechnologytoview,analyseandrespondtooperationalinformationfromanywhereatanytime.Phoonexplainsthat,“Although
16manufacturinginformationisoftenbehindtherestoftheITworld,industrialoperationsarenowbenefitingfrombetterwaysofpresentingdatathroughwebportals,toolsandlibraries.”TheRockwellAutomationweb-basedmanufacturingbusinessintelligenceplatform,FactoryTalkVantagePoint,nowprovidesaccesstoproductioninformationonmobiledevicesaswell.Providingtherightinformationtotherightpersonattherighttimedeliversflexibilityinmanufacturingprocesses,providingthecapabilitytomakedecisionsremotely,improveefficienciesandreducedowntime.Throughtheuseofrealtimealarming,mobiledevicescanalertoperatorstoissuesthatifleftunchecked,wouldimpactonproduction.Thisallowstheoperatortoaddresstheproblembeforeitescalates,reducingdowntimeandimprovingefficiencyandreliability.“Thesoftwaredesignprocesscanalsotakeintoaccountmobilityrequirementsbyidentifyingimportantinformationforoperators,programmingalarmingasrequiredandbestpracticefordatapresentation.Thisprocessprovidesasolutionthataddressestheoperator’srequirementsandallowsthemtomakesmartbusinessdecisionsquickly,”saidPhoon.SmartsoftwarebridgesthegapTheinformation-enabledConnectedEnterprisecandelivergreaterproductivity,betterutilisationofassetsandimproveddecisionmaking.Whendesignedcorrectly,smartsoftwaresolutionscanunlockdataprovidingoperationalinsightandimprovedproductivity.“Advancedsoftwaresolutionsaredesignedtogetthemostfromhardwaresolutions.Forexample,RockwellSoftwarecanimproveoperationsandlowerthetotalcostofownershipbybridgingthegapbetweentheplantfloorandbusinessenterprisesystems,”saidPhoon.“Inspeakingwithcustomers,wefindthatidentifyingthespecificdatarequiredandthenconfiguringthesystemtomeettheseuniquerequirementsisachallengetheyneedtoaddress.Tohelpwiththis,ourlocalGlobalSolutionsteamworkswithcustomerstohelpdesignandconfigurethesoftwaretosuitspecificrequirementsandreduceimplementationtime,”heexplained.
FactoryTalkVantagePointprovidesaccesstoproductioninformationonmobiledevices
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SmartsoftwaresolutionscanunlockdataprovidingoperationalinsightandimprovedproductivityAboutRockwellAutomationRockwellAutomationAustraliaandRockwellAutomationNewZealandaresubsidiariesofRockwellAutomation,Inc.—aleadingglobalproviderofindustrialautomationandinformationsolutionsthathelpsmanufacturersachieveacompetitiveadvantageintheirbusinesses.ThecompanybringstogetherleadingglobalbrandsinindustrialautomationwhichincludeAllen-Bradley®controlsandservicesandRockwellSoftware®factorymanagementsoftware.Itsbroadproductmixincludescontrollogicsystems,sensors,human-machineinterfaces,drivecontrollers,powerdevices,andsoftware.RockwellAutomation,Inc.(NYSE:ROK),theworld’slargestcompanydedicatedtoindustrialautomationandinformation,makesitscustomersmoreproductiveandtheworldmoresustainable.HeadquarteredinMilwaukee,Wis.,RockwellAutomationemploysapproximately22,000peopleservingcustomersinmorethan80countries.Allen-Bradley,FactoryTalkVantagePoint,LISTEN.THINK.SOLVE.andRockwellSoftwarearetrademarksofRockwellAutomation,Inc.