Eco-electricity and heat from biomass

 Safety technology for a groundbreaking biomass power station

A biomass power station generates electric power by burning biomass like wood chips, bark and untreated wood. This is based on a high-tech process which has been modified in Oberwart, Austria. Here, the biomass is gasified under high temperatures in order to generate energy. Safety technology from Pilz makes sure that everything happens according to plan.

The technology behind wood gasification is not fundamentally new, as it has in fact already been known for several decades. Particularly in times of war or other crisis, during which there was often a shortage of fuel, vehicles were operated with wood gas engines. Of course, issues like "alternative production of energy" and "energy efficiency" were of no concern then. In the biomass power station in Oberwart, state-of-the-art wood gasification technology is used to achieve the maximum possible efficiency.
Today, the wood gas produced in the power station passes through a highly sophisticated purification process, and only then is it used to run two large gas engines. The electricity generated in this way is fed into the public grid. As a by-product of the system, large quantities of heat are also generated.

Special methods deliver high performance
Every year the biomass power station in Oberwart generates 16 GWh of eco-electricity and 21 Wh of heat. This is enough to supply around 4,300 households with electricity and around 1,600 households with heat.
The special technique used in the biomass power station is based on dual fluidized bed gasification technology. Here, the combustion zone and gasification zone are kept separate. Water vapor is used as the gasification agent. In this way, a product gas is generated in the gasification zone which is low in tar and virtually free of nitrogen. It also has a higher calorific value than the product gas obtained with other gasification methods.
With the technology applied here, the biomass power station in Oberwart is at the cutting edge in terms of efficient use of biomass for the production of eco-electricity and heat.

Flexible safety concept
In terms of safety, Ortner GmbH in Innsbruck/Tyrol who constructed the plant used the programmable PSS 3000 control system from Pilz for the first time. As a freely programmable system which is suitable for modular expansion, PSS 3000 can be flexibly adapted to the specific requirements of the plant. Looking at the required functionality, the number of inputs and outputs which needed to be integrated and the usability of the system, it became clear that this control system was the ideal solution for the safety requirements which needed to be implemented. It records and processes all safety-related messages and signals in the system, including the signals from the emergency stop, temperature and pressure sensors, lance monitoring and flame monitor systems. Networking of the signals into a standard PLC was implemented via the inputs and outputs.

Packaged with care

Foodstuffs must be packaged precisely, safely and carefully. When positioning or spacing products, it is particularly important to avoid flattening or damage during the packaging process.
The “Dynamic Stocker” accumulator made by the French firm Euro Cri converts an irregular product flow at the output of a production machine into a regular flow, as found when packaging biscuits, for example. The accumulator gathers the unpackaged products as they arrive and creates a “buffer store”, which can be regulated according to the change in the material flow.
The greatest challenge was to arrange the packaging process so that it was 100% synchronous with the rhythm of the existing horizontal flow-packer. The flow-packer forwards incoming products in an irregular sequence. Development and design demanded an automation solution capable of controlling complex movements and handle various transport speeds simultaneously. The focus was on the movement of a total of six axes. It had to be possible to coordinate the axis movements with 100% accuracy, so that the various speeds at different points of the conveyor could be synchronised precisely and safely regulated.
Euro Cri opted for a Pilz motion control solution (PMC), which enables precise synchronisation of the respective motion processes.

Complete packaging solution
As a supplier of complete automation solutions, Pilz France supported Euro Cri from planning and development to implementation and commissioning.
The central element of the motion control solution is the controller-based PMCprimo 16+, which performs the complex motion and control functions.
Used in conjunction with the servo amplifiers PMCtendo DD and servo motors PMCtendo AC, the result is a drive solution which can react flexibly to different format specifications and can be used to implement high cycle counts with ease. The absolute position of the motors can be read during operation, after the machine is shut down or after power failure. Systems with PMCtendo are modular and expandable. As a result, users can react flexibly to product changes. In addition to simplifying positioning and storing motion tasks, the PMCtendo DD also provides the power supply and motor drive on the “Dynamic Stocker”.

Packaging process is safely monitored
The packaging process can be monitored and regulated using PMIvisu operator terminals. The motion curves relevant for the cycle are calculated in the simplest way possible: the operator simply enters the set data on the operator terminal – the packaging length and the position of the section to be embossed, etc – and the system automatically calculates the motion profile for runtime. Adjustments are made via the operator terminal, whereby the material flow control system fulfils different product type requirements. The display can be used not only to select recipes but also to view error messages. The cause of the error always appears first; at the touch of a button the operator receives specific instructions on how to rectify the error.
Safety-related functions such as emergency stop, emergency off, or safety gate monitoring on the “Dynamic Stocker” are monitored via the compact safety relay PNOZsigma. The PSENmag safety switch was incorporated into the safety gate to ensure the packaging process is not interrupted unnecessarily; it is suitable for the very highest hygiene requirements and provides one hundred per cent protection against defeat.
“With Pilz we have gained a competent partner in the automation industry. We will continue to work with them in the future to develop leading-edge packaging systems for our customers,” says Mathieu Carie, Head of Automation at Euro Cri.



Author: Yannick Le Héno,
International Sales
Market Development
Pilz GmbH & Co. KG

Stanford Linear Accelerator Center- Laser Source Protection and Access Control

Stanford’s Linear Accelerator Center (SLAC) has built a safety and notification system for the variety of laser source equipment that is used at SLAC. The laser source safety configuration is designed with two major levels of protection; Access Control and Laser Source Protection. Pilz’s PNOZ Multi is used to monitor the status of the safety sensors and access control modules that are in place around the laser sources. The laser source itself is contained in a Laser Source area with entrances through various access doors and covers/flaps; these access points are all monitored using the Pilz PSENmag sensors. The PSENmag sensor status are monitored with a PNOZmulti, a Device Net Module is added to the system for annunciation of the safety system’s status. The access to the various laser sources and control areas while monitored by the PNOZmulti are used in conjunction with the Device Net Module, this allows those working in the Laser Source area to manage the status of access points to the laser. As part of the monitoring system, Pilz E-STOP pushbutton PIT is used to shutdown components during maintenance or configuration of the laser source or enclosure areas. The combination of safety products that SLAC has implemented thus far gives the several benefits from a safety design standpoint; the component nature of the system design itself, allows for a high degree of flexibility and reconfiguration allowing for the system to grow/change with minimal downtime. Additionally, the use of PNOZmulti monitors the amount of wiring involved in installation makes the safety system itself more economical. Finally, system status and safety diagnostics can be completed through use of a fieldbus as opposed to manual inspection, giving the system higher level of system integrity and accuracy. SLAC has plans to expand the safety system to create a more robust and efficient system for other areas of the SLAC research tools and equipment.

SLAC National Accelerator Laboratory is home to a two-mile linear accelerator—the longest in the world. Originally a particle physics research center, SLAC is now a multipurpose laboratory for astrophysics, photon science, accelerator and particle physics research. Six scientists have been awarded the Nobel Prize for work carried out at SLAC and the future of the laboratory promises to be just as extraordinary.

Schiphol Airport - Luggage Conveyor System Amsterdam, The Netherlands

Vanderlande Industries and Schiphol Airport made a joint decision to use Pilz PSS programmable control systems. The use of conventional relays was examined, however the different sectors and the respective shutdowns made it virtually impossible to implement the system using relay technology.

The PSS programmable control systems are connected via SafetyBUS p. This connection enables various areas to be shut down when different emergency stop buttons are operated or when different safety gates are opened.

The use of the Pilz PSS programmable control system allows Schiphol Airport and Vanderlande to connect to SCADA systems, provide precise fault analysis and perform complex safety options. The PSS programmable safety and control systems monitor safety functions such as E-STOP on extended conveyors. Integrated diagnostic functions enable faults to be located and rectified quickly. The low wiring costs and short commissioning times increase productivity and reduce costs.

With PSS programmable safety and control systems the conveyor system at Schiphol Airport meets the highest safety requirements in accordance with the international standards for machine safety EN 954-1, EN/IEC 62061 and prEN ISO 13849.

Vanderlande Industries designs, builds and services leading baggage handling systems for airports of all sizes. These belt, tub and/or track solutions combine operational effectiveness (low IR rates), short connection times and high conveyability. Based on proven technology, in-depth business knowledge and industry best-practices, they deliver the highest availability, reliability and lowest costs per bag. For more information about Vanderlandes other capabilities visit http://vanderlande.com

A Letter From Douglas K. Woods, President, AMT

AMT-The Association For Manufacturing Technology has made the decision to no longer continue its role as the Standards Development Organization (SDO) for the B11 series of standards. The association is in the process of refocusing its efforts in order to enhance its support to members in areas of more pressing concern and greatest impact on our membership.

AMT will continue to participate in B11 efforts — the association will retain its position on the Accredited Standards Committee of B11. However, it will be relinquishing its Secretariat position in the development of standards, and will be disbanding its Standards Department, which is a part of AMT’s Technology Department.

AMT remains committed to offering member support on standards issues, and during the transition of the Secretariat role and beyond, resources will be available for any member with a need for standards-related assistance. AMT will offer such support on a continual basis, either through in-house staff or by the use of outside experts as necessary.

As the needs of the industry have evolved, AMT is adjusting its focus accordingly. This includes working to forge coherent government policy for the manufacturing industry, promoting innovation, and bringing about collaboration within the manufacturing community. Additionally, AMT feels that as the industry has evolved into a global realm, standards would be best handled by an internationally focused entity.

Meanwhile, AMT’s Technology Department will reposition its resources to address emerging technology needs and find ways that will allow members to utilize them in the best possible way. The emphasis will be on helping members embrace new technologies so that they can keep their businesses moving forward.

Within in the next few months, AMT will be working with Mr. Dave Felinski in establishing a new organization, apart from AMT, that will take on the role of SDO for B11 activities. This is being done to assure that the important responsibility of Secretariat to B11 is transferred to a highly capable new organization.

This decision was announced to the B11 Accredited Standards Committee at their recent meeting held at Boeing Corporation in Seal Beach, California.

More details will be coming about this change as AMT continues to evaluate the needs of its members. If you have any questions, you can contact Paul Warndorf, VP-Technology at AMT, by phone at (703) 827-5291 or email at pwarndorf@AMTonline.org.

Sincerely,

Douglas K. Woods
President, AMT

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Pilz PSS programmable control system monitors coil-coating machine

Alcan Singen GmbH of Germany manufactures rolled products, extruded products, moldings, composites, components, systems and lightweight aluminum airfreight containers. Center stage is taken by a coil-coating machine. The lacquer is hardened in air flotation systems, which can generate hot air up to 400°C.
The process uses a programmable control system, PSS, mainly to monitor the kiln, which is heated directly with gas. The use of the Pilz PSS considerably reduces the wiring. The upgrade to Alcan Singen’s system divided functions into specific groups, providing a better overview for service personnel, given that individual control cabinets only contain modules that affect that specific plant section. The PSS provides user-friendly diagnostics and allows specific information about plant errors that are acquired at one point to be evaluated at several points.

The world leader in SAFE automation; Pilz offers a full range of leading-edge safe automation products and services. The company’s innovative technologies and safety expertise provides customers with the leanest and safest solutions. Products include sensor technology, electrical monitoring relays, and automation solutions with motion control, safety relays, programmable safety and control systems and an operating and monitoring range. Wireless and safe bus systems are also available for industrial networking.Pilz also provides a comprehensive range of consulting, engineering and OSHA-approved training services. Certified consultants provide a wide range of services in USA, Canada and worldwide including risk assessment, safety concept, safety design, LeanSafeTM services, CE -marking and safety sign-off. Pilz also performs facility safety reviews for due diligence relating to mergers and acquisitions. For more information about Pilz products and services visit www.pilz.us.
Alcan Inc. (NYSE, TSX: AL) is a leading global materials company, delivering high quality products and services worldwide. With world-class technology and operations in bauxite mining, alumina processing, primary metal smelting, power generation, aluminum fabrication, engineered solutions as well as flexible and specialty packaging, today's Alcan is well positioned to meet and exceed its customers' needs. Alcan is represented by 68,000 employees, including its joint ventures, in 61 countries and regions, and posted revenues of US$23.6 billion in 2006. The Company has been featured on the Dow Jones Sustainability World Index consecutively since 2003. For more information, please visit: http://www.alcan.com

Langen Packaging Inc. Chooses Pilz Automation Safety L.P. For Safety Applications

Langen Packaging Inc., a recognized leader in the packaging industry, has partnered with Pilz Automation Safety for safety related machine guarding applications.
Using multiple base units that can easily communicate with each other, Pilz hardware and software gives Langen the ability to distribute safety devices around the entire machine. “This allows us to build independent machine modules that can be interconnected with very few electrical connections,” said Langen electrical engineering manager, Patrick Strauss. “This aids in wiring, shipping and generally in pre-building standard modules.” Langen also has the ability to view the status of all safety I/O available, over Ethernet I/P, so that individual guard statuses can be easily reported on the HMI. Because the individual guard statuses are now easily accessible, Category 4 safety can be reached while only wiring two contacts per door, reducing the cost of door switches and wiring. Before using the PNOZmulti, up to three contacts per switch were required to be wired in order to have individual guard door statuses available at the HMI, the safety was only rated Category 3. Using the PNOZmulti, Langen is now able to easily create more complex safety zoning and sequencing. The Pilz system includes some modules that aren’t available on other safety controllers, including speed sensing modules, allowing complex safety functions when needed.
The new system has also aided in the reduction of manufacturing costs. Langen now has the ability to purchase the simplest light curtains because the PNOZmulti can handle tasks such as muting which the light curtain no longer has to be able to do on its own. “Pilz was able to offer the best flexibility and power within the price range,” notes Strauss.
The PNOZmulti is multifunctional and freely configurable for use in many areas of mechanical engineering. The safety system monitors safety functions such as E-STOP, safety gates, light beam devices, two-hand switches and much more. PNOZmulti can also be used to resolve standard control functions economically. Instead of wiring, users can generate the safety circuit on a PC using an intuitive configuration tool. The configuration is stored on a chip card and inserted into the base unit.
Langen Packaging has enjoyed great success in using the Pilz solution and is always involved in the development of future products and improvements by Pilz.


The world leader is SAFE automation; Pilz Automation Safety L.P. offers a full range of leading-edge safe automation products and services. The company’s innovative technologies and safety expertise provides customers with the leanest and safest solutions.
Products include sensor technology, electrical monitoring relays, automation solutions with motion control, safety relays, programmable safety and control systems and an operating and monitoring range. Wireless and safe bus systems are also available for industrial networking.
Pilz also provides a comprehensive range of consulting, engineering and training services. Certified consultants provide a wide range of services worldwide such as risk assessment, safety concept, safety design, CE services and safety sign-off. To keep a company LEAN and SAFE, there is no better partner than Pilz. For more information about Pilz Automation Safety L.P. or packaging solutions visit http://www.pilz.us/ or 734-354-0272.

Langen Packaging Inc. is North America’s foremost designer and manufacturer of high-speed cartoning and case packaging machinery, as well as integrated packaging solutions, ranging from standard models through to customized packaging lines. In the last several decades, Langen has become an advanced solution provider, integrating cartoners, accumulators and case packers into complete turn-key systems, taking on projects ranging in value from a few hundred thousand dollars to over $10 million. For more information about Langen Packaging visit http://www.langeninc.com/ or call 905-670-7200.