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VOLUME

31
NO 8 AUGUST 2015
R26 incl VAT
Official publication of the SAIMC

Food & beverage | Process measurement | Valves, actuators & pumps


Electrical power & efficiency | IT in manufacturing
VOLUME 31 NO 8 AUGUST 2015

OUR COVER 26
REGULARS
VEGA now supplies SIL-qualified
measuring instruments for 04 News digest

06
radiation-based level and point
level measurement. The ProTrac News & events
series was developed accord-
ing to the strict specifications 13 Training
of IEC/EN 61508 and all sensors
in this series fulfil the highest 17 System integrators
standard requirements. In addi-
tion, all ProTrac sensors have an 20 SAIMC news
ingenious asset management
system at their disposal. See this 24 Nick Denbow
month’s cover story on page 26
for more. 92 Product news

FEATURES
Cover story 26 Radiation-based instrumentation for extreme process conditions

Food & beverage 28 Krohne SA, Siemens Southern Africa, ifm electronic SA,
ABB South Africa

Packaging & bottling 34 Prime Automation, RET Automation, SEW-Eurodrive, Beckhoff


Automation

Process measurement 40 Krohne SA, WIKA Instruments, R&C Instrumentation, Allpronix,


Emerson Process Management, Siemens Southern Africa,
Instrotech, ifm electronic SA, Mecosa

Robotics & mechatronics 48 Horne Technologies, SMC Pneumatics, Parker Hannifin SA,
ifm electronic SA

Valves, actuators & pumps 52 Metso Automation, IQ Instruments, Pinnacle Instruments SA,
Emerson Process Management, Macsteel Fluid Control, Mitech,
Gemü Valves Africa, Raptech, Parker Hannifin SA, Heaton Valves
Africa, Valve & Automation, AT Technical Services, Pneumax
Southern Africa

Control system design 66 Michael Brown Control Engineering cc

Electrical power & efficiency 68 Yokogawa South Africa, Zest WEG Group, Adroit Technologies,
ABB South Africa, Vert Energy, Rockwell Automation,
Comtest Group

Wireless & telemetry 76 Yokogawa South Africa, Phoenix Contact, RET Automation,
SICK Automation SA

IT in manufacturing 80 RJ Connect, ARC Advisory Group, Emerson Process Management,


Alien Systems & Technologies, Wonderware Southern Africa,
Honeywell Southern Africa, Yokogawa South Africa

Condition monitoring & vibration 91 Pepperl+Fuchs, SKF South Africa

www.instrumentation.co.za August 2015 1


welcome VOLUME 31 NO 8 AUGUST 2015

Manufacturing software and MANAGING EDITOR


Graeme Bell
NHD Elec Eng (L.C.), MBA

drone technology – two to watch


gbell@technews.co.za
EDITOR
Steven Meyer
Bsc (Elec Eng), IMM (Unisa)
steven@technews.co.za
But, the problem is multi- for deadly missile attacks against DEPUTY EDITOR
Kim Roberts
faceted. On the one hand, process targets on the ground. For com- MSc Chem
expertise gained over 30 or 40 years mercial purposes, Amazon brought kimroberts@technews.co.za
must be preserved through docu- the technology to the public’s CONTRIBUTING EDITORS
Michael Brown
ments, while on the other, the next attention with its bold idea to BSc (Eng) (Rand), CEng MIEE MSAIEE
generation of workers is attracted use drones to create an airborne Nick Denbow
CEng, Churchill College Cambridge
by modern computer technology, courier system for the delivery of
not by ancient paper trails and the customer packages. Locally, the ADVERTISING
Sales manager
dirty side of manufacturing. technology has also been trialled Jane van der Spuy
Enter the latest interactive in crime fighting applications. jane@technews.co.za
Tel: +27 (0)31 764 0593
manufacturing software platforms. Specifically, drones are used to
Gauteng
These can help companies elec- follow suspected offenders flee- Tina van Kerckhoven
tronically capture the wisdom of the ing from the scene of a police raid, tina@technews.co.za
Tel: +27 (0)11 543 5800
experienced process worker, while which enables them to be recap-
KwaZulu-Natal
Knowledge is the basis of any manu- at the same time meeting the tech tured before they evaporate on Jane van der Spuy
facturing endeavour. Therefore, when expectations of the next generation foot into the back alleys. jane@technews.co.za
Tel: +27 (0)31 764 0593
process nous is lost through the bulk of production staff. When a worker For industrial purposes, drones
DESIGN AND LAYOUT
retirement or resignation of skilled undertakes a task that requires offer enormous potential in routine Technique Design
workers, one of the inevitable results is accuracy and precision, electronic maintenance where inspections Tel: +27 (0)31 764 0593
a drop in productivity. tutelage delivered on an immer- are required on equipment that SUBSCRIPTION SERVICES
For address changes, subscriptions, renewal status
In fully industrialised regions, like sive HMI eliminates uncertainty is difficult to reach any other way. or missing issues, call +27 (0)11 543 5800,
those of western Europe and the USA, and provides everything the line Typically of multi-rotor helicopter subs@technews.co.za or write to: Technews
Publishing (Pty) Ltd, Box 385, Pinegowrie 2123
the problem relates to the generation needs to work in an uninterrupted design and fitted with a camera
SUBSCRIBE ONLINE
of baby boomers who have been run- manner. Engineering specifications, platform, one of the first examples www.technews.co.za
ning things since the late 1960s, and safety directives, machine set-up was a gas flare inspection at a UK PUBLISHERS
are now about to trigger a mass retire- and more are only a screen touch petrochemical facility. Technews Publishing (Pty) Ltd,
Box 385, Pinegowrie 2123
ment event. In emerging economies, away. With all the information they Apart from the development
PRINTED BY:
like those of Africa and Southeast Asia, need at hand, workers become effected by the US and other Paarl Media KZN
there is a shortage of skills to start more efficient and confident as military, rapid advances in wireless Pinetown, KwaZulu-Natal
+27 (0)31 714 4700
with, often compounded by political they complete tasks. A system that data communication and lighter
LETTERS TO THE EDITOR
and socio-economic factors which guides operations seamlessly from battery and camera technology Letters to the editor should be addressed to
drive the existing talent to find more one process step to the next greatly are opening up applications in Steven Meyer at steven@technews.co.za.
Sending material to this publication will be
desirable circumstances elsewhere. increases overall performance the industrial space. Companies considered automatic permission to use in full or
Either way, the end result is a new efficiency on the factory floor, much like Cyberhawk in the UK and in part in our Letters column. Be sure to include
your name, e-mail address, city and zip code.
generation of manufacturing work- as an experienced operator would South Africa’s own Knysna-based We reserve the right to edit all letters.
ers, often tech-savvy, but without the have done in the past. The ARC SteadiDrone are among the early
process smarts hard-won through Advisory Group’s Janice Abel has adopters. Drones have the poten-
experience by their predecessors. more on page 83. tial to reinvent the way remote
Software assistance is at hand though, inspection is accomplished, read all
for those companies ready to use Drone technology about it on page 24.
technology to preserve their manufac- In his report from Europe this
turing ‘brains’. To avoid the inevitable month, Nick Denbow writes on All rights reserved. No part of this
publication may be reproduced,
loss of capability experienced when another subject much in the local
adapted, stored in a retrieval
the lion’s share of a skilled workforce news lately. Unmanned aerial system or transmitted in any
form or by any means, electronic,
departs, producers can now retain this vehicles (UAVs or drones) have been
mechanical, photocopying,
expertise through the intelligence of a deployed in military applications for Steven Meyer recording or otherwise, without
the prior written permission of
collaborative manufacturing execu- many years now, mainly for aerial Editor: SA Instrumentation & Control Technews Publishing (Pty) Ltd,
tion system. reconnaissance, but sometimes also steven@technews.co.za Reg No. 2005/034598/07

Disclaimer
While every effort has been made to ensure the accuracy of the information contained herein, the publisher and its agents cannot be held responsible for any errors contained, or any loss
incurred as a result. Articles published do not necessarily reflect the views of the publishers. The editor reserves the right to alter or cut copy. Articles submitted are deemed to have been cleared
for publication.
Advertisements, inserts and company contact details are printed as provided by the advertiser. Technews Publishing (Pty) Ltd cannot be held responsible for the accuracy or veracity
of supplied material.

2 August 2015 www.instrumentation.co.za


NEWS & EVENTS

www.instrumentation.co.za August 2015 3


NEWS &
DIGEST
EVENTS

Local consultants to manage Honeywell selected for expansion of major liquefied


Kilimanjaro airport upgrade natural gas terminal
Construction supervision of the €37-million (R450-
million) upgrade to Tanzania’s Kilimanjaro International
Airport is to be undertaken by local consultants Royal
HaskoningDHV and Tanzanian sub-consultant, Howard
Humphreys. Work started in July this year and will be
completed by early 2017.
The scope of Royal HaskoningDHV’s involvement
includes the review of the detailed designs that will be
prepared by the Design & Build contractor, contract
administration of the Design & Build contract as the
Employer’s Representative (the Engineer) and supervision
of all construction works on site.

Honeywell Process Solutions has Specific key deliverables include


announced that its automation and a number of Honeywell technologies
security systems will help Freeport LNG including LEAP (lean project execu-
Development expand its southeast Texas tion services), Experion PKS Orion
liquefied natural gas terminal into a world- with distributed systems architecture
class liquefaction and export operation. (DSA), Experion security integrator,
Honeywell will be the integrated main fault tolerant Ethernet (FTE), universal
automation contractor (I-MAC) for the process and safety I/O, virtualisation,
expansion project. In this role, it will be advanced control, safety manager,
responsible for designing, delivering and OneWireless network, advanced alarm
installing the automation, instrumentation, management software and PHD data
controls, and safety and security systems. historian.

Yokogawa acquires label-free cell image analysis technology


Yokogawa has announced that it has obtained a labelled with a dye and then irradiated by a laser cell activity. Cells that are being cultured for
label-free image analysis technology from Chip- so that they can be observed more easily under a transplantation must also be label-free. Yokogawa
Man Technologies of Finland. Using this technol- microscope. However, this exposure to light often has acquired this technology to strengthen its
ogy, detailed computer analyses can be con- has a phototoxic effect on the cells. Therefore, capability in applications such as in vitro fertilisa-
ducted of live cell images that have been taken during the clinical trials that are required for tion (IVF) and the coagulation and organisation
with a microscope using a label-free technique. regulatory approval, it is necessary to carry out of differentiated cells in regenerative medicine,
In basic research, live cells are typically label and irradiation-free observations of in vivo where quality and safety are utmost concerns.
NEWS & EVENTS

www.instrumentation.co.za August 2015 5


NEWS & EVENTS

Obituary: Andrew Ashton SEW-Eurodrive streamlines the automotive


9 December 1950 – 18 June 2015 manufacturing process in SA
It is with deep sadness that the staff of Technews
Publishing heard of the death of our dear friend and
much esteemed colleague, Andrew Ashton. Jon (Andrew)
Charles Ashton passed away on Thursday, 18 June 2015
following a five-week fight with cancer.

Professional
Andrew’s integrity illuminated everything he did. He
never accepted second-best from himself, on both per-
sonal and professional levels. His honesty shone through
in his journalism and as an editor.

Personable
More than one colleague described Andrew as being “a
true gentleman”. But that wasn’t the only gentleness that
we experienced. His genuine concern over the wellbeing
The automotive industry is based on manufacturers to reduce both the com-
of his colleagues and friends was a hallmark of our inter-
‘just-in-time’ (JIT) and ‘just-in-sequence’ plexity of their systems, as well as their
action with him. His smile was infectious and his humour
(JIS) processes for material provision and installation costs. “Our drive technology
was never at the expense of someone else.
production. JIT is a methodology aimed and expert knowledge ensures maximum
primarily at reducing flow times within productivity, energy efficiency and reli-
Perspicacious
production as well as response times from ability for clients’ systems,” he continues.
Andrew was one of the smartest people with whom we
suppliers and to customers, while JIS is a Variolution is essentially a ‘packaged
have had the privilege to work. He was highly intellectual
specialised inventory strategy to achieve offering’, whereby 80 percent of the pack-
with a remarkable understanding of extremely complex
JIT, whereby components and parts arrive age is standard and 20 percent is cus-
technical problems across a broad range of subjects. His
at a production line right in time as sched- tomisable. This provides customers with
multiple technical and commercial qualifications com-
uled before they get assembled. some level of customisation on top of
bined with a drive to reach perfection in everything he
Maximum system availability is, there- the benefit of a standard tried and tested
did, made him an unparalleled technical writer that the
fore, essential as any downtime results in solution. The benefit is that the customer
industry will sorely miss.
high follow-up costs. SEW-Eurodrive pro- has to deal with less variables and suppli-
Andrew, we will miss you not only for what you did,
vides the local automotive industry with ers during the process of setting up a new
but for who you were.
a unique product portfolio specifically application.
designed to meet these requirements. “There are ten Variolution packages
SEW-Eurodrive Port Elizabeth branch which include conveyer line, packing and
manager Francois Sieberhagen says that unpacking, and lifting, to name a few.
the product offering ranges from indi- Special modifications to meet different
vidual components to complete packages requirements such as energy-efficiency or
and system solutions. “Leading automo- hygienic design have also been taken into
tive manufacturers choose SEW-Eurodrive account. With Variolution, customers are
as the company provides cost-effective provided with on-site commissioning and
drive solutions that deliver more value installation as well,” says Sieberhagen.
over the long-term. We provide a modular According to Sieberhagen, SEW-
design and a reduced number of variants, Eurodrive’s recent involvement in the local
which increases flexibility and minimises automotive industry has been primarily
Andrew and Christine Ashton. costs,” he explains. focused on machine builders and com-
SEW-Eurodrive products most com- ponent suppliers. He does, however,
Andrew’s long association with Technews dates back
monly used in the local automotive anticipate an increase in market share
to his student days when one of his lecturers was Ray
industry are; standard gear motors, with scheduled upgrades due to take
Beaumont, the founder of Technews.
synchronous and asynchronous servo- place at various manufacturing facilities.
In 1990 he became a client of Technews whilst he
motors, Movidrive B application inverters, “We continue to work on expanding our
was MD of Prolocon.
Movifit FC decentralised standard invert- extensive product and service portfolio
In 2004 he joined Technews full-time as the editor
ers, Movipro SDC decentralised standard in order to support and fulfil the needs of
of two of Technews’ publications, SA Instrumentation &
inverters and Movipro ADC decentralised the automotive industry,” he concludes.
Control and Motion Control in Southern Africa.
application inverters.
In 2009 he left full-time employment with
Sieberhagen indicates that the For more information contact Rene Rose,
Technews but remained as consulting and contribut-
latest-generation SEW-Eurodrive SEW-Eurodrive, +27 (0)11 248 7000,
ing editor until his death.
Variolution packages enable automotive rrose@sew.co.za, www.sew.co.za

6 August 2015 www.instrumentation.co.za


NEWS & EVENTS

www.instrumentation.co.za August 2015 7


NEWS & EVENTS

Schneider Electric hosts services event for installed base customers

The Schneider Electric presentation team.


Schneider Electric recently held a two-day its lifespan; cutting costs and increasing sav- delegates at the event, each won a free
event at its Midrand campus to showcase its ings; and improving return on investment. Schneider Electric installed base audit for
expertise in installed based services. Over “To achieve the above objectives, their respective employers, City Power and
130 customers, representing industries such Schneider Electric has divided its installed Iritron. The audit will assess the performance
as water and wastewater; food and bever- base services into seven service modules, of these companies’ electrical installations and
age; electrical utilities; mining, minerals and namely: Schneider Electric will propose improvements
metals; and facility management, attended • Remote technical assistance to meet their business energy needs.
the informative sessions by local and interna- • On-site expert assistance. The audit methodology is based on four
tional Schneider Electric experts. • Software update and support. steps, producing four detailed plans per
Keynote speaker, Bongani Twala, vice • Preventive and predictive maintenance. customer. These include a maintenance plan,
president for the services business unit at • Extended warranties. modernisation plan, monitoring plan, and a
Schneider Electric South Africa, pointed out • Spare parts management. management plan – resulting in a clear action
that when it comes to electrical distribution • Exchange and repairs. plan for the customer.
and industrial automation infrastructure, the Discussions focused on Schneider Electric’s Since 2005, when services audits were first
answer is straightforward: “Get professional installation and commissioning services, which introduced by Schneider Electric, more than
expertise. Doing business in today’s economic have been created specifically to improve the 400 customers from industries as diverse as
environment is challenging enough. For peace launch phase of electrical installations. “With buildings, electric utilities, healthcare, mining,
of mind, it is advisable to outsource the man- the modernisation solutions from Schneider and oil and gas, have undergone assessments.
agement of an electrical installation.” Electric, you get a cost-effective means of
The event highlighted that installed base updating your installed base. Whether it For more information contact
services should be developed to assist com- requires retrofit, retrofill, or replacement of Ntombi Mhangwani, Schneider
panies to increase productivity, reliability and ageing equipment, we can help you save time Electric SA, +27 (0)11 254 6400,
safety; mitigating risk and limit downtime; and money,” explained Twala. ntombi.mhangwani@schneider-electric.com,
keeping equipment up to date and extending Sibusiso Bakana and Johann Pienaar, www.schneider-electric.com

NLA-SA launches new job RJ Connect awarded shared agency of Videotec


opportunities service RJ Connect has been awarded the shared heavy duty housings, night LED illumina-
agency of Videotec video security products tors and advanced artificial intelligence
The National Laboratory Association – SA (NLA-SA) has in South Africa. Videotec was founded in devices. Product connectivity is based on
announced its new Job Opportunities service, available on Italy in 1986 and has specialised in the high resolution analog and IP architecture,
the website for laboratories and laboratory personnel. The creation and design of state-of-the-art CCTV providing the highest degree of protection
service promotes both positions being offered, as well as products ever since. Over the years, the and immediate situational awareness. Thus
for those seeking employment. company has expanded its product line to the response to threats and incidents is rapid
“For many years the NLA-SA has been requested by become one of the largest CCTV product and effective.
those involved in testing, as well as calibration laborator- range manufacturers on the market. With the cooperation of international
ies, to provide an easy to use mechanism to match suit- The European manufacturer supplies universities, Videotec remains abreast of new
ably qualified employment seekers with those companies industries such as oil and gas, marine and technologies and cutting edge engineering
or organisations looking to fill positions,” said Steve Sidney, harbour with professional CCTV and certified techniques and materials. This knowledge
executive director of the NLA-SA. products and accessories for indoors and is applied to the company’s products to
Currently there will be no charge for using the system outdoors video surveillance applications in produce new solutions for a rapidly evolving
and the NLA-SA encourages the use of this facility. environments with high temperatures or market.
severe climatic conditions.
For more information contact National Laboratory The company’s wide product range For more information contact Sales,
Association – SA, +27 (0)12 349 1500, includes PTZ camera positioning systems, RJ Connect, +27 (0)11 781 0777,
steves@nla.org.za, www.nla.org.za certified explosion-proof camera systems, info@rjconnect.co.za, www.rjconnect.co.za

8 August 2015 www.instrumentation.co.za


NEWS & EVENTS

www.instrumentation.co.za August 2015 9


NEWS & EVENTS

Mitech’s commitment to localisation wins Umgeni Water order


Mitech has received a substantial order for
rubber lined butterfly valves for Umgeni
Water’s storage and purification plants situated
between Pinetown and Durban. The valves are
used to isolate the reservoirs, either in opening
or closing, to allow the water to pass through
to individual municipalities. Water entering the
reservoir will also be passed through the new
valves which are able to cope with pressures of
up to 16 Bar.
In order to secure the order, Mitech had to
comply with stringent requirements and the
company’s one hundred percent localisation
was a key factor. “This order is a significant
breakthrough, not only for Mitech, but for all
South African valve and actuator manufactur-
ers. It underlines the willingness of SOCs to
support locally manufactured products and the
readiness of local manufacturers to produce
world class, quality products,” explains Mitech
MD, Jacob Mtolo.
The order was for a total of 42 valves rang-
ing in sizes from 300 mm to 1,6 m. The rubber
lined butterfly valves are robust, corrosion Back (left to right): Waylon Naidoo (Mitech KZN), Monica Malunga (Umgeni Water), Pieter Badenhorst
resistant and feature an EPDM liner. During the (Mitech). Front: Victor Hlophe (Umgeni Water), Cyril Gamede (Umgeni Water), Thulani Mpotshane
(Umgeni Water) and Nevil Naidoo (Mitech KZN).
manufacturing process different techniques
were applied, including the bonding of the cope with the chlorine content in the water, as as a top supplier of valves, both locally and
rubber lining. Mitech’s new factory lends itself well as the EPDM Liner to eliminate leakage. internationally.
to these techniques and has an on-site auto- Umgeni Water was impressed by Mitech’s
clave allowing for quicker turnaround times. capabilities, its compliance with local content, For more information contact
The valves are manufactured from special the creation of new jobs, as well as quick Jacob Mtolo, Mitech, +27 (0)11 927 4850,
materials including the WCB carbon steel body delivery and excellent back-up service. The enquiries@mitech.co.za,
and duplex stainless steel shafts and disks to order will further strengthen Mitech’s position www.mitech.co.za

Dehn launches powerful lightning impulse current laboratory


The extremely high lightning currents, which 800 square metres. It is equipped with
may occur in the event of direct lightning the latest devices and technologies
strikes, are the primary source of lightning essential for developing new products and
damage to structures as well as electrical practical solutions. It offers the following
devices and systems. To prove the effective- services:
ness of protection measures, it is often neces- • Testing of surge protective devices (SPDs)
sary to perform lightning current tests on according to IEC 61643-11, IEC 61643-21 and
complete systems. Dehn’s newly designed test UL 1449.
laboratory generates extremely high lightning • Testing of surge protective devices (SPDs)
currents with a peak value up to 400 kA in the used in photovoltaic systems according to EN
standardised 10/350 μs test wave form. This 50539-11.
powerful test laboratory allows for the testing • Testing of external lightning protection com-
of lightning protection systems for installations ponents according to IEC 62561.
and systems requiring maximum protection. • High-voltage testing with lightning impulses
The performance of the test laboratory according to IEC 60060-1. photovoltaic systems and cell sites according
has been doubled so that lightning impulse • Complete lightning current tests for low- to IEC 62305-1 and IEC 61400-24.
currents twice as high as that required for the voltage distribution boards according to IEC • Functional testing for low-voltage switchgear
maximum lightning protection level (LPL I: 62305-1, IEC 62305-4 and IEC 61643-12. installations according to IEC 60947.
200 kA (10/350 μs)) described in the latest IEC • A surge immunity test according to IEC
62305-1 lightning protection standard, can 61000-4-5. For more information contact Alexis Barwise,
now be simulated. • A surge immunity test for telecommunication Dehn Africa, +27 (0)11 704 1487,
The test centre consists of five different systems according to ITU-T and CCITT. alexis.barwise@dehn-africa.com,
laboratories, extending over a floor space of • Lightning current tests for wind turbines, www.dehn-africa.com

10 August 2015 www.instrumentation.co.za


NEWS & EVENTS

Honeywell technology modernises mill for SEW-Eurodrive appoints new MD


Europe’s largest forestry industry company
Honeywell Process Solutions has Honeywell’s Experion PKS, which
announced that Europe’s largest unifies people, processes, assets and
pulp, board and paper manufacturer business needs, by having one unified
will use HPS process automation, architecture for process control, safety
safety system and manufacturing systems and automation software.
optimisation technologies to Experion process, machinery and
modernise one of its key mills, drives (PMD) controllers, which use
helping it to meet rising demand for a single, consistent set of engineer-
renewable packaging board. ing tools for lower capital costs and
Stora Enso is implementing more cost-effective execution of pro-
Honeywell’s technologies as part of duction line and plant-wide control.
a modernisation and optimisation Uniformance process history
effort at its paper mill in Varkaus, database (PHD), which helps users
Finland. Headquartered in Helsinki, make better and faster decisions
Stora Enso is the largest pulp, board with superior data management,
and paper producer in Europe, and higher data security and reliability,
one of the largest in the world. and lower total cost of ownership.
“Stora Enso’s business objective Safety Manager, which integrates
is to produce and deliver the highest process safety data, applications,
quality paper and board products in system diagnostics and critical control
the world, and Honeywell’s portfolio strategies, and executes defined
of technologies will help it reach this safety applications in a fully
goal safely, reliably and efficiently,” redundant architecture.
said Ali Raza, vice president, HPS. OptiVision MES, an advanced
“We have worked with Stora Enso for order-to-cash solution designed to
about 40 years and I am pleased that help pulp and paper companies and
Honeywell can help them modernise flat sheet manufacturers address
this facility.” critical issues determining
Raymond Obermeyer.
The Stora Enso project coincides profitability.
with conversion of the facility to After 12 years of service, SEW-Eurodrive South Africa MD, Ute
produce kraftliner, a fibre-based For more information contact Boni Schoeman, has stepped down to open up her own business as a
container board. Upgrades to the Magudulela, Honeywell Southern consultant in the industrial sector. She made a name for herself as
Varkaus mill include: Africa, +27 (0)11 695 8000, one of the youngest and first female MDs in the power transmission
Migration of the plant from its boni.magudulela@honeywell.com, game, and led the company to double its turnover during her time.
previous control system to www.honeywellprocess.com SEW-Eurodrive would like to thank Schoeman for her years of
service to the company and wish her the best of luck in her future
endeavours. She will be replaced by general manager operations,
Raymond Obermeyer, who boasts more than 25 years of operational
experience at SEW-Eurodrive.
Obermeyer, who officially took office on 1 July, was instrumental
in the upgrading of SEW-Eurodrive’s facilities countrywide. All
factories have been equipped to handle additional tonnage, been
fitted with load test benches, tooling upgrades and new assembly
lines.
He was also involved in the streamlining of process flow in the
factories, which has led to optimum productivity and reduced
delivery times. Obermeyer hails from Nelspruit, where he was init-
ially the branch manager before his promotion to operations
and logistics general manager three years ago.
“I have every confidence in Raymond’s ability to lead the
company to new heights. SEW-Eurodrive has grown by leaps and
bounds in the last ten years and Raymond has the necessary
operational experience and passion for the business to ensure that
this trend continues,” concludes Schoeman.

For more information contact Rene Rose, SEW-Eurodrive,


+27 (0)11 248 7000, rrose@sew.co.za, www.sew.co.za

www.instrumentation.co.za August 2015 11


NEWS & EVENTS

A different kind of roadtrip A new strategic alliance


A group of students and lecturers from the University
of Johannesburg were on a roadtrip of a different kind
when they travelled over 4000 km through Namibia and
Botswana at the end of June to test out their solar powered
car. Mechanical engineering lecturer at the Energy
Movement lab, Nickey Janse van Rensburg says that the
Ilanga II can do up to 140 km/h.
The aerodynamic lines of the orange and white Ilanga Seen at the signing event are, from left : Mick Baugh, sales manager, BMG Electronics; David
II drew delighted crowds along the way. The Solar Car Dyce, division manager, BMG Electronics; Marco Airola, senior sales director, Danfoss southern
Europe; Leif Flojgaard, president, Danfoss Middle East & Africa; Gavin Pelser, managing director,
Project promotes the study and development of efficient BMG Engineering; Roland Sargent, sales manager, Danfoss South Africa.
energy use, environmental awareness, energy management
Consolidating a longstanding partnership, BMG’s R350 million expansion of its
and innovative engineering. The solar panels on top of
BMG and Danfoss Drives have signed a distribution and engineering facilities in
the vehicle are similar to those that powered the Mars
strategic alliance agreement that augers Johannesburg includes new electronic
Rover. The Ilanga II’s tool box is a 3D printer to replace
well for both companies, stakeholders workshops and a technical resources
parts needed for running repairs. It has already produced
and customers. centre for the repair, maintenance and
the steering interface, buttons, battery holder and
“This new development formalises and commissioning of the Danfoss product
brackets for the roof panel.
strengthens the original distribution agree- range. This 24 hour service is supported
The Ilanga II is UJ’s third solar-powered car. The team
ment for Danfoss variable speed drives by mobile technicians who conduct
hopes to take her to next year’s Sasol Solar Car Challenge
and soft starter range, which has been in onsite breakdown and routine mainten-
where the Ilanga 1.1 previously won the Technology
place since 2007,” says David Dyce, division ance when necessary. BMG delivers daily
and Innovation award. Local and international solar car
manager of BMG Electronics. “Through this to all major centres around South Africa.
developers compete in that race between Pretoria and
alliance, BMG is set to increase awareness Its purchasing system at Danfoss will
Cape Town.
of the Danfoss brand; create a stabilised become e-based, providing live updates
The Ilanga II is being used to research and develop
pricing structure; and ensure efficient on delivery times to ensure a highly
sustainable and green engineering that can be used in
enquiry turnaround times and a reliable efficient supply chain process.
the real world. The team already has plans to introduce
support service for Danfoss systems. BMG currently has BEE Level 3
the technology to power village pumps.
The Danfoss range of technically certification, with recognition as a
advanced variable speed drives and soft value-add supplier (VAS). This allows the
For more information contact Nickey Janse Van Rensburg,
starter systems, is available from BMG’s market to source Danfoss equipment from
University of Johannesburg, +27 (0)11 559 2538,
national branch network of over 140 BMG and comply with the B-BBEE charter.
nickeyjvr@uj.ac.za, www.ujsolar.co.za
outlets. It enhances energy savings, food This status represents a significant benefit
preservation, care for the environment to customers as a BEE procurement
and optimum productivity. “With a recognition of 137,5% against all
complementary product and customer purchases from BMG can be claimed.
base and a perfect business ethics fit,
BMG and Danfoss are committed to For more information contact
working closely with industry to achieve a Dave Dyce, BMG Electronics,
more efficient and sustainable environment +27 (0)11) 620 1530,
and contribute to a productive and globally daviddy@bmgworld.net,
competitive region,” he continues. www.bmgworld.net

Appointments
Indecon Instrumentation SEW-Eurodrive has Tectra Automation has
has appointed Lester appointed Erlou Labuschagne appointed Wayne Neethling
Swart as instrumentation as mechatronics application as branch manager for its
sales representative. engineer. Cape Town office.
InterCal has moved
As from 1 July, InterCal will be conducting business from
its new more modern premises. The address is:
581 Lupton Drive
Cnr Johnic Boulevard
Halfway House Ext 12
Midrand
GPS:26.003046S 28.133519E
Tel: +27 (0)11 315 4321
intercal@intercal.co.za
www.intercal.co.za Lester Swart. Erlou Labuschagne. Wayne Neethling.

12 August 2015 www.instrumentation.co.za


TRAINING

Learning versus training – the power of


know- how
Process engineering is anything but simple: how can we impart
information that is hard to digest in an easily accessible manner? For the
process automation sector, it is not only difficult to find suitably qualified
staff, but the ones who are available are often not the most experienced
having just completed their studies.
The life cycle of technology is getting shorter and shorter. How does a
technical person stay up to date? As for the process plants and factories,
how can they be sure that they exploit the options of the technology and
field instruments you are using today? In today’s cost cutting efficiency
requirements; plant availability, product quality and safety are becoming
key – with the instrumentation technician or engineer needing to understand
the complete life cycle of a plant to ensure maximum sustainability of a process
plant. This change is no longer merely just a question of maintenance.
Apart from hiring new staff and on-boarding these members, another
aspect that needs attention is the further education of staff. How much
does a company invest in further education and do they have any idea
if the money is well invested? It is no longer a matter of just ‘attending’
training, but to learn and comprehend while being able to utilise these
skills the very next week in plant conditions.
In the past the focus was on the delivery of training, which means
that a check mark was made after a person attended a course, and it was
assumed that they now had the knowledge and skills to perform better
in their jobs.
Endress+Hauser stands for a shift in this paradigm. Its focus is not
on delivering a training course, but on the learner to ensure they really
acquire the new knowledge and skills to apply in their jobs. To ensure
the success of such a program, an instructional system design model has a variety of training possibilities. An agitator (level disturbance), heater
been designed. Called “The Training Cycle” it consists of 5 steps: element (temperature changes) and injected compressed air (entrained
First: Analyse the training needs. A gap analysis is done to clarify gas) allow the process conditions to be interrupted in a controlled
questions about target group, necessary and existing preconditions, and manner giving the trainee a practical perspective of the sensitivities of
other frame conditions. each instrumentation type operating under varying field conditions. All
Second: Develop learning objectives. A learning objective is a specific operational parameters including instrument selection are controlled via
performance statement about knowledge or skills which should be the integrated PLC and touch screen display.
gained during the program. They are essential because based on the Endress+Hauser now offers two new intensive five-day training
learning objectives, the content will be developed and also the success courses targeted at technical plant personnel from technician and
of the program will be assessed. engineer grades right through to maintenance, engineering and project
Third: Design the program. Based on the needs-analysis only the management. The courses cover all of the major process measurement
necessary content is developed, which will then be transferred using classes including level, flow, pressure, temperature and analytical, starting
an interactive style that takes into account the latest findings about from the principles of operation through to application topics such as meter
adult-learning. selection, installation, application issues and basic trouble shooting. The
Finally steps four and five are implemented to address the trainee is introduced at a practical level to the standard Endress+Hauser
implementation and complete the final evaluation. instrument selection and sizing software tool “Applicator” plus hands on
Endress+Hauser South Africa has addressed these needs and instrument configuration and troubleshooting using the device keyboard
launched the Universal Training Rig (UTR) at the Africa Automation Fair and display as well as the service software tool “FieldCare”.
in May. Purpose built at the company’s Application Training Centre (ATC) As well as “real life” instrument and control operation, the UTR also
in Switzerland, the UTR utilises 20 devices from the company’s extensive allows different field communication strategies to be presented via its
range of flow, level, pressure and pH measuring instruments, in a variety use of Wireless HART, Profibus as well as standard 4-20 mA connections.
of flow and control loop configurations. Supplementary topics such as reading and understanding P&ID
The integrated oil, water, acid and alkaline reservoir tanks, combined diagrams and plant asset management are also included. The courses
with mixing and separation chambers allow a huge range of flow, level are interactive with all theory accompanied by extensive practical
and pH conditions to be created through the utilisation of different assignments on the UTR itself followed by written assessments thus
control loop strategies based on pressure, temperature, level, density maximising the learning experience.
and pump speed primary values.
Whilst not emulating a production process of any specific industry, For more information contact Chris Gimson, Endress+Hauser,
the UTR presents the application frame conditions in a way that offers +27 (0)11 262 8000, info@za.endress.com, www.za.endress.com

www.instrumentation.co.za August 2015 13


TRAINING

Who will benefit from Who will benefit from this


this ­training? Instrument Who will benefit from this ­training? Automation Engineers
Technicians and Engineers ­training? Automation Engineers
Moxa Basic & Intermediate Training –
Process measurement and Practical Radio Telemetry Systems for Industry Industrial Network Design
instrumentation 3-4 Sep 15-17 Sep
TC1001 – Part I: P&I Diagram, Pressure, Flow
& Level Study Your National Certificate: Engineering Moxa Advanced Training – Network
24-28 Aug Four engineering streams to Redundancy
choose from: 29-30 Sep
TC1002 – Part II: Controls Loops, Electrical
Temperature, Digital Communication, Life Electronics Wireless
Cycle Management and Density Instrumentation 1 Oct
31 Aug – 4 Sep Mechanical
Start date: 7 September, 2015 For more information contact RJ Connect,
TC1004 - Understanding of Temperature +27 (0)11 781 0777, info@rjconnect.co.za,
Measurement Principles and Sensor 4-hour online courses www.rjconnect.com
Selection Fundamentals of Process Plant Layout and
17-18 Sep Piping Design
17 Sep
Michael Brown’s practical
For more information contact Cezanne
control courses
­Gonsior, Endress+Hauser, +27 (0)11 262 8097, For more information contact Cheryl ­Reyneke,
cezanne.gonsior@za.endress.com, IDC Technologies, +27 (0)11 024 5520, Michael Brown’s well known courses on
www.za.endress.com cheryl@idc-online.co.za, www.idc-online.com practical process control are unique and
invaluable to novices, as well as to experienced
practition­ers in the field of regulatory control
optimisation. They offer a new and practical
approach to a clear understanding of the
complexities of feedback control.
The series consists of two courses:
• Introduction and appreciation of practical
process control: 1 day for non-instrument
personnel who work in process plants, but
have no previous experience or practical
training in control, such as: process engineers;
production managers; metallurgists and
chemical engineers. It is also recommended
that people who are attending the Parts 1
& 2 the following week should attend the
introductory. Date: 4 September.
• Practical Process Control Parts 1 & 2:
Five days for instrument and control
personnel like senior mechanicians,
technicians and engineers. Even people with
years of ­experience in this field have found
the course an eye-opener. Subjects covered
include: loop problems and troubleshooting;
tuning and control of processes with difficult
dynamics and techniques like feed-forward.
Dates: 7-11 September.
All prices exclude VAT.

For more information contact


Michael Brown Control Engineering,
082 440 7790, michael.brown@mweb.co.za,
www.controlloop.co.za

14 August 2015 www.instrumentation.co.za


TRAINING

Who will benefit from this


SEW-Eurodrive Drive Who will benefit from this ­training? Automation Engineers
Academy courses ­training? PLC Engineers
Field Instrument Product Training
Maintenance and repair of AS-I Concept and Implementation Course Roodepoort 7-11 Sep
geared motors and braking 2 Sep
systems Centum VP Essentials
Johannesburg 8-9 Sep Modbus Concept and Implementation KZN 9-11 Sep
Course
Movidrive MDX 61 B Inverter: 3 Sep PCI Advanced Product Training
Operation, start-up and Roodepoort 14-18 Sep
troubleshooting Certified Profibus Installer with
Johannesburg 15-17 Sep Troubleshooting Centum VP Engineering
16 Sep Roodepoort 14-16 Sep
Movitrac MC07 B Inverter:
Operation, start-up and ProCentec COMbricks and ProfiTrace CAMS Training
troubleshooting Training Roodepoort 21-23 Sep
Johannesburg 29 Sep 18 Sep
For more information contact
For more information contact For more information contact Angelique ­Human,
Erika Louw, SEW-Eurodrive, Michael G
­ arnham, Industrial Data Xchange, Yokogawa South Africa,
+27 (0)11 248 7294, +27 (0)11 548 9970, +27 (0)11 831 6300,
elouw@sew.co.za, michaelg@idx.co.za, angelique.human@za.yokogawa.com,
www.sew.co.za www.idxonline.com www.yokogawa.com/za

www.instrumentation.co.za August 2015 15


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SA Instrumentation & Control leads to controlled decisions


SYSTEM INTEGRATORS

Autotronix designs large water


­metering application
Project definition than planned due to government intervention
The client had initiated a contract to construct and therefore timeframes had to be accelerated.
a new 500 NB (nominal bore) pipeline to supply In spite of difficulties, all of the cited deadlines
potable water to the municipality from its pump were met.
station approximately 36 km away. The pipeline
needed to transport this water into a reservoir Project implementation
approximately halfway along its length at a From the start, fortnightly project meetings
place called Midpoint. The Midpoint storage were held and progress was continuously
tank would retain approximately 10 Ml of water, monitored. The client requested the Magflow
which can gravitate to a reservoir of the same meter to be installed in the pipeline and the
capacity at the municipality. Part of the contract concrete chamber built around it. This was
was awarded to Autotronix to provide flow not an ideal situation but was stipulated and
metering, instrumentation and control. necessary in order to ensure compliance with
This project involved the installation of the government deadline.
flowmeters, pressure sensors and level meters Two Magflow meters were installed, the
for the monitoring of flow and pressure along first at Midpoint and a second at the munici-
the pipeline, and tank levels at Midpoint and pality. The client and Autotronix selected the an outdoor galvanised steel kiosk and particular
on the municipality reservoirs, as well as the Endress+Hauser Promag DN500 electromagnetic attention was paid to unauthorised entry and
remote monitoring of these parameters at the flowmeter for its inherent accuracy for billing frequent power failures. Microwave radar level
central control rooms. purposes and long-term reliability. The meter transmitters were mounted on the roofs of
The pipeline parameters flow, pressure was electrically isolated from the pipeline to the reservoirs and housed inside galvanised
and tank levels data, had to be transmitted by avoid stray currents from influencing the sensors. steel containers to protect from lightning and
a GPRS telemetry link to two control rooms The isolation is achieved with insulating sleeves mechanical shock. Visual readings of flow in
where it was displayed on the Wonderware and washers that fit around the bolts. Ml/day, and reservoir level in percentages, are
scada for operators to monitor and control the Electrical continuity and earthing in the available inside the kiosk.
water flow. This data was also made available to vicinity of the meters was also maintained in The client is extremely pleased with the final
various subscribers. order to prevent corrosion and electrical noise. outcome of the project – a product of the
There were a number of stakeholders in this On completion of the installation, the meter highest quality in terms of excellence of engi-
project including the municipality, the client, was checked and certified by Endress+Hauser neering design and functionality. Training and
the pipeline contractor, the civil contractor personnel. A Modbus output from the meter operating manuals were delivered to the client
on the Midpoint reservoir and Autotronix on was routed to a GPRS modem for transmission to assist the maintenance staff when necessary.
instrumentation. The coordination of the various to a central control room. The transmitter also
contractors was handled by the client and all provided digital and analogue I/O for processing For more information contact Roy Ward,
parties were required to meet a common dead- level and pressure signals, including alarms. Autotronix, +27 (0)16 422 7644,
line, which unfortunately commenced later All process instrumentation was housed in royw@autotronix.co.za, www.autotronix.co.za

www.instrumentation.co.za August 2015 17


SYSTEM INTEGRATORS

System integrators
Abacus Automation Afrilek Automation
Abacus Automation supplies innovative, custom-developed technical Afrilek Automation provides superior turnkey automation and electrical
solutions using standard PLCs, drives, scada and motion control solutions, as well as service and support for production facilities. With a
equipment and is now Siemens approved for crane automation. fresh and innovative approach, the company is involved in every stage of
With 16 years in the market, this BEE-certified, award-winning and the project, offering ongoing functional and technical support. Its extensive
internationally acclaimed company has highly qualified, experienced skills encompass all aspects of implementation and operation, including
and professional staff. It operates out of offices in KwaZulu-Natal. panel manufacturing, power management and product distribution.

Tel: +27 (0)31 702 5767 Tel: +27 (0)11 372 9340
sales@abacus-automation.co.za su-anne@afrilek.com
www.abacus-automation.co.za www.afrilek.com

Altech Alcom Matomo Autotronix


Altech Alcom Matomo specialises in the design and supply of turnkey Autotronix is a recognized leader in industrial automation design and
communication systems such as wide area voice and data networks and implementation having attained its ISO9001 certification. Autotronix
scada/telemetry solutions, as well as user terminal supply and support. offers its clients turnkey control system integration services for energy
Backed up by highly experienced engineering, project management, management, PLC/HMI/SCADA,VSD, manufacture of control panels,
systems integration and field engineering departments, these systems applications for water distribution and manufacturing. The company
use products from the extensive Motorola network range. operates from offices in Gauteng and KwaZulu-Natal.

Tel: +27 (0)11 235 7640 Tel: +27 (0)31 705 0400
nwatermeyer@alcom.co.za or +27 (0)16 422 7644
www.alcommatomo.co.za sales@autotronix.co.za
www.autotronix.co.za

Control Systems Integration Hybrid Automation

Supported by high work ethics, high quality of work, high Hybrid Automation is an approved Siemens system
level of skills, and excellent experienced resources, CSi is integrator and partner for automation and drives, process
ranked amongst top systems integrators in South Africa by instrumentation as well as motion control. This enables it to
various automation industry suppliers and customers. provide its clients with the latest technology and solutions.
Its client base includes major blue chip companies and has
Tel: +27 (0)12 653 7901 gained a strong foothold in virtually all the engineering
andreb@controlsi.co.za verticals.
www.controlsi.co.za
Tel: +27 (0)31 573 2795
info@hybridautomation.co.za
www.hybridautomation.co.za

Iritron New Africa Control Engineering


Iritron, a TUV accredited ISO 9001:2008 technology company, NAC Engineering (ISO9001:2008 accredited by TÜV) is a team of highly-
is able to offer its clients PLC, DCS and scada software and experienced engineers, offering complete EC&I Design, engineering and
hardware, as well as electrical and instrumentation design, commissioning solutions. We have extensive experience in the writing of
engineering, project management and commissioning specifications and the development of client specific control documents.
services. The company’s fields of expertise encompass all the Our designs are followed through to completion and we have an
levels in the automation hierarchy. excellent record for site management and commissioning.

Tel: +27 (0)12 349 2919 Tel: 0861 NAC ENG (622 364)
alwyn.rautenbach@iritron.co.za admin@nac-eng.com
www.iritron.co.za www.nac-eng.com

18 August 2015 www.instrumentation.co.za


SYSTEM INTEGRATORS

System integrators
Process Dynamics PSY Systems
Process Dynamics specialises in industrial automation and PSY Systems is an ABB, LG and Omron system integrator and is involved
process control. The company is one of Africa’s leaders in turnkey in building management systems and process control. Specialising
automation projects and process dynamics, and specialises in in electronic modules, the company offers consultation, project
the integration of scada (Wincc, Wonderware, Citect) and PLC management, project design, development, commissioning and
(Siemens, Schneider, Allen Bradley) as well as panel manufacturing installation of electronic components and control systems for specialised
and installation. applications.

Tel: +27 (0)11 394 5412 Tel: +27 (0)11 782 5449
systems@process-dynamics.co.za paul@psysystems.com
www.process-dynamics.co.za www.psysystems.com

Pulse Control Systems SAM – Systems Automation and Management


Pulse Control Systems is an independent BEE level 1 market special- Systems Automation and Management is a supplier of data acquisition
ist, designing and supplying customised automated solutions to the systems and innovative automation solutions and is one of the leading
manufacturing industry of South Africa. Utilising Siemens technology integrators of PLC, scada and fieldbus systems in South Africa. The
with innovative and flexible applications we deliver on time and within company’s comprehensive range of capabilities includes industrial
budget to the highest international standards. We work with our high- networks, automation and control, scada, custom solutions, information
end client base to provide end to end engineered systems based upon delivery, data warehousing, hardware and
individual needs and requirements. software, BMS, MIS and MES.

Tel: +27 (0)31 262 6299 Tel: +27 (0)11 231 8900
nimelen@pulsecontrol.co.za info@sam.co.za
www.pulsecontrol.co.za www.sam.co.za

www.instrumentation.co.za August 2015 19


SAIMC NEWS

From the President’s desk


At the time of writing this letter, I had just returned from we not disciplined enough? Is it colonialism or apartheid
a trip to Japan and Hong Kong for both business and a that held us back? The one thing I do know is that we had a
bit of a holiday. The experience can only be described as lot of innovation and industrialisation due to our isolation
mind boggling. Within Japan, Tokyo and Osaka are massive by sanctions during apartheid, e.g. the CAT scan, oil from
metropolises with huge population densities and hence have coal (SASOL), the Kreepy Krauly pool cleaner, ISCOR (now
very sophisticated and reliable public transportation systems ArcelorMittal) etc. Is part of the problem that it is too easy
(much larger than the European and American systems in my for us to buy technology from other countries since our
experience). The sheer number of people one encounters in re-admission into the world in 1994? Have we just become
one of the massive metro stations, which have become under- dumb consumers instead of creators of technology? Or is the
ground malls, is really intimidating for a South African who is socio-economic or socio-political environment not conducive
Vinesh Maharaj.
accustomed to using private transportation and hence only to innovation? What happened to The Joule, our first all-elec-
having direct contact with perhaps 50 or 100 people per day tric car? Government partnered with the Nissan Leaf instead.
at the office etc. Whereas Osaka Station copes with 400 000 We are planning on buying nuclear plants from around the
travellers a day and as a traveller you will be in close proxim- world and killed our own nuclear technology project after
ity to hundreds if not thousands of people. No wonder a lot pouring billions into it. I hear this modular pebble bed reactor
of people wear surgical masks whilst in public. Imagine what is soon going to be licensed in the US.
an influenza outbreak would do to the working population Whatever the problem is, we need to fix it and fix it fast!
under such circumstances. All this discipline and orderliness The rest of the world is not waiting for us to catch up. We
is probably what made the Japanese such a successful nation. cannot rely on government to fix everything, but they have a
They were occupied by the Americans for a number of years very important role to play in creating an enabling environ-
post-WWII and identified that industrialisation/modernisation ment for the economic success of our country. The policy
was required. This was in conflict with their historical roots uncertainty needs to be dealt with quickly, all the noises
which caused some significant political strife. However, about industrialisation and beneficiation need to become
the tough decisions were made by the government of the tangible actions. The black industrialists being touted, need
time and the resultant prosperity is apparent to all. I would to be created faster and by creating new wealth, not redis-
never believe that this country has been in two decades of tributing existing wealth. Local companies should push for
deflation! local manufacturing/assembly of goods. We as individuals
So what is the point of my ramblings above, you may need to live by the Proudly South African motto, we should
justifiably ask? This is supposed to be an automation and have a natural preference to buy and use South African goods
control piece right? Not a travel blog . . . However, during and services. We should do this even if it costs more than
these travels I continued to ask myself why we as South the imported product, because it will create jobs and in the
Africans in particular and Africans in general, have not been long-run that will be cheaper for our country as a whole as
able to develop such successful economies? Japan has limited there will be less people living off government grants and
natural resources and imports raw materials from SA for their they will have greater self-esteem, because they are making
motor and other industries. In fact they import the majority a contribution. The social ills associated with lower economic
of their raw materials for their large industries. Hong Kong groups should also then decrease and make for a more stable,
imports gold and diamonds from SA and then makes these equitable society. Currently we stand on the precipice where
into desirable, expensive jewellery which is then resold world- those who ‘have not’ far outnumber those of us who ‘have’!
wide, including SA! Imagine the boost to our automation They have nothing to lose and hence their behaviour is
and control industry and the contribution it could make if we congruent with this.
could get massive industrialisation in SA? However, as one of As usual, please mail me your thoughts on
my colleagues on the trip pointed out . . . he sees more and vinesh.maharaj@saimc.co.za. I thank you all for taking the
more warehouses popping up around SA to store mainly time to read this column.
imported goods. Working together, achieving more,
So what is the difference? Is it cultural differences, are Vinesh Maharaj, President

20 August 2015 www.instrumentation.co.za


SAIMC NEWS

Group photograph with the technicians at Tata Steel.

Richards Bay branch


The last Technology Evening was held downtime or breakdowns by developing process operation by the Tata steel
on 4 June at the Umhambi Lodge and appropriate maintenance schedules. technicians, from raw materials handling
was sponsored by Yokogawa where KZN right up to the finished product sections.
regional sales manager, Andre Verreyne, Mangosuthu University of Technology Most of the students had never been in
gave a presentation on the topic “How C&I site visit to Tata Steel a plant before and the visit gave them
diagnostics benefit the industry”. On Friday 5 June, the branch hosted a suc- the opportunity to see and experience
Andre gave an in-depth overview cessful site visit to Tata Steel KZN for a group the instrumentation and processes in
of how to manage diagnostic data. To of S3 and S4 students from the Mangosuthu practice. Unfortunately the plant was off
illustrate the extent that downtime has on University of Technology. The twenty-four for winter shut-down, so they could not
the productivity, he stated that according students, accompanied by lecturer James witness the tapping of molten metal from
to recent statistics, it was estimated that Rwafa, were taken through the smelting the furnace.
downtime contributed almost $20 billion
in lost revenue – hence the need to iden-
tify and predict problems through analysis
of diagnostic data.
Starting from the field level, he
explained various types of data residing
in instruments and showed the hierarchy
with which this data moves from the field
level, and the processing involved until
it gets to the high level MES and ERP sys-
tems. Of interest was the integration into
systems like SAP. Different systems are
available such as CMMS (computerised
maintenance management systems) that
provide core information and allow the
user to do an analysis to identify repeat
offenders and pinpoint losses. The infor-
mation can be analysed by employing
techniques such as regression analysis,
and the data can be used to help reduce Mervyn Govender (right) thanks Andre after the presentation.

www.instrumentation.co.za August 2015 21


SAIMC NEWS

Durban branch
The Durban branch held its annual golf day on green (considering the drought conditions) day, as well as the golfers, sponsors and prize
Friday, 3 July. As often happens with mid-win- and the sponsors’ banners and flags lent a donators, without whom this day would not be
ter days in Durban, the weather was warm and festive air to the occasion. Prize-giving was possible, let alone the success that it was.
breezeless with not a scarf or jacket in sight, a jovial affair with a great array of prizes for In the photos, the winning four-ball from
and the 100 golfers entered into the four-ball everybody and a good old Durban curry and Endress+Hauser (Thys Labuschagne, George
alliance competition were relaxed and in good rice for supper. It also happened to be branch Dyman, Kushal Bugareth and Thys Otto) is seen
spirits as they teed off. The committee decided chairman Howard Lister’s birthday, so a rousing about to tee off and then accepting their trophy.
on a new venue this year and the Kloof Country ‘Happy Birthday’ set the tone for the evening. To view other photographs from the day
Club provided a great and convenient location. The Durban committee would like to thank please go to http://www.instrumentation.
The greens were nicely kept and reasonably Steve Sanders for his help with organising the co.za/7075r

John Owen-Ellis (right) is seen thanking Carmine at the Durban branch July technology meeting. of using this as opposed to existing technolo-
Canale, business development manager of the This very specific and interesting topic gies and of course pipe-centric integration.
Gas Analytics Division of Endress+Hauser who included aspects such as: on-line gas analysis, Judging by the many and varied questions
gave a very interesting presentation on modern sample conditioning system issues, basic prin­ and interaction after the meeting it was a well
gas analysis techniques for process applications ciples of Raman Spectroscopy, the advantages received and well presented topic.

22 August 2015 www.instrumentation.co.za


SAIMC NEWS

Johannesburg branch
At the last technology evening, Gary Friend, sales director from Extech
Safety Systems, walked us though the topic “Making Safe Waves in
Hazardous Areas”. Or in other words, can wireless be used in hazard-
ous areas especially when radiated energy has the potential to initiate
explosions?
As wireless devices such as mobile phones and laptop comput-
ers become more reliable and cost effective, there is growing interest
amongst the process industry about the benefits to be found from
enabling such devices for hazardous areas. However, this is not a simple
task. Installing wireless networks in hazardous areas requires careful,
expert planning and execution.
It has always been understood that radio frequency (RF) can cause
ignition in the right set of circumstances. There are now a number
of approval standards that must be adhered to, including the CLC/
TR50427, EN60079 series, IEC60079 series and others such as FM3600.
Fortunately, much of the latest wireless technology that is of interest to
users to deploy in their plants, such as WiFi or RFID, has RF power levels
lower than the 2 W limit. Providing antenna gain does not cause these
levels to be exceeded, and they are installed with adequate protec-
tion e.g. Ex d enclosure, they can be used in a hazardous area without
restrictions. However, when the amount of power is above the safe
levels then CLC/TR50427 can be used to assess the installation for safe
Eric Carter (left) thanks Gary after the presentation.
use in hazardous areas.
A recent development by Extronics, represented by Extech Safety e.g. access points and standard antennas, without further Notified Body
Systems here in South Africa, has completely altered the landscape of certification.
deploying wireless networks in hazardous areas by using the intrinsic The SAIMC thanks Gary for presenting and hosting respectively this
safety protection concept and being able to deploy wireless hardware valued and informative presentation.

Johannesburg: Eric Carter at eric@turbotrain.co.za, Mobile: +27 (0)83 300 3321


Cape Town: Mothibi Thabeng at thabeng.m@gmail.com, Mobile: +27 (0)82 708 5783
Durban: Howard Lister at howard@nickzn.co.za, Mobile: +27 (0)83 320 8590
Richards Bay: Mervyn Govender at mervyn.govender@rbm.co.za, Mobile: +27 (0)83 299 2260
Secunda: Johan Maritz at johan.maritz@kentz.com, Mobile: +27 (0)82 856 3865
Vaal: Christiaan Steyn at christiaanalbrechtchristoffel.steyn@sasol.com, Mobile: +27 82 411 9811
Zambia: Widdy Chimba at widdy.chimba@mopani.com.zm, Tel: +26 096 347 3078
Council: Ina at admin@saimc.co.za, Mobile: +27 (0)82 440 8957, Tel: 08610 72462 (08610 SAIMC)

www.instrumentation.co.za August 2015 23


NICK DENBOW

Image courtesy SteadiDrone.

Drones for remote inspection


The capability for the use of UAVs (Unmanned The first serious use of a helicopter drone for Welding and Inspection Personnel) quali-
Aerial Vehicles, or drones) for remote inspec- for inspection duties on a petrochemical plant fied, who knew what they were looking for,
tion has grown at a rapid pace over the last in the UK was reported around five years and what was important.
five years, because of the boom in wireless ago, from Cyberhawk, based in Edinburgh, Cyberhawk has expanded, and established
data communications, lighter batteries, but and initially focused on the petrochemi- operating bases in Norway, Malaysia and Abu
above all because of the effort devoted to the cal and oil industry in Scotland and the Dhabi: they recently carried out their 10 000th
technology from the military use of UAVs. The Northern UK, plus offshore in the North Sea. commercial ROAV flight, which was a survey
style that has aroused most attention in the Cyberhawk undertook the world’s first live of a new power station site. The helicopter
commercial and public arena is the helicopter gas flare inspection, using an ROAV (Remotely drone used was an 8 rotor type incorporat-
drone, using multi-rotor devices as platforms Operated Aerial Vehicle) flying at a height of ing the latest triple redundant autopilot,
for cameras. So fast did this ‘take-off ’, that the 100 m: this work was for a major Scottish gas a significantly more expensive unit than
authorities in several countries took time to refinery. The ROAV was flown within a few a gadget shop drone! In the USA, Aetos, a
catch-up, which led to various banning orders metres of the live flare: this provided highly Michigan based company, has been granted
and then proposals for regulations and licens- detailed images of the condition of the flare a special exemption by the FAA to operate
ing of drones, and their pilots. In the UK, at tip and associated structure using HD video, drones commercially for inspections of petro-
least, this did not seem to stop the appearance plus still imagery and thermal imaging equip- chemical plants and facilities. The Aetos CEO,
of low cost hobby type drones for amateur ment. More important was that the work on Bill Donberg, had done 30 years working at
use, in growing numbers in high street camera site was carried out by Cyberhawk inspection Dow Chemical, and their first clients included
shops and gadget supplier outlets. engineers – all CSWIP (Certification Scheme the likes of Dow Chemical, Eastman Chemical,

Nick Denbow’s European report


Nick Denbow spent thirty years as a UK-based process instrumentation marketing man-
ager, and then changed sides – becoming a freelance editor and starting Processingtalk.
com. Avoiding retirement, he published the INSIDER automation newsletter for 5 years,
www.iainsider.com, and now acts as its EMEA editorial correspondent. His blog is on
www.nickdenbow.com.

24 August 2015 www.instrumentation.co.za


NICK DENBOW

Exxon Mobil and Phillips 66. Their drones are


Image courtesy SteadiDrone.
built by Aeryon, and cost around $75 000
each. The final FAA regulations covering
commercial drone flights and their pilots are
expected to be issued in late 2016 or 2017,
but already their other ‘special exemptions’
allow specific drone use in the movie and
video industry; for real estate adverts; for
­agricultural monitoring and aerial surveying.

Drone flying regulation


Regulations generally accept that a land-
owner owns his own airspace, up to say 91 m
upwards at least, so that makes flying a drone
over your property, for example to look in
your windows, not permissible. The push by
paparazzi photographers using drones to
get ‘at home’ celebrity photos needs to be
quashed. So regulations require that drones
cannot fly over anywhere without the land-
owner’s permission. Incidentally, this brings
the FAA in the USA up against Amazon, who drone: from the beginnings of inspecting flare civil engineering survey work: monitoring rail-
want to trial delivery systems using drones: stacks, many more inspections have been way lines across bridges and other structures
Amazon has threatened to move their R&D on made of offshore structures, for example oil from the air. Flying at 150 m, these drones
this topic out of the USA, unless there is some platform legs – anywhere where putting a can monitor rail line positioning to within
progress to gaining FAA agreement. Google man up alongside the area to be inspected 2 mm. In The Netherlands, a company spun
are doing their drone delivery system research is difficult and hazardous. The Royal Navy out of the Aerospace Engineering Department
project in Australia. has used them to inspect the external hull from the Delft University of Technology has
In the UK, if you intend to fly a camera areas of warships. In the UK there are many specialised in building robot helicopters: their
equipped drone for commercial uses you old buildings, and regrettably many of these latest multi-copter will automatically take-off
will need a PfAW (Permission for Aerial Work) are damaged by fire. Long after the event, and land from a transport box, so reducing
from the CAA. This is issued after the requisite structural engineers can do a detailed survey the workload for the operator. The university
training of the pilot has been completed, of the damage to the internal walls by flying has also pioneered various research projects
and it is renewable annually, for a fee: s­ everal a drone inside the building, to assess whether to improve the situational awareness of the
providers of approved training courses are it is safe for engineers to enter the shell of the operators of these drones to other air traffic,
operating. The website www.droneuav. building at all. so that they can be used more effectively for
co.uk gives useful data and links: there Ben The technologies now added to the drone police and military operations in urban areas.
Lovegrove of www.WessexAerialPhotography. include infrared thermal cameras, and GPS Further partners are being sought for this
com describes from his own experience that positioning linked into the drone flying con- work, as well as other industrial inspection
the training took six months and the total cost trols, to accurately position the drone, know and maintenance tasks.
to gain the UK PfAW including accessories and where it is, and keep it there. These aspects
insurance was around £3000. Ben often uses can help searches for hot spots (i.e. electri- The future
a drone made by a South African company, cal faults) on solar power farms, or electricity As ever, once the technology and operational
SteadiDrone, which is based in Knysna. distribution networks, and for locating steam rules have been established, the potential
In South Africa, new regulations for or gas leaks – or insulation failures – on petro- for many new drone applications will arise.
operating drones were announced in May by chemical plant pipework. New markets for drone services are going
the CAA. These regulations took effect from Some of the start-up companies providing to open up for service providers, and these
1 July. They follow the same patterns as being drone inspection services seem to emerge will be pioneered by the specialists who
imposed in the USA and UK, and will require from research projects based in university have a problem or a project, and can make
an operator to have a Remote Pilots License departments. A typical surprising applica- the link with friends or service providers: it is
(RPL). A lot of useful information can be found tion was described at InnoRobo, the robot the combination of the drone pilot and the
on www.safedrone.co.za. technology exhibition in Lyon in March 2014. corrosion engineer, structural engineer, or
Philippe Bidaud of GdR-Robotique, the French another inspection or measurement tech-
Recent applications co-ordinating body for robotics research in nologist who needs to get his eyes up close
Many recent industrial applications use and government institutions, reported on the use or into a difficult environment that will make
show the capabilities of the camera equipped by CNRS (the French Railways) of drones on the break-through.

www.instrumentation.co.za August 2015 25


Radiation-based instrumentation
for extreme process conditions
VEGA now supplies SIL-qualified measuring gauges remain completely unaffected by high Cesium-137 or a Cobalt-60 isotope is usu-
instruments for radiation-based level and point vessel pressures, aggressive media, extreme ally used as the radiation source. A special
level measurement. The ProTrac series was medium temperatures or difficult physical detector mounted on the opposite side of the
developed according to the strict specifications product properties.” tank picks up the radiation. This scintillator
of IEC/EN 61508 and all sensors in this series How is that possible? “ProTrac sensors is able to convert the radiation received into
fulfil the highest standard requirements. In can measure right through container walls flashes of light that are counted and evalu-
addition, all ProTrac sensors have an ingenious with the help of gamma radiation,” continues ated. Because gamma rays are attenuated by
asset management system at their disposal. Groom. “Our radiometric technology provides changes to the process medium, this technol-
you with reliable measurement data on filling ogy can calculate the level, the limit level, the
Radiation based technology level, limit level, density, separation layer and density or mass flow from the intensity of the
Why the need for radiation-based technol- mass flow.” incoming radiation, i.e. from the number of
ogy? “Under extreme process conditions many light flashes.
measuring principles quickly reach their limits,” How it works
explains John Groom, MD of Johannesburg- The basic element of radiometric (also known Security at the highest level
based VEGA Instruments SA. “This is where as nucleonic) measurement is a radio-active ProTrac is equipped with the optimised
ProTrac is different: these radiation-based preparation that emits gamma rays. A source container VEGASOURCE. The lead-filled

26 August 2015 www.instrumentation.co.za


COVER STORY

housing protects the surroundings against connected in series for level measurement measurement of lime water in flue gas
gamma rays so well that it allows operation in round and conical vessels. Now there is de-sulpherisation. The gauge can also be
even without a control area and at the same FiberTrac, a sensor with flexible plastic fibres. applied to a conveyor belt to measure mass
time protects the isotope from damage. The The flexible detector can be up to 7 m long flow of a hot product such as clinker.
container is also available in a fire-resistant and very simply contoured to the vessel shape.
version as per ISO 7205 and IEC 60405. So today, one single instrument often suffices Set-up and adjustment
The radiation is emitted through a narrow where several were previously required. To ProTrac speaks the language of automation
ray path in the housing and focused in the allow for extremely long measuring ranges, equipment and can be simply integrated
direction of the detector. This radiation emis- FiberTrac can also be cascaded. into any process control system. Setting up
sion channel can be completely closed if For measurement in straight sided vessels a radiometric measurement is now simpler
required. The shutter mechanism of the source there is SoliTrac, which has a classic PVT rod than ever: users can set the parameters of
container can also be pneumatically operated. detector. With its crystal scintillator in compact normal level or density applications with
design, MiniTrac is the specialist for density the on-site adjustment module PLICSCOM
Asset management measurement. And last but not least there is directly on the instrument. For more com-
All ProTrac instruments are equipped with PoinTrac, a level switch that offers a convincing plex measurement setups, the powerful
a smart asset management system for self price and performance capability. and highly effective DTMs and EDDs take
monitoring and diagnosis. It continuously over this task.
checks all components and functions for A range of applications for level, overfill Groom concludes: “With ProTrac,
accuracy and correctness, fully automatically. protection, density and mass flow the user gets perfected radiation-based
ProTrac switches from ‘green’ to ‘yellow’ status measurement measurement technology from a leading
according to the traffic light principle when it VEGA’s ProTrac series of gauges are suitable producer of sensors and gauges. The instru-
recognises even the smallest deviations from for a range of applications; for example, for ment sets standards in the area of safety as
the optimal state. This allows sufficient time to level measurement in a polyester melt process, well as being particularly easy to handle.”
correct the problem well before a real distur- where the gamma radiation penetrates the
bance or breakdown can occur, thus prevent- cylinder despite the rotation of the cylinder For more information contact
ing expensive system standstills. and the great heat generated during the Chantal Groom, VEGA Instruments SA,
process. +27 (0)11 795 3249,
Flexible application options ProTrac is also suitable for level detec- chantal.groom@vega.com,
Until now, multiple rod detectors had to be tion in cellulose production and for density www.vega.com

www.instrumentation.co.za August 2015 27


Optimising ESL milk standardisation
Krohne’s Otiquad M streamlines drinking milk production at Ammerland dairy.

Although the process steps involved in the regarding indirect fat standardisation, the real required optimisation of calibration. To do so,
production of drinking and extended shelf life fat value must be regularly checked by way of samples are first taken by way of the integrated
(ESL) milk are different, fat standardisation is sampling and laboratory measurements. These sampling valve. During sampling, a button is
generally still taken care of indirectly in both tests take a relatively long time in the laboratory, activated to notify the analyser unit and the
cases using Coriolis flowmeters. A new method meaning intervention in the process is thus cor- measurement, determined over the entire
of fat standardisation using a non-contact, inline respondingly delayed. In the case of deviations period of sampling, is saved in the operating
analysis device capable of measuring the fat from the required fat content, the target value unit. The reference value as determined in the
content in ESL milk with extreme accuracy is is manually changed and more or less cream is laboratory is then entered. If several samples
introduced here. added accordingly. have been measured and entered, the current
calibration can be optimised at the touch of a
The basics of milk production Spectroscopic analysis simplifies the button.
To produce drinking milk with various minimum process The measurements of the Optiquad M were
fat contents, the raw milk is separated in the Krohne’s new Optiquad M is a spectroscopic recorded over several months. The accuracy was
dairy into skim milk (approx. 0,05% fat content) analysis system well suited to the task of fat found to be in the range of the reference mea-
and cream. The Coriolis flowmeter is placed in standardisation, as it performs continuous surements determined in-house and in inde-
the flow of cream to measure the fat content. inline non-contact measurement of fat content pendent laboratories. “Our confidence in the
In addition to measuring the direct mass flow, directly in the drinking milk. In addition, it also device grew when we heard this,” commented
Coriolis flowmeters also measure the density of measures the protein and lactose content in dairy production manager, Armin Tjards. “With
the product. The fat value is calculated using this milk products. The Ammerland dairy processes Krohne’s solution we can measure the fat and
density and a fixed formula. approximately 3,3 million litres of raw milk per protein content directly in the standardised ESL
However, the only reason this fat measure- day and was looking for a solution to the prob- milk, in other words, exactly where we want to
ment is relatively accurate is because the fat lem of fat standardisation in ESL milk. Particular measure. We can now continuously look into
content in the cream flow is sufficiently high. emphasis was placed on continuous accurate the process which means that we were able to
Measurements done in the drinking milk, where measurement to enable improved process set the desired fat content precisely, even in the
producers would actually like to measure the control without time delay. The dairy installed complex production processes of ESL milk.
value, are not nearly accurate enough to regu- an Optiquad M 4050 W. The analyser unit was
late the fat content. installed directly in the production line by way Optiquad M functionality:
Using the current flow rates of skim milk of a standard Varinline process connection The analysis system uses optical spectroscopy to
and cream, it is possible to calculate how much without bypass. This entire measuring section measure the contents of milk products continu-
cream must be added to achieve the desired fulfils the high hygienic requirements and is ously and without contact. In the process, light
fat content in the standardised milk. In addition FDA-compliant. of varying wavelengths is coupled into the
to the inaccuracies of the measuring and final The analyser unit contains no moving parts, product through an optical window. The system
controlling devices, the approximate 0,02% and the wetted parts are cleaned via CIP. The simultaneously determines the values of up to
fluctuation range of the fat value in skim milk operating unit, built in a stainless steel housing, four optical effects (transmission, scattering,
plays a role when it comes to customer require- is installed in close proximity to the analyser and fluorescence and refraction) which manifest in
ments for high accuracy. Consider also the many connected using a serial interface. Its purpose is different ways depending on the substances in
process steps involved in ESL milk production, to display the measurements, make them avail- the product, and then uses them to calculate the
whereby partial flows can be pasteurised, able to the control unit via 4-20 mA outputs and amounts of protein, fat and lactose.
homogenised and micro filtered, it is easy to see enable all entries and actions. To this end, the
why the inline measurement of fat content is operating unit is fitted with a modern industrial For more information contact John
advantageous. PC featuring touchscreen operation. Alexander, Krohne SA, +27 (0)11 314 1391,
Taking into account the various uncertainties The operating unit also takes care of any j.alexander@krohne.com, www.krohne.com

28 August 2015 www.instrumentation.co.za


???

www.instrumentation.co.za August 2015 29


FOOD & BEVERAGE

Siemens Simatic technology


optimises honey centrifugation
German-based Harzer Antriebstechnik
specialises in the planning and engineering of
sophisticated automation solutions focusing
on drive technology. The company recently
began to fit honey extractors with Siemens
technology, optimising the efficiency of the
entire honey centrifugation process from the
controller through the frequency converter to
the operator unit.
To harvest the best quality honey, bee-
keepers use what are known as honey extrac-
tors to extract the honey out of the comb by
centrifugal force. The key to efficient opera-
tion is to ensure the seamless interaction
between the controller, the operator unit and
the drive. The production conditions for the centrifugal force flings the honey against the 2,2 kW with a single-phase 230 Volt AC supply.
different types of honey are defined at the inner wall of the drum. It flows down the wall Using a Simatic HMI KTP400 Basic com-
discretion of the beekeeper by simply select- and is collected at the base of the drum. To bined button and touch operator panel, the
ing the spin program and setting the drive ensure that honey is centrifuged out of both beekeeper selects the spin program and the
parameters. sides of the comb, the combs are turned by configuration. It is also possible to monitor the
reversing the motor direction. Finally, the program sequence and individually modify
Centrifugation honey is guided through a drain valve into a the set motor speed. An exchangeable cover
A honey extractor comprises a cylindrical collecting bin. film protects the panel’s control buttons and
stainless steel drum which accommodates a Harzer Antriebstechnik honey extrac- switches from becoming gummed up with
honeycomb basket with a rotating axis. This tors work using a controller model based on honey. If maintenance is required, only the
is connected to the drive below the drum. Simatic technology, and a Sinamics G110 controller itself needs to be sent in.
Depending on the size of the extractor, frequency converter as a variable-speed drive.
the honeycomb basket can accommodate During the extraction process, a motor con- For more information contact
between 4 and 16 comb frames in which the nected to the frequency converter is con- Keshin Govender, Siemens Southern
combs are placed. Once the lid is closed and trolled via the communication module by a Africa, +27 (0)11 652 2412,
the spin program has been selected, the drive Simatic S7-1200 controller from Siemens. The keshin.govender@siemens.com,
sets the honeycomb basket in rotation. The motors have an output of between 0,37 and www.siemens.co.za

Flush-front temperature sensors for


the food industry
Flush-front temperature sensors from ifm electronic are now available for
applications such as in agitators or pigging systems. Thanks to the inte-
grated process connection with G ½ sealing cone, the compact design of
the TA3597 sensor allows quick and easy installation. The sensor has an
integrated 2-wire transmitter analog (4-20 mA) output.
The one-piece hygienic and robust metal housing with Peek
(Polyetheretherketone) wetted parts has been specially developed for
harsh applications. Meeting IP69K and FDA requirements, the sensors
operate from 18-32 VDC in an ambient -20 to 70°C temperature range,
and medium temperatures of 0 - 100°C. Electrical connection is via M12
connectors.

For more information contact ifm electronic SA, 086 143 6772,
info.za@ifm.com, www.ifm.com/za

30 August 2015 www.instrumentation.co.za


www.instrumentation.co.za August 2015 31
FOOD & BEVERAGE

Purifying raw sugar juice


The challenges of pH measurement in the sugar mill.
To extract raw sugar juice, the mill first crushes, The raw juice from extraction is acidic with Attempting to control a nonlinear variable
shreds, or presses the cane or beets. The raw juice a pH of about 5,5 – usually controlled by the such as pH in a continuous, dynamic process using
that is extracted is highly pure, but contains unde- addition of sulphur dioxide. Before entering the these methods can easily lead to loss of process
sirable organic and inorganic non-sugar constitu- pre-carbonation tank, the juice is heated to a tem- control. Prior to improvements in both pH glass
ents, along with colour. At this stage, the mill may perature of 76-82°C. The additions of milk of lime and reference technology, online measurements
add formalin or other antibacterial agents to the and carbon dioxide in the pre-carbonation step were virtually impossible. Excursions of pH regu-
recycled press water to inhibit bacterial growth. begin to raise the juice pH. The chemical addition larly occurred, and shutdowns were common.
The next steps, pre-carbonation and liming, has three desirable effects:
act to purify the raw juice. During purification, • The high pH prevents the sugar from becoming The ABB Solution: TBX551 and TBX587
insoluble solids, gums, polysaccharides, and starch or reverting to non-sucrose forms. pH sensors
dissolved colorants coagulate out for removal by • Organic acids are changed into salts for later Most sugar mills will operate through a growing
settling and filtration. removal by precipitation. season (referred to as a ‘campaign’). The campaign
Mills purify the juice using lime and carbonic • Foreign matter is kept in suspension for removal will last 3-6 months, depending if beet or cane
acid. To create lime the mill heats limestone by filtration. sugar is being refined. If the pH sensor can last
(calcium carbonate) in kilns to produce burnt lime On leaving the initial lime tank, the juice pH has through the entire campaign then this is consid-
(calcium oxide) and carbon dioxide. The end prod- been raised to a value near 9. Continued addition ered to be a success.
uct is mixed with water, becoming milk of lime of milk of lime in the main liming tank raises the The largest obstacle in controlling pH in the
(whitish lime particles suspended in water) and the pH to 11 or more. From this point the juice travels sugar mill is finding equipment that will tolerate
carbon dioxide introduced to the pre-carbonation to the first carbonation step to remove excess lime the harsh conditions found in this environment.
tank mixes with water to become carbonic acid. and filter out precipitates. Lime addition takes place before any filtration,
Cane processors practice partial liming while introducing precipitation and coating issues. The
beet processors apply complete liming. The goal of Challenges in measuring pH temperature of the process after pre-carbonation
complete liming is to reduce invert sugar (glucose Sugar refining is a high-temperature, caustic is typically greater than 80°C, and finally, many
and fructose) as much as possible by adding process requiring tight pH control in almost mills do not have the extensive instrumentation
an excessive amount of lime. Cane processors every stage. Because the process is so physically staff that other industries have, and so lack educa-
partially destroy the invert sugars, using less lime. demanding, in the past pH measurement was tion on cleaning and calibration of the pH sensor.
Some refiners use a combined purification process typically made in cooled sample lines (introduc- For these applications, ABB’s Twist Lock
consisting of phosphoric acid and lime by which ing significant lag time) or via grab samples (even TB(X)551 is ideal for sample line installations. The
30-37% of the syrup colour is removed. longer lag time). bayonet style mounting makes sensor removal for
cleaning and calibration very easy. If the pH sensor
is inserted directly into the process, then ABB
recommends a retractable sensor with extraction
housing. The housing has flushing ports which can
be used to loosen congealed sugar and particu-
lates. The TB(X)587 or TB(X)557 are good examples
of retractable sensors that work in these processes.
For all liming applications the coat resistant “J”
Glass electrodes should be specified. The Wood
Next Step Reference can be used for the applica-
tions below 11 pH and PTFE can be specified
above 11 pH.

For more information contact


ABB South Africa, +27 (0)10 202 5000,
instrumentation@za.abb.com,
www.abb.com/measurement

32 August 2015 www.instrumentation.co.za


???

www.instrumentation.co.za August 2015 33


Pilz safety products in packaging
applications
Pilz has developed a one-stop solution for How much safety does a packaging more than a subordinate role. Interaction
most industries, including packaging. It has machine need? with the machine is mostly limited to pack-
tailor-made solutions for complex applications Safety is gaining ground in modern engineer- aging refills, or brief interventions in the
using the PSS4000 safety PLC or straight-for- ing. Every day new functions are being added case of a fault. For this reason, not too much
ward applications using the tried and tested to packaging machinery in order to cope importance is attached to the use of qualified
safety relays. For everything in between, Pilz with the different types of products in terms personnel to operate the machine. Covers,
has a range of programmable safety relays of design, size and container. Machinery is fences and gates are used as safety devices
(the PNOZ multi range), which is cost effective, now more flexible as a result of decentralised to prevent direct access and exclude the
expandable and easy to configure. drive technology, which means the demands possibility of injury. Hazards arise when the
Pilz has an excellent reputation on the on safety, including the implementation of machine is run outside of production mode,
control side and now it is able to offer a full the relevant safety functions, has increased. during setup or cleaning for example, or
range of safety sensors for all applications on The question “How much safety does a when the process requires some interven-
automated lines, which includes light curtains, machine actually need?” is easy to answer: tion while the machine is active. In this case,
e-stops, coded sensors, gate locks, etc. A new The protection of man and machine must machine safety must be designed to enable
coded sensor has just been launched with a be guaranteed, as must the ability to design human errors to be intercepted.
magnetic holding force, so that a latch is not production processes individually. Safety in the classical sense will always
necessary, and the advanced light curtains Short product life cycles, high variability refer to personal safety: risk must be kept to
come with a full range of options, such as and modern packaging materials mean that a minimum. To exclude the risk completely
blanking and muting. machines are ever more flexible and place manufacturers would actually need to stop
When it comes to choosing a safety sensor heavy demands on technology and processes using operating personnel all together.
or control device it should not just come down alike. Everyday life is governed by the frequent However, the huge increase in machine
to price: when a risk assessment is done there interchange of contents and packaging. flexibility has only come about as a result
are a number of factors to be considered and Automation technology with individual drives of improved interaction between man and
one of these is the mean time to dangerous meets this requirement for flexibility, dynam- machine. Complete automation, including
failure. (This value is determined in systems ics fault reaction, and changeover at the touch during setup and cleaning, would increase
as a safety parameter according to standard of a button. Generally it offers even greater costs and labour exponentially. Over the next
EN ISO 13849.) Pilz carries out repeat testing availability while still increasing performance. few years, this interaction between man and
of equipment and safety devices, to make In doing so, the limits of automation are often machine will result in even more develop-
sure that these meet and exceed the safety reached, while operator capabilities must ments in the area of safe sensor technology
standards. also be considered as part of the production and safe data communication.
Safety devices are often seen as a hin- process.
drance to productivity, but with the correct For more information contact
design and best choice of products, safety Safety devices protect operating Craig Cuff, Prime Automation,
and productivity can be achieved. Machine personnel +27 (0)41 819 7746,
operators should not feel that life or limb is in Even on packaging machinery with high craig@primeautomation.co.za,
danger while they are working. quantity output, the operator often plays no www.primeautomation.co.za

34 August 2015 www.instrumentation.co.za


PACKAGING & BOTTLING

Laser contrast sensor


with background
­suppression
Banner Engineering’s Q3X laser contrast contrast changes where a background needs
sensor with fixed background suppression to be ignored.
reliably detects targets within the desired A typical application is label detection on
sensing range, while ignoring objects in the a bottle where contrast differences between
background. the label and bottle provide reliable detec-
Out of the box, the Q3X LD50 operates tion but the sensor must ignore the shiny
like a fixed-field laser sensor and detects metal rail in the background. The shiny metal
targets within its 50 mm sensing range. background could cause a false trigger for
However, the sensor can be programmed standard diffuse-mode sensors.
for low-contrast sensing within this range, Banner’s Q3X is designed with a unique
while ignoring objects at least 60 mm away. angled, three-digit display of signal intensity,
This allows the sensor to detect its target which provides high visibility of operating
without background objects affecting conditions from multiple angles. For an intui-
performance. tive user setup, the unit has two tactile but-
“With fixed background suppression, the tons conveniently located below the display.
Q3X overcomes the problem of standard The robust nickel-plated zinc die cast
diffuse-mode sensors, where objects in the housing ensures reliable performance even in
background affect the application,” said environments with exposure to cutting fluids
Dennis Smith, technical marketing manager and oils. Sensors are also rated to IP67, IP68
at Banner Engineering. “The Q3X LD50 is an and IP69K for enhanced protection to water
innovative solution for our customers’ hard- submergence and high-pressure wash down.
est detection and error-proofing problems.”
Featuring high-speed part detection as For more information contact Brandon
fast as 250 μs, the sensor can capture up to Topham, RET Automation,
2000 events per second. This, along with +27 (0)11 453 2468,
background suppression, makes the Q3X brandon.topham@retautomation.com,
ideal for solving applications with small www.retautomation.com

www.instrumentation.co.za August 2015 35


PACKAGING & BOTTLING

Servo technology is the key


Q&A with Michael Kurz on the design of the filling processes for Capri-Sonne using drive
systems from SEW-Eurodrive.

Michael Kurz is manager of the design and systems. We even produce the pouches pouch on the market known as Caps. Were
development department at Indag Germany, ourselves. Only the foil, which is just a tenth of you not worried about breaking with
a subsidiary of Wild, a world leading supplier a millimetre thick, is produced and supplied tradition?
of natural flavour ingredients for the food by an external company according to strict A: It was a clever marketing concept to
­industry. Capri-Sonne and Caps are private specifications. extend the product range and revitalise the
brands of Wild. Indag, founded in 1952, devel- brand. The target group for Capri-Sonne is
ops and implements state-of-the-art process Q: Each year, 5 billion pouches across the children up to 12 years of age. Caps on the
systems and filling and packaging machines world are filled with Capri-Sonne. You other hand are designed to appeal to young
for the food and beverage industry. would think that would give you enough to adults. We were tasked with designing a
do, but you also supply machines to other resealable shaped pouch without affecting
Q: What drives the systems of the Capri- branded companies, don’t you? the throughput rate of the machine. We are
Sonne manufacturer Wild? A: We have been designing and manufactur- proud to have come up with such a good
A: With the exception of the US, it is almost ing systems for other companies for about solution. We have had a great deal of success
always SEW-Eurodrive. When I started at Indag three years now under the name Indag Pouch with this new machinery, particularly on the
in 1994, my first project was to speed up Systems. We supply systems to the food, open market.
process times in production. Servo drives from drinks, pet food and pharmaceutical industries.
SEW-Eurodrive were best equipped to handle We take on turnkey projects covering the Q: Capri-Sonne, Caps, intelligent filling
this task. The next quantum leap in filling entire process chain, including downstream technology, marketing solutions – is there
speeds followed at the end of the ‘90s – from and upstream equipment. anything left that can challenge you as a
324 to 500 pouches per minute. Now, one line development manager?
is able to fill and close the pouches, attach Q: What was the most challenging problem A: At present, we are designing stand-up
straws, and package the drinks ready for deliv- you were faced with when improving the pouches for other foodstuffs, such as milk
ery. It is true to say that servo technology is the systems? drinks, coffee or tea. These types of products
key in the production processes today. A: It may not sound very interesting for cannot be kept at warm temperatures for
anyone unfamiliar with the industry, but long after sterilisation because the ingred­
Q: The stand-up pouch has been part of one of the most challenging problems was ients, particularly the flavour additives, would
the branding of Capri-Sonne for almost 40 to develop a solution for attaching straws to suffer. They must be kept cold, which means
years now. Do you think it is also the reason the Capri-Sonne pouches. In this process, the they must be filled under aseptic conditions.
for the product’s worldwide success? horizontal pouches must be transferred to a We are concentrating our energies on this
A: Yes, it is one of the factors of the company’s conveyor belt at full speed (1,2 m/s) with exact project at the moment. I am sure we will be
success, besides the brand and the recipe. ­positioning. As our development partner, SEW- able to introduce a prototype by the end of
Company founder Rudolf Wild established Eurodrive had an important part to play in the year. That would represent another break-
the packaging as an integral part of the brand this development. In fact, we were one of the through for our packaging philosophy.
right from the beginning. The stand-up pouch, first companies to use the new Movi-PLC in an
made of a three-ply composite material, is a industrial application. For more information contact Rene Rose,
packaging concept in its own right. This is why SEW-Eurodrive, +27 (0)11 248 7000,
we produce our own filling and packaging Q: In 2002, Wild launched a new type of rrose@sew.co.za, www.sew.co.za

36 August 2015 www.instrumentation.co.za


www.instrumentation.co.za August 2015 37
Safe and hygienic packaging for
consumer products
Enhanced performance and reduced costs in bottle cap lining and post-moulding
automation equipment.

The cap lining machines from MMC Packaging from MMC can also run several tooling types, electrical designer, MMC Packaging. Using auto-
cut the lining material (pulp, foam, cardboard eliminating the downtime associated with matic timing in software, the LM-270 machine,
or foil) and insert it into the cap. Depending on production changeover. with all its connected peripherals, can change
the machine configuration, cutting may take speed on the fly and adapt the production rate
place as rotary die cutting; i.e. rolls of liners are PC-based control increases efficiency of the machine to the client’s needs to main-
pre-cut and subsequently fed to the insertion The control hardware previously used by MMC tain high throughput, among other concerns.
station. With punch and die technology, the Packaging had reached its technological limits: TwinCAT 3 NC PTP controls and synchronises
liners are cut and inserted into the cap in a “The processing speed, system memory, data the indexing, cutting, and insertion of the lining
single operation. Subsequently, a vision system storage and database capabilities would not material with registration marks. “TwinCAT 3
inspects the caps to ensure they are free of allow any further optimisation of our machine,” Scope records all the data in the process,” con-
defects before they are sorted or moved to the explains Mathieu Ouellet, vice president of tinues Letourneau. “The PC is not only a central
next production step. business and product development. “We controller, but also a production data recorder.”
MMC Packaging has designed various lining needed more processing power on the one
machine versions to suit different cap sizes and hand, and greater flexibility of the control Modernised machine operation with
types: up to 1200 caps can be processed per platform on the other. In addition, we wanted multi-touch
minute, depending on the type of machine a state-of-the-art user interface with a wide The LM-270 lining machine uses a multi-touch
and the operating mode. MMC’s best-selling variety of standard programming tools.” control panel from the Beckhoff CP391x
machine, the LM-270, performs 150 cycles per The complete automation of the LM-270, series as its HMI hardware. “With the PC and
minute, according to president and owner, including the feeding, cutting and mounting of EtherCAT-based control platform, we created
Philippe McNally. The cutting and insertion the liner, inspection/rejection, and the con­ a state-of-the-art user interface that provides
of the liner can be done both for one and firmation of rejects, runs on a PC-based control the client with important production data in
two caps at a time, so that up to 300 parts system from Beckhoff. A C6525 Industrial PC real-time,” comments Letourneau. “This also
can be processed per minute. The settings (IPC) with Intel Celeron dual-core processor includes comprehensive operational and per-
of every component in the line are managed and TwinCAT 3 automation software provides formance data from the machine. MMC clients
automatically, so changing a recipe or produc- the foundation for the control system. “With have up-to-the-second information regard-
tion parameters can be done at the press of TwinCAT 3, manual intervention is minimised ing the health and efficiency of equipment,
a button and production changeovers take when performing timing changes on the optimising maintenance efforts and boosting
less than 30 minutes. Some machine models machine,” stresses Yan Letourneau, senior machine uptime.”

38 August 2015 www.instrumentation.co.za


PACKAGING & BOTTLING

MMC Packaging utilises 3D models and tutorial videos for operator as an interface to other networks and protocols when required.”
training and support regarding the handling of the new control platform. “The first stage of the controller upgrade has now been successfully
“The ability to run the Windows-based graphical interface, as well as PLC completed,” states Anthi Balafoutis, sales and marketing coordinator,
and motion control tasks, on a single device was, in our view, a huge MMC Packaging. “So far we have converted the LM-270 machines, our
factor in favour of PC-based control,” stresses Ouellet. “Our 3D manual MMC-icon user interface, and our QTVision inspection system to the
uses multi-touch functionality, programmed using C++ and C with pinch PC-based control platform. The next step will be to implement this
gestures for zooming in and out, allowing customers to view valuable ­technology in our entire range of machines.”
equipment information, for example.”
Tried and tested in the LM-270 cap lining machine, the PC-based For more information contact Kenneth McPherson, Beckhoff
control platform is now also employed by MMC Packaging in its QTVision ­Automation, +27 (0)11 795 2898, k.mcpherson@beckhoff.com,
inspection system, which checks the quality of the caps. In this case, www.beckhoff.co.za
a CX2040 Embedded PC, with TwinCAT 3 automation software and
EtherCAT as the system bus, simultaneously runs several automation, con-
trol, and data acquisition tasks. “With four cameras, we can now inspect
up to 2400 caps per minute and process up to 9 600 images per minute
without causing strain on the CPU,” confirms Letourneau.

EtherCAT as the universal system bus for I/O, motion and safety
“Thanks to EtherCAT, control speeds in the low microsecond range are
now commonplace for MMC Packaging, such as triggering cameras in the
vision system at 250 microseconds,” notes Letourneau. “The integrated
TwinSAFE safety solution from Beckhoff represents further added value.
We use standard Ethernet cables for safety technology as all the safety
data now goes through the EtherCAT protocol and there are TwinSAFE
terminals in use throughout the machine. A system-integrated pro-
grammable safety solution is much easier to modify in the future as our
machine designs evolve.” MMC Packaging primarily uses TwinSAFE for
emergency stops, safety devices, and for safety measures on drives. The
TwinSAFE drive option cards are used on the Beckhoff AX5000 Servo
Drives to implement safe stop functions (STO, SS1).

Machine footprint reduced, performance increased


MMC Packaging uses servomotors from the AM8000 series which feature
one cable technology (OCT). “The OCT, along with high-density EtherCAT
I/Os and integrated TwinSAFE safety solution are perfect for the stream-
lined machine design that was our goal,” says Ouellet. “Instead of manag-
ing all control wires from the central units to all of our peripherals, we
now only have to wire a single Ethernet cable, which dramatically cuts our
wiring cost and saves approximately 20 to 24 hours of installation time per
setup. A further advantage is that EtherCAT allows the integration of any
standard Ethernet device. MMC also uses the EtherCAT gateway terminals

www.instrumentation.co.za August 2015 39


PROCESS MEASUREMENT

Krohne’s complete pressure p


­ ortfolio
The release of the Optibar series extends Smallest measuring span of 10 mbar is ideal for flow instruments can be wet calibrated up to
Krohne’s range of process instrumentation applications with small turndown ratios, and DN 3000.
to include pressure measurement. Since the quick step response times allow for use with Hydrostatic pressure is used to measure
release of the first compact pressure transmitter pulsating flows. liquid level, density or liquid-liquid-interface in
in 2012, the company has continuously been All Optibar PC, PM and DP transmitters are open and pressurised vessels of any size. The
working on its pressure portfolio. The new based on a modular concept and share inter- Optibar modular product line offers a complete
Optibar series includes a variety of pressure changeable housings, electronics, display, and portfolio of pressure and DP transmitters,
transmitters with ceramic or metallic meas­ adjustment modules. Hereby, different require- diaphragm seals and accessories for measure-
uring cells, application-specific diaphragm ments such as intrinsically safe/explosion proof ment of corrosive and non-corrosive liquids and
seals, primary elements, and accessories to concepts or 4-20 mA HART 7, Foundation field- slurries up to 450°C and 420 bar. As a simple
equip flow, level or process pressure applica- bus and Profibus PA communication options level measurement solution for wells or tanks,
tions – from single transmitter to complete can be met with just one platform. submersible probes are available. A large port-
measuring points. For DP volume or mass flow measurement folio of process connections, including different
Starting with transmitters, the portfolio of liquids, gases or steam, Krohne offers a wide hygienic process connections for a hygienic and
holds pressure transmitters with ceramic or portfolio, from primary elements to complete dead-zone free installation covers the require-
metallic measuring cells for standard applica- measuring points with matched, pre-­configured ments of various industries.
tions: Optibar PC 5060 with capacitive ceramic components. Medium temperatures -200 to The Optibar modular product also covers
measuring cell is aimed at all applications up to 1000°C, process pressure up to 420 bar, and line process pressure applications to measure
100 bar. Optibar PM 5060 with metallic measur- sizes from DN25-12000 can be covered. As pri- pressure in pipes or vessels from -1 to 1000 bar
ing cell and fully welded process connection is mary elements, averaging pitot tubes are avail- gauge and 0 to 600 bar gauge absolute. Over
used for high pressures up to 1000 bar, aseptic able as a simple, cost-efficient and long-term 250 thread, flange and aseptic process connec-
processes, and, in combination with diaphragm stable alternative to orifice plates. Pitot tubes tions are available for different industry stan-
seals, for high temperature or corrosive applica- are especially suitable for applications that dards, including special materials. As standard,
tions. Compact and ultra-compact transmitters, require a low pressure loss, retrofit of existing the transmitters cover process temperatures up
e.g. for OEM applications, are also available. pipes with a flow measurement, line sizes > DN to 150°C without diaphragm seal. For tem-
The differential pressure transmitter Optibar 300, or low pressure gases. The portfolio also peratures up to 450°C or corrosive mediums,
DP 7060 marks the centre of the transmitter includes wet-calibrated meter runs for small Optibar DS diaphragm seals are available, also
range. It can be used for either flow, level or line sizes and low measurement uncertainty, a pre-configured with direct, capillary or com-
process pressure applications up to 420 bar. flow computer, optional pressure and tempera- bined direct/capillary mounting.
The integrated absolute pressure measurement ture compensation as well as accessories for
eliminates the need for an additional sensor safe and easy installation of pressure transmit- For more information contact John Alexander,
in flow and level applications, e.g. to measure ters in the process such as valves and manifolds, Krohne SA, +27 (0)11 314 1391,
head pressure in closed/pressurised vessels. condensate pots, or general accessories. All DP j.alexander@krohne.com, www.krohne.com

40 August 2015 www.instrumentation.co.za


www.instrumentation.co.za August 2015 41
PROCESS MEASUREMENT

How accurate is your infrared pyrometer?


A thermal imaging camera only reads the
electromagnetic radiation it receives in a
specific range of wavelengths. To display this
reading the camera makes several calculations
to convert data into actual temperature, and
one that is vitally important is emissivity.
Emissivity is efficiency with which an object
emits infrared radiation at a given temperature
by comparison with a black body at the same
temperature and with the same surroundings.
Values range from 1.0 for lampblack down
to 0,02 for polished silver. And in most cases
the pyrometer/camera readings need to be The temperature of the steel and the tape should be the same, but a 4°C error due
to emissivity is observed.
adjusted to take this emissivity into account.
If its value is incorrect, the actual tempera- info@randci.co.za with your details and the it before installation and during regular IR
ture will be exponentially different to the company will e-mail back a booklet covering window maintenance.
display temperature; the Stefan-Boltzmann law the basics. 1. Pour hot water into a cup and place a target
explains the science behind this. Worse still the The safe practice of using infrared windows of known emissivity on the side, such as a
margin increases in line with temperature so on switchgear and other inspection points, strip of electrical tape or an IR-ID label.
the results are not just different, but seriously rather than removing covers whilst equipment 2. Set the camera’s transmission to 1.
skewed. A phase imbalance that may seem to is live, is becoming more of a requirement and 3. Measure the temperature of the target
be just a few degrees can actually be upwards can introduce errors in readings if not done without the IR window.
of 30°C. correctly. 4. Place the window in front of the camera and
The visual set-up of the pyrometer/camera With windows the infrared passes through complete the measurement again.
would be the only other way of determining a very specific material and some intensity is 5. Use the camera or the reporting software
the severity of the fault. But as any experi- lost. Almost all cameras and pyrometers have to change the transmission coefficient of
enced thermographer will tell you, the visual a transmissivity setting that compensates for the image until the adjusted temperature
component is not a reliable alternative. this. Also different materials react in different (taken through the window) and the original
Depending on the level, span and range ways. The polymer based windows have a temperature are the same.
on the pyrometer/camera it is still very easy to fixed transmissivity that is compensated for 6. Record the transmission rate on the IR
miss a severe problem. on installation, whilst crystal based windows window label and in the report template for
It is therefore vital that users understand vary throughout their lifetime as they are future reference.
emissivity and how to set-up a thermal hydroscopic and absorb moisture which affects
imaging camera accordingly. Understand- their transmisivity. For more information contact
ing the basics of infrared temperature The coffee cup test is a simple way to check R&C Instrumentation, 086 111 4217,
measurement is easy; just send an e-mail to the transmission of any infrared window. Use info@randci.co.za, www.randci.co.za

Miniature thermometer now autoclavable


New application possibility for the TR21 miniature resistance
thermometer from WIKA.

The basic requirement for the use of the (4-20 mA output) in a range of -50 to 250°C.
TR21 in sterilisation processes under With a case diameter of only 19 mm, the
saturated steam is its consistent sealing TR21 can also be integrated into the smallest
concept (IP69K ingress protection). The units. The thermometer also offers explosion
new instrument option adds to this feature protection and is certified as intrinsically safe in
with an electrical system of high-quality accordance with ATEX and IECEx.
components which are matched to the high
temperatures (134°C) found in autoclaves. The For more information contact
hygienic thermometer operates with a direct WIKA Instruments, +27 (0)11 621 0000,
sensor output (Pt100) or integrated transmitter sales@wika.co.za, www.wika.co.za

42 August 2015 www.instrumentation.co.za


PROCESS MEASUREMENT

Emerson flowmeters certified


for power piping standards
ASME B31.1 certification extends the breadth of Micro Motion and
Rosemount technologies for use in power applications.

Emerson Process Management’s Micro Motion gain better insight into their processes for meet B31.1 design standards and code stamp
Coriolis and Rosemount 8800 vortex flow- improved operations.” certification include all carbon steel flanged,
meters have been certified to the ASME B31.1 B31.1 power piping design standard certifi- reducer and dual vortex meters with flange rat-
power piping design standards, in addition to cation applies to all areas of the power plant ings up to and including ASME Class 1500 (PN
the existing B31.3 process piping standard. except for boiler external piping (BEP), and is a 160) on 1-inch (DN25) through 8-inch (DN200)
“We are committed to serving the power basic design requirement for products sold into meter body sizes and ASME Class 600 (PN100)
industry and are excited to announce compli- the power industry. B31.1 code stamp certifica- on 10-inch (DN250) and 12-inch (DN300) meter
ance to B31.1 power piping design standards,” tion applies to the BEP area of the plant. body sizes.
said Andy Dudiak, president of Micro Motion at Compliance with B31.1 power piping
Emerson Process Management. “Micro Motion design standard is offered on several of the For more information contact Michael
Coriolis and Rosemount vortex meters bring Micro Motion Coriolis Meters – including Elite, Eksteen, Emerson Process Management, +27
accurate, reliable measurement to a wide range F-series and R-series meters. (0)11 451 3700, michael.eksteen@emerson.
of applications, helping electricity generators Rosemount 8800 vortex products that com, www.emersonprocess.com

Allpronix releases new laser level meter


Allpronix has added a new longer range laser level/distance meter to
its portfolio. The AL-100 is a new longer range unit that has a 100 m
measuring range that can be displayed as either level or distance. The
AL-100 has a universal power supply as either 90-240 VAC or 24 VDC as
standard, and comes complete with a 4-20 mA output and two
programmable relays.
A feature of the AL-100 is that it comes standard with a local LCD
backlit display and four pushbuttons for programming, making set up
and interface user friendly and quick to complete. Aiming is also simple
using the visible laser pointer that can be disabled after installation
using a simple DIP Switch.
The AL-100 is locally designed and manufactured in Johannesburg,
which makes pricing competitive and stock readily available.

For more information contact Greg Christison,


Allpronix, +27 (0)11 795 9500, greg@allpronix.com,
www.allpronix.com

www.instrumentation.co.za August 2015 43


PROCESS MEASUREMENT

Higher-precision pressure
­transmitters added to Sitrans ­family
Siemens has extended the Sitrans P family of with an orifice meter the Sitrans P410 is ideally deviation to 0,065 percent with a turndown
its pressure transmitter portfolio. By adding suited for applications such as the flow of 1:1 to 5:1. This allows plant efficiency to be
the newly developed Sitrans P310 and P410 measurements required when filling and further increased when performing processes
to the basic and advanced segments, and the emptying gas tanks. The same applies to such as level measurement, as the new
proven Sitrans P500, in the premium segment, pressure measurements for process gases or technology enables better utilisation of
Siemens is now able to offer the right device fluids in low and high pressure applications shut-off limits for tank filling levels. These
class to address every conceivable measurement up to 700 bar. The Sitrans P500 rounds off the improvements and the wider relative pressure
requirement. The proven Sitrans P DS III has Sitrans P family in the premium segment with range, which has been extended with a
also been technically innovated. The new standard measurement ranges from 50 mbar 250 mbar cell, make this the highest
developments deliver even more accurate to 32 bar. In terms of performance, precision, performing transmitter for flue gas measurements
measurement results across the whole long-term stability and diagnostic scope, the in power stations and incineration plants.
pressure transmitter range. differential pressure transmitter is capable of All of the transmitter series are simple to
The Sitrans family provides a high-precision coping with the most stringent demands. operate using just three push buttons, and
product portfolio to cover any conceivable With a response time of 88 ms and an ability offer a long-term stability of 0,125 percent
measurement need with its comprehensive to operate in temperatures of -49 to 125°C, over a period of five years, allowing calibration
range of device classes, from the basic model, the Sitrans P500 is ideally suited for the cycles to be extended and maintenance work
the P310, through the advanced Sitrans P410 ultra-precise measurement of differential reduced with all the associated cost savings.
to the proven premium Sitrans P500. The P310 pressure, filling level and flow rate. They are also certified to SIL 2/3 and dispose
pressure transmitter offers a measurement Still available is the tried and tested Sitrans the commonly required Ex zone certifications.
accuracy of 0,075 percent, making it ideal for P DS III. This product from the advanced
applications in fields such as water supply and segment has been innovated to feature For more information contact Keshin
disposal. premium sensor technology, bringing about Govender, Siemens Southern Africa, +27 (0)11
With its extreme measurement accuracy an improvement in accuracy and temperature 652 2412, keshin.govender@siemens.com,
of 0,04 percent, when used in combination range, as well as optimising measurement www.siemens.co.za

44 August 2015 www.instrumentation.co.za


PROCESS MEASUREMENT

Ultrasonic level sensor


for solids and liquids
Due to the many advantages offered by an
ultrasonic level measurement, ACS Control
System has developed a new future-oriented
range of devices. The product line is divided
into the Sonicont USN, a compact device with
built-in display, and the Sonicont USF/USG
with its separate transmitter.
The Sonicont devices are universal
ultrasonic level sensors that can be used both
for liquids as well as bulk material. When the Transmitter
with hazardous
Sonicont USG/USF is in use, the transmitter is
separately mounted to the sensor. The

area approvals
measurement ranges are in liquids up to 25 m
and in solids up to 12 m. The Sonicont USG/
USF is mainly used in places where the opera-
tion does not take place locally, e.g. in high
silos or tanks, or when the user wishes the
display and parameterisation to be external WIKA’s multi-function UPT-2x is a solution for
to the sensor. The designs range from front tasks in pressure, level and volume measurement.
panel mounting housings for the cabinet Its sensor, with a measuring range between
door, on to weather-proof DIN rail mounting 0-400 mbar and 0-1000 bar depending on the
up to wall-mounted versions. requirement, operates with an accuracy of up to
All devices of the series Sonicont have 0,1% of the measuring span. For applications in the
a backlit TFT display that combines bright pharmaceutical and food industries, flush-mount
display of the measured values with an USG/USF devices can also be supplied with versions are available. The electronics are protected
excellent operability. The combination of a real-time clock with battery backup to save by a conductive plastic case, or optionally by a
large buttons, the bright display, and intui- the time stamps. Other features include: stainless steel case in hygienic design.
tive menu navigation, simplifies the installa- • Process temperature range from -40 to 85°C. The measuring ranges of the UPT-2x are
tion. Commissioning is usually completed in • Weather proof (IP68). freely scalable and can therefore be adjusted to
a few minutes via the software that records • Analog output 4-20 mA and 4 switching individual measurement tasks. An intuitive-to-use
the environmental conditions with various outputs. menu in accordance with the HARTv7 standard and
diagnostic functions designed to fade out • Accuracy 0,2%. the integrated display make programming easier.
any false echoes. The sensors all have a data • Hermetically sealed sensors made of PVDF With its handling without the need for tools, its
logger that allows over 500 000 recorded for the highest chemical resistance. high long-term stability and its universal applica-
measurements, which can be seen directly • The Sonicont USG sensor can be installed tion possibilities, the UPT-2x is also a cost-effective
as a chart representation. Since the user may up to 30 m from the transmitter. solution.
choose the timeframe in which to record,
there is the possibility of measuring values For more information contact Veni Reddy, For more information contact WIKA Instruments,
over weeks to analyse, visualise and opti- Allpronix, +27 (0)11 795 9500, +27 (0)11 621 0000, sales@wika.co.za,
mise processes. As an option, the Sonicont veni@allpronix.com, www.allpronix.com www.wika.co.za

www.instrumentation.co.za August 2015 45


PROCESS MEASUREMENT

Flexible relative
humidity instruments
for industrial users
Michell Instruments has released its latest range of
relative humidity transmitters for industrial applications.
As well as being flexible, for use in a wide range of
processes, the HygroSmart 280/290 series includes
an interchangeable sensor that allows for routine
maintenance to be made in just 30 seconds for most
models.
At the heart of each instrument is the new
HygroSmart I7000XP. This sensor is fully replaceable,
and, because all the calibration data is incorporated,
makes routine maintenance and recalibration as easy as
changing a light bulb. The I7000XP uses Michell’s latest
polymer capacitive sensing technology, the H8000 tile to
provide reliable accuracy of 1% RH.
The HygroSmart 280/290 series features a number
of configurations designed to suit different applications.
This includes duct- and wall-mounted as well
as remote sensor versions, each with optional
displays for easy interrogation and configuration. New
software also allows for easy access to all configuration
settings and data collection from a control room.
The units are configurable to suit specific needs
including outputs, units and alarms. Michell Instruments

Compact vortex
is a provider of field measurement solutions of
humidity and temperature.

flowmeter with
For more information contact Instrotech,
+27 (0)10 595 1831, sales@instrotech.co.za,
www.instrotech.co.za

TFT display
The new vortex flowmeters from ifm known as the vortex principle, is virtually
electronic are space-saving devices independent of pressure and temperature
that quickly inform the user about the fluctuations of the medium.
current volumetric flow and medium The new SV type devices are best
temperature. The multi-colour display suited for use in cooling water circuits.
can be rotated electronically and the They can be used for water with and
red/green colour selection for process without conductivity. Outputs for flow
values can be set. Installation can be rate and temperature are switched
independent of orientation due to the output, analogue current signal
rotatable G and R process connections (4-20 mA), as a frequency signal, or
which are optionally available. via IO-Link. Thanks to the vortex
Behind a bluff body integrated in the principle with its simple constructive
measuring pipe, the flowing medium design, the sensors are cost effective
generates swirling vortices depending on and feature intuitive menu-guided
its velocity. These vortices are detected programming.
by a piezo-ceramic sensor. If the cross-
section is known, the number of vortices For more information contact
allows determination of the flow rate. ifm electronic SA, 086 143 6772,
This flow rate measurement principle, info.za@ifm.com, www.ifm.com/za

46 August 2015 www.instrumentation.co.za


PROCESS MEASUREMENT

User-friendly
mass flow
controller
EL-Flow Prestige is the next generation of Bronkhorst mass flow meters/
controllers for gases. Nearly all core components have been redesigned
and many improvements and innovations have been incorporated. With
this new series Bronkhorst introduced the ‘differential temperature
balancing’ technology to ensure high accuracy and superb sensor
stability.
New, power-efficient micro-processors with innovative multistage
control loops have been applied to achieve enhanced dynamic
behaviour and the new metal housing is of robust yet compact design.
EL-Flow Prestige represents a ground-breaking shift in versatility and
user-friendliness, featuring an on-board gas conversion model, various
fieldbus options and customisable I/O functions.
The control performance is factory adjusted for swift response to
setpoint changes, without overshoot. Moreover, the controllers are
highly resistant to mechanical shocks and pressure fluctuations that may
be caused by other devices consuming gas from the same source. As an
option the MFCs can be tuned for extra fast flow response (down to 500
milliseconds) or extra smooth control, depending on the requirements
of the user’s process. The dynamic behaviour can also easily be tuned
on site by adjusting the controller speed settings via the FlowTune or
FlowPlot software tools. These can also be used for device diagnostics or
alarm and counter settings.

For more information contact Mecosa, +27 (0)11 257 6100,


measure@mecosa.co.za, www.mecosa.co.za

www.instrumentation.co.za August 2015 47


Philae on the comet surface / Photo: ESA/ATG medialab.

A comet chaser stirs


By Steven Meyer, editor, SA Instrumentation and Control.

Drive systems from Faulhaber defy the harsh conditions of a 10-year journey through the vacuum
and low temperatures of space.

4:33 AM 14 June 2015. “Hello Earth! Can you hear Because of the small size of the comet, further important tasks to perform in order to
me?” A lonely robot, freezing on an isolated about the size of Mt. Fuji in Japan, the force transform the kinetic energy generated during
space fragment, cheerily reaches out through of gravity is very low in the region making the landing into electrical energy and finally
Twittersphere to herald its reawakening. Seven it difficult to ensure a secure stance on the into heat using a spindle drive. A Faulhaber
months after being forced into an ultra low- surface. Thus, the Max-Planck-Institut for 3557 series bell-type armature motor was
power state of hibernation, the Rosetta Mission’s Extraterrestrial Physics developed a special connected directly through an external resistor
Philae lander has finally stirred from its slumber anchor system for the probe. Immediately and operated as a generator in this case.
on the icy surface of Comet 67P/Churyumov- after ground contact on landing, two har- Additional drives from the 1224 series
Gerasimenko, some 600 million kilometres away. poons were to be shot by a propellant charge were used in the three-legged landing gear of
In November 2014, Philae had touched into the surface of the comet to lodge into it. the craft in order to swivel or rotate the upper
down to global applause as it became the first (Barbs were provided to prevent these anchor part by means of a cardan joint, so that the
spacecraft ever to land on the nucleus of a fittings from tearing themselves loose again.) solar panels would always remain optimally
comet. But, it had come to rest in the shadow As each harpoon shot out, it would have aligned. Microdrives were also needed for
of a crater. With its solar panels now unable unwound a cable from a circular magazine. By taking samples: the lander has a drill that
to harvest the sunlight required to keep the means of a Faulhaber 1628 series brushless feeds core samples into an oven for pyrolysis.
batteries charged, the diminutive craft had servomotor with a 16/7 planetary gearhead, Small 1016 series motors with 10/1 planetary
been able to work only 60 hours before being this cable would then be wound back onto a gearhead drive a cam via a worm arrange-
obligated to “go dark” in the primordial wilder- drum until taut in order to secure the probe ment. This provides feed to a ceramic breech
ness it had come to explore. to the surface. At least that was the plan – piece on the oven and simultaneously closes
As luck would have it, Comet 67P’s ellipti- unfortunately the harpoons were not fired, the electrical contacts for the oven heating
cal orbit has now changed its position relative the rewinding mechanism was not used, and element. The combustion gases generated
to the sun just enough for the rays to light up Philae ended up bouncing three times even- in the furnace are then routed through tubes
the solar panels of Philae’s outer shell. This is tually coming to rest in a crater. Nevertheless, in the oven latch to the scientific instru-
what breathed life back into the little comet the miniature laboratory was still able to ments for analysis. During its first scientific
chaser, including the 14 Faulhaber drive sys- begin its analyses as planned. phase, which lasted a total of 60 hours, the
tems which defied the harsh conditions of the lander performed all of the planned scien-
10-year journey through the vacuum and low Landing gear and sample analysis tific measurements on the comet surface.
temperatures of space. During the landing phase, other motors had Philae successfully transmitted this data to

48 August 2015 www.instrumentation.co.za


ROBOTICS & MECHATRONICS

the Lander Control Centre before it went into


hibernation. Now that the orbit has shifted
and its upper part is better aligned with the
sun, Philae has revived itself and is once again
ready to perform the galactic research for
which it was designed. The European Space
Agency regards the mission as a complete
success, but evaluation of all the received data
will take some time.

Outer space and its demands


The demands that outer space place on these
drives are high: every kilo of mass that is shot
into space costs energy, i.e. fuel – hence money
too. Therefore, small, light solutions are sought.
At the same time, however, they must also be
able to withstand the enormous vibration and
acceleration forces during take-off, as well as
the constant very-low temperatures and the
many years of vacuum conditions prevailing in The harpoon system / Photo: DLR.
outer space.
Because cost also plays a major role when specifications as possible. They found what comparably few modifications at ­negligible
selecting components for space projects, they were looking for in the comprehensive additional cost.
the developers wanted to do without costly drive systems product range from Faulhaber.
custom developments if at all possible. The standard drive solutions fulfilled all For more information contact David Horne,
Accordingly, they first looked for standard mechanical requirements, and the special con- Horne Technologies, +27 (0)76 563 2084,
products which complied with as many of their ditions in space could then be met by making david@hornet.cc, www.hornet.cc

www.instrumentation.co.za August 2015 49


SMC Pneumatics steps up a gear
with Renault
LEF actuators reduce production times and save space.

When Renault began development on its new drive to improve production efficiency. involves the use of robotic technology.
generation K9 engine to meet the now obliga- Renault was one of the original adopt- However, these utilise valuable space and are
tory Euro6 regulations, it needed to develop ers of SMC’s electric range of products and costly, and complicated to program and main-
new processes in various areas of its Valladolid has not been disappointed with the results, tain. So, it was Renault’s ambition to replace
plant in Spain. All of these were required expressing its satisfaction with the LEF actua- these, where possible, with more efficient
to support its SPR and lean manufacturing tors. According to Bester, the actuators have alternative solutions.
principles. According to Johan Bester, head of provided Renault with the high degree of As a result, SMC’s LEF actuators have been
sales at SMC Pneumatics South Africa, the K9 flexibility required for the development of new installed in place of a robot, with the ability to
produces fewer than 80 mg/km of nitrogen products, and at a very competitive price. cover eight different positions whilst with-
oxides, which is a requirement of Euro6. It Renault also believes that continuous col- standing heavy loads. The actuators are also
features steel pistons that generate less friction laboration with SMC has been key to the easy to program and maintain, and deliver
and delivers 3% lower fuel consumption. integration of the electric actuators, and has production efficiencies across all key areas.
The particular challenges facing Renault’s reinforced the image of the company as a com- Since installing the electric actuators,
production system (SPR) was how to maximise ponents supplier for the automotive industry. Renault has significantly reduced the cycle
efficiency and output while optimising the and overall operation times, as well as saving
available space and keeping maintenance as Continuous improvement is the vision significant space in production area.
simple as possible. Being Japanese owned, SMC shares Renault’s “It’s a great example of lean manufactur-
SPR principle through the kaizen (continuous ing and has provided Renault with the perfect
LEF actuators meet the requirements improvement) philosophy and collectively solution to its production challenges, and
With ambitious targets to reduce overall both teams are always striving to enhance the ultimately helped it to bring a highly competi-
costs of the new engine whilst maintaining manufacturing process, so that it is as lean tive product to market,” concludes Bester.
quality, Renault needed an experienced and and efficient as possible. This allowed the key
trusted components supplier. SMC with its LEF objectives of reducing production time by 50% For more information contact SMC
actuators met the requirement to support the and minimising maintenance time and cost, to ­ neumatics South Africa, +27 (0)11 568 2407,
P
screw driven parts of the process. Their highly be comfortably achieved. sales@smcpneumatics.co.za,
repeatable action was a key benefit in the A key part of Renault’s production process www.smcpneumatics.co.za

50 August 2015 www.instrumentation.co.za


ROBOTICS & MECHATRONICS

AS-I M8 compact
modules for limited
space
The AS-i M8 modules from ifm electronic are suitable for applications
where space is limited. The units are equipped with ecolink connec-
tion technology and full potting ensures high shock and vibration
resistance.
The compact modules require little space due to their slim design.
They are suitable for robotics, handling technology and assembly tech-
nology. They have a protection rating of IP67/IP68 and are quickly and
easily installed via two fixing holes from the front or from the side.
The ecolink technology mounts easily. An integrated mechanical end

Parker Hannifin stop protects the O-ring from damage and rapid and secure installation
is possible without a torque wrench.

extends air motors For more information contact ifm electronic SA, 086 143 6772,
info.za@ifm.com, www.ifm.com/za

series
P1V-M air motors now offer two new power
­ratings plus ATEX certification.

Parker Hannifin has extended its P1V-M air vane motors range to include
two new sizes, namely 900 and 1200 Watts, combined with new ATEX (II 2
GD C IIC T4) certified variants and a non-gearbox derivative. Together with
the existing 200, 400 and 600 Watt models, the P1V-M series represent one
of the largest power ranges available in the global market today.
Due to its compact design, the P1V-M is suitable for deployment in a
wide range of industries such as machine builders, food and beverage,
packaging and conveying, chemical industry, and in plant automotive.
This compact design also helps to reduce machine build footprint. The
P1V-M is also suitable for use in particularly harsh environments, under
extremes of vibration and operating at temperatures between -20 and
110ºC. Similarly, as there are no electrical connections, the air motor can
be used in hazardous environments hence the ATEX (II 2 GD C IIC T4)
certification.
The P1V-M is capable of providing output shaft free speeds from 32
to a maximum of 10 500 rpm, with torque up to about 120 Nm. High
levels of torque can be achieved at low speeds, and in common with all
Parker air motors, the P1V-M can be used as a replacement for traditional
electric motors and – power for power it offers a more compact solution.
Featuring the ability to be loaded until stall, the P1V-M can be stopped
and started continuously without damage. What’s more the direction of
rotation is reversible simply by changing the direction of the airflow.
Designed and manufactured from hardwearing robust materials the
P1V-M series features a patented vane change system. This innovation
delivers real benefits in terms of minimising machine downtime. When
it comes time for service, the motor can be left in situ and all the user
needs to do is to loosen the screws that hold the rear piece to the motor,
and then remove the old vanes if they are worn and insert new ones.

For more information contact Lisa de Beer, Parker Hannifin SA,


+27 (0)11 961 0700, lisa.debeer@parker.com, www.parker.com

www.instrumentation.co.za August 2015 51


VALVES, ACTUATORS & PUMPS

Metso valve expertise strong


enough for Goliat platform
Making its way from the Hyundai yard in
South Korea in early 2015 to its home in the
Barents Sea, the giant Eni Norge owned Goliat
floating, production, storage and off-loading
(FPSO) plant is the first ever to equip all of its
automated pneumatic valves with intelligent
valve controllers. Metso’s range of stainless steel
controllers, featuring plug-and-play functional-
ity and an easy-to-use remote graphic interface,
was chosen for the project.
Goliat is one of the largest industrial projects
ever and the first oilfield to be developed in the
Barents Sea. It is also the first FPSO plant to have
chosen to equip all of its automated pneumatic
valves with stainless steel valve controllers
in order to enhance safety and minimise the
operational and maintenance costs associated
with its large number of valves.

Maintaining maximum control of the


giant
Metso’s special portfolio of stainless steel smart
controllers was selected for the close to 900 us to make the necessary modifications to Goliat-sized success
pneumatic actuated control, on-off and emer- our products so that they perfectly fit the ABB Goliat will be able to use the diagnostic infor-
gency shutdown (ESD) valves in the Goliat plant. system,” says Juha ­Yli-Petäys, head of Metso’s mation provided by the smart controllers and
Now all the automated valves on the offshore valve controls business line. “For example, we integrate this with its asset management and
platform will be under continuous online condi- made a new version of our ValvGuard VG9000 enterprise resource planning (ERP) system
tion monitoring, enabling Eni Norge and Statoil firmware for the ESD valves as well as designed to manage maintenance scheduling and the
as well as their maintenance partners to better a stainless steel version of SwitchGuard for the number of staff needed onboard. This results
monitor and report valve performance for the on-off valves. We made joint tests with ABB to in significantly fewer working hours and
asset management purposes of the owners. prove to Eni Norge and Statoil that we had all less risk for the operators’ health and safety.
The Goliat platform is equipped with elec- the capabilities that they required.” Moreover, the system considerably lowers any
tronic nerve fibres in all of its production equip- negative impact on the surrounding marine
ment and auxiliary systems. Approximately 200 Predictive diagnostics help cut costs environment.
devices, such as compressors and heat exchang- The ability to bring intelligence to any valve With intelligent predictive diagnostics and
ers, feature model-based performance monitor- made Metso the ideal choice for the demand- maintenance capabilities, offshore as well as
ing. Alerts with appropriate action proposals will ing offshore environment. The unrivalled third onshore project owners can decrease opera-
be given whenever real performance deviates generation diagnostics and plug-and-play tional costs by reducing the number of valves
from the model’s expected performance. This functionality of the stainless steel smart valve needed overall. Maintenance costs are cut
gives Goliat the maximum control over the controllers convinced Eni Norge and Statoil that too as service visits can be better scheduled
entire plant. Metso could meet the targets. in advance and occur only as needed, which
“Our superior third generation diagnostics is reduces servicing time and associated expenses.
A smart move with speed and agility one of the biggest assets of our product portfo- Safety of the operations and the personnel
To guarantee that everything works seamlessly, lio. For operators, the easy-to-use graphic inter- is also paramount. Therefore, truly knowing
Eni Norge chose ABB to be the main supplier for face quickly shows them how a valve is function- the condition of the valves at any given time
the automation, instrumentation complete with ing,” states Juha. “This enables our customers to enables the operators and management to have
all the valves, telecommunications and elec- better optimise their processes and effectively a full picture of how to best mitigate risks. This
tronics. ABB, in turn, chose Metso to supply the manage the maintenance work. Especially in an is exactly what the stainless steel smart valve
smart valve controllers. offshore environment, the costs of unscheduled controllers from Metso bring to the Goliat plant.
What made this project special is that ABB maintenance can be incredibly high.
and Metso partnered closely from the very early “We have the know-how, but even more For more information contact Metso
phases onwards. “It was important for us that importantly, we know how to add value with Automation, +27 (0)31 502 9350, nsdu@
we understood the requirements. This allowed our offering to the offshore business.” metso.com, www.metsoautomation.com

52 August 2015 www.instrumentation.co.za


www.instrumentation.co.za August 2015 53
VALVES, ACTUATORS & PUMPS

Rubber lined ball sector valves


A sustainable solution to the challenge of handling abrasive
fluids in mining applications.

Controlling abrasive fluids is known to be a cover ring and seat ring. When inspecting the
challenge for any industrial application. All valve valves approximately 40 days after the installa-
technologies have pros and cons, and they need tion, water leaked through the body. The water
to be evaluated in the light of the media to be was leaking through a hole just in the middle of
controlled. The main ratios to be taken into the body and additionally, the inlet cover ring,
account are purchase cost, installation cost and ball sector and seat ring were badly worn.
most importantly when it comes to abrasive
media; the cost for maintanance. Application 1: Iron ore dressing plant
Ramén’s KSG is a rubber lined valve that Throttling of deposit from thickener:
offers extended resistance to wear and tear in • Flow 120-240 m3/h with 10–30% solids. Measures and results
the valve for slurries, gravel, powder, iron ore • Grain size about 1 mm. Two years after installation the KSG rubber
and other highly abrasive media. The natural • Inlet pressure – 0,8 bar. lined valve was taken out of service. The rubber
rubber design, applied on the ball sector and in • Pressure drop 0.8 bar. was beginning to come loose from the sector
the valve house gives a valve with very long life but the valve was in very good condition.
time in any situation with maintained throttling Measures and results Experiences has established the KSG valve
and isolating characteristics. The KSG was devel- Soft natural rubber is, in certain cases, much design as the preferred valve technology in
oped in the beginning of the 1970s together more resistant than steel. A soft rubber lined severe services and replaced other valve tech-
with mining companies in Sweden. When a size 150 mm was installed in exactly the same nologies e.g pinch valves.
high end control or a long life isolating valve is application.
needed for tough media the Ramén KSG valve The valve was then taken out for inspection Conclusions
can be used in wafer and flanged design. after 6 months (after 4 months continuous ser- Since the development of the Ball Sector
vice), and absolutely no damage from wear was Valves in 1968 and the KSG in 1973 Ramén Ball
Challenge observed. Several other valve technologies had Sector Valves have been used successfully in
Prior to the development and use of rubber been tested e.g. rubber pinch valve, lined but- thousands of installations in mining and other
lined valves, the standard solution found in terfly valves etc. in the same service and none industries for controlling abrasive media with
mining operations handling abrasive media had lasted more than about 2 months. outstanding ratios for purchase cost, installa-
were stainless steel or iron cast valves. This tion cost and mostly important, the costs for
proved to be an inefficient solution, both Application 2 maintenance and replacements.
technically as well as financially. To provide an Throttling control of water to magnetic separa-
example Ramén, at several occasions in mining tor where iron is separated from granite. For more information contact
operations, installed a standard stainless steel • Flow 90 m3/h with 12–15 g solids/litre. Pinnacle Instruments SA, +27 (0)11 450 4885,
ball sector valve type KS size 150 mm, with hard • Inlet pressure – 2 bar. pinnaclesales@pinnacle-ice.com,
chromium faced ball sector and stellite inlet • Pressure drop 2 bar. www.pinnacle-ice.com

Rotex solenoid valves in South Africa


Rotex Automation is a leading manufacturer of
solenoid valves and air operated valves. Now
available in South Africa through local distributor
IQ Instruments, Rotex offers a range of valves to
control the flow of air, gas, water, oil and steam.
Specialties include pulse jet valves for the air filtra-
tion industry, and high pressure solenoid valves.
Prices are competitive, especially valves in stainless
steel. 2/2, 3/2, 5/2 and 5/3 valves are available with
orifice sizes up to 80 mm in aluminium, brass and
316 stainless steel with wetted parts in a variety of
materials to suit most applications.

For more information contact


IQ Instruments, +27 (0)11 792 1210,
rotex@iqinstruments.com,
www.iqinstruments.com

54 August 2015 www.instrumentation.co.za


VALVES, ACTUATORS & PUMPS

New Emerson metal-


seated ball valves
Increased protection for critical assets
in severe service applications.

Emerson Process Management has introduced the Fisher Z500 line of


metal-seated ball valves to its severe service portfolio. The valves are
engineered to withstand higher temperatures, pressures and more
erosive conditions than a standard on/off ball valve, providing increased
reliability and protection of critical assets in demanding applications.
A bi-directional sealing design offers a unique solution to process back
pressure and shutoff requirements in both directions, safeguarding
control valves and other equipment in the line.
Fisher Z500 valves are designed with an integral metal seat and self-
energised metal body gasket to help eliminate leak paths and withstand
extreme temperature changes. Live-loaded packing, side-mounted
brackets, and fixed centrelines help reduce side loads on the packing
and decrease overall wear for a longer service life. This addition of on/
off valves to the Fisher portfolio complements the existing control valve
offering and helps ensure seamless integration between products.
“The combination of isolation valves and control valves gives our
customers the opportunity to work with a single solution-provider to
achieve the process protection and reliability they need for their critical
applications,” said Kevin Meyer, president of Emerson’s Fisher Valves &
Instruments business. “We feel that adding another quality product to
our wide-reaching network of Emerson sales offices and service centres
around the world will not only give our customers a comprehensive valve
assembly, but the local support to go with it.”

For more information contact Michael Eksteen, Emerson Process


Management, +27 (0)11 451 3700, michael.eksteen@emerson.com,
www.emersonprocess.com

www.instrumentation.co.za August 2015 55


VALVES, ACTUATORS & PUMPS

High resolution, fast and reliable


Motorised valve actuator with optimised precision and speed.

Normally, control valves for use in process control circuits band setting of a mere 0,2 %, even with these small strokes, this
are equipped with pneumatic actuators. The advantages of motorised actuator achieves a repeatability accuracy of up to
this design are rapid positioning speed and high resolution 0,1 %. These values for resolution and repeatability are better by
of the valve position, both being prerequisites in achieving a a factor of 10 than those of valve actuators available up to now
satisfactory standard of control accuracy. However, in this case on the market and are setting new standards for motorised
the power supply can be a cause of concern since a supply of actuators – in particular where small strokes are involved.
instrument quality air is needed for the actuation of the almost
always required positioner. In principle, an electrical power Quick commissioning and sturdy construction
supply would be less problematical for this purpose, but the Furthermore, this motorised actuator offers self adaptation for
positioning of motorised control valves is very often slow and quick commissioning.
they are subject to very high hysteresis which makes them By pushing a button, the actuator searches for the end
unsuitable for many control tasks. positions of the valve. As a result, it takes the operator just a few
seconds to adapt the actuator to the particular valve. Naturally,
New motorised actuation from Schubert & Salzer this can also be done by using the optionally available commu-
The new motorised actuation from Schubert & Salzer Control nications software DeviceConfig. Moreover, the software also
Systems has overcome these drawbacks as it sets new bench- offers the opportunity to define all parameters extremely easily.
marks in terms of resolution and positioning speed. The Monitoring and self diagnostic functions optimise operating
actuation of the 2030 series, comprising an electric stepping reliability and simplify preventive maintenance.
motor, a flexible coupling, gear box and stroke detection, is Its sturdy aluminium body and separate terminal box are
designed and manufactured to a high degree of precision. The ideal prerequisites for harsh operating conditions, which are
stepping motor defines 400 steps per revolution. Every part of reflected also in the high IP67 protection level. The terminals
the gearbox is made of steel which guarantees a long service are easily accessible and enable connections for 230, 115 and
life. Therefore, each step of the motor results in a displacement 24 VAC or 24 VDC power supplies, and set point signal connec-
of a mere 1,5 μm. At the same time, the new 2030 actuator can tions of 0-20 mA or 0-10 V. A binary actuation (On/Off/Stop)
achieve positioning speeds of up to 1,3 mm/sec. via a 24 VDC signal is also available, as is a separate manual
Furthermore, the stroke detection for feeding back the operation mode.
position consists of extremely sturdy metal guides, a linear The new Schubert & Salzer Control Systems motorised valve
potentiometer and limit switches with Hall sensors. By using a offers high speed and precision for control processes involv-
12 bit AC/DC converter and a special interpolation process, the ing neutral to highly aggressive media flows in the chemical
position of the stroke can be detected precisely with a resolu- industry or process engineering.
tion of about 3 μm. Although the sliding gate valves 8038 series
combined with this 2030 actuator has a stroke of only 6 mm, For more information contact Keith Hedges, Macsteel Fluid
the resolution and, therefore, the level of control, are very high, Control, +27 (0)82 575 9354, keith.hedges@macfluid.co.za,
taking just 4,5 seconds to open or close. With a standard dead www.macsteel.co.za

56 August 2015 www.instrumentation.co.za


VALVES, ACTUATORS & PUMPS

Safety in
high pressure
applications
Metso’s new XH series high pressure ball valves by Neles
have been designed to deliver safety and reliability for
multiple high pressure applications. Modern safety and
emission standards are setting a new demand level for
valve products. The new XH series is ready to meet these
requirements in higher pressure classes, ASME 900/EN PN
160. The XH, designed to meet low emissions (ISO 15848),
functional safety (IEC 61508-2:2010, SIL 3) and fire safety
(API 607) standards still provides all the traditional bene-
fits that Neles ball valves are famous for. These provide
a low cost of ownership due to less need for servicing,
high production yield due to long lasting high tightness
and general trouble-free operation in both shut-off and
throttling applications.
The benefits are delivered through Metso’s extensive
experience in ball valve technologies including applica-
tion-based seat selection, material and coating technolo-
gies, and robust bearing construction. Reliable operations
are ensured in temperatures ranging from -50 to 600°C.
Material options range from a forged carbon steel body
to fully Ni-based high grade alloys used in oxygen service.

For more information contact Metso Automation,


+27 (0)31 502 9350, nsdu@metso.com,

Positioners for precise www.metsoautomation.com

valve adjustment
Mitech’s pneumatic and electro-pneu- standard, the positioners are suitable
matic positioners are advanced control for a 20-100 kPa or 4-20 mA signal
devices that provide stability in diffi- with an air supply of up to 10 bar.
cult environments and great precision Mitech’s conventional positioners
in valve adjustment. The positioners offer two alternative supply ports and
are ideal for harsh environments while two alternative signal ports. They are
maintaining precise, accurate posi- intrinsically safe with ATEX approval
tioning of the control element. Units and no regulator is required making
can easily be changed from direct to them ideal for 1 000 kPa operation.
reverse action, or vice versa. Low air The positioners can be mounted
consumption keeps operating costs to linear actuators to DIN/IEC 534,
at a minimum, while still responding mounted to linear power cylinders,
quickly and accurately. and mounted to rotary actuators to
Easy to set up and calibrate, the VDI/VDE 3845.
positioners are modular in design
making them suitable for almost For more information contact Pieter
any pneumatic application. They are Badenhorst, Mitech, +27 (0)11 927
available in rotary, linear, single and 4850, enquiries@mitech.co.za,
double acting versions. With Ex ia as a www.mitech.co.za

www.instrumentation.co.za August 2015 57


VALVES, ACTUATORS & PUMPS

Extendable multi-port valve blocks


by GEMÜ
Lightweight, taking up less space, quick to Application example – dosing installations Multiple functions in one multi-port
fit and multipurpose – these requirements for detergent in industrial laundries valve block
are becoming increasingly important for The Seitz company in Germany produces both a In order to achieve a more compact design,
valve system components. Complex control wide variety of detergents for industrial laundry all dosing, distribution and flushing func-
of liquids and gases is generally carried out applications, and automated systems for dosing tions are combined in one multi-port valve
by means of numerous individual valves, these detergents. Compact multi-port valve block. The dosing pump for each medium
connected to one another by fittings and blocks from GEMÜ are the key element of these is connected to a variable area flowmeter
piping. But this takes up a lot of space, and systems as they make the corresponding dosing, which are each connected directly to the
assembly is time-consuming because of the distribution and flushing functions possible. multi-port valve block. The valve block
higher number of individual parts. Also, every consists of three rows of pneumatically
assembly point and pipe connection is a Operation of detergent dosing installations actuated diaphragm valves. Here, the first
potential leak, which increases the safety risk. Automated detergent dosing installations valve row at the bottom is used to dose the
Compact plastic multi-port valve blocks provide industrial laundries with flexibility, medium. Depending on the requirements,
are the ideal components here, as they can allowing them to adjust the required detergent quantities of 10-200 ml are metered out.
perform various functions while saving composition individually to each specific clean- The valves in the second row control which
space. GEMÜ’s experience with producing ing program. Depending on the hardness of the washing machine the medium is sent to
thousands of versions within the pharma- water and the type and level of soiling, the clean- and the upper, third row of the valve block
ceutical industry is now being transferred to ing agents, special additives and care products is used to flush the unit with water after
other industrial sectors. The bodies of plastic can be dosed to match the type of textile being every dosing process.
multi-port valves are made as standard of washed.
PVC-U, PP, PP natural, PVDF, PEEK and PTFE, In the case of conventional dosing installa- Expandability of existing plants
but designs are also possible using other tion designs, a separate dosing pump is required Multi-port valve blocks can be extended.
materials. for each washing machine and medium. The If an industrial laundry adds washing
Multi-port valve blocks can also fulfil resulting large number of pumps, hoses, unions machines to its plant, the existing dosing
safety functions, double shut-off (double and distribution components, makes extensive unit can be extended by the required
block and bleed), cross connections and maintenance and calibration work necessary. number of valves with just a few simple
control functions. These individual functions modifications without the need for addi-
serve very specific purposes in individual Compact design improves plant reliability tional piping, solvent cemented joints or
situations, such as the taking of samples, The use of GEMÜ multi-port valve blocks allows welds.
the distribution of chemicals, the connec- the number of pumps, hoses and fittings to be Generally speaking, multi-port valve
tion of cleaning media (CIP) and ensuring a kept to a minimum on modern dosing instal- block technology by GEMÜ can be applied
minimum flow rate. There are also numer- lations. Here, only one pump is required per on all kinds of industrial processes, wher-
ous more complex functions in connec- medium and multiple washing machines can ever mixing, dividing, diverting, draining,
tion with process automation: pressure or be supplied with one dosing installation. Fewer feeding and other processes are occurring.
temperature sensors can be integrated for welded and solvent cemented joints improve
example. Intelligently designed, multi-port plant reliability because fewer leaks can occur as For more information contact Claudio
valve blocks can be developed into compact a result. Quick and easy assembly of the cus- Darpin, Gemü Valves Africa, +27 (0)11 462
system components with a high degree of tomised units also reduces the assembly time 7795, claudio.darpin@gemue.co.za,
functionality. required and saves costs. www.gemu-group.com

58 August 2015 www.instrumentation.co.za


www.instrumentation.co.za August 2015 59
VALVES, ACTUATORS & PUMPS

Pumping solutions
from Parker Hannifin
AC30 variable speed drive helps to mitigate flooding in
park pumping application.

Residents of the United Kingdom have out a series of SMS messages via a low-
not been able to escape the floods that cost modem to the mobile phones of
have affected the region over the past few maintenance personnel should certain
years. One caravan park, situated on the predetermined events occur. Specific text
south coast of England decided to take messages will be sent in the instance of
an innovative and proactive approach pumping being initiated by the drive,
to flood management. Recognising the power failure, RCD trip (stating exactly
threat that flood water could have on its what caused the trip), water level change,
business, the management of the Warner pump stall, or any a number of other
Farm Touring Park approached Arun pre-determined triggers. This gives
Electrical, a Parker Hannifin SSD drives maintenance teams the ability not only to
products customer, to provide a cutting monitor the system, but also take immedi-
edge pumping system to minimise the ate corrective action when required.
threat of flooding. Controlling the motor via a variable
After significant flood damage during speed drive in this application also gives
2013, Warner Farm set itself the challenge benefits in terms of efficiency. The VSD
of pumping water swiftly and efficiently matches system demands by matching
from the grounds to protect customers the workload of the motor to the pump-
and the grounds themselves. The concept ing requirements, keeping running costs
is based on a series of interconnected to a minimum, and reducing energy

Submersible
ponds and pools on site. The water drains wastage. The drives are installed in fully
into the first pool and is then pumped outdoor rated enclosures and, unlike
into the second, then third and so on, many other drives in this class, the AC30

sewage pumps eventually being returned to the sea.


Parker Hannifin was asked to provide
an interconnected and intelligent drive
also has a conformal coating for harsh
environment protection (3C3 as standard
with 3C4 for hydrogen sulphide as an
system to control the pumping process. option).
LEO’s XSP range of single-phase submersible sewage The Parker AC30 variable speed drive is at “The AC30 offers significant advan-
pumps are designed for wastewater drainage in factories, the very heart of the system. tages over other drives in this class,” stated
construction sites and commercial facilities. The pumps AC30 has been designed to provide Dave Kemp of Arun Electrical. “The inbuilt
are also ideal for drainage systems in municipal treatment users with exceptional levels of control software and programmability negates
plants as well as in methane pools and for field irrigation. for pump applications, whilst being both the need for a PLC. What’s more the func-
The XSP range is durable, economical and effectively flexible and modular in design. tionality was exactly what was needed
transfers liquids with solids of up to 15 mm as well as The system controls water levels via in this application. The technical support
long fibres. With the distinct design of the wetted parts, an internal PID controller. The user sets team at Parker were able to listen to our
the pump has a wide flow range with a total head (non- the desired water level for each of the requirements and support us in building a
overload) feature. The XSP is anti-corrosive as it is con- pools, ensuring that the set level will customised system.”
structed from stainless steel and special cast iron mate- allow for efficient natural drainage. If the Commissioned in December 2013
rial. Complete drainage is achieved due to the bottom water rises above the pre-set levels then the installation had a real opportunity
suction structure and its large channel helps to prevent the pump will work faster, and if below, to prove its merit during some of the
the impeller from clogging. A float switch automati- slower, ensuring that the water levels worst weather the UK has experienced
cally turns the pump on/off according to the change remain within the safe pre-set boundaries. on record. Due to the system’s effective-
in the liquid level. In addition, a protector in the motor The system can also be programmed to ness, the team at the park identified other
automatically shuts off the pump in case of overheating take into account seasonal variations in potential risk areas and have added more
or over-current, thus ensuring safety and reliability in water levels allowing the user to specify pumping stations to safeguard the site.
unfavourable environments. pre-set values for summer and winter.
The communication capabilities of For more information contact
For more information contact Carl Mulock, Raptech, the AC30 give users a real-time system Lisa de Beer, Parker Hannifin SA, +27
+27 (0)11 693 5110, enquiries@raptech.co.za, overview right in the palm of their hand. (0)11 961 0700, lisa.debeer@parker.com,
www.raptech.co.za The drives can be programmed to send www.parker.com

60 August 2015 www.instrumentation.co.za


VALVES, ACTUATORS & PUMPS

Locally manufactured
ball valves
The Titan range of extreme service ball valves is designed for very
aggressive service in applications that require repeatable tight shut-off
and long life characteristics. The valves can be used in tight shut-off
isolating as well as in modulating control applications, ranging from
cryogenic to temperatures up to 850°C. When replacing other valve
types, a comparison of CV values can often indicate a selection of
smaller valves than is possible with conventional gate and globe types.
Titan valves can be considered in applications where the following
conditions are encountered:
• Temperatures higher than 300°C combined with large temperature
fluctuations.
• Erosion by abrasive media such as catalyst, coke, fines, slurries and
pipe scale at high velocity.
• High cycle – in excess of three times per hour.
• Emergency shutdown – isolation of flow in less than five seconds.
Features include:
• Ball and seat coatings several times harder than the ‘valve industry
standard’ Stellite.
• Zero leakage.
• Ball and seats in constant wiping contact.
• All metal to metal construction.
• Seats protected from flow in open and closed positions.
• Integral seats.
• Full round port as standard.
• High CV.
• Uninterrupted flow path for abrasive media.
• Quarter turn operation.
• Easily automated.
Many users try to avoid using ball valves to control slurry applica-
tions, but the Titan ‘D’ Port slurry control valve design can handle the
most severe high temperature and pressure slurry applications, giving
a valve life of three to five years maintenance free. Live loaded packing
ensures that zero leakage to atmosphere is maintained, and continu-
ous wiping of the seat by the ball ensures drop tight shut-off when
required. Local manufacture ensures that spare parts for maintenance
are always available at short notice.

For more information contact Keith Mitchell, Heaton Valves Africa,


+27 (0)31 902 8241, keithmitchell@heatonvalves.co.za,
www.heatonvalves.co.za

www.instrumentation.co.za August 2015 61


VALVES, ACTUATORS & PUMPS

Stafsjö invest in increased capacity


Stafsjö has recently made substantial investments to increase capacity lines and a new testing facility for product development and R&D.
and raise production efficiency. The €2,3 million investment includes two “Now we have the opportunity to increase our valve body machining
new multi-operation machines, three new assembly and pressure testing capacity to meet the increasing demand of our products,” says Stafsjö
president Thomas Carlson.
The investment in the two
new machining centres is only
one in a series carried out in
the recent years. In 2007 a new
multi-operation machine was
acquired to machine valves
up to DN 1600 and a few years
later a new grinding machine
was acquired. This year Stafsjö’s
research and design depart-
ment has also expanded and
modernised its testing facilities
to meet the demand for larger
valves and products for the
mining industry, Stafsjö’s fastest
growing business segment.
As part of the company’s lean
strategy, integrated assembly
and pressure testing lines have
also been installed. This is an
important element in streamlin-
ing and optimising the produc-
tion, according to Carlson.

About the multi-operation


machines
HC Nexus 6800-II from Mazak
is a flexible and modularly
designed machining centre
which will be used to machine
valve bodies. It has 180 tool
pockets and 12 pallets which
gives flexibility, speed and mini-
mal down time. MVC 1600 from
Spinner will mainly be used to
machine gates.

For more information contact


Fred Venter, Valve &
Automation, +27 (0)11 397
2833, sales@valve.co.za,
www.valve.co.za

62 August 2015 www.instrumentation.co.za


VALVES, ACTUATORS & PUMPS

Valve testing units from


AT Technical Services
AT Technical Services’ test equipment delivers test capability for the
integrity and performance of any gate, globe, plug, ball, check, slide, or
butterfly valve with flange, thread or weld connections in the range ¼ –
120’’ (DN6 – 3000 mm).
The shut-off valve test units are capable of manual or fully automated
testing for body and seat leakage with re-circulating liquid test systems
0-2000 bar and gas test systems 0-1000 bar.
The vertical operating test unit ‘VCB’ is complete with a heavily
constructed clamping system for quick and easy positioning and clamp-
ing of all common shut-off valves in the vertical position (valve stem
horizontal).
The universal rig is well designed and equipped for use in the valve Special VCBs
repair shop, or for smaller series testing. The standard VCB is equipped Smaller, bigger or special applications are available on request. Optional
with sealing adaptors for DIN/ANSI RF flanges, but is also prepared for features include:
use with ‘inner seal’ adaptors for valves with butt or socket weld ends. • Windows operated computer registrations system.
The VCB Clamping system can be used for: • Vacuum quick filling system, electronically controlled.
• Clamping on the inlet flange only: The flanged valve is clamped on the • Test- and operation systems for actuators.
inlet flange only, keeping the outlet fully open for visual inspection and • Digital seat leakage measuring systems for gas and liquid.
location of any seat leakage. • Torque test and measuring system (up to 500 000 Nm).
• Clamping between the clamping tables: The valve is clamped between • Full surround safety closure.
two clamping tables for both body and seat testing. This method is also
applied for clamping and testing valves with butt weld, socket weld or For more information contact Chantell Swanepoel, AT Technical
threaded ends. Services, 086 100 2887, admin@atts.co.za, www.atts.co.za

www.instrumentation.co.za August 2015 63


VALVES, ACTUATORS & PUMPS

Pump protection
for power
generation

Schroeder Valves has introduced the Schroeder


High Pressure Valve SHP. This automatic
re­circulation valve was developed for extremely
high pressures and also works reliably under
fluctuating load conditions. With this innova-
tion, the company is responding to the require-
ments of its customers, primarily from the field
of power plant and plant construction and the
offshore industry.
The SHP builds on existing Schroeder Valves
technology. The individual system components
have simply been modified and innovatively
combined, such that they enhance the depend-
able and low-wear area of application of the
existing technology to meet the increased
requirements. Thus, the new SHP-series auto-
matic recirculation valve enables and promotes

Valves for high


the energy-efficient operation of modern power
plant facilities.
"The SHP takes the general development
of higher pressures and temperatures and the
increased energy-efficiency requirements into
account," explained Axel Mücher, managing
temperature and
partner at Schroeder Valves. "Alongside this, the
changing way in which plants work was also
taken into consideration in the development of
pressure applications
the SHP. Special load sequence power plants,
such as modern combined cycle power plants Mitech’s high pressure stop globe valves are stellited plug and seat and an anti-rotating
and coal-fired power plants, are operated at par- designed to handle some of the industry’s system on the stem. The travel indication
tial load for a large proportion of their operating most extreme pressure and temperature allows the valve position to be visible at all
time, on account of the increasing high propor- applications. Providing low cost and hassle-free times. The yoke flange design accommodates
tion of regenerative energy generation and inline maintenance, the one-piece forged body various actuation devices and an optional live
highly fluctuating load conditions." design accommodates various end-connec- loaded packing system is available.
Schroeder Valves has each valve undergo a tions. The valve has a T-pattern body style with The valves are suitable for use in a variety
100% pressure and functionality testing prior to pressure ratings up to ANSI 2500. of industries including power generation,
delivery. The high performance valves are suitable oil and gas, petrochemical and in boiler
Valve & Automation are the exclusive agents for operation in a -30 to 620°C temperature ­manufacturing to name a few.
for Schroeder. range and are manufactured in a choice of
either A105, A182-F22, A182-F91 or A182-F316 For more information contact Pieter
For more information contact Fred Venter, materials in sizes ½” through 2”. ­Badenhorst, Mitech, +27 (0)11 927 4850,
Valve & Automation, +27 (0)11 397 2833, Additional features include a replaceable enquiries@mitech.co.za,
sales@valve.co.za, www.valve.co.za seat for ease of maintenance, erosion resistant www.mitech.co.za

64 August 2015 www.instrumentation.co.za


VALVES, ACTUATORS & PUMPS

Pneumax introduces economical


solenoid valves
Pneumax Southern Africa has added the new cost-effective Italian made
Eco 22 solenoid valve to its product offering.
Available in 1/8” and 1/4”ports in 3/2, 5/2 and 5/3 versions, this new series
of valve comes with an aluminium valve body and spool/seal arrangement,
optimising both the flow rate and the valve switching time.
“We pride ourselves in offering innovative, versatile and reliable prod-
ucts designed to meet the needs of various industry sectors, therefore we
are pleased to add the Eco 22 series to our range,” says Deon Steenkamp,
managing director Pneumax Southern Africa.
This compact series is on average 40% cheaper than the traditional
488/484 Eco valve, also supplied by the company. The valves can be
­supplied with or without the solenoid coil.
“Customers realise the quality and cost benefit of a European product
being on offer at a fraction of the expected price,” continues Steenkamp.
These valves have an average life of 15 million cycles depending on the
application and air quality. Repair kits with seals and spools are available for
overhauling the valves. Monostable or Bistable versions are available and For more information contact Marius de Wet, Pneumax Southern
include an integrated technopolymer solenoid operator with 9 mm stem Africa, +27 (0)11 573 0900, marius@pneumax.co.za,
and built in manual override. www.pneumax.co.za

www.instrumentation.co.za August 2015 65


CONTROL SYSTEM DESIGN

Case History 143


Report after optimisation exercise – Part 4.

Michael Brown is a specialist in control loop optimisation with many years of experience in process
control instrumentation. His main activities are consulting, and teaching practical control loop analysis
and optimisation. He gives training courses which can be held in clients’ plants, where students can have
the added benefit of practising on live loops. His work takes him to plants all over South Africa and also
to other countries. He can be contacted at Michael Brown Control Engineering cc, +27 (0)82 440 7790,
michael.brown@mweb.co.za, www.controlloop.co.za

This is the fourth article taken from a report this temperature did in fact have quite fast problem that shows just how important flow
which was prepared for various departments dynamics. loops can be. This is the control of combustion
in a process company after some optimisation A new tuning with a proportional gain of air flow in a boiler system. The flow of air is con-
work was performed for them. (The other three 1,5 and an integral of 2 minutes per repeat was trolled by means of a damper. Figure 2 shows
articles were published in preceding issues.) then inserted into the controller. (This tune has an open loop test on this system.
Once again, the first example in this article good robustness, i.e. safety factor.) The damper is very bad and there is no
is of a success story. The loop in question is the The ‘before’ and ‘after’ performance of the way that any, even reasonable, control can be
control of an important temperature. The opera- control is shown in Figure 1. This recording is obtained. The damper has stiction, particularly
tors were controlling it as well as they could, but taken from the plant’s trend recording system, on closing, and the controller output moves
mostly in manual, as it did not seem to be able and unfortunately is not of great quality, but through 12% after which the damper bangs
to hold the temperature at set-point in auto- it does show the remarkable improvement in down. There is little repeatability and it is
matic. There were frequent load disturbances control variance. By the way, the scale of the essential that this be sorted out before any rea-
and the temperature jumped around badly. temperature is zoomed up quite considerably. sonable boiler firing control can be achieved.
On a scale of 0-100% the temperature would This is a vitally important control.
Example 1: for once the valve was not be drawing a straight line. The cycling caused by this control is affect-
the culprit This is a typical case of poor original tuning. ing all the other loops and causes cycling even
Open and closed loop tests were performed Temperature controls, being relatively slow, are on the steam temperature, which is controlled
on the loop, and it was found for once that notoriously difficult to tune by the normal ‘trial by a sophisticated cascaded desuperheater
the control valve was not the culprit, but and error’ method used in 98% of all tuning. It control system. It is impossible to just tune the
was in fact operating very well. The problem shows the importance of using a good tuning loop. The damper needs repairing or replacing
lay with the tuning. The original tuning had package. before any decent control can be obtained.
a proportional gain of 1 and an integral of
12 minutes per repeat. This is tuning typically Example 2: flow loops are important Example 3: important pressure control
for a relatively slow temperature process, but The second example is dramatic and of a huge The last example, also of a problem loop, is

Figure 1.

66 August 2015 www.instrumentation.co.za


CONTROL SYSTEM DESIGN

that of an important pressure control. This seen in Figure 3, which shows an open loop and poor tuning of the positioner. Luckily the
control modulates the feed to a large distilla- test. (The valve had been serviced recently, pressure was quite slow, which still allowed
tion column. and it is a common complaint in plants, that relatively good control of the feed to the
It is very important to keep the feeds to valves coming back from service often display column.
distillation columns as steady as possible, as more problems after the service than they did This is another example of the power
fluctuating feed creates all sorts of instability in before!) of feedback control. With all the valve prob-
the processes, which the controls downstream The test shows a big overshoot on open- lems encountered in about 70% of control
cannot deal with effectively. ing, and a massive overshoot on closing, loops worldwide, it would be impossible
In this case there was a large problem which was causing control problems. This is to run plants without the use of feedback
with the pressure control valve as can be probably due to excessive stiction in the valve control.

Figure 2.

Figure 3.

www.instrumentation.co.za August 2015 67


ELECTRICAL POWER & EFFICIENCY

Yokogawa’s integrated control


­system for power stations
Power generating plants have traditionally • Uniformity of platform. recommended with an SIS logic solver/safety
used many ‘systems’ to control their processes • Common HMI. PLC.
even after the DCS was embraced by the indus- • Common engineering station. Conventionally, two separate monitoring
try as the control system platform. Typically, • Common network without the need of and operating environments were required for
one would find the following different systems gateways. the DCS and SIS. Different communications and
in a power plant: • Basic hardware commonality in terms of form distinctive hardware architectures had to be
• Dedicated OEM supplied systems (PLCs) from factor, power requirement etc. set up. Yokogawa put an end to DCS-SIS incom-
steam/gas turbine vendors. • Compliance to industry standards. patibility with the ProSafe-RS, a truly integrated
• Plant-wide DCS. • Improved equipment reliability, plant avail- safety PLC for the process industry.
• Electrical control and monitoring system ability and ease of use. ProSafe RS (TUV SIL 3 certified) safety PLC
(ECMS). • Improved plant safety. and Centum VP DCS are tightly integrated with
• Dedicated burner management (BMS) and As a leading DCS vendor, Yokogawa has Yokogawa’s dual redundant, 1 Gbps Vnet/IP
boiler protection systems (BPS), often based strived to lead this effort and bring to the DCS network.
on a SIL 3 rated safety system. table an integrated platform for power genera-
• Various PLCs for different ‘packaged’ systems. tion plants. In review, this is how the features Turbine governor control and protection
However, such a wide variety of platforms of Yokogawa’s Centum VP DCS have been Turbine control and protection for governors
was always a matter of inconvenience for the designed to achieve convergence. requires very fast control and many special
plant operation and maintenance crew. The types of inputs and outputs; e.g. direct speed
following difficulties were faced by the plant Organisation of the control system pick-up from magnetic/active pick-ups, servo
O&M team: Boiler/HRSG (heat recovery steam generator) and drive, LVDT measurement etc. Special I/O mod-
• Non uniform HMIs, leading to difficulty in BOP (balance of plant) control ules have been developed which have these
switching from one mode to another while This is the core of the control system (DCS) with capabilities. These special purpose modules
operating the plant – especially during critical the majority of I/O modules and controllers, have the same form factor and configuration as
plant conditions. which run the interlocks, sequences and closed other conventional I/O modules, and are sup-
• Difficulty in asset management of instrumen- loop control system. These various analog ­ ported by advanced features like 1 msec SOE
tation and control as well as increased inven- I/Os are typically equipped with HART pass and module redundancy. They use the same
tory of spares for the different systems. through function to enable integrated asset DCS controller and I/O bus as a backbone. Thus
• Complicated training needs for both main­ management (Yokogawa’s PRM: Plant resource the turbine governor control and protection
tenance and operation. Manager) for smart devices. Very often, digital (over speed, power imbalance etc.) is truly
To circumvent this, many power generation fieldbus technologies such as Foundation, integrated in the plant DCS. This solution is
companies would select the control system Profibus or wireless technology (ISA 100.11a) deployed in many retrofit projects.
over the turbine supplier, so as to keep the are adopted, which is an integrated feature
control system ‘uniform’ at least for a part of the of the DCS. Redundancy at all levels, includ- Integrated 1 msec SOE
plant. However, very soon, everybody realised ing redundant I/O modules, is often used to An SOE (sequence of events) with 1 msec
that this resulted in a very narrow choice of increase the reliability and availability of the accuracy and resolution is an important feature
control system platform, which was not always control system. in a power plant DCS. Yokogawa’s Centum
the best on techno-commercial merit. It was VP system design allows all DI (digital input)
soon recognised that an important component BMS (burner management system) and BPS modules to have this capability and selectively
of the plant, the control system (DCS), was (boiler protection system) assign DI channels for SOE reporting. The spe-
­piggybacking on the turbine systems under Often, many conventional DCSs are extended cial purpose turbo machinery cards also have
these situations. for BMS and BPS functionalities. The NFPA 85 DI channels with 1 msec SOE. Similarly, DI cards
The industrial automation industry has guideline insists on independently working for safety systems also have 1 msec capability.
always been receptive to the aspirations of hardware for BMS/BPS. This is achieved by This is a very important tool for diagnostics of
users and has tried to bridge the gap between separate sets of I/O modules and control- plant upsets and helps tremendously when
the needs of the industry and the solution. As a lers and independent sensors in the field. performing root cause analysis investigations.
result, the DCS vendors consciously developed However, in many cases, as per the HAZOP
solutions to cater for the need of an integrated study recommendation, this is identified as an CAMS (consolidated alarm management
control system platform that provided the area where Safety Instrumented System (SIS) software)
same look and feel across applications. The with a requirement of SIL 3 should be used. CAMS for HIS (human interface station) is
focus was on: In that case, a certified SIL 3 safety system is consolidated alarm management software that

68 August 2015 www.instrumentation.co.za


ELECTRICAL POWER & EFFICIENCY

is included at no additional cost. It acquires with the IEDs (Intelligent electric devices) of an importantly, it is possible to capture alarms
real-time alarms and events from various electrical system. This allows fast, bi-directional and events with their original time stamp. This
systems, and then sorts and delivers only the communication with the electrical system is a big benefit to the plant O&M team trying
necessary alarms to the right person at the from and to the DCS. Thus, a separate electrical to increase plant productivity, and assists with
right time. This type of alarm sorting enables scada became superfluous. analysing plant abnormalities and trips from a
users to identify the root cause of alarm or trip MMS (manufacturing message specifica- single platform.
occurrences. Alarms and events are displayed tion) is a communication protocol for control
with their original time stamping, up to a mil- and monitoring among industrial automation Conclusion
lisecond, even when acquired from third-party devices and systems. MMS is adopted as one of Convergence of control system platforms is a
systems through interfaces like OPC A&E, IEC the protocols for communications among IEC big productivity enhancement tool for plant
61850 etc. 61850 IEDs. The DCS communicates with IEDs O&M management today. Further applica-
The EEMUA 191 guidelines are followed using the MMS service protocol. tions of plant performance monitoring and
in the software design and the following The biggest advantage of an integrated optimisation using advanced process controls,
advanced alarm management features like control, safety and electrical system is the ease such as Exapilot to ensure repeatability, can
prioritisation, suppression, eclipsing, sorting, of operation by the plant operators. They get easily be built on the plant-wide DCS, which is
filtering, shelving, load shedding etc. are avail- the same HMI to operate the entire plant and integrated in nature. Worldwide, Yokogawa is
able. These capabilities, along with plant-wide all plant-related data, alarms or messages are currently delivering many projects with these
alarm reporting and analysis in a consolidated made available in a single platform. This can be features.
window, are a major achievement towards achieved without compromising the advanced The industry is excited about control
convergence and consolidation of the control features of a modern DCS using state-of-the- system convergence. Power generation com-
system platform for a power generation plant. art technology. panies are showing an increased inclination to
buy a modern DCS from the open market with
ECMS (electrical control and monitoring Third-party system integration through such capabilities. As a market leader in DCS
system) open protocols (especially OPC) technology, Yokogawa is striving to match
Traditionally, power generation plants had a Practically, there are control systems beyond the aspirations of power plant owners and
separate electrical scada system to cater for the the plant-wide DCS, which are typically operators.
control and monitoring of HV/MV/LV electrical delivered by OEMs e.g. turbine control systems
boards and systems. However, thanks to the for new plants, PLCs from packaged systems For more information contact Christie Cronje,
standardisation of matured digital communica- etc. Thanks to OPC connectivity (both OPC DA Yokogawa South Africa, +27 (0)11 831 6300,
tion protocols like IEC 61850, a modern DCS and OPC A&E) these control systems can be christie.cronje@za.yokogawa.com,
has the capability of directly communicating seamlessly integrated with the plant DCS. Most www.yokogawa.com/za

www.instrumentation.co.za August 2015 69


ELECTRICAL POWER & EFFICIENCY

Zest WEG Group


provides the optimum
generator set
The current power constraints facing South of snow on top of the container, and the
Africa have resulted in companies being subsequent blocking of the louvres,” says
requested to cut their power consumption Bradley van der Spreng, project engineer,
by at least 10% in order to alleviate the Zest WEG Group.
pressure on the overburdened transmission Another area where Zest WEG Group’s
and distribution infrastructure. This appeal experience comes to the fore is its knowl-
will, of necessity, result in companies seeking edge of local regulations pertaining to dif-
alternative power sources to accommodate ferent metropolitan areas. “Regulations also
the energy requirements shortfall. differ with regard to the particulate levels of
However, cautions Craig Bouwer, sales diesel fuel storage and sound decibel levels
engineer at Zest WEG Group’s generator set related to noise attenuation. In order to
division, there is an apparent lack of under- disseminate relevant and important informa-
standing of the many issues surrounding tion, we form close working relationships
standby power. “Companies are generally with consultants and, wherever possible, we
unaware of how to assess the standby power become involved during the design stage of
requirements of a facility or building. By a project,” says van der Spreng.
implication, this suggests that companies All equipment is supplied standard
are also often unaware of what the optimal with a 12 month warranty. The Group has a
solution for a given application should be.” dedicated service department, which offers
A standby power solution is an important basic maintenance contracts that include
capex decision that needs to be considered ­measures such as replacing the generator
carefully in terms of the company’s overall sets’ oil and filters. Extended or long term
requirements. Moreover, the supplier needs maintenance contracts are also offered
to have the necessary technical expertise where the equipment is for critical applica-
and relevant experience to offer a custom- tions such as standby power at a hospital.
ised solution. A key consideration for a Bouwer cautions that, while maintenance
standby power solution is to understand the is critical, companies should take ownership
environment in which the generator set has of their generator sets. “We propose to miti-
to function. gate risk and that a dedicated member of the
Original equipment manufacturer Zest customer’s staff be trained through our man-
WEG Group’s generator set division has a ufacture, test, installation and com­missioning
dedicated facility in Cape Town and offers process. This enables the ­customer to be
generator sets ranging from 20 kVA up to more self sufficient and complements all
250 kVA off-the-shelf products, 300 kVA to aspects of aftermarket support.
2000 kVA individual customised units as well “There are numerous factors to con-
as multiple sets to achieve turnkey solutions sider when selecting an appropriate fit for
in excess of 12 MVA for large-scale applica- ­purpose solution so it is important for com-
tions or projects. The company has supplied panies to align themselves with a supplier
a large number of bespoke generator set who is qualified to discuss all eventualities.
solutions based on the specific application Flexibility in approach to design and engi-
and environment in which they operate. neering will ensure that the installation is
“A couple of recent examples include geared towards minimising the capital cost
the containerised three-generator unit and running expenses, whilst concurrently
we designed and manufactured for DRA optimising energy output for an uninter-
Minerals’ Liqhobong Diamond Mine in rupted and reliable power supply,” concludes
Lesotho and a turnkey power station for AVI van der Spreng.
Group’s Indigo Brands. At Liqhobong, we
designed a generator set container with a For more information contact Kirsten
collapsible snow roof. When the roof is col- ­Larkan, Zest WEG Group,
lapsed it facilitates easy transportation and +27 (0)11 723 6000, kirstenl@zest.co.za,
once deployed on site prevents the build-up www.zest.co.za

70 August 2015 www.instrumentation.co.za


ELECTRICAL POWER & EFFICIENCY

Mitsubishi Electric’s
low voltage switchgear
The complete solution for line and load side.

Mitsubishi Electric’s groundbreaking research Reliability is provided due to high operat-


and design has resulted in innovative LV ing durability.
switchgear that provides users with greater 3. Global – in addition to complying with
quality, safety and reliability. Today’s LV well-known international norms and stan-
products feature meticulously designed dards, the low voltage switchgears are also
technology providing greater safety and high certified by several marine approvals.
voltage breaking performance. 4. Best solution – high flexibility of the vari-
By meeting global norms and standards, ous ranges with plenty of accessories for
Mitsubishi low voltage switchgear meets all easy installation enable the best solution
the standards and specifications laid down in for each application.
the EU Low Voltage Directive 73/23/EEC and 5. Intelligent – main functions, including trip
the Machinery Directive 98/37/EC. All units status, alarm and load current are dis-
carry the CE mark and are certified to UL, cUL played on the LCD screen and can also be
and GOST conformance levels. output as signals.
Six reasons to choose Mitsubishi Electric 6. Customer friendly – functionality, com-
low voltage switchgear: patibility and perfect mechanical design
1. High performance – one class higher are the main features of the low voltage
performance realises superb breaking switchgear supplied.
performance, hence the safety of valuable
circuits can be securely maintained. For more information contact
2. High reliability – safe and fault-free Adroit ­Technologies, +27 (0)11 658 8100,
operation is guaranteed by various protec- info@adroit.co.za,
tive mechanisms and safety functions. www.adroit.co.za

www.instrumentation.co.za August 2015 71


ELECTRICAL POWER & EFFICIENCY

Solar installation reduces utility bill


ABB string inverters make cost savings possible for a commercial property owner in Port Elizabeth.

The recently completed installation of a roof- to 98,2% due to the flat efficiency curves that
top grid-tied photovoltaic plant designed by ensure optimal performance at all output levels,”
Genergy and ABB value added service provider, says Alessanda Romoli, ABB area sales manager,
All Electrical, has enabled a Port Elizabeth prop- solar products.
erty owner to reduce their reliance on daytime Advanced design features include a high effi-
utility power. According to Warren Alistoun, ciency integral heat sink compartment and a front
design engineer at Genergy, in the period April panel display system. Furthermore, the system
to June 2015 the plant reliably produced a total does not rely on electrolytic capacitors, as a result
of 33,25 MWh of electricity. The building relies the product enjoys an extended lifetime.
on the photovoltaic (PV) plant to augment util- All Electrical’s technical specialist, Riaan
ity electrical supply and is primarily occupied Gerber notes: “Installation of the ABB range of
during the daytime hours, making it well suited inverters is made easier by numerous design
for a grid-tied PV solution. features such the detachable wiring box and field
The PV plant is rated to produce 100 kWp and selectable grid codes. The wide range of products
relies on three ABB Trio 27,6 kVA inverters, and manufactured by ABB, with specific focus on the
a single ABB Trio 10 kVA inverter, to provide the solar industry, allows for the protection and con-
flexibility required by the design. trol of the solar installation to be offered through
ABB’s Trio range of string inverters offers high a matched product suite.”
levels of flexibility and control for system design-
ers and installers, allowing for the optimal har- For more information contact Alessandra
vesting of energy from strings that are oriented ­Romoli, ABB, +27 (0)10 202 6995,
in different directions. “The technology employed alessandra.romoli@za.abb.com,
in these inverters delivers efficiency rating of up www.abb.co.za/lowvoltage

72 August 2015 www.instrumentation.co.za


ELECTRICAL POWER & EFFICIENCY

Reliable power supplies for


harbours and shipping
Vert Energy works closely with the marine and offshore sector, offering multi-function controller platforms and engineered solutions for the
the supply of quality branded components and the support of a com­ offshore oil and gas industry’s ships and rigs.
prehensive repair and maintenance service. These user-friendly controllers encompass advanced load dependent
“An important part of our service to the shipping industry is the stop/start controls, integrated remote control from alarm and monitor-
highly technical installation and repair work undertaken out at sea by ing systems, long-time parallel operation diesel/shaft generators and
factory trained Vert engineers,” says Vert Energy managing director, combined emergency/harbour generators.
Grant Robertson. “A reliable power supply is a top priority in shipping.
For this reason, Vert Energy has tailored its capability to assist vessel For more information contact Ryan Robertson, Vert Energy, +27 (0)11
owners not only with routine maintenance programmes, but also in 453 9669, ryan.robertson@vertgroup.co.za, www.vertgroup.co.za
emergency breakdown situations,
with no interference to the daily
activities of the vessel.
“Vert Energy’s field services
encompass re-assembly, installation
and commissioning, inspections
and diagnostics, as well as on site
maintenance and repair.
“Recent projects include the
rewinding of a 750 kVA exciter
stator, in situ below deck, on
board a vessel out at sea near
Mozambique. There were no inter-
ruptions to the normal operation
of the ship. Vert technicians have
also installed and commissioned
the retro fitment of new generators
on board a vessel in Namibia. These
units were tested under various
loads and operating conditions at
sea.”
Vert Energy has been appointed
exclusive distributors in sub-Saha-
ran Africa for the sales and support
of DEIF generator controls.
DEIF power management
systems encompass diesel, gas
and hydro control technology for
offshore vessels and on/offshore
platforms, as well commercial,
military and leisure vessels. Special
vessel applications include dredg-
ers, fishing vessels, heavy lift ships
and pipe laying vessels. The safe
and reliable systems ensure opti-
mum performance, high accuracy,
minimal maintenance and reduced
downtime. The company’s ‘green
technology’ focuses on energy
efficiency, fuel optimisation and
reduced emissions.
DEIF products for marine and
offshore applications include
analog instrumentation, single and

www.instrumentation.co.za August 2015 73


ELECTRICAL POWER & EFFICIENCY

Rockwell Automation expands


medium voltage motor control
capability
Since medium voltage motors are typically designed exclusively for induction motors. voltage drive product line enables a high level
some of the largest consumers of power in Designed for smaller field applications, it of production optimisation, and increases
heavy industries, implementing precise, smart supports motor cable lengths of up to 300 m information sharing across the enterprise. By
motor control is an effective way of reducing and has a 7” WinCE colour touch screen. empowering users to gain access to valuable
power consumption and energy costs, along Supported protocols include Modbus-RTU performance and resource information from
with significantly better process control. Since RS-485, Modbus-TCP, Modbus-PLUS R-S485, their systems, companies can attain higher
they were first manufactured in 1983, Rockwell Profibus R-S485 and EtherNet/IP communications asset availability, reduced energy and
Automation Allen-Bradley medium voltage protocols. maintenance costs and enhanced asset and
drives have earned a reputation for reliable, The PowerFlex 7000 remains the flagship personnel protection.
efficient motor control across the industry’s PowerFlex product, offering multiple All PowerFlex medium voltage drives are
most demanding applications. The company configurations and high-performance, compatible with standard motors without
recently extended this medium voltage range customisable options for the diverse derating and do not require an inverter duty
with the addition of the PowerFlex 6000, control needs of heavy industrial requirements. motor. PowerFlex configurations have
providing a cost-effective and fit-for-purpose Utilising Active Front End (AFE) technology near-sinusoidal output current and voltage
drive. and a patented switching technique, the waveforms at all speeds and loads.
The PowerFlex 6000 supplements the PowerFlex 7000 product line, rated from As the global economy continues to
existing PowerFlex 7000 range in providing a 2,4 kV to 6,6 kV, guarantees industrial expand, constraints to growth arise as the
motor control solution that is ideal for new and applications the highest overall system demand for energy approaches – and in
retrofit centrifugal fan and pump applications efficiency whilst complying to stringent some instances exceeds – power generating
rated up to 10 kV. international standards. The drive achieves capabilities. The Rockwell Automation
Utilising the industry-accepted and robust lower line harmonics and improved power Allen-Bradley Medium Voltage PowerFlex range
cascaded “H” bridge (CHB) voltage source quality through the AFE rectifier, which features enhances the performance of medium voltage
inverter (VSI) topology, the PowerFlex 6000 a single rectifier bridge to maintain the lowest motor control for the most efficient industrial
drive provides low-input harmonics and component count and system complexity. enterprise.
near-unity power factor, ultimately reducing
power system issues and maximising motor A control solution for the future For more information contact Henry Craukamp,
efficiency while providing simple use and Through the power of the Rockwell Rockwell Automation, +27 (0)11 654 9700,
maintenance requirements. Automation networked control platform, the hscraukamp@ra.rockwell.com,
PowerFlex 6000 is an air-cooled drive expanded Allen-Bradley PowerFlex medium www.rockwellautomation.co.za

74 August 2015 www.instrumentation.co.za


ELECTRICAL POWER & EFFICIENCY

A better battery analyser


Stationary batteries need to be maintained and tested regularly and even
maintenance-free batteries can deteriorate over time. All it takes is one battery
in a string to fail to take the entire string offline. One bad battery can affect the
usable life of adjacent batteries by raising their charge voltage; and a battery
or interconnect with a high impedance can overheat, ignite or explode during
discharge. In addition to providing backup power, stationary batteries are also
increasingly used to store renewable energy. These batteries are subject to the
same potential degradation and also need to be tested regularly.
Fluke noticed that most of the battery testers on the market had either
no CAT rating or a low CAT rating and as a result developed a more efficient
battery analyser with a CAT III safety rating, the Fluke 500 series. The company
was also able to address the requirements of IEEE Standard 1188, which was
established in 2005 after most other battery analysers on the market had been
developed. This standard governs maintenance, test schedules and testing
procedures for optimising the life and performance of stationary batteries.
The Fluke 500 series is intuitive and specifically designed for measuring all
kinds of stationary batteries, including GEL, AGM (absorbed glass MAT),
ithium-ion and wet-cell lead-acid. The analysers offer improved impedance
test performance, even in high-ripple environments. The intuitive user
interface and intelligent test probes simplify the testing process by guiding
technicians quickly through setups. The result is reduced measurement
complexity and cost, with increased accuracy, safety and operational efficiency.
All three Fluke 500 series battery analysers – the BT 510/520/521 –
offer a broad range of battery test functions, including simultaneously
measuring DC voltage while testing internal resistance and full condition
testing using automated string function testing.
The BT520 and BT521 include an intelligent test probe with an integrated
LCD display that shows measurements right on the probe. Measurements
can be captured automatically in sequence mode or manually by pressing
the save button on the probe. The LCD display indicates that the measurement
has been taken and saved and uses audible voice cues to indicate which
measurements in the sequence have been made. The voice count battery ID
identifies which battery is being tested to help keep track of progress –
especially handy when testing a long string of batteries.
The BTL21 intelligent probe on the BT521 analyser has an infrared
temperature sensor to measure temperature and up to two other data
points simultaneously – 1000 V DC, 600 VA C and ripple – to provide a
more complete view of battery health. All models also include ergonomic
two-prong test lead probes with a Kelvin connection to ensure resistance
measurement accuracy; replaceable tips to extend test lead life and
further reduce the cost of ownership; and long reach test probe extenders
for testing double stacked battery cells.
When testing is finished, measurements can be exported to a PC
using Fluke battery management software so that users can easily
compare results, analyse trends and generate battery analysis reports.

For more information contact Comtest Group, +27 (0)10 595 1821,
sales@comtest.co.za, www.comtest.co.za
WIRELESS & TELEMETRY

Yokogawa releases Plant


Resource Manager (PRM) R3.20
Improved management functionality for HART and ISA100 wireless field devices.

Yokogawa has announced the release of facilitate the collection of information from the console screen so that operators can
version R3.20 of its Plant Resource Manager field devices for use in optimising device monitor the status of the entire wireless
(PRM) software tool for the centralised maintenance and plant operations. The network as well as the status of individual
management of large amounts of data from product enhancements include the following: devices on that network.
plant monitoring and control devices and
manufacturing equipment. PRM R3.20 is an 1. Quick access to HART device status 3. Compliance with FDT2.0, the latest
upgrade to R3.12 and includes an improved information FDT standard
management function for HART and ISA100 Using the Centum VP R6.01 integrated FDT2.0 is the latest version of the field device
Wireless field devices. With this new PRM production control system’s N-IO (network-IO) tool (FDT) communications interface that links
version, Yokogawa aims to capture a larger field input/output (IO) device, PRM can now field devices and control systems. FDT2.0 has
share of the plant maintenance market. obtain start-up, stop, failure, and other entered wide use because it improves device
Manufacturers are constantly looking for status information from Yokogawa HART7 response times and performance. As this
ways to improve maintenance efficiency by compliant devices in almost real time. For new PRM version is compatible with FDT2.0,
using software tools like PRM that can centrally other companies’ HART5, 6, and 7 compliant it is easier now to monitor and set up
manage large amounts of maintenance and devices, PRM can collect information at FDT-compliant devices.
other types of data from plant monitoring 1 minute intervals. With PRM R3.12, data PRM is a software package that centrally
and control devices and manufacturing collection at intervals of 10 to 60 minutes was manages large amounts of status and mainte-
equipment. Maintenance personnel use such supported. nance information from plant monitoring and
data to reduce plant downtime and enhance control devices and manufacturing equipment.
safety by proactively spotting and responding 2. Management functions for field With PRM, users can monitor the status of their
to device failures. wireless devices devices and perform online diagnosis via a
To optimise plant operations, it is essential This new PRM version comes with improved network. In addition, PRM centrally manages
not only to keep devices in good working management functions for ISA100 Wireless maintenance information, including device
order but also to have up-to-date information devices. Diagnostic information can be viewed ledgers, in a database, and supplies mainte-
on device status and maintain records on all on screen and in real time not only in the nance information for plant field devices and
maintenance work that is performed. Such PRM window, but also in the operation and equipment to maintenance personnel.
information is most useful if operators can view monitoring screens of the Centum series
it on screen at their control system human integrated production control system. The new For more information contact Christie Cronje,
interface stations. PRM version also works with the console that Yokogawa South Africa, +27 (0)11 831 6300,
With such needs in mind, Yokogawa has centrally manages plant field wireless devices. christie.cronje@za.yokogawa.com,
developed new functions for its PRM tool that When it accesses this console, PRM can call up www.yokogawa.com/za

76 August 2015 www.instrumentation.co.za


WIRELESS & TELEMETRY

Wireless vibration
and temperature sensor
Banner Engineering now offers a wire- failure or potential problems,” said Scott
less vibration and temperature sensor; Pritchard, director of wireless global sales
designed to monitor machines for at Banner Engineering. “This allows facil-
increases in vibration and temperature, ity managers to reduce labour costs by
the sensor measures RMS velocity and eliminating manual checks and the risk of

Multi-point temperature. This enables identification


of machine problems before they become
human error.
The wireless vibration and temperature

multiplexer
too severe and cause additional damage sensor is ideal for a variety of machine
or result in unplanned down time. monitoring applications, including motors,

for process use


The sensor is optimised to work pumps, blowers and many other types of
with 1-wire serial radio devices, such as machines throughout a facility.”
Banner’s wireless Q45VT Node, the P6 Protected by a robust zinc alloy housing,
performance node and the MultiHop the sensor provides reliable performance
Phoenix Contact has introduced a solution that combines M-H6 radio. Operators can easily set in harsh environmental conditions. It also
the new RS-485 bus coupler with Radioline I/O wireless vibration thresholds based on the ISO offers multiple mounting options, including
modules to provide customers with a multiplexer system 10816 standard. When a threshold has hex screw, epoxy, thermal transfer tape or
specifically for process use. been exceeded, the wireless node can magnetic bracket mount, to accommodate
As in the Radioline wireless system, thumbwheels on provide local indication, send the signal to diverse applications.
the front provide a fast and simple way to address the a central location, and send the vibration
head modules and easily perform I/O mapping of the and temperature data to the gateway for For more information contact Brandon
expansion modules. This allows users to distribute I/O collection and trending. Topham, RET Automation,
signals in an RS-485 bus system without any programming “Banner’s wireless sensor provides +27 (0)11 453 2468,
or software configuration. continuous vibration and temperature brandon.topham@retautomation.com,
In addition to operation by means of a two-wire measurements to detect any machine www.retautomation.com
RS-485 bus line with up to 99 stations, the new RS-485
stations can also expand the Radioline wireless system,
so that I/O mapping can be extended to cover all media.
Alternatively, the stations can also be operated in
stand-alone mode on a Modbus/RTU master, thus
allowing for direct connection to a controller.
For robust use in continuous industrial operation,
the I/O expansion modules from the Radioline product
family feature electrical channel-to-channel isolation and
a wide operating range from –40 to 70°C. The system also
offers an extensive package of approvals including ATEX,
IECEx, and UL certifications.

For more information contact Patrick Rowland,


Phoenix Contact, +27 (0)11 801 8200,
patrickr@phoenixcontact.co.za, www.phoenixcontact.co.za

78 August 2015 www.instrumentation.co.za


WIRELESS & TELEMETRY

Track and trace


Production and logistics chains are growing together with RFID.

Continuous data recording on the vehicle itself


can be used to identify a customised dream car
through the entire production process right
through to delivery. Track and trace process’s
can increase product customisation which can
be implemented in the context of Industry 4.0.
The sensor technology detects which
assembly steps must be taken on the basis of
the car body itself – thus ensuring unique iden-
tification – and guarantees continuous trans-
parency right through to delivery. Processing
steps on the object are updated via rewritable
RFID transponder. Reading reliability is a must,
as errors could lead to misrouting, mix-ups,
or loss of production. This is where RFID data
cards, which can be attached to components
or even integrated unseen within them, are
coming into play more and more. They ensure
maximum availability in practice, for example,
when subjected to high temperatures on the
painting line, and can then be reliably identi- complex manufacturing and logistics processes to be transported. Every single car is made-
fied once covered in paint. stands at the forefront of this field. A transpar- to-order. Every car is different to the next.
ent material flow is required in production and However, when information is stored on an
Keyword: “Batch size 1” logistics so that production decisions can be RFID tag, the customer’s dream car is located
Aspects such as transparency and traceabil- made more quickly. quickly and can be loaded up for transport
ity are playing an increasingly essential role in no time. This ensures transparency and
for manufacturers, particularly as the level Delivery traceability monitoring right through to the
of variability in the production lines of large The transparent material flow based on RFID customer.
automobile plants is constantly on the rise and plays a key role at the delivery stage too. Until
assembly lines are seeing ever more variants the completed cars are ready to be picked up For more information contact Mark Madley,
installed in parallel. and transported to the dealerships, they are SICK Automation SA, +27 (0)11 472 3733,
Vertical integration is the keyword for track left parked in large parking lots. The problem info@­sickautomation.co.za,
and trace. The traceability of products during occurs when it comes to finding a car that has www.sickautomation.co.za

www.instrumentation.co.za August 2015 79


Securing edge devices and data in
industrial applications
By Johnny Fang, product manager, Moxa.
Thanks to the Internet of Things, the era and networking devices that will serve them wireless encryption of wireless links into WPA2,
for building distributed big data industrial must be located in public and commercial backbone communications over encrypted vir-
applications has dawned. Power companies spaces, or in private residences – places where tual private networks (VPN), and strong packet
are working hard to build the smart grid by the actual owners of the devices (say, the filtering with fully implemented AAA protec-
melding IT technology with electricity services. electrical company) have no real control over tions. Before exploring how to integrate data
Oil companies are integrating their machinery their physical security. This makes the physical security into the device’s physical layers, let’s
into digital oil fields. Photovoltaic technology security of these cloud devices an easy attack first examine how packet filtering and VPNs
is being developed as a consumer product, to vector, and is the one layer that traditional IT work together to build highly secure networks.
integrate with the smart grid centralised solar has not much addressed.
farms, and distributed residential solar stations. Packet filtering and firewalls
Urban environments are deploying monitoring Enhancing conventional wireless Packet filtering and firewalls are a relatively
systems for public security and accountability, security simple consideration. Essentially, network engi-
while intelligent transportation systems are At the same time, there remain the conven- neers must cut off all available entry points to
preparing for a future where cars drive them- tional challenges of securing data across the a client, and restrict communications between
selves, and those that don’t are advised by open Internet, and over local wireless links like it and the server to only those packets and
traffic systems that communicate instructions 3G cellular, or Wi-Fi. Electrical smart meters ports which are absolutely necessary. Some
relevant to one’s location and destination, to must not be corruptible by simple home hacks. features are a requirement, today: stateful and
reduce or eliminate bottlenecks and jams. ITS systems must not be vulnerable to wireless application-aware firewalls are a must, for most
Yet each of these future systems faces one DoS or man-in-the-middle attacks. Residential cloud applications, for instance. Fortunately,
significant challenge: data security, not just for and public data must maintain appropriate there are very powerful tools freely avail-
user-space input/output, but for protection standards of confidentiality, and not be liable able to help implement these technologies.
of low-level OS integrity – including the boot to unauthorised manipulation. As data travels The Linux-based Netfilter/IPtables package
loader and BIOS – as well. Moreover, unlike IT from remote, edge devices like traffic monitors, is a stateful, application-aware firewall that is
environments, where AAA security protocols smart meters, and mobile devices, the infor- among the most widely used on the Internet.
(authentication, authorisation, and accounting) mation will often first travel through wireless Netfilter’s modular design, flexible configura-
may be served from machines located behind gateways and then be forwarded over the tion options, and scalability allow for practically
a very large physical security layer, for these open Internet. Fortunately, IT solutions already limitless deployment and feature expansions.
industrial cloud deployments the computers provide trustworthy guarantees for these links: The only drawback to using Netfilter/IPtables

80 August 2015 www.instrumentation.co.za


IT IN MANUFACTURING

is doing the hard work of designing multiple and can affect your final network design. For giants AMD, Cisco, Hewlett-Packard, IBM, Intel,
layers of packet filtering security over a widely instance, the reliability of a VPN is dependent Microsoft, and Wave Systems Corp, today the TCG
distributed computing architecture. Widely upon the quality of the connection maintained continues to evolve, with input from over 105
distributed networks like those found in the by the service provider. If high reliability is a participating members, all of them world-class
industrial cloud will require multiple layers of requirement, network engineers will need to enterprise IT manufacturers. Consequently, TPM
overlapping security zones, and while Netfilter work closely with the ISP to guarantee the has typically been associated with the IT industry,
admirably fulfils its role as the only packet quality of the network connections or else and not least because up until recent years there
filter you will ever need, the task of designing compensate by designing the network using has never been much of a need for encrypting
a highly secure filtering layer into a network distributed redundancies over shorter seg- data on industrial networks. Where enterprise
composed of thousands of devices will require ments. Similarly, to guarantee future scalability, networks were responsible for storing and
a lot of time-consuming and minutely detailed care must be taken to either use established manipulating sensitive, strategic business data
design and testing. open standards – which may be freely that could be exploited by hostile competitors,
Firewalls strive to keep unauthorised expanded as needed – or be at peace with IA networks were responsible solely for localised
intruders and services from gaining network the idea that future expansions may require input/output, monitoring processes, and remote
access. In contrast, a virtual private network, expensive proprietary alternatives that cannot control. Yet in today’s era of distributed big-data
or VPN, strives to keep communications across be easily integrated with the original system. industrial systems, this is now changing: the
the open Internet a private affair, giving
remote clients full access to a private network
by wrapping all communications between
the two sides in a heavily encrypted stream
managed by a dedicated VPN gateway. IPsec
is currently the most commonly used form of
VPN encryption, a strong algorithm with full
AAA functionality. By using a proven VPN suite,
network engineers may configure a remote
device to connect to a server using either IPsec
or TLS, making it very, very difficult for mali-
cious attackers to intercept or interfere with
the data stream.

The basics of VPN tunnelling


On a VPN’s server side, cryptographic keys (or
passwords) are set up to allow remote clients
to identify themselves and connect to the
central network. The clients’ cryptographic keys
are kept secret by a process similar to what
occurs with wireless encryption, and allow the
server not only to authorise the device to con-
nect, but also to verify the integrity of all data The power of trusted platform types and amounts of information available on
received from it. These two aspects represent computing industrial systems present a very real security risk
the mix of authorisation (determining what – if While VPNs and packet filtering are a necessary for everyone, both individually and as a society.
anything – the client may do on the network), part of any industrial cloud deployment, these Data encryption is today as necessary in industrial
accounting (keeping track of what packets elements only satisfy part of the requirements. networks as it is in IT networks.
have been sent, what have been received, and As described above, industrial computing While already quite common on enterprise
whether any packets in the stream have been platforms that are deployed into commercial, IT hardware, TPM has rarely been applied to
tampered with), and authentication (verify- residential, or public areas require strong embedded RISC computers. Bringing these
ing that the device and its data stream are guarantees for the physical security of the edge two tools together gives system integrators
what they claim to be) that makes a VPN so devices. Fortunately, there exists a powerful, and industrial engineers a powerful new tool
powerful. When clients are configured with currently under-utilised tool that fulfils just this in their security arsenal. The virtue of TPM
strong (256 bit) cryptographic keys, a VPN data need: the Trusted Platform Module, or TPM. is that it defines a hardware standard that
stream is uncrackable by brute-force means. For those who aren’t familiar with it, TPM permanently incorporates cryptographic
Additionally, VPNs may be easily integrated was developed by a consortium of IT corpora- keys into a device’s physical composition. By
with Radius or Diameter servers, as well, which tions called the Trusted Computing Group (TCG), outfitting each hardware system with a unique,
provide additional, powerful accounting pro- who worked with the ISO and IEC to establish a hardcoded cryptographic key, it becomes
tocols that log and report on resource usage means of developing highly secure computing possible to give every computing platform
by remote clients—very useful for around-the- platforms that provide strong encryption and or networking device virtually unbreakable
clock services like utilities, or ITS. security guarantees for use in large enterprise encryption and AAA layers that protect not
While VPNs provide some very useful secur- networks where every computing station on only all software and data, but also the physical
ity and accounting features, their deployment the network must be secured against tamper- composition of the device, including chipsets
does demand a bit more planning and care, ing. First composed of a core group of industry Continued on page 82

www.instrumentation.co.za August 2015 81


IT IN MANUFACTURING

Continued from page 81 in a hardware-based platform configuration locked down from any input interfaces. That
and peripherals. Because each cipher is unique register (PCR). From that point on, TPM will means that all console and USB interfaces must
to each device, TPM allows the integration of be able to detect any changes in the operat- be able to be turned off so that they cannot be
the very lowest levels of device software and ing system. Similarly, TPM can use the same used, thereby shutting down any possibility
firmware with physical-layer security, allowing method to test things like the BIOS, chipsets, of infection from viruses, or cracking exploits.
for the possibility of creating computing plat- MACs, and so forth. Once this has been achieved, pretty much the
forms that can detect any physical alteration or Software support for TPM is already robust, only possible way to further increase security
interference in the device’s normal functioning, with established vendors like Microsoft and would be to disconnect the computer from the
and issue emergency shutdown orders. Cisco providing solid, feature-filled (but closed) Internet and lock it away in a strong box.
To get an idea of how TPM can work, end solutions. At the same time, open source
imagine the VPN situation described above. projects in GNU/Linux also provide numer- Bringing it all together
When a client requests access to a VPN, the ous software packages which may be freely A RISC platform that features TPM, a kernel-
server responds using an encrypted, asym- adapted, enhanced, and integrated to provide authenticating secure boot feature, strong
metric handshake that keeps all root keys whatever combination of features is needed. encryption, VPN tunneling, and full interface
(or “passwords”) hidden from public view. These software systems empower TPM to take control delivers a strongly secure device suitable
Using this asymmetric process, the VPN a variety of emergency security actions that for deployment in residential and commercial
server and the client exchange encrypted range from ordinary corrective maintenance settings. An embedded computer featuring
messages that authenticate the client and to alarms and full system shut-down. TPM can carefully engineered security of this sort may be
allow the server to authorise access to the be put to many uses: password management, used in smart metering applications, residen-
remote network, all without ever exposing the disk encryption, or binding and sealing of the tial solar solutions, intelligent transportation
private, cryptographic keys they are using to entire platform (hardware plus software), and it systems, and any number of wide area industrial
confirm the login. What TPM does is create a can also be configured and administered using cloud applications. To find out more how these
specific cryptographic key for each individual remote, mass deployment software. Generally features come together to give you a powerful,
device, hardcoded within the platform itself. speaking, TPM brings only strong benefits to compact, small-footprint embedded computing
Devices may then use this key to both gener- the industrial user. platform, visit the Moxa website and read up on
ate more keys, and to authenticate hardware the UC-8100 universal computer for distributed
components within the system. For instance, Locking down the inputs computing applications.
to verify that a read-only operating system There is one other feature that should be
has not changed, TPM can create a hash of standard on any embedded computing device For more information contact RJ Connect,
the drive image, encrypt this using its highly intended for deployment in wide area industrial +27 (0)11 781 0777, info@rjconnect.co.za,
secure cryptographic key, and store it locally, networks: the device should be able to be fully www.rjconnect.co.za

Video networks for mission-critical


surveillance
Moxa has introduced its new V-ON technology, with Moxa’s patented Turbo Ring/Turbo Chain
which is designed to prevent video loss from protocols, V-ON technology optimises complex
mission-critical surveillance networks. Robust video streaming to implement layer 2 video
surveillance networks are an increasingly recovery within 50 ms, and layer 3 routing
important aspect of public safety and critical recovery within 300 ms after a video network
security applications. To support non-stop failure.
video stream monitoring, V-ON technology
overcomes layer 2 and layer 3 multicast limita- Video-always-on solution
tions to recover from layer 2 video loss in under V-ON can be implemented on a wide range
50 ms, and to provide layer 3 routing redun- of Moxa robust Ethernet switches by a simple
dancy of under 300 ms. firmware update. “As a matter of fact, video-
“Security events can happen in the blink of always-on networking depends on V-ON’s
an eye, and video surveillance networks that optimised connectivity, device robustness, switches, customers can complete configura-
fail to deliver key images in real time could and management efficiency to achieve opera- tions 10 times faster, and utilise the live-view
delay response, resulting in disasters that tional reliability, availability, and efficiency for topology and event playback functions to
endanger both people and property,” said Ray mission-critical surveillance,” said Hsu. run intuitive surveillance network monitoring
Hsu, product manager of Moxa’s industrial “To facilitate fast network deployment and operations.”
Ethernet infrastructure division. easy event tracking, Moxa offers MXstudio,
To achieve non-stop video surveillance, a user-friendly network management suite For more information contact RJ Connect,
Moxa’s V-ON network technology maximises that does NOT require IT skills,” he added. “By +27 (0)11 781 0777, info@rjconnect.co.za,
IP surveillance network uptime. Combined incorporating MXstudio with V-ON enabled www.rjconnect.co.za

82 August 2015 www.instrumentation.co.za


IT IN MANUFACTURING

MES and the new worker g­ eneration


By Janice Abel, principal consultant, ARC Advisory Group.

Manufacturing Execution Systems can help “on-board” the new generation of workers.

Recent ARC Advisory Group research indi- Companies must figure out how to capture
cates that the improving global economy and the knowledge and experience that will be
population dynamics were major influencing leaving as the baby boomers retire. Companies
factors in the collaborative production system/ can utilise the intelligence provided by CPM/
manufacturing execution systems (CPM/MES) MES solutions to enable newer, less-experi-
market in 2013 and 2014. Improving economic enced personnel to make better decisions.
conditions, uncertainty in the European manu- The response to the retirement trend
facturing sector, oil and gas price declines, and is multi-faceted. Some manufacturers are
geopolitical issues – all affected market growth. making a strong effort to integrate these solu-
Lower oil and energy prices contributed to tions into their processes; others are just ignor-
more consumer spending and demand for ing the problem, possibly due to poor planning
consumer products result in an uptick in many or recent economic conditions. However, the
industrial markets in 2014 and 2015. problem is not going away – so companies
Population dynamics, including the need to address the issue.
impending retirement of the “Baby Boomer”
generation of workers and the associated need Retiring workforce and knowledge
to quickly “on-board” the next generation of transfer
workers in industrial plants and facilities, are Many soon-to-be-retiring workers have as
helping drive demand for CPM/MES solutions. much as 30 to 40 years of knowledge and expe-
This applies to the process, batch and discrete rience. One way to transfer this information
Janice Abel.
manufacturing industries. quickly to new workers is to utilise software
that integrates the data, analysis, intelligence, about work processes. But due to today’s
Demographic changes and the tech- and decision making with the process. CPM/ high turnover rates, workflow software must
savvy generation MES can help enforce workflow standards be more intuitive and include the necessary
Loss of worker knowledge due to a retiring and responses to abnormal conditions and intelligence to enable complex workloads
workforce and inexperienced workers impacts therefore improve overall performance for all and guide workers. Dynamic engine rules for
industrial organisations in both developed and generations. workflow are being integrated within CPM/MES
emerging economies. Many managers facing As “digital natives”, the newer, tech-savvy that can help workers make the right decision,
retirement will not embark on a new project millennial workers do best with modern which should help inexperienced workers gain
unless there is a relatively low risk of failure and software. As manufacturers face challenges experience quickly. Other workflow solutions
ROI is relatively easy to attain and document. in skill gaps and shortages of skilled workers are being used to address batch processes.
In lieu of this, they would prefer to focus their due to the retiring workforce, recruiting and
limited time on incremental updates to existing retaining a younger generation of worker is CPM/MES solutions evolving
applications rather than embark on new, riskier essential. One key issue for many companies is As the manufacturing environment continues
projects. However, due to cybersecurity vulner- finding workers that can fill the skills gap. One to change, CPM/MES solutions are evolving by
abilities and technology obsolescence issues user told ARC that the new tech savvy worker integrating new technologies and solutions to
related to many legacy systems, there is often generation “does not want to work on the old meet new demands and expectations.
no option available except to implement new technologies, so keeping older systems run- Future manufacturing processes will be
CPM/MES applications. ning is increasingly problematic” and a driver more connected than ever, smarter and have
The demand for these solutions will for CPM/MES purchases. highly intuitive software solutions that predict
continue as new-generation workers get more Interactive, immersive, and up-to-date outcomes, anticipate needs, and provide tools
automation experience, economies stabilise software tools can help companies meet the that can provide insight for better, faster and
and companies release capital. Today’s produc- expectations of the next generation of manu- more accurate decisions. Wearables such as
tion processes and products are increasingly facturing employees. digital watches will be incorporated into the
complex, global, and multi-faceted, challeng- daily work routine. These, and many other
ing many manufacturers to find methods to New workflow enforcement features characteristics, help make evolving CPM/MES
simplify and streamline complex processes helps less experienced workers make solutions attractive and effective for the new
while maintaining product quality and encour- decisions workforce.
age innovation. Product and process complex- Workflow software that improves and enforces
ity, innovation, manufacturing intelligence, work processes is another important reason For more information contact Paul Miller,
analytic tools and ease of use (including “app- for implementing these solutions. In the past, ARC Advisory Group, +1 781 471 1141,
like” functionality) drive CPM/MES growth. workers were expected to be knowledgeable pmiller@arcweb.com, www.arcweb.com

www.instrumentation.co.za August 2015 83


IT IN MANUFACTURING

Emerson enhances reservoir


modelling software
Latest version of Roxar RMS comes with new structural modelling and uncertainty
management tools.

Emerson Process Management has launched gridding. This enables users to build fault that allows users to manipulate large amounts
the latest version of its reservoir modelling uncertainty models in full and investigate a of data with advances in well administration
software, Roxar RMS. The new version – RMS wide variety of scenarios corresponding to the and fault grouping/sorting.
2013.1 – comes with enhanced structural uncertainty in the input data. Finally Roxar RMS 2013.1 also comes with
modelling tools that acknowledge realistic In addition, horizon uncertainty modelling new predictive analytics tool for identifying
uncertainties in the data and improve volumet- is significantly enhanced, allowing users to sweet spots within unconventional fields.
ric sensitivities. This makes it faster and easier create horizons and zones based on uncer- Kjetil Fagervik concludes: “When it comes
for modellers to build geological scenarios, tainty data and information derived from to strengthening operator confidence in their
investigate the full effects of structural uncer- well picks, velocities, seismic travel times and reservoirs’ economics, improving decision-
tainty, and maximise the value of their reservoir isochores. Uncertainty modelling has also been making and increasing workflow productivities
assets. extended with new parameters added such and efficiencies, Roxar RMS is changing the
“Too often in the past reservoir modellers as the modelling of fault sealing effects and reservoir modelling landscape. RMS 2013.1 will
have had to resign themselves to using best fractures. be the first of a number of significant model-
case estimates of faults and horizons, with the The accuracy of the models can be further ling advances over the coming months.”
inherent uncertainty in these interpretations improved with the new tool for adjusting the Emerson’s Roxar RMS is comprised of 24
often neglected and thereby underestimating 3D grid to well picks, and enhanced isochore fully integrated software modules that form
the actual uncertainty in reservoir volumes,” modelling tools that provide users with full a seamless and fully integrated seismic to
said Kjetil Fagervik, managing director of quality control over isochore input data. simulation workflow. This includes seismic
Emerson’s Roxar Software Solutions. The focus on the geophysical domain sees interpretation, structural model building, 3D
He continues: “With our new version of further enhancements to the new Model- gridding, facies and petrophysical modelling,
Roxar RMS and our tightly integrated structural Driven Interpretation (MDI) tools first released flow simulation, well planning and uncertainty
modelling and gridding tools, users will be able in RMS 2013 with improvements to MDI and modelling tools. RMS operates on Red Hat
to quantify uncertainty more effectively and velocity modelling through new tools for Enterprise Linux 64-bit versions 5 and 6 and on
increase confidence when it comes to crucial QC-ing the velocity model, providing input Windows 64-bit 7.
decisions on where to drill, what production for horizon uncertainty modelling, and for
strategies to adopt, and how to maximise well-ties. For more information contact Michael
recovery.” Efficiencies and performance is improved Eksteen, Emerson Process Management,
As part of the new enhancements, RMS through multi-threading (the ability for com- +27 (0)11 451 3700,
2013.1 also sees fault uncertainty tools further puting to take place in parallel), new SEG-Y michael.eksteen@emerson.com,
integrated with structural modelling and 3D importing functionality and RMS Data Explorer www.emersonprocess.com

84 August 2015 www.instrumentation.co.za


IT IN MANUFACTURING

AST Africa introduces Whisp-Air


Silent delivery nozzle eliminates vibration damage to hard drives when a gaseous fire
extinguishing system discharges in the data centre.

Today, many hard disk drives are designed and produced in China with
little to no vibration testing. This has created something of a problem
when one considers the potential vibration damage that could result
when a gaseous fire extinguishing system discharges a data centre.
Noise issues, and the vibration damage associated with these, have been
attributed to all gas types, and IT specialists need to investigate specific
measures that can be implemented because as the mechanical disk
drives become more sensitive due to performance and cost objectives,
this problem will only get worse.
However, for the interim, Alien Systems & Technologies has devel-
oped and manufactured a product that will treat the symptoms and
lower the risk of damage to hard disks. The Whisp-Air Silencer Nozzle has
been designed specifically for use in applications where protection of
sound sensitive equipment such as hard drives is required.
The Whisp-Air’s full-flow design uses interposing sound waves, redirected into smaller streams that rebound off opposing walls of the
multiple-stage velocity deceleration, an obstruction-free expansion chamber. When these steams collide head-on with each other, the veloc-
chamber and a metal fibre disseminator to dissipate potentially damag- ity is reduced and the extinguishant is dispersed throughout the large
ing discharge noise. A large peripheral exhaust surface area diffuses exit surface area. This technique eliminates noise without sacrificing flow
the extinguishing media, further lowering its velocity and reducing rate or increasing back pressure.
discharge noise.
The Whisp-Air silent nozzle product eliminates excessive discharge For more information contact Samantha Wright, Alien Systems
noise by dividing the extinguishing media stream and turning it back & Technologies, +27 (0)11 949 1157, sam@astafrica.com,
on itself. As the extinguishant enters the muffler at high velocity, it is www.astafrica.com

www.instrumentation.co.za August 2015 85


IT IN MANUFACTURING

More data is only useful if it leads


to more wisdom
By Deon van Aardt, Wonderware Southern Africa.

Making sense of big industrial data without being a genius.

Today, in every aspect of our lives but more more data faster than any other. It’s all hap- from one another. Also, they will have been
particularly in the industrial IT world, Big Data pening in real-time down to the millisecond. designed to address specific issues and prob-
is all the rage. The old ‘KB’ has been turned Most of these data simply show that things ably in isolation of one another and of the
into the new ‘GB’ – Microsoft’s original and are operating normally, but others may bigger enterprise-wide business picture.
(now) laughable limit of 640K memory has indicate that potentially dangerous trends Figure 1 shows the process of transforming
now been turned into the run-of-the-mill 640 are emerging while the remainder are cause data into knowledge – note the all-important
Gigabyte hard drive. And while ‘GB’ is morph- for immediate concern. But how do you tell? central block of contextualisation. Context can
ing into ‘TB’, just around the corner is the ‘EB’ – Data isn’t information, yet companies run on be described as the additional data or infor-
the Exabyte (1 EB = 1billion Gigabytes) – if you information so the conversion from one to the mation pertaining to the conditions and cir-
wanted Big Data, you got it. But now what? other is an important aspect of effective decis- cumstances under which a measurement was
While today’s industrial automation and ion making. Data only becomes information made. For example, knowing that the night
information technology is geared to produce after they are collected, validated and collated shift exceeded the production of the day shift
more data than ever before, what does it all within the context of the situation and envi- may well be due to their motivated approach
mean? Data only becomes useful if it can be ronment in which they originated. but it could also be due to the fact that they
turned into information and then into action- Any production environment generates a had eight uninterrupted hours of electricity,
able knowledge – so it could be said that more variety of data from many different sources. quality raw material with which to work, high
data is only useful if it leads to more wisdom. Some are stored together in the same data- machine availability (which may mean that
base (e.g. process control data in a real-time they look after plant machinery better than
Turning big data into actionable database) while others are stored elsewhere their colleagues), etc., etc. A single datum
knowledge (e.g. LIMS, MOM, etc.). Of necessity, these on its own has value but never as much as
The world of industrial automation generates varied databases will be structurally different when viewed in relation to other events that

Figure 1: The information generation process.

86 August 2015 www.instrumentation.co.za


IT IN MANUFACTURING

influenced it. This may mean digging in other So where to from here?
data repositories in order to collate it all. Reporting software is available but to do
The information process is replicated and the above is going to require the services
applied to each item or each group of the data of an expert (who will most probably not
sources showing that enterprise information fully understand the needs of the end-user).
is complex and multi-dimensional in nature Another avenue is the use of spreadsheets but
– imagine the information process ‘stacked’ who’s going to maintain them? On the other
six or seven layers deep as shown. And that’s hand, Flow Software allows the average indi-
where things get interesting. vidual to connect to the real-time historian as
well as other databases, aggregate data (e.g.
The dynamic and multi-dimensional daily/weekly reports), perform calculations
nature of information (e.g. efficiency of production processes by
Different people need to know different area or shift, energy consumption, machine
things at different times. Operators, super- efficiency, etc,), enter manual data and correct
visors and maintenance personnel need to / validate existing data before using one of
know a great deal more about the details of the standard reports supplied to provide the
operational processes (and in real-time) than required information – all through drag-and-
corporate operations management. Yet what drop easiness. What’s more, Flow is designed
both groups need to know is often derived to cater for the easy and frequent report
from the same data or groups of data which is, changes necessary for analyses.
thankfully, finite (although mind-bogglingly
large). About Flow software
The Structured Query Language (SQL) Flow is a configuration-based calculation
used for retrieving data from relational and reporting engine that integrates directly

Figure 2: Crossing information boundaries.

databases is still the standard for individual, into and extends various data sources such
application-specific databases. But when as Wonderware Historian, Microsoft SQL,
we get to the situation where the relevant OPCHDA and others. Measurements are taken
information is spread across several of these from points of interest that are configured in
databases, things become more complex – the Flow system which automatically retrieves
not because of the technology involved to do and aggregates data from the underlying
this but because of the nature of the informa- data sources. Calculations, manual data entry,
tion required which is often unknown before limits, reports and forms are configured in a
it is required. So what we need is a super SQL drag ’n drop manner.
that can cut across database boundaries yet With its simple configuration environ-
provide the friendly interaction necessary for ment, Flow promises an ease of use that even
multiple views (depending on your needs) business users will adopt, moving the system
into a seemingly seamless pool of factual ownership to end users and lowering the total
information so that you can make the right cost of ownership. Flow is typically used as a
moves – oh yes – and it’s all got to be time- production or manufacturing performance
stamped for correlation purposes. Continued on page 88

www.instrumentation.co.za August 2015 87


IT IN MANUFACTURING

Continued from page 87


management system. Because it is able to Flow also provides for the addition of the has always required computer experts to make
connect to and automatically collect data all-important context to information (e.g. sense of it all. Computer experts, though, are
from multiple systems, Flow is an ideal system batch numbers, products, operators) which not usually experts in what a particular com-
for centralised reporting and data analysis all contributes to a far better informed evalu- pany needs to know – the company’s staff and
and a number of prominent South African ation of performance against targets. management, on the other hand, are. With
companies have adopted Flow Software as • Visualise – The single Flow repository is the Flow software, they have a tool that puts them
their information tool of choice. There are source for all reporting. Pre-aggregated and in the driving seat by easily cutting through the
three phases to the Flow information delivery pre-calculated information enhances the difficulties of sourcing data from a multitude
process; collect, calculate and visualise: performance of reporting as well as increas- of sources and also lets them cross traditional
• Collect – Flow collects information from ing business intelligence. It’s also possible information boundaries to get to the decision-
multiple data sources automatically and to integrate Flow information into other support knowledge they need.
understands historians, databases, text files applications such as Wonderware Skelta BPM So, you no longer have to be a genius to
and even on-line data stores. Information (workflow management), ERP, etc. make business sense from an avalanche of
can also be entered manually. This all industrial IT data. You do, however, still need
contributes to keeping all the necessary Conclusion to retain your genius status regarding what to
information in one place and maintaining a For more than two decades, anyone involved do next – but even there, help is on the way.
single version of the truth. with industrial automation has been after the
• Calculate – Flow provides for the aggrega- Holy Grail of profitability – information. That’s For more information contact Jaco Markwat,
tion of information for time periods ranging because it lets you know when you’re doing the Wonderware Southern Africa,
from hours to days, weeks or even months. right thing and alerts you when you’re not. But +27 (0)11 607 8100,
Flow’s calculation engine allows for the the diversity of the production environment jaco.markwat@wonderware.co.za,
evaluation of KPIs, ratios and efficiencies. with its multitude of voluminous data sources www.flow-software.com

Figure 3: The elements of Flow Software.

88 August 2015 www.instrumentation.co.za


IT IN MANUFACTURING

Honeywell’s Uniformance
technology boosts uptime
Uniformance Asset Sentinel can reduce unplanned downtime by up to 10 percent and
cut maintenance cost by 15 percent.

Honeywell Process Solutions has announced process-based domain knowledge to build best practice templates for more than 100
the launch of Uniformance Asset Sentinel, solutions that solve problems from basic to the equipment types, such as pumps, com-
which continuously monitors equipment and most complex.” pressors, exchangers, valves and turbines
process health, assisting industrial facilities to Uniformance Asset Sentinel helps compa- combined with its seamless interface to its
predict and prevent asset failures and poor nies with industrial assets increase utilisation process design simulation software (UniSim
operational performance. of those assets by up to 10 percent by reducing Design) helps customers rapidly deploy
The new offering expands HPS’ unplanned downtime. It can also cut main- equipment or process monitoring on any
Uniformance software suites and supports the tenance costs by up to 15 percent by better plant asset, eliminating the need for complex
emergence of the Industrial Internet of Things predicting and preventing catastrophic equip- model development.
(IIoT) in the process industry, enabling com- ment failure and inefficient operations. Several major refining and chemical
panies to collect, organise and analyse data The technology works by continuously facilities are now implementing Uniformance
for a specific asset or ‘thing.’ These analytics accessing data from a variety of sources, Asset Sentinel to help them overcome the
can transform work processes from reactive to including process parameters, vibration data challenge of accessing data from multiple
proactive, helping industrial plant operators. and alarms. Using a real-time complex event sources and turning it into actionable infor-
“Uniformance Asset Sentinel is the latest processing engine, Uniformance Asset Sentinel mation. In addition to the positive impact on
evolution of proven technology that is cur- continuously performs performance, health, safety, this capability can translate into higher
rently watching over billions of dollars of assets efficiency and safety-related calculations and operational efficiency, agility and, ultimately,
across industries, including oil and gas, power compares those results of the current actual higher margins.
generation, mining, refining, and chemi- performance to an expected performance
cal manufacturing,” said Mike Brown, global model. Predicted or detected deviations from For more information contact Boni
marketing director for HPS’ advanced solutions these models are used to generate notifications Magudulela, Honeywell Southern Africa,
business. “With more than four decades of to facilitate investigation and intervention to +27 (0)11 695 8000,
experience in process control and automa- minimise the cost and frequency of an event. boni.magudulela@honeywell.com,
tion, Honeywell is uniquely qualified to bring Uniformance Asset Sentinel’s pre-defined www.honeywellprocess.com

www.instrumentation.co.za August 2015 89


Yokogawa’s Enterprise Pipeline
Management Solution
Yokogawa has announced the release of the Based on a well-designed modular platform to the setpoint so that both compressors and
Enterprise Pipeline Management Solution that is both IT friendly and secure, the EPMS is pumps can be operated as close as possible to
(EPMS), a modular software suite that is the a sustainable solution that can deliver pipeline the optimal efficiency point. To manage excep-
product of over 20 years of practical experience applications in combination with common tions during startup, the EPMS allows the assign-
in implementing pipeline management solu- supervisory and monitoring functions. As no ment of business rules for the management of
tions globally. two pipeline applications are identical and oper- load sharing, compressor/pump restrictions, and
Developed for deployment at the heart of ational philosophies can differ from one pipeline alarm notifications at the compressor/pump sta-
the pipeline operations management environ- operator to the next, the EPMS’s templates and tion level. To identify areas for improvement, the
ment, the EPMS supplements the basic pipeline functions can be easily modified without having EPMS can also record all key power statistics.
management system with specific gas and to call in pipeline application experts.
liquid applications that enable a pipeline opera- Less product waste at batch delivery points
tor to manage delivery contracts and associated Contextual online integrity management To minimise product waste, the EPMS measures
logistics in a time and energy efficient manner. The EPMS features improved alarm and human and calculates the position of batches as well as
With a scada platform covering monitoring, machine interface (HMI) management functions, anomalies such as trans-mix on a near real-time
alarming, trending and reporting, the EPMS and both it and its application platform were basis, and reports on the inventory balances.
handles functions such as metering, batch developed based on standards put forward
scheduling and tracking, leak detection and by the American Petroleum Institute (API) and Enhanced gas and liquid metering
energy management, all within the same unified the International Society of Automation (ISA), With its transparent management of parameter
user environment. and comply with the strict regulations of the exchange and the measurement of gas, liquids,
Many pipeline systems in use today have US Department of Transportation’s Pipeline and gas composition, the EPMS easily adapts
been tailored to suit a specific set of circum- and Hazardous Materials Safety Administration to the desired measurement methodology and
stances and lack both a standard system (PHMSA). The EPMS employs leak detection, the level of intelligence of intermediate devices
foundation for supporting pluggable applica- compensated volume balancing, and hydraulic like flow computers, remote terminal units
tion modules and a core design that ensures profiling methodologies to monitor pipeline (RTU), and instruments. It processes the avail-
interoperability with enterprise IT environments integrity under every type of operating condi- able inputs into normalised flow, volume, and
and policies. The maintenance and upgrade tion. The EPMS is thus able to register possible energy values in accordance with the applic-
of tailor-made applications, and their often integrity violations together with contextual able American Gas Association (AGA) and API
complex system architectures to protect them information about the operational state of the standards.
from breaches and security compromises, poses pipeline so that personnel can quickly get to the
increasing challenges for pipeline operators. bottom of any problem. For more information contact Christie Cronje,
Yokogawa South Africa, +27 (0)11 831 6300,
Key benefits Reduced energy consumption christie.cronje@za.yokogawa.com,
Unified user environment based on a modular design The EPMS continuously makes adjustments www.yokogawa.com/za

90 August 2015 www.instrumentation.co.za


CONDITION MONITORING & VIBRATION

New FieldConnex
FieldBarrier from
Pepperl+Fuchs
Twelve outputs with diagnostics and
monitoring.
Intelligent Fieldbus from Pepperl+Fuchs is
synonymous with a generation of components
that brings diagnostic capabilities into the
field. The new FieldConnex FieldBarrier is the
perfect addition to this concept of uncompro- changes in the installation and faults in the This package of integrated intelligence is
mising availability. The FieldBarrier comes with control room to be reported. This monitor- completed by the FieldBarrier self-monitoring
innovative technical features that offer reliable ing function ensures an even higher degree function, which can transmit alarm signals to
protection against typical fault scenarios to of transparency and covers a significant gap the control room. These innovative features do
ensure maximum reliability. in the monitoring process as it proactively not require any engineering. The FieldConnex
An intelligent component is an ideal com- identifies maintenance requirements. Another FieldBarrier is the perfect addition to diagnos-
ponent: FieldConnex FieldBarriers can detect feature is the sophisticated load management. tics-enabled intelligent fieldbus components
the special dynamics of faults, such as loose The twelve outputs start sequentially, reduc- and is another key step toward achieving the
contacts or contact bounces. As a result, faults ing the load on the power supply from the goal of 100% availability.
can be identified and isolated both quickly and inrush current. What’s more, if the segment
reliably. current reaches critical levels, automatic load- For more information contact Mark Bracco,
The new component is the first to allow shedding of less critical nodes is activated in Pepperl+Fuchs, +27 (0)87 985 0797,
monitoring of the physical layer at each order to safeguard against failure of the mbracco@za.pepperl-fuchs.com,
FieldBarrier output. This enables gradual entire segment. www.pepperl-fuchs.co.za

SKF’s latest turbo-machinery


monitoring solution
SKF has launched its latest magnetic bearing world’s leading manufacturers and operators of
E300V2 control cabinet for use with a wide onshore, offshore and sub-sea turbo-machinery.
range of turbo-machinery. The new E300V2 is the culmination of this knowl-
The new E300V2 is a digital electronic con- edge and experience, offering the opportunity
trol cabinet that replaces an earlier version, of to minimise costs while improving reliability. Its
which 650 units have been installed at different optimised control system reduces commissioning
sites around the world. It is a modular system time of the rotation equipment. Moreover, the
for improved reliability and maintenance, new system provides plant operators with high
and incorporates a number of important new degree of autonomy.”
features. These include remote monitoring and These advantages are extended still further
diagnostics, redundancy of key components, through the use of SKF S2M magnetic bear-
backup UPS and a high-resolution data acquisi- ings. These can increase the operating range of
tion system. The latter monitors operating con- turbo-machines, allowing rotation at higher-
ditions, such as rotation speed, vibration and speeds with much greater operating flexibility.
temperature in real time, allowing engineers When used in integrated motor-compressors,
to visualise rotation orbits, with 3D waterfalls they eliminate the need for lubrication thereby
and graphs showing spectral analyses, time reducing the footprint and maintenance, and also
snapshots and other critical parameters. It has eliminate gear boxes, seals and auxiliary cooling
embedded tools, qualified on sub-sea projects, systems, to cut capital and operating costs.
for remote access that allows performing analy-
sis and adjustment of operating parameters. For more information contact Samantha
Askar Gubaidullin, business development Joubert, SKF South Africa,
manager for SKF Magnetic Mechatronics explains, +27 (0)11 821 3602,
“SKF has worked closely for many years with the samantha.joubert@skf.com, www.skf.com

www.instrumentation.co.za August 2015 91


PRODUCT NEWS

Intelligent surge protection Next generation WEG contactors save energy


for process technology
Phoenix Contact’s Plugtrab PT-IQ surge protection
devices for MCR and process technology warn plant
operators before protection of the plant is lost. To
achieve this, each voltage-limiting component in the
protective plugs is continuously monitored. If the
performance limit has been reached as a result of
frequent surge voltages, this is indicated by a yellow
indicator on the protective device and via remote
signalling. At this time, the arresters are still functional
and the plant is protected. However, replacing the
component is recommended to prevent unnecessary
servicing.
Plugtrab PT-IQ Ex protective devices are available for
intrinsically safe areas. These devices can be installed in
Ex Zone 2. The intrinsically safe protective circuits can be
routed up to Ex Zone 0.
Thanks to multi-level monitoring and signalling,
the plant operator always knows the status of
protective devices and therefore has an overview of
surge voltage protection in the plant. This intelligent
surge voltage protection is available with traditional
screw connection technology as well as innovative
push-in connection technology. A controller supplies
up to 28 protection modules with voltage and allows
for connection of a central remote monitoring
system.

For more information contact Tony Rayner,


Phoenix Contact, +27 (0)11 801 8200,
tonyr@phoenixcontact.co.za,
www.phoenixcontact.co.za
The next generation of WEG contactors 508 international specifications. The
has been engineered to facilitate energy range has been specifically designed to
savings as well as the optimisation accommodate electric motors up to
of space within electric panels. These 18,5 kW at 380/415 VAC.
environmentally friendly devices use only These contactors are ideal for applications
non-toxic and eco-friendly materials. where the majority of the motor starters
Designed using in-house software in an electrical panel are direct online,
modelling programmes, the WEG CWB forward reverse, or star delta. The seamless
range of contactors has been engineered integration between the contactors,
to accommodate surge suppressors overload relays and motor protection
directly in the device. This is not only a circuit breakers allows fast and easy
space saving feature, but also allows easy assembly of compact starters and protection
access for maintenance or replacement. sets for low voltage motors. These
Another important feature is that coil modular devices offer a wide variety of
replacement can be accomplished combinations allowing greater flexibility.
without the need for any tools making The WEG CWB range of contactors
this a simple and time saving task. affords customers a high level of flexibility
Energy savings are achieved through owing to the modular design, which is
the low consumption of the coils used in complemented by a full range of
the contactors, which also allow direct accessories including auxiliary contacts,
switching from PLCs without the need for spare coils and wiring kits.
interface relays. This facilitates both space
and cost savings for the end-user. For more information contact Kirsten
Developed by WEG’s R&D department Larkan, Zest WEG Group,
in Brazil, all devices in the WEG CWB con- +27 (0)11 723 6000, kirstenl@zest.co.za,
tactor range meet the IEC 60947 and UL www.zest.co.za

9292August
August www.instrumentation.co.za
2015www.instrumentation.co.za
2015
PRODUCT NEWS

Diffuse proximity light curtain from Telco Sensors Efficient earth leakage protection
The New SGP 30 Telco Sensors proximity those channels to be ignored when
light curtain has been successfully used operation is resumed. Other features
in the board, paper and pulp and sawmill include:
and industries where different shapes and • Discrete output is generated whenever
lengths need to be detected. By using the one or more of the channels are
SGP 30 users can create a compact wide activated.
coverage of beams so that the product • Distances ranging from 510 to 1980 mm
being sensed will always be detected, no and up to 40 channel pairs.
matter what shape size or form. The same • Multiple transmitter/receiver channels in
system is being used by manufacturers same profile, paired in horizontal axis.
for the detection of different log and box • Channels operate in diffuse proximity
sizes. mode over active zone of profile.
The SGP30 is a diffuse proximity light • Object is detected when emitted light
curtain system housed in a sturdy from transmitter element is reflected
aluminium profile housing multiple back by an object to the paired receiver.
transmitter/receiver pairs that generate
an array of channels. For more information contact
It features a blanking function which Gail Norton Instrumentation,
is configurable using a control input to +27 (0)31 701 4861,
memorise the channels which detect an telco@telcosa.co.za,
object (activated) during set-up, allowing www.gailnortoninstrumentation.co.za

Industrial LED light bar for increased productivity

NewElec’s earth leakage relays are becoming the


preferred earth leakage protection device for all
industries. This move can be attributed to the original
design criteria that include harmonic filters to suppress
nuisance trip conditions on starting higher kW motors on
DOL. The original design permitted users to select either
instantaneous or inverse tripping curves easily on the
relay itself while still using the same earth leakage core
balance sensing current transformer. This design remains
the backbone of the now popular GA range of relays
The GA is available in diverse configuration options,
including latched or non-latching main trip contact,
RET Automation Controls has introduced diverse installation needs. To ensure fail-safe or non fail-safe options, as well as 110 – 220 V
the WLB92 industrial LED light bar from continuous run and permanent installa- or 380 – 525 V AC auxiliary supply voltages. The trip
Banner Engineering. Featuring bright, tion, the WLB92 is equipped with contact current rating is 6 A at 220 V and 3 A at 525 V AC.
high-quality and uniform light, the WLB92 industry-standard conduit knockouts. A latched contactor trip changeover contact is an added
is designed to increase worker productivity An optional dimming function is also safety feature, optionally reset by pressing the control
and ergonomics. With a rugged metal available to allow users to customise light panel mounted pushbutton.
housing and shatterproof light cover, the levels. Sensitivities range from 30 to 1000 mA with user-
WLB92 is optimal for a variety of industrial The WLB92 is available in 550 or selectable instantaneous or IDMT curve selection while
lighting applications including robotic 1100 mm lengths. All WLB92 models using the same earth leakage core. Three models are
work cell lighting and quality inspection, offer enhanced light quality with bright, offered: the GA with a standard 74 mm x 134 mm cut-out;
while having aesthetics suitable for an densely spaced LEDs to ensure even, the GA-ELX with an adaptor plate to fit a 71 mm x 94 mm
office environment. bright and highly efficient illumination. cut-out; and the compact GA MS0, designed for use on
The WLB92 LED light bar delivers a AC models are also DLC qualified and underground gully boxes. GA relays provide harmonic
versatile lighting solution with models have a five-year warranty. suppression and isolation to IEC 255-5 App A. As a
available in AC or DC voltage supply and door-mounted unit, the front control panel clearly
multiple connection options, including For more information contact Brandon displays the user-selected tripping curve by means of
AC quick disconnect and AC conduit. The Topham, RET Automation, suitably coloured LEDs, as well as the relay trip status.
WLB92 also features several mounting +27 (0)11 453 2468,
options, such as surface, swivel, snap brandon.topham@retautomation.com, For more information contact NewElec, 086 010 3041,
and hanging brackets to accommodate www.retautomation.com sales@newelec.co.za, www.newelec.co.za

www.instrumentation.co.za
www.instrumentation.co.za August 20159393
August2015
PRODUCT NEWS

Miniature photoelectric Toolless custom-built electrical enclosures


sensors with high
­performance
The new O6 diffuse reflection sensors from
ifm electronic provide reliable background
suppression, even in case of highly reflec-
tive backgrounds such as moving machine
parts. The clearly defined consistent light spot
ensures precise object detection. There is no
scattered light which could interfere with other
photoelectric sensors in close vicinity.
For connection, users can choose between
a potted cable, M12 pigtail or an M8 metal con-
nector on the housing.
The O6 range features a potentiometer for
intuitive setting, and the light-on or dark-on
mode is selected via a rotary switch. The diffuse
reflection, through-beam and retro-reflective
sensors are distinguished by a good price/
performance ratio. An extensive range of acces-
sories is available making the sensors ideal for
universal applications.
NewElec manufactures custom-built electrical are required, NewElec is able to receive the
For more information contact ifm electronic enclosures using computer-controlled manu- design and quote within 48 hours. Once
SA, 086 143 6772, info.za@ifm.com, facturing equipment. The use of PMPT tech- the quote is accepted, the prototype phase
www.ifm.com/za nology eliminates the need to manufacture ­commences. This usually takes one to two
expensive tools and moulds, resulting in faster weeks depending on the demands of each
development times. enclosure design. The manufacturing pro-
Toolless technology compares favourably cess takes two weeks or more, depending
with injection moulded parts in appear- on the demand in the shop. The result is a
ance, finishing and durability, with a minimal flexible, affordable plastic enclosure that
non-recurring engineering charge. If changes meets the customer’s needs. NewElec’s quick
are made using thermoforming or injection turnaround process takes the enclosure (ABS,
moulding technologies, a charge is incurred acrylic or HIPS) from design to 3D model to
for a new mould each time the product needs prototype to manufacturing faster than any
to be modified. With PMPT, there is no need other process.
for a new mould as NewElec’s in-house engi-
neers are able to modify the part quickly with For more information contact NewElec,
minimal cost. 086 010 3041, sales@newelec.co.za,
When fast, high quality plastic enclosures www.newelec.co.za

12 channel thermocouple compensating module


This unit was designed to replace the old and temperature sensor to prevent interac-
12 way unit which comprised a heated block tion between the different thermocouples.
with reference thermocouples imbedded The compensating module uses either a
into it, and maintained at 70˚C. It was used PT100 or a Ni100 sensor to measure the cold
in applications where it was deemed to be junction temperature (at the terminal block)
unecono­mical to run long lengths of compen- and generates a temperature dependant mV
sating cable and is still currently used in some signal which is added to the thermocouple
installations. signal. The offset has the same effect as the
This new unit can be supplied as just the 70°C reference thermocouple used in the
circuit board for mounting into the exist- older units. Typical accuracy is 0,5°C over the power failure the offset becomes zero, which is
ing chassis or complete with the chassis as ­ambient range of 0-70°C. the same as the old unit.
a replacement module. Two versions are A SPDT relay is powered by one of the
offered for use with either type K or type T power supplies. This relay is energised when For more information contact IQ Instruments,
thermocouples. power is applied to the module and can be +27 (0)11 792 1210, sales@iqinstruments.
Each channel has a separate power supply used to signal a loss of power. In the event of a com, www.iqinstruments.com

9494August
Month
Month 2012
2015 www.instrumentation.co.za
2012www.instrumentation.co.za
www.instrumentation.co.za
PRODUCT NEWS

High-performance, safe coupling relays just Microwave level switch for


6 mm wide food and pharmaceutical
applications
Kobold Instrumentation has introduced a
microwave level switch – model LNM – made
of stainless steel and food-approved materials,
developed for almost all applications in the
food and pharmaceutical industries.
The microwave field penetrates several mil-
limetres into the medium and the level, even
in the most difficult media, can be detected.
The level switch is particularly suitable for use
with foaming media because the foam, con-
densate or remains of the transported medium
that sticks to vessels, is not detected. It is also
possible to detect non-conductive media.
The output only switches when the coupling
section is completely covered by the medium,
which means it is possible to install LNM in
tanks, independent of mounting position.
In combination with the weld-in sleeves
model LZE or LZE-R, the probe provides a
­measuring point that has no dead space and
meets European Hygienic Engineering and
Design Group standards (EHEDG). This level
switch is therefore very well suited for CIP/SIP
The new PSRmini safety modules from Phoenix is made possible through Phoenix Contact’s cleaning applications.
Contact are slim safety relays with the power of newly developed relay technology. The design A variety of adaptor sleeves are also avail-
a large device. With their compact 6 mm width, is based on a slim, powerful, and force-guided able for different process connections such
they ensure high safety thanks to positively basic relay characterised by minimal space as Varivent, dairy connection and tri-clamp
driven contacts. For users, these slim modules requirements, low energy consumption, and adaptors, so that the LNM may also be used in
require up to 70 percent less space. high system availability. Despite its compact existing systems without problems.
A comprehensive package of tests and width of just 6 mm, the component features Electronics integrated in the stainless steel
approvals ensures that the modules can also the same performance as traditional EN head enables direct sensor signal process-
be flexibly used in applications and environ- 50205-compliant elementary relays with forced ing and the output signal can be transmitted
ments that exceed the norm. For example, guidance. The elementary relay consists of directly to a PLC for further processing.
the relays are G3-compliant according to ISA an NO and an NC contact and is suitable for a
S71.04-1985 for use in especially corrosive modular application configuration. To achieve For more information contact Instrotech,
atmospheres and are IECEx-certified, thereby the manufacturing precision required to meet +27 (0)10 595 1831, sales@instrotech.co.za,
facilitating the decentralised design of an Phoenix Contact’s high quality requirements, www.instrotech.co.za
application down to Ex Zone 2. Repeat tests the elementary relay and all of its individual
in a process plant, which are prescribed by parts are manufactured entirely in-house.
standards, can easily be performed visually Since the 6 mm modules only require a
and directly on the device. Complex manual single enabling contact, applications can be
measurements that are currently required built with new and improved cost-effective-
when using standard relays that are not ness. The termination carrier also provides the
forcibly guided according to EN 50205 are option of using system cabling solutions for
therefore often unnecessary. In addition, in quick, error-free commissioning and con-
some common control systems, monitoring nection in the field. The complete PSRmini
of the controls of the coupling module may range of safety relays consists of 28 products
be influenced in the event of an error, so that for mechanical engineering and the process
the repeat test, the so-called proof test, can be industry.
designed to be almost fully automated. This
increases efficiency since downtime can be For more information contact Kevin Preston,
reduced without necessitating additional effort Phoenix Contact, +27 (0)11 801 8200,
for required hardware or installation. ­kevinp@phoenixcontact.co.za,
The compact design of the safety modules www.phoenixcontact.co.za

www.instrumentation.co.za
www.instrumentation.co.za
www.instrumentation.co.zaMonth
Month 20129595
2012
August 2015
PRODUCT NEWS

Five lighting tests in 30 seconds Supply voltage influences and damage control

It is often wise to include supply voltage pull-up and pull-out torque. When the
monitoring as a useful tool for prolong- supply voltage is reversed, the connected
ing motor life expectancy and possible motor will rotate in the opposite direction
Building maintenance technicians for commercial, retail or mechanical damage to equipment due and will almost always result in some or
institutional facilities with fluorescent lighting have hun- to, for example, motors turning in the other form of mechanical damage.
dreds, if not thousands of fluorescent tubes that have to wrong direction as a result of voltage In conclusion, no stress should be
be routinely checked and maintained. Even though these phase rotation. Essentially, the protec- placed on electric motors and other
may last for tens of thousands of hours, they do ultimately tion given falls into three categories: electrical equipment as a result of oper-
fail, some prematurely, and some stop working because of the detection of an over-voltage condi- ating a power system at or near the ends
other problems with the installation ballast. tion; the detection of an under-voltage of voltage limits. The best life and most
Fluke has now developed a tool that takes the trial and con­dition; and the detection of voltage efficient operation usually arise when
error – and a significant amount of time – out of maintain- phase rotation on the supply side. motors operate at voltages very close to
ing fluorescent lighting. The result is the Fluke 1000FLT High voltage on a motor tends to the nameplate ratings.
fluorescent light tester, specifically designed for building push the magnetic portion of the motor NewElec offers a variety of prod-
maintenance professionals. It is an all-in-one fluorescent into saturation. This causes the motor ucts that include protection for supply
lamp tester, ballast tester, non-contact voltage tester, pin to draw excessive current in an effort to ­voltage influence.
continuity tester and ballast-type discriminator. This device magnetise the iron beyond the point
takes care of all the essential lighting tests, saving time, tool where magnetising is practical. Low volt- For more information contact NewElec,
bag space and trips up and down ladders. The 1000FLT is age can lead to overheating, shortened 086 010 3041, sales@newelec.co.za,
able to make the following measurements: life, reduced starting ability, and reduced www.newelec.co.za
Lamp test: Allows testing without removing the tube from
the ballast. The tester sends a pulse of energy that lights up Helukabel launches industrial plug connector with
the tube if there is gas in it. The 1000FLT is compatible with Profinet fast ­connection technology
T5, T8, and T12 fluorescent tubes.
Ballast test: Determines whether the ballast is working. Helukabel has introduced its new Profinet designed to be used with both bunched
Non-contact voltage test: Checks for the presence of volt- plug connector, the Helukat RJ45 Cat5 and solid wire conductor types.
age without touching the source. IP20, which has built-in fast connection The Profinet plug connector can be
Pin continuity test: Tests whether filaments in the tube technology. The fieldbus-compatible plug installed without the need for special
have continuity. comes in a linear and angled design. It is tools. The single wires must be arranged
Ballast-type discriminator: Allows technicians to identify therefore well-suited for industrial use in in accordance with the colour coding
easily whether the ballast is electronic or magnetic without tight installation spaces. of the RJ45 plug and, in the folded-up
taking the fixture apart or climbing a ladder. The tester Helukat has coloured contact ele- guide element, inserted into the contact
is aimed at the ballast from the ground and immediately ments to prevent the installers from points up to the stop. To achieve a full
identifies if the tube needs maintenance or replacement. making connection errors. The clear connection, the user presses the guide
The user interface was designed to be as simple as labelling matches the wire sequence of element downward to the stop, closes
possible, with all tests delivering instant results. The ballast, the Profinet standard whose four single the housing cover, and fixes the front
voltage and pin continuity tests indicate results with either wires can be quickly connected. The screw cap. The development of a 145°-
Go or No Go indicator lights. The ballast-type discriminator metal housing enables it to be used in angled version as well as an 8-pin variant
lights up either the magnetic or electronic LED on the face industrial applications. Transmission rates is currently in the planning process and
of the tester, while the lamp test result is determined by the are up to 100 MHz Cat 5. The shielded will expand the product range once suc-
user. Users can run all five tests on the 1000FLT in about 30 plug connector comes in a linear and cessfully completed.
seconds, so if there are hundreds of fluorescent lights to 180° and 90° angled versions. Designed
maintain it can save hours of testing time every week. to protection grade IP20, it can withstand For more information contact
operating temperatures of -20°C to 70°C. ­Helukabel SA, +27 (0)11 462 8752,
For more information contact Comtest Group, +27 The Helukat RJ45 Cat5 IP20 is compatible sales@helukabel.co.za,
(0)10 595 1821, sales@comtest.co.za, www.comtest.co.za with AWG 22 and AWG 24 cables, and www.helukabel.co.za

9696August
Month
Month 2012
2015 www.instrumentation.co.za
2012www.instrumentation.co.za
www.instrumentation.co.za
quickfind august 2015
C0MPANY TELEPHONE E-MAIL WEBSITE PAGE

A.T. Technical Services +27 (0)12 345 1005 admin@atts.co.za www.atts.co.za 61*,63
ABB South Africa +27 (0)10 202 5000 instrumentation@za.abb.com www.abb.com/measurement 32
ABB South Africa +27 (0)10 202 6995 alessandra.romoli@za.abb.com www.abb.co.za/lowvoltage 72
Adroit Technologies +27 (0)11 658 8100 info@adroit.co.za www.adroit.co.za 71
Alien Systems & Technologies +27 (0)11 949 1157 sales@astafrica.com www.astafrica.com IFC*,85
Allpronix +27 (0)11 795 9500 sales@allpronix.com www.allpronix.com 43,45*
Ana-Digi Systems +27 (0)21 914 9030 info@anadigi.co.za www.anadigi.co.za 71*
ARC Advisory Group +1 781 471 1141 pmiller@arcweb.com www.arcweb.com 83
Autotronix +27 (0)16 422 7644 royw@autotronix.co.za www.autotronix.co.za 17
Beckhoff Automation +27 (0)11 795 2898 k.mcpherson@beckhoff.com www.beckhoff.co.za 38,39
Bürkert Contromatic +27 (0)11 574 6000 sales.za@burkert.com www.burkert.com 65*
Comtest +27 (0)10 595 1821 sales@comtest.co.za www.comtest.co.za 75,96
Current Automation +27 (0)10 591 1713 ca@rectifier.co.za www.rectifier.co.za Stitched insert*
Define Instruments South Africa +27 (0)87 945 2700 sales@defineinstruments.co.za www.defineinstruments.co.za 47*
Dehn Africa +27 (0)11 704 1487 info@dehn-africa.com www.dehn-africa.com 10,75*
Emerson Process Management +27 (0)11 451 3700 michael.eksteen@emerson.com www.emersonprocess.com 43,55,77*,84
Endress+Hauser +27 (0)11 262 8000 info@za.endress.com www.za.endress.com 13,31*
Flow Software +27 (0)11 607 8100 jaco.markwat@wonderware.co.za www.flow-software.com 87*
Gail Norton Instrumentation Agencies +27 (0)31 701 4861 telco@telcosa.co.za www.gailnortoninstrumentation.co.za 93
Gemü Valves Africa +27 (0)11 462 7795 info@gemue.co.za www.gemu-group.com 55*,58
Heaton Valves Africa +27 (0)31 902 8241 keithmitchell@heatonvalves.co.za www.heatonvalves.co.za 56*,61
Helukabel South Africa +27 (0)11 462 8752 sales@helukabel.co.za www.helukabel.co.za 70*,96
Honeywell Southern Africa +27 (0)11 695 8000 boni.magudulela@honeywell.com www.honeywellprocess.com 89
Horne Technologies +27 (0)76 563 2084 david@hornet.cc www.hornet.cc 48,49
IAC +27 (0)12 657 3600 info@iacontrol.co.za www.iaconline.co.za 79*
ifm electronic SA 086 143 6772 info.za@ifm.com www.ifm.com/za 29*,30,46,51,94
Instrotech +27 (0)10 595 1831 sales@instrotech.co.za www.instrotech.co.za 46,95
IQ Instruments +27 (0)11 792 1210 rotex@iqinstruments.com www.iqinstruments.com 54,94
Krohne SA +27 (0)11 314 1391 j.alexander@krohne.com www.krohne.com 28,40
Macsteel Fluid Control +27 (0)82 575 9354 keith.hedges@macfluid.co.za www.macsteel.co.za 56
Macsteel Fluid Control +27 (0)31 581 7800 rowan.blomquist@macfluid.co.za www.macsteel.co.za 53*
Mecosa +27 (0)11 257 6100 measure@mecosa.co.za www.mecosa.co.za 47
Metso Automation +27 (0)31 502 9350 nsdu@metso.com www.metsoautomation.com 52,57,59*
Michael Brown Control Eng +27 (0)82 440 7790 michael.brown@mweb.co.za www.controlloop.co.za 66,67
Mitech +27 (0)11 927 4850 enquiries@mitech.co.za www.mitech.co.za 10,57,62*,64
National Laboratory Assoc. (NLA) +27 (0)12 349 1500 steves@nla.org.za www.nla.org.za 4*,8
NewElec 086 010 3041 sales@newelec.co.za www.newelec.co.za 93,94,96
Omron +27 (0)11 579 2600 info.sa@eu.omron.com www.industrial.omron.co.za 85*
Parker Hannifin +27 (0)11 961 0700 lisa.debeer@parker.com www.parker.com 51,60
Pepperl+Fuchs +27 (0)87 985 0797 mbracco@za.pepperl-fuchs.com www.pepperl-fuchs.co.za 91
Phoenix Contact +27 (0)11 801 8200 patrickr@phoenixcontact.co.za www.phoenixcontact.co.za 72*,78,92,95
Pinnacle Instruments +27 (0)11 450 4885 pinnaclesales@pinnacle-ice.com www.pinnacle-ice.com 54
Pneumax Southern Africa +27 (0)11 573 0900 info@pneumax.co.za www.pneumax.co.za 47*,65
Prime Automation +27 (0)41 819 7746 craig@primeautomation.co.za www.primeautomation.co.za 34,35*
R&C Instrumentation 086 111 4217 info@randci.co.za www.randci.co.za 39*,42
Raptech +27 (0)11 693 5110 enquiries@raptech.co.za www.raptech.co.za 60
RET Automation Controls +27 (0)11 453 2468 brandon.topham@retautomation.com www.retautomation.com 7*,35,78,93
RJ Connect +27 (0)11 781 0777 info@rjconnect.co.za www.rjconnect.co.za 80,81,82
Rockwell Automation +27 (0)11 654 9700 hscraukamp@ra.rockwell.com www.rockwellautomation.co.za 74
SA Gauge +27 (0)31 579 2216 sales@sagauge.com www.sagauge.com 5*
SAEE +27 (0)18 290 5130 convention@saee.org.za www.convention.saee.org.za 15*
SEW-Eurodrive +27 (0)11 248 7000 rrose@sew.co.za www.sew.co.za 6,11,33*,36
SICK Automation Southern Africa +27 (0)11 472 3733 info@sickautomation.co.za www.sickautomation.co.za 37*,79
Siemens Southern Africa +27 (0)11 652 2412 keshin.govender@siemens.com www.siemens.co.za 30,44
SKF South Africa +27 (0)11 821 3500 sales.za@skf.com www.skf.co.za 49*,91
SMC Pneumatics South Africa +27 (0)11 568 2407 sales@smcpneumatics.co.za www.smcpneumatics.co.za 50,OBC*
Specialised Exhibitions +27 (0)11 835 1565 kerrysharp@specialised.com www.electramining.co.bw 9*
Technews Publishing +27 (0)31 764 0593 jane@technews.co.za www.technews.co.za 16*
UIC Control & Automation +27 (0)31 468 2561 stuartb@uic.co.za www.uic.co.za 78*
Valve & Automation +27 (0)11 397 2833 sales@valve.co.za www.valve.co.za 62,63*,64
Varispeed +27 (0)11 312 5252 ralphr@varispeed.co.za www.varispeed.co.za 73*
VEGA Instruments SA +27 (0)11 795 3249 chantal.groom@vega.com www.vega.com OFC*,26,27
*denotes advertiser

Vert Energy +27 (0)11 453 9669 ryan.robertson@vertgroup.co.za www.vertgroup.co.za 73


WIKA Instruments +27 (0)11 621 0000 sales@wika.co.za www.wika.co.za 3*,42,45
Wonderware Southern Africa +27 (0)11 607 8100 jaco.markwat@wonderware.co.za www.flow-software.com 86,87,88
Yokogawa SA +27 (0)11 831 6300 christie.cronje@za.yokogawa.com www.yokogawa.com/za 41*,68,69,76,90
Zest WEG Group +27 (0)11 723 6000 kistenl@zest.co..za www.zest.co.za 70,92

For more information on these and other suppliers please see www.ibg.co.za

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