Intrinsically safe ethernet Interface.

Eaton has launched an intrinsically safe (IS) Ethernet interface, MTL ExLAN, as part of its Crouse-Hinds series portfolio. MTL ExLAN enables OEMs to simplify their product design and certification, saving time and associated costs in launching products for mounting in Zone 0 or 1 hazardous areas, while offering the benefits of open Ethernet connectivity.

The MTL ExLAN interface provides compatible IS signal parameters to allow interconnection to a wide range of IS Ethernet devices, so signals can be sent safely over copper, fibre or wireless Ethernet. It is ideal for data acquisition device applications for process control and monitoring in industries such as oil and gas, pharmaceutical, chemical and mining. For example, complex devices such as process weighing systems, gas analysers, flow meters or radar level gauges, can benefit from Ethernet connectivity, as part of the Industrial Internet of Things (IIoT).

As well as providing the essential network LAN interface for standard Cat 5e/Cat 6 Ethernet cabling systems, the module also voltage clamps the equipment’s main supply rail (typically 5 V or 3.3 V). Together these ensure the Ethernet signals generated are limited to low IS levels. As a result, plant managers across process industries worldwide can be assured that they are operating safely in hazardous locations.

“MTL ExLAN enables instrumentation OEMs to offer increases in safety for their end users and reduced installation cost with an intrinsically safe solution,” said Roger Highton, product line manager at Eaton. “Now, more than ever before, there are increasing demands for greater efficiency, higher reliability and lower cost of ownership of field equipment, and users are looking towards the Industrial Internet of Things to deliver these requirements.”

MTL ExLAN ensures full IS compatibility of interconnected devices including Eaton’s current range of MTL 9400 Ethernet modules, which allow for live connection and disconnection of the end device in Zone 0 or Zone 1 hazardous areas. In addition, it is also fully compatible with PoExTM, 12 VDC Power over Ethernet for Hazardous Areas, to provide power and communication over a single cable in harsh environments.

@eatoncorp #Ex #PAuto

Protects plants from Cyber-attacks.

Eaton has launched its next generation Tofino industrial security solution. The 9202-ETS MTL security system provides the highest level of network security for process automation applications. The MTL Tofino security system is exceptionally easy to install compared with alternative systems and includes the latest configurator software to protect industrial networks from cyber-security vulnerabilities. This maximises plant uptime and process availability while protecting it from external network attack.

“When Industrial Control and Supervisory Control and Data Acquisition (SCADA) systems were not connected they were considered immune to attacks, but the trend towards open standards such as Ethernet TCP/IP and web technologies has seen these systems affected by a growing number of threats,” said Roger Highton, product line manager, Eaton. “Traditional firewalls are not designed for control systems or industrial threats, thereby putting essential utilities at risk, and each year, the damage to critical infrastructure from network incidents and cyber-attacks runs into billions of dollars. The MTL 9202-ETS gives process managers in the power, utilities, oil and gas and water and wastewater industries a cost-effective security protection that is highly effective and quick to install.”

It supports all popular industrial protocols with the Firewall Loadable Security Module (LSM) which compares network traffic against a set of rules. The new release includes the EtherNet/IP Enforcer LSM for deep packet inspection of EtherNet/IP (CIP) communications. Tofino can also be configured remotely with the Netconnect LSM, providing further flexibility to the user. Further LSM’s can also be specified such as the Modbus enforcer and OPC enforcer LSMs providing deep packet inspection for these key industrial protocols and the Event Logger LSM logs security events and sends alarms. The LSMs are available pre-installed or can be purchased separately.

The 9202-ETS MTL security appliance delivers defence in depth for a wide range of DCS, PLC, SCADA, networking, and automation systems. As it does not have its own IP address, it sits as an invisible device on the network and is designed to stop threats without disrupting the critical process application.

The Tofino system includes a number of templates for use with a wide range of automation protocols to further ease installation. In addition, it provides a number of rules and a test mode, so users can check the proposed configuration will not interfere with the operation of the plant before putting the security appliance into operation. Tofino Configurator checks for missing or invalid rules and suggests solutions, thereby aiding set-up.

The 9202-ETS MTL security appliance has a rugged hardware design suitable for use in harsh and hazardous environments. It has a robust metal housing for DIN rail mounting,
-40°C to +70°C operating temperature ratings together with Class 1 Division 2 and ATEX Zone 2 hazardous area approvals. This ensures it will give years of reliable service, providing secure networks with security zones as per NERC, ANSI/ISA, and IEC standards.

Ex ic - Intrinsic safety’s new protection level!

Power management company Eaton has released a new whitepaper, Ex ic – Intrinsic Safety’s New Protection Level, that helps users and manufacturers understand more about Ex ic, the new intrinsic safety protection level for electrical apparatus in flammable environments. The paper is authored by Phil Saward, training and technical consultant, Eaton’s Crouse-Hinds Division. Phil Saward has 25 years’ experience in hazardous area products and applications and has served time on various FOUNDATION™ fieldbus committees.

“The concept of a third level of protection for intrinsic safety has existed for several decades,” said Phil Saward. “Only in recent years has it been formally adopted into the major standards systems in common use worldwide. Meanwhile, other methods of protection have filled the gap. In particular, Ex nL has provided a workable, but somewhat loosely defined alternative until its recent withdrawal from international standards. The paper therefore covers the essential differences between Ex ic and Ex nL, and discusses the pros and cons of the two techniques.”

The whitepaper deals primarily with the impact on countries that follow IEC and ATEX practice - but there are parallels with the ‘non-incendive’ technique that is adopted in North America. The paper is aimed at those who are familiar with the principles of explosion protection for electrical apparatus, but will also appeal to readers who are responsible for compliance to the ATEX Directive and relevant IEC standards. Topics covered include:

• What is Ex ic?; 
• The position of Ex ic in the Intrinsic Safety family; 
• Changes to the IEC standards; 
• Why things are changing now; 
• Background and links to the ATEX directive.

One of the most helpful elements of the whitepaper is the inclusion of a case study which demonstrates how the new Ex ic standard can fundamentally change the design of a FOUNDATION™ fieldbus network, compared with implementations that were based on the Ex n standards. This practical illustration will help readers understand the potential impact in terms of network design and hardware selection.

Companies co-operate in design of integrated production control system.

Eaton is supporting Yokogawa in the development of its next generation integrated production control system, CENTUM VP R6.01. Yokogawa wanted to design a new system with an intrinsically safe universal input/output (I/O) module for greater efficiency in system configuration and engineering and approached MTL, part of Eaton’s Crouse-Hinds business, for its expertise in intrinsic safety devices for hazardous area and general process control applications.

“We have a long standing relationship with Yokogawa, having worked together globally for more than 20 years on various projects, so we were delighted once again to partner with them on the CENTUM VP R6.01,” said Riccardo Codega, MTL marketing director, Eaton’s Crouse-Hinds Division. “We worked closely with them to understand their requirements for a universal I/O module and recommended our MTL4500 intrinsic safety isolators, which have been adapted to work in a universal environment. The backplane mounting series is designed with systems vendors in mind and is perfect for DCS applications such as this.”

Yokogawa  launched its first version of CENTUM in 1975, and the company has continued to improve the platform by applying the latest technologies.

Recognising the challenges faced by today’s manufacturing plants for increased flexibility as well as improved process efficiencies, with the need to maintain safe operations, Yokogawa wanted to develop an intrinsically safe universal I/O module that would allow its customers to reduce the time required for installing and configuring a control system.

“We chose to work with Eaton MTL for its credibility and expertise in intrinsic safety,” said Nobuaki Konishi, Vice President of Yokogawa Industrial Automation Platform Business. “The company is recognised in the industry as being a key supplier and we were confident we could rely on them to provide a high quality and safe solution.”

As part of the CENTUM VP R6.01, Yokogawa has expanded its range of I/O devices, which are critical control system components, and a key feature is a new N-IO field I/O device with an I/O module that can easily handle multiple types of I/O signals. As such, it eliminates the need for I/O modules to be replaced according to the signal they convey, which reduces rewiring, footprint and the time spent on installation and associated costs.

Eaton’s MTL product specialists added additional diagnostic features and functionality so line fault detection is integrated into the Yokogawa system. Now, there are channel level diagnostics in the control system that help users avoid downtime and increase plant productivity.

A key benefit of the MTL4500 Series isolators is that the base plate does not require intrinsic safety certification. The field connection is on top of the module, so it does not need any additional accreditations and it is accessible to all regions worldwide. As a result, the approval process into a plant is simplified in virtually any application.

The MTL4500 isolators are a compact integrated solution for flexible cabinet layout. Incorporating advanced circuit design, a common set of components and innovative isolating transformer construction, the isolators achieve a significant reduction in power consumption while increasing channel packing densities. The 16mm wide design reduces weight and gives exceptionally high packing density.

Eaton’s MTL4500 isolators are plug-and-play with easy commissioning and set up, therefore simplifying project engineering and reducing installation and maintenance costs. The design is based on existing, proven technologies and provides a reliable solution for manufacturing plants and process industries including oil and gas, petrochemicals, chemicals and pharmaceuticals.

Eaton continues to work closely with Yokogawa in its development of control systems that will provide customers with an improved operating environment by increasing the safety and efficiency of their operations and achieving greater synergy between their control system and field devices. In addition to improving production efficiency, this will allow the optimisation of maintenance of the production control system, safety instrumented system, programmable controllers, all field devices, and other components, thereby reducing costs and ensuring the long-term stability of operations.

MTL products, part of Eaton’s Crouse-Hinds portfolio, provide leading electronic instrumentation and protection capabilities for the process control industries. Key applications include intrinsic safety, fieldbus, industrial networking, surge protection, HMI and visualisation, gas analysis and alarm management.

See also our story: Integrated production control system! (18/11/2014)

Signal conditioners enable plants to reduce operational costs!

Eaton has launched a new series of signal conditioners for safe-area applications – the MTL1000 Series. Process managers can now specify Eaton’s signal conditioners for all areas of their plant, enabling them to reduce the complexity of their supply chain and save on operational costs. The MTL1000 Series is designed to ensure reliable and high quality communication between the field device and control units located in the plant and is ideal for safe areas in the oil and gas industry, chemical, petrochemical and pharmaceutical plants.

The compact MTL1000 Series is exceptionally quick and easy-to-install. It features a special power system which reduces wiring by up to 30 percent and lowers installation time and associated costs. With less wiring, risk of installation error is also reduced, assisting with on-time plant start-up and improved reliability over the lifetime of the installation. In addition, more space is available in the panel board which allows for a higher density of signal conditioners.

“For large installations of signal conditioners, a wiring reduction of up to 30 percent can save a lot of space and allow users to have clear access to the modules,” says Roger Highton, MTL product line manager, Eaton’s Crouse-Hinds division. “With the new MTL1000 Series, we bring more than 40 years of hazardous area experience and industry expertise to safe-area applications, enabling customers to benefit from a single source supplier that will enhance the integrity of their supply chain and lead to cost savings. Using the MTL1000 Series, our customers can now specify reliable signal conditioners for use throughout their plants, in both hazardous and safe areas.”  

Eaton’s intrinsically safe isolators are reliable in hazardous areas and the new MTL1000 Series complements this range and offers high quality signal conditioning for general purpose applications. With an operating temperature range of -25º to +60º C, the MTL1000 Series is designed for long-term protection with a product life in excess of 10 years in even the most demanding of environments.

Eaton’s signal conditioners use galvanic isolation which is designed to prevent transmission and control errors which can lead to an interruption in the safe processing and monitoring of control signals. The MTL1000 Series is engineered to make sure that excessive voltages and noise do not affect the overall communication and can amplify, convert or isolate signals. The new signal conditioners provide excellent protection for equipment and personnel, so equipment and plants can operate safely and efficiently.

In addition, the MTL1000 Series is backed by Eaton’s global technical support team enabling users and systems integrators to simplify their design engineering.

Integrated production control system!

Agile and intelligent system configuration and engineering!

Yokogawa Electric Corporation is developing the CENTUM® VP R6.01, an enhanced version of the company's flagship integrated production control system, and plans its release in February 2015. R6.01 marks the first step in the development of an all-new CENTUM VP that will play a central role in Yokogawa's VigilantPlant® strategy for the IA business. With applications in operation, monitoring, and automatic control of plants, it is targeted at manufacturing companies in process industries such as oil and natural gas, petrochemicals, chemicals, electric power, pulp and paper, pharmaceuticals, foods, iron and steel, and water and wastewater.

The latest enhanced version of Yokogawa's flagship integrated production control system

Development background
Manufacturers today need a high degree of certainty and confidence to achieve timely production, and flexibility to make changes in product and material specifications. This enables them to effectively respond to intense global competition and major market shifts.

The adaptive evolution of the new CENTUM VP focuses on addressing customers' needs to keep up with the fast pace of change in the business landscape and technology while delivering maximum return on assets and the lowest total cost of ownership. This first R6-level release of the CENTUM VP system represents much more than conventional functional improvements. R6 brings together smart engineering, advanced operation, system agility, and sustainable plant. With R6, plant operators can be assured of an optimum engineering environment that spans the entire plant lifecycle, from plant design and the engineering and installation of systems and devices to the start-up of production, maintenance, and renovation. In addition, it is designed to meet the most stringent industry requirements for safe and reliable plant operations and environmental protection.

R6.01 features an exciting expansion of Yokogawa's lineup of I/O devices and introduces crucial new control system components. Combined with an intuitive engineering environment, it dramatically reduces the time required to configure and install a control system.

Outline of new features
1. N-IO (Network-IO): A field I/O device with a versatile I/O module that can handle multiple types of I/O signals
Control systems rely on field I/O devices for the transfer of data to and from sensors, valves, and other types of field instruments. Using this data, they automatically control a plant's operations. Depending on instrument models, the type of electric signal used to transfer this data varies. With Yokogawa's current field I/O device, a compatible I/O module is needed for each signal type.

N-IO their versatile 

Field I/O device

The N-IO, a new CENTUM VP field I/O device, fulfils the functions of universal I/O and a signal conditioner, enabling configurable software and flexible I/O assignment. It has an I/O module that accommodates multiple I/O signal types, accepts up to 16 I/O points, and allows specification of an individual signal type for each point. Both analogue and digital I/O signals, which account for the majority of I/O signal traffic, can be handled solely through software settings. Pulse and relay I/O signals can be managed by using additional adaptors. With the N-IO, it is no longer necessary to replace the I/O module, reducing the amount of rewiring that must be done when changing sensor types and/or layouts during a plant revamp. This significantly reduces the amount of work that has to be performed by plant engineers and maintenance personnel.

In addition, Yokogawa has signed OEM agreements with Pepperl+Fuchs GmbH and MTL Instruments Group Limited, under which Yokogawa will receive baseplates and market them as its own products. These will be used in combination with the company's N-IO modules and intrinsic safety (IS) isolators procured from the two companies. Both partners have solid track records in the development of interface products for use in hazardous areas. This tie-up means that Yokogawa is able to ensure that the N-IO conforms to the major IS regulations in Europe, Asia, and the Americas.

2. FieldMate™ Validator: A software tool that is used with N-IO devices to check field device wiring and verify that the device operates correctly
Upon installation of a field instrument and completion of all wiring, the wiring must be checked. Until now, such verification could only be conducted using the CENTUM operation/monitoring screen, which required engineers to wait for all field I/O devices to be installed and the entire CENTUM system, including all operation/monitoring stations and system controllers, to be set up.

The new CENTUM VP R6.01 features the FieldMate Validator N-IO loop commissioning software, a software tool that is used to verify the wiring and relevant operations for any newly installed field instrument or field I/O device. FieldMate Validator is provided with FieldMate, Yokogawa's field device management PC software. When FieldMate establishes a connection with an N-IO device, the FieldMate Validator tool can check in real time the wiring of all field instruments, based on the control loop I/O information in the control system's application software, to verify that they operate correctly. There is no more need for the whole CENTUM system to be installed to do this, thus saving significant time and providing added versatility in project execution.

3. Automation Design Suite (AD Suite): A first-of-its-kind integrated engineering environment that goes beyond traditional DCS engineering functionality
Leveraging its engineering expertise and the experience gained through the execution of myriad projects, Yokogawa has developed the AD Suite integrated engineering environment.

AD Suite is an integrated platform that ingeniously facilitates project execution, system integration, and site execution, bringing certainty and confidence through all project phases and the start-up, operation, maintenance, expansion/upgrade, and extension stages of the plant lifecycle.

With advanced program templates for heat exchangers, filters, and other types of equipment commonly used in the field, AD Suite improves engineering efficiency and helps to ensure uniform quality. It is able to centrally manage the functional design documents that provide the basis for control system engineering, along with all the control program master data stored in the CENTUM database. This simplifies history management when programs are modified and makes certain that the latest design information is available when system expansion, modification, or maintenance is performed.

In essence, AD Suite generates a total engineering environment, with an entirely new database structure that feeds standardised and consistent engineering information, maintains engineering data integrity, eliminates inconsistencies between the design information and the actual system, manages change, and supports the automation lifecycle. At the same time, it facilitates the reuse of valuable engineering knowhow, eliminating the duplication of work for subsequent projects. This both saves time and reduces cost.

Ongoing development
Since the release of the CENTUM integrated production control system in 1975, Yokogawa has continually strived to improve this platform by incorporating the latest technologies. In 2008, Yokogawa released CENTUM VP, the latest generation of this series. To date, more than 25,000 CENTUM series systems have been delivered around the world.

For the development of the all-new version of CENTUM VP, four different types of innovation are emphasised: Hyper-intuitive operation, total automation management, intelligent plant conductor, and sustainable plant. This aims to provide customers with an optimum operating environment that will improve the safety, reliability, and efficiency of their operations, and bring greater synergy between control systems and devices in the field. This will significantly improve production efficiency and optimise overall maintenance of their production control systems, safety instrumented systems, programmable controllers, and all field devices, resulting in reduced costs, long-term stability of operations, and optimum plant performance.

Workstation for oil and gas applications!

Eaton has launched a next generation Azonix Barracuda 15” HMI workstation in the MTL product line for the oil and gas industry that enables users to reduce operational costs while increasing productivity and rig safety.  Designed in response to demands for increased processing power and a more rugged HMI for operation in hotter environments, the robust and reliable Azonix Barracuda 15 is expected to set a new high standard for monitoring and controlling processes in oil and gas applications worldwide.

This workstation for Zone 2 hazardous areas features an Intel i7 2.5GHz processor and up to 8GB of DRAM to deliver increased processing power compared to alternative technologies.  This increase in computing power provides the bandwidth to run the most demanding DCS or SCADA software packages, therefore avoiding configuration challenges.  The workstation is available with wireless and Bluetooth options which offer high speed communications for fast rig-up rig-down applications, therefore increasing productivity. 

The Azonix Barracuda 15 is quick and easy to install and connect. Fitted with identical mounting options and the same connector interfaces as its predecessor, the new workstation is a simple drop-in replacement, which lowers installation costs and downtime, thus increasing rig uptime and process efficiency.

The workstation is exceptionally user-friendly.  It incorporates a state-of-the-art touch panel which allows for either a resistive or projected capacitive touchscreen. These sensors support glove touch capability for use in harsh and cold environments. Thanks to the new LED backlit 1024 by 768 display screen, the workstation is visible in virtually all working conditions.

Azonix Barracuda 15 workstation has a wider operating temperature range than alternative systems, providing reliable operation between -40ºC and 60ºC.  It uses industrial grade parts and a cast aluminium housing for extreme environmental conditions, which makes it robust, therefore increasing reliability and improved asset uptime.    

The workstation is lightweight and has a small footprint enabling the user the flexibility to install it conveniently in challenging rig environments.  In addition, the systems do not require external panel housing, saving users approximately $1000-$3000 per installation, and multiple mounting options accommodate installation across various rig configurations. 

Designed for use in tough and hazardous environments worldwide, the Azonix Barracuda 15 workstation is fully certified for the most demanding conditions found in up- and downstream oil and gas applications.  It has hazardous area approvals, including AEx, ATEX Zone 2, and is IECEx class 1 Zone 2 rated, providing increased rig safety.  In addition, customers can use one configuration globally which reduces their cost of sustaining multiple hardware and software assets.

“Cost of rig downtime is exceptionally high and is estimated at up to $500,000 per day, so it is clear to see that increasing reliability and uptime goes a long way towards increasing productivity and profitability,” says Kevin Gillespie, MTL marketing communications manager, Eaton’s Crouse-Hinds division. “With over 25 years of experience in developing HMIs for the oil and gas industry, we have extensive knowledge of the challenges faced by our customers, and Azonix Barracuda 15 has been designed to fulfil all their requirements, enabling users to reduce operational costs while increasing rig safety.”

Adapter & Fieldbus power supply module for hazardous area applications!

Power management company Eaton has an Ex ic adapter and fieldbus power supply module, the latest addition to its Crouse-Hinds division’s MTL line of FoundationTM fieldbus physical layer components. The new MTL F30 Ex ic adapter and MTL 9192-FP fieldbus power supply module provide users with a straightforward, dependable and convenient way of connecting field instruments to FoundationTM fieldbus networks in hazardous area applications.

“Our solutions help meet the growing and rapidly changing demands of customers working in Zone 2 hazardous areas,” said Roger Highton, MTL Product Line Manager, Eaton’s Crouse-Hinds Division. “By providing compatibility with Ex ic standards, our new line allows customers to maintain intrinsically safe practices when working on live, suitably certified field instruments in hazardous areas.”

The new adaptor is designed for use in conjunction with MTL F300 series Megablock wiring hubs. This product release makes it easier for users to demonstrate that their solutions fully comply with Ex ic requirements, while eliminating the need to declare host H1 systems as safety extra-low voltage/protected extra-low voltage (SELV/PELV) compliant. The new line also serves as the only available solution to use the same simple fieldbus input/output (I/O) and power supply cabinet design in general-purpose installations, reducing the number of cabinets required and helping to enhance safety.

The flexibility of the MTL F30 adaptor solution supports Ex nA, Ex d and Ex i devices on the same segment. The MTL F30 adaptors also provide a single solution for Fieldbus Intrinsically Safe Concept (FISCO) and Entity spur applications and eliminate the severe restrictions on segment length that are often associated with alternative solutions in FISCO applications. The new products are ideal for Zone 2 hazardous areas where gas, mist or vapours may be present.

MTL products, part of Eaton’s Crouse-Hinds portfolio, provide leading electronic instrumentation and protection capabilities for the process control industries. Key applications include intrinsic safety, fieldbus, industrial networking, surge protection, HMI and visualisation, gas analysis and alarm management.

User-friendly modular gas analyser for the biogas market!

Eaton has launched a new ‘next generation’ MTL GIR6000 biogas analyser to help ensure reliable, accurate measurement of gases in biogas production. The MTL GIR6000 gas analyser is the first truly modular biogas analyser, requiring minimal maintenance and enabling process engineers and biogas plant managers to reduce downtime and improve their processes.

“Our newest modular gas analyser is designed to meet and exceed the measurement needs of the biogas industry,” says Iain Gordon, Gas Analysis Product Line Manager at Eaton’s Crouse-Hinds Division. “With more than 30 years of experience in gas analysis, our team has developed a simple-to-use, high performance fit-and-forget solution, which enables process managers and engineers to increase uptime, with low cost of ownership.”

The MTL GIR6000 analyser uses an innovative modular concept that makes it user-serviceable and reduces lifetime service costs through quick and easy maintenance procedures that require no special tools or training. As a result, service engineer site visits are largely avoided with the guidance of the built-in self-diagnostic routines and pre-configured intelligent sensor modules.

The gas sensor modules can be individually replaced – simply slide in and lock with an automatic seal integrity check – which helps to ensure minimal downtime, increased process efficiency and reduced operational maintenance cost.

The analyser can measure up to six gases, including methane, oxygen and hydrogen sulphide, and is designed with dedicated sensor modules and long-life, established sensor technology to provide continuous, accurate and reliable readings. The integrated platform concept makes it easy to upgrade the MTL GIR6000 analyser to meet future demands as the plant’s measurement needs evolve.

The MTL GIR6000 analyser is designed to be secure and reliable. It requires key-lock access and PIN-codes to change the key parameters making the data safe. Setting up the unit on-site is facilitated by the large bright 7-inch LCD display and rugged keypad as well as an intuitive menu-driven structure. The display provides a clear visual warning when there is a system fault or when a sensor is reaching the end of its life-cycle, allowing users to predict or plan maintenance requirements. Data is transmitted to the plant host system through a number of communication methods, allowing live real-time data to be monitored remotely.

The MTL GIR6000 analyser is an integrated IP65 weatherproof solution and is ATEX approved for Zone 2 Hazardous Areas for installation flexibility around the biogas plant.

User-friendly gas analyser for launch next month!

A next generation gas analyser dedicated to the anaerobic digestion and biogas market at the AD & Biogas Show 2014 (2-3/7/2014, Birmingham, GB).  Visitors to the Eaton’s Crouse-Hinds stand will be the first to see the company’s innovative MTL gas analyser, which is the first truly modular solution and is expected to bring significant cost savings to gas measurement.  In addition, visitors can meet experts from MTL to learn more about hazardous area electrical equipment and how it is used to help meet ATEX safety certification requirements on a Biogas plant.

“The anaerobic digestion and biogas industry has been demanding a more user-friendly solution in the market, and our modular gas analyser is specifically designed to meet and exceed that need,” says Iain Gordon, Gas Analysis Product Line Manager at Eaton’s Crouse-Hinds Division. “With more than 30 years of experience in gas analysis, our team has developed a simple-to-use, high performance, fit-and-forget solution, which enables process managers and engineers to increase uptime and reduce operational costs.”

MTL GIR6000 is Eaton’s first gas analyser dedicated to the biogas market and uses sensor technology initially developed to provide continuous and reliable online gas measurement in the oil and gas industries.  The company is now extending its hazardous area knowledge and experience built on protecting equipment in the oil and gas industries to the biogas markets.

An expert will also be on hand to answer queries on hazardous area safety around the Biogas plant, enhancing safety and ensuring that plants meet the standards required for measurement and control in the hazardous area.  For more information on the new easy-to-use MTL GIR6000 gas analyser and to book a hazardous area discussion visit Hall 3 stand C031 at AD & Biogas trade show 2014, or contact mtlenquiry@eaton.com.

MTL products, part of the portfolio from Eaton’s Crouse-Hinds business, provide leading electronic instrumentation and protection capabilities for the process control industries.  Key applications include intrinsic safety, fieldbus, industrial networking, surge protection, HMI and visualisation, gas analysis and alarm management.

Hazardous area remote terminals!

Eaton has launched a new MTL GECMA RT remote operating terminal, which enables plant managers to reduce operation costs, optimise productivity and increase plant safety. This terminal has a unique modular design and is a next generation remote terminal which features state-of-the-art technology to offer unparalleled levels of safety, making it ideal for use in hazardous EX zone areas in chemical, pharmaceutical, refinery and oil and gas industries worldwide.

It consists of five electronic modules; the display unit, power supply, communications modules, keyboard and mouse. The terminal’s modularity means upgrades to existing installations are quick and easy, which can save time, and minimise costly maintenance and downtime. Traditionally, the whole unit would have to be dismantled off site, but now with MTL GECMA RT, individual parts can be replaced simply on site, increasing plant availability.

Of vital importance, the modules are individually approved to global hazardous certification for Zone 1 environments. This offers safe handling on site and independent of the housing, and guarantees high reliability - worldwide.

The MTL GECMA RT features a couple of unique safety functions. First is a unique intrinsically safe cable for secure data transmission. Users can specify an Ethernet or fibre optic cable between the control room and remote terminal, with no need for additional external cable protection. This provides a saving of approximately 50% of wiring cost.

Secondly, the terminal features a unique visual alarm to immediately warn users in the event of a process failure. The alarm visualization system checks the correct data transmission to the display in real time and alerts users by way of a flashing red icon, enabling them to act straight away to rectify the problem. The MTL GECMA RT is the only remote operating terminal of its kind on the market to feature a visual alarm – other terminal screens typically freeze if there is a process fault – and it is expected to help plant managers reduce downtime and associated operating costs.

Available from stock and pre-tested, the MTL GECMA RT operating terminals are designed to enhance visualization within plant processes using displays ranging from 19 to 24 inches, with full HD versions offered in 22 and 24 inches. Displays are of the highest industrial quality and to ensure the best readability, the terminal incorporates optical bonding and LED-backlit technology resulting in a high resolution image in a low power display.

The USB interface future-proofs investment and allows easy expansion for additional connected devices, such as scanners or printers. MTL GECMA RT also supports WLAN and Bluetooth. MTL GECMA RT is available with a large range of cost effective specialist housing options. The flexibility of the design allows engineers to customise the housing to suit their application and the slimline stainless steel housing can be mounted to the floor, ceiling or other suitable stable object as required.

“Plant managers are under increased pressure to reduce costs, optimise productivity and increase plant safety and our new MTL GECMA remote terminals have been designed to meet these specifications and fit process needs,” says Axel Tischendorf, MTL GECMA Product Line Manager, Eaton’s Crouse-Hinds division. “The driving force of our investment is based on the knowledge and understanding of our customers’ requirements and the new generation of terminals is built on over 15 years’ experience in the industrial market.”

MTL products, part of Eaton’s Crouse-Hinds portfolio, provide leading electronic instrumentation and protection capabilities for the process control industries. Key applications include intrinsic safety, fieldbus, industrial networking, surge protection, HMI and visualisation, gas analysis and alarm management.

Certified in Functional Safety Management

MTL is now certified as a Functional Safety Management (FSM) Company. The International standard IEC 61508:2010 mandates that everyone involved in the safety systems lifecycle must demonstrate Functional Safety Management.

Assessed through an external certifying body (SIRA) which is audited by an accredited national body (UKAS), MTL demonstrates its competence to design and market products in accordance to the standard. This gives customers confidence and assurance of quality process management when using MTL products in safety instrumented systems (SIS) without the need for further verification of documentation.

MTL’s FSM is certified to cover a range of Signal interfaces, IS barriers, Isolators, Fieldbus Instruments, Alarm systems, Communication devices and Instrument Power Supplies. MTL continues to expand their FSM product offering with the latest additions to include the MTL4500 and MTL5500 series Isolators, which can now be now used in functional safety applications. Alongside this, the previously introduced MTL4850 Hart Multiplexer can now be used for connection to instrument loops performing safety functions up to and including Safety Integrity Level SIL3.

MTL currently shares its knowledge and expertise on hazardous areas and the relevant standards with its ATEX and Flammable Facts pocket posters. Following this accreditation MTL complements this with a Functional Safety poster which provides detailed information about the concepts of FSM and the standards that demand it.

Surge protector eliminates threat of power crossover

The new SSP self-healing surge protector from MTL offers state of the art surge protection with the additional features of AC fault withstand capability and current limiting protection to our traditional and proven hybrid surge technology, adding yet another layer of protection.

The product is suitable for all general Process I/O applications and higher voltage signal applications for SCADA run over private wire networks and is designed to eliminate the most common cause of surge protection device failures (continuous overvoltage/over current conditions) whilst adding current limiting protection to the circuit.

The use of Surge Protection Devices on communication lines has increased significantly over the last number of years. However if the communication lines are subjected to induced AC power or AC power-cross, the surge protector can pose possible safety hazards. In these circumstances, the SSP surge protector will respond and draw AC current providing over current protection to the wiring, the load and the loop equipment.

The SSP’s self-healing capability incorporates circuitry to mitigate the hazards of induced AC or AC power-cross up to 240Vrms by stopping the flow of current in milli-seconds to prevent surge protector and wiring damage. Once the AC power is removed, the SSP will automatically begin normal operation.

The single loop design makes the SSP series resilient to sustained over-voltages caused by earth faults and power faults and is packaged in the well-known IOP/SLP enclosure giving a wider range of performance offering.

Multiplexer gains SIL3 rating!

The MTL4850 Hart Multiplexer gains SIL3 rating for functional-safety related loops

The SIL3 rated MTL4850 Hart Multiplexer is now available. MTL is known worldwide as an intrinsic safety interface specialist, and now takes the lead in functional safety components by introducing the SIL3 rated MTL4850 Hart Multiplexer for connection to instrument loops performing safety functions up to and including Safety Integrity Level SIL3.

This multiplexer is designed to ensure that there is no effect on the analogue loops to which it is connected; multiple concurrent faults in the components that couple the MTL4850 to the analogue loops would have to be present before the isolation would be compromised. The MTL4850 HART multiplexer does not itself implement a safety function but may be applied alongside measurement and control equipment that is providing a safety function.

Unique design features make it suitable for use in applications where the 4/20mA instrument loops, to which it is connected, are implementing safety functions up to SIL3 and the techniques used mean that systematic faults can be prevented.

The multiplexer provides a common bridge to access HART information for the signal channels that are connected to it, This is particularly important when the multiplexer is associated with signal loops that are feeding a safety shutdown system.

MTL continues to increase its functional safety product portfolio which demonstrates its commitment to comply with IEC61508:2010. Moreover, this certification as a Functional Safety Management Company demonstrates that MTL has processes and competence to design and market products according to the international standard. Thus the customer may have the confidence to use MTL’s products in Safety Instrumented Systems.

Isolated device couplers

The Fieldbus Foundation has registered the first isolated device couplers based on its FOUNDATION™ H1 (31.25 kbit/s) device coupler test specification. Devices from MTL and R. Stahl successfully completed the foundation's rigorous registration process.

As part of a FOUNDATION fieldbus infrastructure, isolated device couplers are installed where the fieldbus trunk (i.e., home run cable) is connected to the various device spurs. Isolated device couplers are specifically designed to allow automation end users to connect more devices per coupler while permitting live segment work in hazardous plant areas. These couplers provide isolated, conditioned power to multiple fieldbus devices and protect against short circuits caused by excess current in a spur. By enabling more devices per segment, they also help reduce controller input/output (I/O) points and associated installation costs.

MTL's 9370 FB

MTL's 9370-FB Series Fieldbus Barrier provides a range of complete integrated enclosure systems, instead of stand-alone barrier modules. All internal components are live pluggable, meaning that field maintenance can be carried out quickly and safely. Surge protection devices for the trunk and spurs can be easily fitted without requiring product re-design. The product series includes 6- and 12-spur versions in stainless steel or GRP enclosures, as well as a redundant option enabling improved system availability in critical fieldbus networks.

Stahl 9411/21

R. Stahl's Series 9411/21 and 9411/24 isolated device couplers are suitable for use in Zone 1, Zone 2 and U.S. Division 2, and are available with plastic or stainless steel housings that can be tailored to fit customer requirements. The series also includes a unique power management feature: during the start-up of a fieldbus segment, the spurs energize one after the other. This reduces the inrush current on a segment by up to 50 percent, requiring less spare energy and making longer segment lengths possible.

The Fieldbus Foundation's Stephen Mitschke, director-fieldbus products, commented, "The device coupler test specification provides a high level of robustness in fieldbus systems. And recent enhancements to the FOUNDATION fieldbus physical layer specifications provide end users with greater confidence that registered fieldbus equipment can be employed in a tightly integrated, interoperable control system architecture that is well suited to the most demanding industrial environments. We look forward to seeing additional device coupler offerings joining R. Stahl and MTL on our registered products list."

FOUNDATION fieldbus provides an all-digital communication infrastructure for process automation, with powerful multivariable measurement capabilities, powerful device diagnostics, and the ability to integrate wireless devices across multiple networks. The block structure of FOUNDATION fieldbus is unique, and provides true distributed functionality for implementing control in the field, improved data management, and alarm and alert management.

Maximum protection for LED lighting systems

LED lighting technology continues to grow in popularity due to its fast start up, low energy consumption, long-life and reliability. This is particularly true in markets that include Home Automation lighting, commercial road and street lighting, highway lighting, sign lighting and industrial lighting. Since LEDs are more susceptible to surges and transients, realizing the maximum potential from LED lighting requires high performance surge protection.

MTL Instruments announces the LS10 (serial) and LS12 (parallel) Series of surge protectors purpose-built to protect LED lighting from transients and surges generated by lightning and switching transients.

The LS Series is suitable for harsh environments, including outdoor mounting, and provides high performance circuit protection that saves valuable LED lighting assets, reduces maintenance, prevents unwanted failures and decreases degradation damage for longer lifetimes. Features include:
• Protection of LED lighting systems and drivers
• Space saving footprint for mounting in confined locations
• Protection for 120V-347V and 480V Systems
• High performance to size ratio
• Fully automatic operation
• UL1449 3rd Edition Type 4 Recognized Component
• Rated for harsh environments
• 10 year product warranty

The Series features Metal Oxide Varistor (MOV) technology and high energy discharge tube (gdt) technology with a state-of-the-art failure disconnect network that provides contractors, installers, LED system OEMs and end-users with years of peace-of-mind operation.

Widescreen HMI

GeCma components GmbH, the HMI division of MTL Instruments now has a 22” wide screen option for its  Challenger range of remote HMI data terminals. GeCma is the recognized market leader for visualisation systems in hazardous areas as can be seen from its installed base of over 15000 units worldwide.

Being based upon the range of HMI’s of the same name, this unit offers the same advantages which make the Challenger range the market leader it is today. Features such as IS (Intrinsically Safe) data transmission between the safe area and the hazardous area and IS construction of the components based within the hazardous area allow the user to maintain, move and modify the unit with their process running, thus negating the need for costly shutdown of the production line when the need arises to disconnect the HMI. Customers can also count on GeCma’s usual high standard of construction and durable finish with an IP rating of IP66 that allows GeCma HMI’s to still be functioning in hazardous areas after more than 10 years of use. The new display provides the user with a true 22“ colour display running at a resolution of 1680 x 1050 pixels and an aspect ratio of 16:10. The display will also be available with a resistive touch screen option making it ideal for environments where protective clothing and gloves are a necessity.

GeCma will also be offering the Challenger 22i as an upgrade package which will allow current GeCma users to upgrade their existing screen and housing whilst keeping their existing supporting infrastructure in place; therefore offering a very cost effective route to widescreen visualisation. The upgrade kit is also targeted at users who are migrating to a new Process Control System that requires a higher resolution and demands a bigger (wide) screen to display more information without the need to replace their existing visualisation solution in the field.

The new display is backwardly compatible with other models in the range, there being only the need to replace the display and housing in order to upgrade to the new screen. This operation is completely plug and play with no re-termination of cabling required and does not affect the certification of the system.

GeCma also offers a wide variety of special, customised housings tailored to applications in hazardous areas where space is limited or various control elements must be integrated into the visualization solution, thus requiring a completely customer-led bespoke solution.

Security breakthrough for OPC-based industrial automation

New Tofino® OPC Enforcer technology secures any system using classic OPC, the world’s most widely used industrial integration protocol
Byres Security has released the new Tofino OPC Enforcer firewall, part of the Tofino Industrial Security Solution. This new module locks down any industrial network using the previously hard to secure OPC Classic protocol. Using deep packet inspection firewall technology, the Tofino OPC Enforcer provides superior security over what can be achieved with conventional firewall solutions. The result is improved network reliability, availability and security for any process control or SCADA company using OPC.

Byres Security have published an OPC Feature Page, which is a hub of information on OPC and security, and includes a link to download the new White Paper titled “Securing Your OPC Classic Control System” written by me and Thomas J. Burke, President of the OPC Foundation.

OPC Classic is widely used in control systems as an interoperability solution, interfacing control applications from multiple vendors. Unfortunately, as numerous studies show, the technologies underlying it were designed before network security issues were widely understood. As a result, OPC Classic has been almost impossible to secure until now.

Thomas J. Burke, the president of the OPC Foundation, notes; “The Tofino OPC Enforcer is an important innovation and a great solution for all the systems that currently use OPC Classic – approximately 90% of all industrial networks”.

While the OPC Foundation is working hard to get its new and more secure OPC-UA technology into the market place, it will be years, if not decades, before all legacy OPC DA, HAD and A&E installations are replaced. In the meantime, the Tofino product addresses the security gap by providing a plug-n-protect solution that can be deployed in minutes without changes to existing OPC systems.

The Tofino OPC Enforcer provides two important benefits to control systems users:

1. It provides robust security and stability for any system using OPC DA, HAD or A&E, thus preventing industrial network attacks and accidents. Unlike other firewalls, this product inspects, tracks and secures every connection made by an OPC application, opening only the exact TCP port required for a connection between an OPC client and server.


2. It is implemented without any control system changes. The Tofino hardware is simply installed into the live network and configured using a drag and drop editor to select permitted clients and servers. Once installed, network security is assured, with all OPC traffic managed behind the scenes.

The recent Stuxnet worm attacks against Siemens HMIs and PLC systems has highlighted the need for better security on the plant floor. At the same time, many incidents result from internal network problems.

“Past industrial shutdowns, for example, haven’t been caused by hackers. Instead they were the result of badly configured software causing traffic storms that impacted critical controllers and other systems,” said Eric Byres, security expert and Chief Technical Officer at Byres Security. “The Tofino OPC Enforcer LSM does much more than block hackers and viruses from accessing automation systems. Its dynamic port management techniques prevent many basic network problems from spreading throughout a plant or SCADA system.”

Availability and Requirements
The Tofino OPC Enforcer is available now from Byres Security and from leading automation industrial suppliers MTL Instruments and Belden / Hirschmann. It requires the Tofino Security Appliance, the Tofino Central Management Platform and the Tofino Firewall LSM. The technology will also be available as a stand-alone appliance, the Triconex Tofino Firewall from Invensys Operations Management in Q4 2010.

Fieldbus surge protection

MTL Instruments has released a new Surge Protection Device (SPD) that can be retrofitted to FOUNDATION™ fieldbus systems. The FS32 prevents surges and transient over-voltages conducted along the Trunk, or Spurs, of fieldbus systems from damaging the associated electronics such as terminators, spur blocks and the bus control equipment. Designed to fit MTL’s latest fieldbus products to protect spurs, the FS32 can also be used to protect spurs on Megablock wiring hubs. In addition, the plug-in format makes the product easy to retrofit, and the small footprint assists in the reduction of the size of junction boxes.

The multi-stage hybrid surge protection network at the heart of the FS32 uses a combination of solid state electronics, and a gas filled discharge tube, to provide surge protection up to 20kA. This impressive surge protection circuit is designed to exhibit exceptionally low line resistance, and has negligible voltage drop to the spurs.

In operation the FS32 does not adversely affect the performance, or operation, of the fieldbus or connected equipment. The FS32 allows signals to pass with little attenuation, whilst diverting surge currents safely to earth (ground) and clamping output voltages to safe levels. Fully automatic in operation, the FS32 device reacts immediately to ensure that the equipment is never exposed to damaging surges between lines or the lines to earth (ground). Reacting instantaneously, the FS32 redirects surges safely to earth (ground) and then resets automatically.

New fieldbus barrier

MTL Instruments have a new range of Fieldbus Barrier wiring hubs that establish a new benchmark for connecting intrinsically safe field instruments to FOUNDATION™ fieldbus networks in hazardous areas. The 9370-FB Series Fieldbus Barrier retains the major benefits of the “High Energy Trunk” technique whilst removing the drawbacks associated with existing Fieldbus Barrier implementations. The result is lower cost, safer operation and higher reliability throughout the life-cycle of the fieldbus network. These benefits are not only for the plant operator, but for all parties involved in the design and installation process.

The 9370-FB Series are modular in construction, comprising of a fixed carrier assembly and pluggable components. These are assembled to form complete, self-contained enclosure systems in either stainless steel or carbon-loaded GRP, and sized according to the application requirements.

A key feature of the 9370-FB is the speed and ease in which it can be reconfigured or repaired. All parts of the system containing complex electronic circuits are housed in “pluggable” modules that can be removed and replaced while the equipment is live. This is a sharp contrast to conventional Fieldbus Barrier implementations, where serviceability is made difficult or impossible by the ‘hard-wired’ nature of the field enclosure; which cannot be live worked in the hazardous area. Tracing and fixing faults is also made easier, since rapid substitution can be used to pin-point the source of problems.

The use of innovative connector technology has allowed MTL to provide a Fieldbus Barrier system that has the ultimate flexibility. The barrier modules, terminator and optional surge protection devices are all certified for removal, and replacement, in the hazardous area without causing an ignition risk. This certification not only means safer maintenance, but also provides the unique ability for expansion in service. For example a 12-spur enclosure, fitted with one 6-spur module, can be optionally specified and installed; expansion to 12 active spurs is easily accomplished by plugging a second module into the enclosure. No other configuration is necessary, provided the fieldbus power supply is correctly sized and the full loading of the segment has been anticipated.

Commenting on the new release, MTL’s Technical Manager for Industrial Networks, Phil Saward says, “We are confident that the product’s innovative features will help users to achieve the improvements in efficiency and plant safety that are required in today’s demanding business environment. Not only has MTL responded to the demand for greater flexibility when using the High Energy Trunk technique, but has also exceeded customers’ expectations for easy installation and maintenance of field-mounted equipment in fieldbus applications.”

Optional, integrated surge protection is also a key feature of the 9370-FB Series, and includes plug-in devices to protect the barrier modules from transients transmitted along the trunk and spur cables. In conjunction with additional protectors located at the fieldbus host, and at the fieldbus instruments, they allow the user to install and operate fully protected networks.

Unlike conventional fieldbus barrier enclosures, the plug-in surge protection devices can be included at the time of installation or retrofitted once the system is in service. This streamlines the selection process, avoids clumsy over-specification and allows protection to be added in response to site experience.