Electricity + Control April 2018

FEATURES: • Control systems + automation + systems engineering • Flow measurement + instrumentation • Electrical protection + safety • Lighting • Transformers + substations

COMMENT

ON THE COVER

Converting potential into action

I s there is a turn for the better in South Africa? We avoided a ratings down- grade, and Moody’s even provided a glim- mer of hope in suggesting that we may not be all bad. And, of course, we are not. We find ourselves on a continent with some of the fastest growing economies, and the questions to ask include: What will begin to emerge in our economy?Will the manufacturing industry start to thrive? Will there be investment? If there is, what will drive it? Are there legislative impedi- ments to progress? Take mining, for example. There are many lessons to be learned from the mining industry. Firstly, in terms of the amount of press coverage they seem able to garner; and secondly, in terms of es- tablishing an environment in which things can actually get done! Consider this … it has been suggested that South Africa has the largest mineral reserves in the world, with an estimated value of between US$ 2,5 and 4,7 trillion. The country’s mineral deposits are dominated by platinum-group metals (88% of global reserves), manganese (80% of global reserves), chrome (72% of global reserves), vanadium (32% of global re- serves) and gold (30% of global reserves). It is clear that mining is critical to South Africa because of its geological potential. But potential must be converted into ac- tion after understanding the challenges. Part of this relates to establishing pol- icy and an environment that ensures this wealth is best leveraged. The extended period of regulatory and legislative uncer- tainty that has plagued the industry has had a detrimental effect. A stable frame- work, supported by regulator efficiency, will prompt exploration and mining com- panies to convert geological potential into prospecting and mining rights; this stabil- ity and efficiency being crucial if we are serious about attracting investment.

Without the assurance of being able to ex- ercise these rights within an environment which, at the very least, gives a sense of security that the significant investments required will be protected and will, for the duration of the right be certain − inves- tors will simply review their risk, and walk away (or stay away for longer). Yet, with the best intentions in the world, we created all this mud, which slowed progress – in a country with the richest reserves on the planet, and a dire need for inflow of capital. Are there examples in the manufactur- ing industry that equally stifle investment, progress and growth? I have no doubt there must be – although the response is far more muted than the response from the mining industry. Is it because we (in manufacturing) are a gentler breed; or do we not feel we have the same muscle in the economy? Notwithstanding our rich reserves, it is in the manufacturing industry that our real future lies; and that requires a policy envi- ronment that is stable, clear and attractive to investors. It is also evident mining per se cannot continue to operate as it has in the past – if the upstream and downstream indus- tries are not enabled, and established, I suspect the social licence to operate will simply not be forthcoming. So, let us focus on manufacturing, and consider how to lobby those who can re- ally establish an environment in which it can flourish.

FEATURES: • Control systems+ automation+ systems engineering • Flowmeasurement+ instrumentation • Electrical protection+ safety • Lighting • Transformers+ substations

The biggest grain mill in Switzerland, Swissmill, recognises VEGA as a problem solver and VEGA sensors are a set standard for level measurement at the factory. Read more on page 17. 3/29/2018 8:48:02AM www.electricityandcontrolmagazine.co.za ECAPR2018 cover.indd 1

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CONTENTS

4

Features

Control systems + automation + Systems engineering

4 Fully Automatic Warehousing System Optimises Production Shane Novacek, Beckhoff Automation 6 How Robots will Change the World Andrea Willige, Consultant

8 Round UP

Flow measurement + instrumentation 14 Safe and Reliable Steel Production Dhiren Naidoo Endress+Hauser

18 Round UP

Electrical protection + safety 20 Evading In-flight Lightning Strikes Jennifer Chu, MIT News Office 22 Monitoring Surge Protective Devices Intelligently: Smart Diagnostics and Qualified Testing Dipl.- Ing. Holger Heckler, Phoenix Contact GmbH & Co. KG. Blomberg, Germany 24 Restart and Restart Autotest: A NEW Safety Con- cept Information provided by ACDC Dynamics

25 Round UP

6

Lighting 28 LED Lighting for Manufacturing Information provid- ed by Banner Engineering

30 Round UP

Transformers + substations 32 Solar Implementions – What You Need to Know Up- front Kevin Norris, Jasco Intelligent Technologies 34 Industry 4.0 – Growth Challenges and Opportunity for Manufacturers Dereshin Pillay, T-Systems South Africa

14

22

36 Round UP

Regulars

1 Comment 17 Cover Article 40 Light+Current 43 Social Engineers 44 Events 44 Write @ the Back 44 List of Advertisers

2 Electricity + Control

APRIL 2018

The linear conveyor system moves the fabric rolls onto the racks, from where it removes them for cutting to size before bringing them back again.

CONTROL SYSTEMS + AUTOMATION + SYSTEMS ENGINEERING

Fully Automatic Warehousing System Optimises Production

Shane Novacek, Beckhoff Automation

The introduction of a fully au- tomated warehousing system saves manpower and valuable warehouse space.

S hort delivery times have become a deci- sive competitive requirement for consumer goods manufacturing. The consequence of that is that manufacturers have to fully optimise their production chains. One of the prerequisites for this is fully automated warehousing systems. For example, where automatic conveying systems handle the storage and retrieval of fabrics in a furniture factory, not only manpower but also val- uable warehouse space can be saved. Canadian solution provider DIVEL specialises in this market segment and develops fully automatic warehous- ing systems for the furniture industry. The particular challenge facing furniture man- ufacturers today is the need to meet end cus- tomers’ individual wishes while at the same time maintaining profitability in production. DIVEL has developed a fully automatic fabric storage sys- tem for Canadel, a company founded in 1982 that manufactures home furniture from Canadian birch wood. The conveying system for material handling quickly and quietly zips between the extensive

racks in which the furniture fabrics are stored. “High storage density, automated operation and minimal plant floor footprint were all key goals of Canadel,” says Louis Lupien, President at DIVEL. “Through the integration of leading-edge control technologies, and by leveraging our years of man- ufacturing experience, we struck a perfect balance in terms of performance and form factor.” The warehousing system removes the fabric rolls, which can weigh up to 50 kg (100 pounds) each, from the racks and takes them to the cutting machine, where the fabric is automatically cut to length for the respective order. It is subsequently trimmed exactly to size by a precision cutting ma- chine and the fabric roll is then taken back to its location in the warehouse. The entire procedure is documented by an inventory management system. PC control platform reduces installation space “A myriad of requirements had to be fulfilled when choosing the controller: these included reduced as-

Take Note!

• High storage density, automated operation and minimal plant floor foot- print were key goals of furniture manufacturer, Canadel. Canadian solution pro- vider, DIVEL, develops fully automated ware- housing systems for the furniture industry. Through the integration of leading-edge control technologies – in addi- tion to the years of man- ufacturing experience, a solution was found in the perfect balance between performance and form factor.

2

3

4 Electricity + Control

APRIL 2018

The conveying system for the storage of fabrics seamlessly integrates with existing ware- house shelving and enables high storage density, automated operation and minimal footprint.

sembly and programming time, the inte- gration of advanced programming meth- odologies, a variety of I/O signal types and reduced cabling requirements,” explains Jean-Sebastien Descôteaux, DIVEL Operations Director. For the au- tomation of the fabric storage system, DIVEL selected a Beckhoff CP6202 Pan- el PC with a 15-inch touch screen on which the PLC, drive control and visual- isation run. The PC Control platform re-

as a standard offering in its various product lines over the past seven years. The use of EtherCAT as a universal bus system from the I/Os to the safety components to the motion system is a great advan- tage. The speed of the communication system and its reliability are one aspect, but costs are reduced through the use of EtherCAT. For instance, cabling costs and the commissioning time have been sig- nificantly reduced through the use of standard Ethernet cables. The compact size of the PC-based control architecture also helped reduce the electri- cal cabinet height by an impressive 15 cm (6 inch- es), generating instant savings on each machine. Conclusion Jean-Sebastien Descôteaux highlights the signifi- cant value found within EtherCAT connectivity and the feature-rich TwinCAT development environ- ment: “The openness of the EtherCAT platform enables streamlined connectivity with the vast majority of popular fieldbuses as well as simple data collection for analysis of power quality and energy consumption. Data exchange with external databases is easy with the appropriate TwinCAT libraries, reducing programming time and effort.”

duces the number of components and its compact size also decreases the required installation space. Apart from sequential control, the PC also handles data entry for the manual roll storage feed and with- drawal, alarm annunciation, sequence display, inter- face for manual operation and axis displacement, as well as inventory display and control. TwinCAT software not only automates the order in which rolls are put into storage: With TwinCAT, dynamic graphical elements can be designed, such as on-screen push buttons, pilot lights, monitoring of actual values, recipe acquisition, data table dis- plays, bar graphs and trends, among others. Twin- CAT Modbus TCP Server is used to configure a communication path with the cutter for roll number orders and alarm advising. TwinCAT offers many ad- vantages. The ability to use different programming languages represents a powerful advantage over other software options, since all programming chal- lenges can be easily solved using the most suitable language for the task at hand. Built-in instructions and data conversion facilitate significant flexibility for data handling and management. DIVEL uses synchronous servomotors from the Beckhoff AM series and AX52xx EtherCAT Servo Drives in the motion system. In the Canadel project, two axes of motion had to be used in master-slave mode, in order to create a linear movement with a rotary axis and another linear axis, due to tightness of space. The compact form factor of the Beckhoff components was a welcome addition to combat the space-constrained nature of the project. Time and cost savings create competi- tive advantages DIVEL has implemented the Beckhoff PC platform

The ability to use different programming languages represents a powerful advantage over other software options.

Acknowledgement Images courtesy Divel, Canada.

Shane Novacek is the Marketing Communica- tions Manager for North America at Beckhoff Automation. Enquiries: Michelle Murphy. Email michellem@beckhoff.co.za

Electricity + Control

APRIL 2018

5

CONTROL SYSTEMS + AUTOMATION + SYSTEMS ENGINEERING

How Robots will Change the World

Andrea Willige, Consultant

Automation will replace many menial, routine tasks and generate opportunities for more qualified jobs and wealth creation.

• In Amazon warehouses many orders are picked and packaged by robots. In the wine-making in- dustry in many regions around the world, ‘wine bots’ prune vines to boost labour during the harvest. Apart from legal ‘doc reviews’, inspecting industrial and power plants, bomb disposal and firefighting, robots and AI are helping us in many ways. Take Note! 1 2 3

D ystopian views of robotics, automation and Artificial Intelligence (AI) are a famil- iar staple of popular culture, tapping in to some of our most basic fears. Just like the Spin- ning Jenny and the Steam Engine during the first Industrial Revolution in the late 18 th Century, new automation technologies raise concerns about job losses and even a wider erosion of human control. In reality, the ‘Fourth Industrial Revolution’ is likely to go the same way as the first. Yes, disrup- tive technologies will bring fundamental change to re-train and reinvent themselves. But, as with the first Industrial Revolution, the most like- ly outcome is that automation will replace many menial, routine tasks and generate opportunities for more qualified jobs and wealth creation.

More rewarding work for humans In Amazon’s warehouses, many orders are now picked and packaged by robots. There are 45 000 robots in action in 20 fulfilment centres worldwide. Robots are helping out in rather more refined industries too. In France and other wine-making regions around the world, ‘wine bots’ have tak- en on pruning vines in vineyards, addressing the challenge of finding sufficient labour during the harvest. And it’s not just manual work anymore. For lawyers and paralegals, AI can now take on the tedious, time-consuming ‘doc reviews’ that used to take up countless manhours by automatically pouring over hundreds of documents for mentions of specific words or concepts. Not only is this a faster, more efficient approach, it also means legal practitioners can focus on more rewarding aspects of their jobs. A robot currently being developed by Mitsubi- shi Heavy Industries Group will automate or ‘un- man’ another laborious routine task: Inspecting in- dustrial and power plants. Equipped with cameras

We shouldn’t expect a world of robotic overlords reminiscent of the Terminator movies. Experts view the role of robot- ics AI as being closer to Jarvis in the ‘Ironman’ series – an AI system which assists its human creator rather than replacing it.

CONTROL SYSTEMS + AUTOMATION + SYSTEMS ENGINEERING

and crawler, it operates autonomously and is ex- plosion-proof, freeing up time and keeping human workers out of danger. High risk environments There are many other applications for robots in high-risk environments. Bomb disposal robots have been around for some time doing just that. Not only does their use take humans out of harm’s way, they can often dispose of bombs more ef- fectively. Similarly, Mitsubishi Heavy Industries Group’s new robots do jobs few firefighters would want to take on. They will go to sites which are difficult for human firefighters to access, such as fires in petrochemical facilities, or where flammable sub- stances have leaked. The Firefighting Robot System was being led by the National Research Institute of Fire and Disaster Japan and developed jointly by several companies and universities. It consists of a water-cannon ro- bot, which can extinguish fires where people can- not reach, and a supporting system which automat- ically lays out a fire hose of up to 300 m in length. They are designed to be installed on a fire en- gine so that they can be moved on-site easily and quickly. Automated reconnaissance and command systems ensure that both robots can work largely independently. In addition to reducing the risks to human lives, they have also been found to extin- guish flames more efficiently than a human team could in the circumstances. So robots and AI are already helping us in many ways. But should we worry about them taking our jobs? Conclusion According to a 2016 paper by James Bessen, an economist at Boston University, the relationship between technology and jobs does not have to be inversely proportional. Based on historical data, the paper concluded that occupations that use

computers grow faster than those that do not, and found no evidence of technology causing large scale unemployment. But, of course, history affords us no guarantees for the future, and the study makes it clear that to make the most of the opportunities these technol- ogies are bringing, we must be willing to adapt our businesses, retrain our workers and become used to constant evolution in the workplace. Acknowledgement This article – first published on spectra.mhi.com – has been published in Electricity+Control courtesy © Mitsubishi Heavy Industries, Ltd.

We must be willing to adapt our businesses, retrain our workers and become used to constant evolution in the workplace.

Andrea Willige has spent many years creating content for the international business and technology press, working as a PR advisor to some of the world’s largest technology companies. Enquiries: Email mhi-pr@mhi.co.jp

Electricity + Control

APRIL 2018

7

round up

CONTROL SYSTEMS + AUTOMATION + SYSTEMS ENGINEERING

New software simplifies network operations and maintenance Plant-floor personnel have the difficult task of monitoring and main- taining a growing number of IoT devices on their networks. Rather than using complex or unfamiliar IT tools to do this, they can use the new FactoryTalk Network Manager software from Rockwell Automation . It allows them to monitor the health of their Al- len-Bradley Stratix managed switches, troubleshoot switch issues and quickly configure new managed switches all from one easy-to- use software interface. information, so users can organise devices into specific areas or ana- lyse them individually.

The software also uses user-created configuration templates to get new switches up and running faster and more efficiently. These templates can be shared across an organisation, or with OEMs and system integrators to further ease network deployments, commis- sions and maintenance efforts. The FactoryTalk Network Manager software provides role-based access control with auditing capabilities to help track user-specific activities and changes. The software supports multiple protocols, including Simple Network Management Protocol (SNMP), Com- mon Industrial Protocol (CIP), Modbus, BACnet and PROFINET. Access to the web-based platform is available via a personal com- puter in a control room or a mobile device on the plant floor. As part of the Integrated Architecture system from Rockwell Automation, the FactoryTalk Network Manager software provides seamless integration with the Stratix family of industrial network switches. Enquiries: Christo Buys.Tel: +27 (0) 11 654 9700 or email cbuys@ra.rockwell.com

“Many plant-floor personnel struggle to piece together informa- tion about managed switches and devices from different sources,” said Lorenzo Majewski, product manager, Rockwell Automation. “With the FactoryTalk Network Manager software, they can ac- cess this information in one collective spot. In addition, real-time alarms and events from network switches can help them conduct faster, more precise troubleshooting.” With potentially hundreds if not thousands of devices in a large facility, users can get overwhelmed by the amount of information they need to manage. The FactoryTalk Network Manager software automatically discovers assets, their associated IP addresses, and creates a topology of these connected devices. The software’s in- tuitive interface offers grouping of equipment along with dashboard

Compact speed sensors with IO-Link

Industrial Automation solutions improve SA’s global competitiveness Digitalisation and automation are driving South Africa towards the Fourth Industrial Revolution, where smart technology improves efficiency, upskills workers and cre- ates new jobs. At the forefront of South Africa’s industrial revolution is automation specialist PCMP . The Pretoria-based company has a team of 15 experts that con- duct a detailed analysis of their clients’ manufacturing processes, before providing customised state-of-the-art solutions for all areas of production. PCMP’s core ob- jective is to provide a full turnkey industrial automation service under one roof. “Our engineers have the skills and expertise to integrate automation hardware and software from a variety of manufacturers. The end result is a highly-efficient and integrated system designed to the exact specification of any application,” says PCMP director Matthew Cramb. PCMP engineers are industry-leading specialists in the world’s top automa- tion brands, including Siemens, Rockwell, Schneider, OPCSystems.NET, Invensys WonderWare and ifm. “Our industrial automation service offering includes engi- neering consulting, project management and design that guarantees measurable results and a positive impact on any business,” adds Cramb. PCMP also special- ises in the manufacture of electrical components such as motor control centres (MCC), field panels and remote input/output (RIO) panels to exact client stand- ards and specifications. PCMP electrical installation technicians also offer on-site installations and field commissioning. As part of its value-added service offering, PCMP has invested in developing comprehensive service level agreements to ensure that the company fully under- stands every client’s unique operating environment, and that it delivers flexible service solutions that provide ongoing business value. “An increasing number of manufacturing businesses in South Africa are moving towards integrated automa- tion solutions as the country continues its progression to Industry 4.0, and PCMP is helping themmake the transition a seamless and profitable one,” Cramb concludes. Enquiries: Matthew Cramb.Tel. +27 (0) 12 665 0802 or email info@pcmp.co.za

The evaluation electronics are integrated in the sensor housing.This allows for low-cost and easy monitoring of rotating as well as linear move- ments regarding overspeed and underspeed. The limit of the speed at which the output switches is set via IO-Link. Especially in the field of con- veying technology the compact speed sensors can be used for various applications, for exam- ple for monitoring belt conveyors or bucket ele- vators. Here they are typically used to monitor underspeed, blockage or standstill. The different designs and the large speed range allow for an integration into almost any application. Enquiries:Tel: +27 (0) 12 450 0400 or email info.za@ifm.com

8 Electricity + Control

APRIL 2018

round up

CONTROL SYSTEMS + AUTOMATION + SYSTEMS ENGINEERING

Explosion-proof absolute encoder – fits where others won’t

shaft loads of hundreds of Newtons. The Hengstler AX65 absolute encoder has been engineered to handle all these requirements, and is believed to be one of very few devices that can do this. Certified explosion-proof, the Hengstler AX65 is built with ma- rine-grade stainless steel and has a shock rating of 200 Gs and shaft load of 300 N. This tough encoder is not only the most com- pact in its class, it also offers an exceptionally shallow depth and body diameter of only 59 mm. This means it can be installed in applications where other larger explosion-proof encoders cannot be used. Carrying explosion-proof certification makes it ideal for mines, chemical plants and offshore oil platforms, as well as oth- er applications that require an encoder constructed from marine grade stainless steel. The shaft load rating eliminates the need for load modules, reducing costs. This device can be installed quickly and easily due to its flexible, quick-connect terminal system. It comes standard with the choice of SSI or CANopen interface, and it is also possible to integrate the CANopen encoder in a ring network configuration. The Hengstler AX65 is available from Countapulse Controls . The company has a strong customer service ethic and offers strong engineering and technical support. Enquiries: Gerry Bryant.Tel. +27 (0) 11 615 7556 or email bryant@countapulse.co.za

Many applications that require the use of absolute encoders are de- manding, not just from a performance perspective but also because of the operating environment. An example of this is applications where the encoder has to be explosion-proof due to the dangerous atmosphere in which it operates. Another would be applications that involve harsh environmental influences such as offshore platforms or those that experience huge shock loads of over 100 Gs or even

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10 Electricity + Control

APRIL 2018

round up

CONTROL SYSTEMS + AUTOMATION + SYSTEMS ENGINEERING

Advantages of wireless magnetometers for vehicle detection

The wireless M-Gage sensor from Banner, for example, can be installed above grade or below grade. Below-grade installation requires only a small 3-inch diameter hole drilled into the concrete for each sensor location, which means less downtime for installation.

fluctuations and adjusts accordingly. Final- ly, in cold climates that experience large amounts of snow, it is often necessary to install the magnetometer below grade to avoid damage from snowploughs. Enquiries: BrandonTopham. Tel. +27 (0)11 453 2468 or email brandon.topham@retautomation.com

The ability to reliably detect vehicles offers significant advantages for asset manage- ment, resource allocation, site safety and traffic control. Identifying the right technolo- gy for your vehicle detection application can be challenging, and many factors must be taken into consideration, including task, size of target, sensing range, sensor mounting, and whether the application is primarily in- door or outdoor. What is a Magnetometer? Magnetometers can be either wired or wireless, but for the purposes of this arti- cle we will focus on wireless magnetom- eters, which offer important advantages to the end user. A magnetometer works by using a passive sensing technology to de- tect large ferrous objects (for example, a truck, automobile, or rail car) by measuring the change in the ambient magnetic field. When a vehicle alters that magnetic field, the sensor detects those changes. As with other sensors, the range of the magnetom- eter will depend on the target. A wireless magnetometer provides a cost-effective and convenient alternative to other sensing technologies. It requires no wiring or external control box, but achieves an accurate and repeatable response. 2 Minimally Invasive Wireless magnetometers are much less invasive, less expensive, and easier to commission quickly compared to inductive loops, because wireless magnetometer units are small, self-contained, and don’t require extensive work under the concrete. Advantages 1 Cost Effective

3 Low Maintenance A truly wireless magneto- meter will not only offer wireless communication via radio, but will also be completely self-contained, including the battery. The long life of the battery en- sures continuous perfor- mance for years at a time. In order to reliably de- tect when the magnetic field is disrupted, a mag- netometer must first be taught the typical ambi- ent magnetic conditions. Therefore, a vehicle must not be present when the sensor is being taught. An- other consideration when installing a magnetometer is that if the sensor moves out of alignment over time, it may cease to function properly. Because of this, a magnetometer must be rigidly fixed at the time of installation to ensure relia- ble long-term functioning. Wireless magnetometers from Banner Engineering also feature an advanced algorithm that detects

Electricity + Control

APRIL 2018

11

CONTROL SYSTEMS + AUTOMATION + SYSTEMS ENGINEERING

New Soft Starter with internal bypass expands motor efficiency The new Allen-Bradley SMC-50 smart motor controller with inter- nal bypass from Rockwell Automation brings greater operational control over motor starts and stops. As an extension of the soft starter family, the SMC-50 smart motor controller delivers greater functionality and efficiency across industries. Soft starters tradi- tionally use solid-state, silicon-controlled rectifiers (SCRs) to con- trol voltage to the motor during start-up, runtime and shutdowns. The reduced torque and current slowly introduces energy to the motor, mitigating electrical and mechanical stress to the applica- tion. If these SCRs remain in the circuit once the motor is up to speed, the heat generated by these devic- es leads to electrical inefficiency.

Automotive press for local range of light commercial vehicles Tectra Automation designed, manufactured and commissioned a servo-driven automotive press for Auto Industrial (AI). The appli- cation-specific automotive press is used by AI to assemble various front suspension linkages for a local range of light commercial vehicles in such a way that it pro- duces one part every 40 seconds for 22 hours a day. Tectra Automation was re- sponsible for every aspect of the automotive press aside from the tooling, which was manufactured in-house by the client. To facilitate

“Now, users have the option of choos- ing the proper power structure for their application when purchasing the SMC-50 smart motor controller. For operations that run over an extended period, built-in inter- nal bypass allows users to shift from sol- id-state switches to bypass contactors,” said Rick Anderson, product manager for Soft Starters, Rockwell Automation. “By switching over to the bypass circuit, users can save on energy and decrease opera- tional costs by minimising excess heat build-up.” The SMC-50 smart motor controller with internal bypass provides access to several communication modules, including EtherNet/IP and DeviceNet networks. This

the production of one part every 40 seconds, a Rexroth L25 mo- tion PLC was used with control provided by a Rexroth VEP40 HMIK with on-board PC. Tectra Automation designed and man- ufactured the control panel as well as the operation software. The Rexroth EMC-125-HD electromechanical cylinder, driven by an MSK101D servo motor, was selected for control instead of using a hydraulic cylinder due to its cleanliness, high degree of controllability and operational quietness. “The press has an inte- grated load cell to control and record the press-in force in order to guarantee consistent quality,” explains Kevin Lombard, Gen- eral Manager, Tectra Automation. “The ram is guided by Rexroth heavy duty linear bushes running on hardened and ground linear shafts. The rotary table is driven by a Rexroth MSK050C servo motor driving a GTM planetary in line gearbox. Enquiries: Kevin Lombard.Tel. +27 (0) 11 971 9400 or email kevin.lombard@tectra.co.za

connectivity, combined with its microprocessor platform, brings energy-monitoring capabilities and protection features that make applications easier to troubleshoot and fix. Enquiries: Adrian vanWyk.Tel. +27 (0) 11 654 9700 or email avanwyk@ra.rockwell.com

Actuator switching via IO-Link The new IO-Link output module provides an easy and cost-effective way to add powerful digital outputs to ifm’s IO-Link master module for field use. Typical tasks include decentralised switch- ing of loads and actuators. The module is available in two designs: The orange field module of the coolant series is resistant to oils and coolants and suited for general industrial applications. The grey module is ideally suited for hygienic and food applications due to the material used for the housing. It has the high protection rating IP 68 / IP 69K. The unit features six M12 ports with two digital outputs each. The outputs have full overload and short-circuit protection. They are supplied from two independent, electrically isolated voltage sources. The three left-hand M12 sockets are supplied via pins 1 and 3 of the supply connector and the three right- hand M12 sockets via pins 2 and 4. Both voltage supplies can be loaded with max. 1,8 A. The output current is distributed to the outputs according to the connected loads and is limited to 1,8 A total current per channel. Thanks to the two separate voltage supplies, critical outputs can be switched off selectively by higher-level switching modules, without affecting the outputs in the other electric circuit. In addition, IO-Link allows an in-depth fault analysis. Enquiries:Tel. +27 (0) 12 450 0400 or email info.za@ifm.com

12 Electricity + Control

APRIL 2018

FLOW MEASUREMENT + INSTRUMENTATION

Safe and Reliable Steel Production

Take Note!

High temperatures, molten metal and heavy loads − steel production puts a lot of stress on both man and machine. Safety and availability are the top priorities for steel plant managers. To ensure safety and availability, robust meas- urement equipment that provides reliable data as well as smart control solutions is required.

1

Dhiren Naidoo Endress+Hauser

2

Improve the safety of your steel production with this dedicated measurement and software offering.

3

H igh temperatures, molten metal and heavy loads − steel production puts a lot of stress on both man and machine. So it is only natural that safety and availability are the top priorities for steel plant managers. Not only to prevent potentially deadly accidents from hap- pening but also to make sure that production in an extremely competitive landscape never stops. For that you need robust measurement equipment that provides reliable data as well as smart control solutions. 1,63 mil. tonnes of crude steel were produced worldwide in 2016. This is an increase by 0,8% compared to 2015 according to the World Steel Association.

This solution Comply with functional safety standards IEC/EN 61508 [1] (process hazard categorisation known as SIL - Safety Integrity Level) and IEC/EN 61511 [2] (process safety using instrumentation known as Safety Instrumented Systems) in accordance with EN 13849 [3] with process experts who guide you every step of the way in selecting the best- fit, industry-optimised instrumentation, service and solution package from our complete portfolio based on more than 60 years of experience. • Safe monitoring of critical cooling water cir- cuits • Wireless solutions providing more information about your process • Comprehensive tools and solutions for plant asset management

14 Electricity + Control

APRIL 2018

FLOW MEASUREMENT + INSTRUMENTATION

Electromagnetic flow meter solution – Pro- mag 100, compact flow transmitters for the tight spots around your tundish Electromagnetic flow meters are typically in use for the cir- cuit flow rate measurement. Their physical principle is based on Faraday’s law of in- duction where a voltage is in- duced in a conductor moving in a magnetic field. In elec- tromagnetic measurement, the flowing medium corre- sponds to the moving con-

Flow volume is computed on the basis of the pipe’s diameter. A constant magnetic field is required for accurate measurement.

Figure 1: Leakage detection system.

ductor. The induced voltage is proportional to the flow velocity and is detected by two measuring electrodes and transmitted to the amplifier. Flow volume is computed on the basis of the pipe's di- ameter. A constant magnetic field is required for accurate measurement. This principle of measure- ment is important not to install the flow meter so close to the Electric Arc Furnace’s electrical field. The flow meter can with stand in an external elec- tric field of 90 Gauss (9.10³ tesla). The flow meters are developed to show more process values than ever. All of them are available on a digital network. Assignable measured variables on the current and frequency outputs: • Volume flow • Mass flow • Corrected volume flow

System parameters • For 1 - 15 cooling circuits • Alarms of flow differences (>=0,3% under ref- erence conditions) • Temperature range: 0 - 99°C • Flow range: 10 – 2 700 m 3 /h • Pressure range: 1 – 10 bar • Safety integrated system according to IEC61511 [2]/ EN ISO13849-1 [3] Malfunctions in water circuits can be very danger- ous to both equipment and personnel. Regardless of the cooling circuit type, principles for leaking detection are as follows: the inlet and outlet flow rates of a cooling circuit are measured by means of suitable flow meters, either electromagnetic or ultrasonic. The inlet and outlet temperatures are also acquired from sensors mounted in close prox- imity to the flow meters. Our system uses sep- arate temperature sensors to achieve maximum accuracy. Max. allowed external magnetic field: 90 Gauss (9,10 3 tesla) (Corresponds e.g. to a lead with a max. current of 110 kA and distance of approx. 10 m from the flow meter) Safe, robust and precise water leakage monitoring

• Flow velocity • Conductivity

• Corrected conductivity • Electronic temperature • Temperature

In a furnace leakage detection application we can see added value in using temperature measure- ments to support the control. This can serve as an additional temperature in-line to confirm if the independent temperatures are correct; tempera- ture is a critical measurement in this application. In addition, conductivity can be a water quality meas- urement that can be related to concentration and possible scaling in the line. If your lines become re- stricted because of blocking/ calcification the cool-

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tion, advanced process diagnostics and condition monitoring functions which permit managers to proactively plan maintenance procedures and en- sure availability. • Complete project management including as- sembling, cabling and engineering of the sys- tem • Smart sensors with diagnostic functions • Web-based tools for easy access to informa- tion about the installed devices and automatic device documentation (W@M portal) Endress+Hauser has been a reliable partner to steel companies in over 100 countries for more than 60 years.

ing system will not work optimally and can cause serious plant shut downs and production loss. To help you verify if anything goes wrong in-line, you can use the Proline’s Heartbeat Technology.

200 000+ Temperature sensors installed in safety critical steel production processes worldwide

55 000 Smart sensors integrated in 65 digital optimisation projects

2,6 mil Field instruments delivered to mineral & metals operations since 2007

Figure 2: What Heartbeat Technology can achieve.

Conclusion Digital fieldbus networks connect field instru- ments to the control and maintenance systems, in combination with smart sensors featuring Heart- beat technology. This enables instrument verifica-

References [1] IEC/EN 61508. 2010. Functional safety. [2] IEC/EN 61511. 2018. Safety instrumented sys-

Dhiren Naidoo is Local Industry Manager Prima- ries & Metal at Endress+Hauser South Africa. Enquiries: Tel. +27 (0) 11 262 8077 or email dhiren.naidoo@za.endress.com

tems for the process industry sector. [3] EN 13849. 2015. Safety of machinery.

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FLOW MEASUREMENT + INSTRUMENTATION

Hannover Messe 2018

Visitors to this year’s Hannover Messe (23 – 27 April 2018 in Hano- ver, Germany) can learn how Endress+Hauser helps its customers implement their Industrial Internet of Things (IIoT) strategies. Smart sensors make digitalisation possible Parallel to the measurement values, Endress+Hauser field instru- ments feature the connectivity required to transmit diagnostic in- formation, such as the data generated by Heartbeat Technology, to the cloud. Communication is carried out via an integrated WiFi/ Bluetooth module or WirelessHART, thus eliminating the need to disrupt existing process control systems. For new installations, digital communication occurs directly via OPC-UA or an industrial Ethernet technology such as PROFINET or Ethernet/IP. An edge device simplifies cloud solution connectivity. Innovations for the future Apart from digitalisation, this year’s exhibit will focus on new prod- ucts and other innovations. Functional enhancements to Heart-

beat Technology enable the concrete implementation of predictive maintenance. TrustSens, the world’s first self-calibrating temper- ature sensor, offers users a high degree of process reliability and system availability thanks to automated, inline self-calibration. Automation, services and e-commerce Endress+Hauser offers tailored solutions and services for every phase of the life cycle, from measurement point design, automation system programming and SIL-based commissioning, to on-site cali- bration and training. In order to optimise the measurement instru- ment order process, making it more customer- and future-oriented, Endress+Hauser has also added integrated online shop functions to its website to augment the existing e-commerce solutions. Visit the People for Process Automation in hall 11, booth C43, and experience all of the innovations first-hand. Enquiries: Email Visit suanne.willemse@za.endress.com or visit www.za.endress.com

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COVER ARTICLE

VEGA provides fast, reliable stocktaking in a grain mill using Vendor Managed Inventory

FEATURES: • Control systems+ automation+ systems engineering • Flowmeasurement+ instrumentation • Electrical protection+ safety • Lighting • Transformers+ substations

ECAPR2018 cover.indd 1

3/29/2018 8:48:02AM

T he manufacturing processes in the biggest grain mill in Switzerland – Swissmill – are com- plex. Every processing step, intermediate storage and delivered product quantity is recorded and cal- culated meticulously. The measured values from VEGA's installed level sensors, which form the basis for reliable tracking of the product streams, make this possi- ble. In conjunction with VEGA'sWeb-based Vendor Inventory System (VIS), a software system for data recording and visualisation of level data, optimum logistics of raw materials from the supplier up to the production plant are enabled. From a level measurement point of view, flour is not easy to measure. A lot of dust is generated during the filling process and the dust cloud settles very slowly in the silo. The estimated 120 various types of flour all differ slightly in their dielectric constant (Dk). In summer, when the grain is dryer, it is even more difficult because the dielectric con- stant drops further. One of the more challenging measurements is bran, which only has an epsilon value of 1.4 in the summer. Adding to the meas- urement difficulty is the fact that the bran is stored in a very slim, 10 m high steel-reinforced concrete silo. “Thanks to VEGA's products, we are manag- ing very well,” says Mario Keller, Head of Electri- cal Maintenance at Swissmill. I will never forget how, 25 years ago, a VEGA technician visited us, analysed the measuring situation with the bran and explained that we must approach the problem from a different angle. A few months later, a new device, at that time still a VEGAFLEX guided wave radar sensor with adapted software, was installed and it really did provide reliable measured values.” Over the years, new sensors from VEGA have been tested again and again. On rare occasions, the cable of the guided wave radar would twist and get trapped in the grain. This sent a false meas-

uring signal. This measuring instrument type was replaced by the VEGAPULS 69 radar level meas- uring instrument which operates with a frequency of 80 GHz. Since this measure is contact free and can also measure reliably through heavy dust, the measurements now work trouble-free. “However, we must say that, since we have been working with VEGA, measuring uncertainties have never re- ally been a problem because VEGA always feels re- sponsible and takes us seriously,” Keller explains. Level measurements are made all over the fac- tory for which many different instrument types are used. For example, 137 VEGACAP 63 capacitive probes operate in wheat reception. Level sensors are also used for process control, for instance in the production of fodder. When these are pel- letised, the primary hoppers must always be full so that the pellets have the right density later. A reliable measuring signal is therefore crucial in the overflow cell in the pelletiser because other cells can be opened or closed, depending on the level. When the cell overflows, the feeder closes. If the instruments do not function optimally, the mills may even be shut down. Here, the process planners need a 100% signal because otherwise the whole production plan could get out of control. This is an operation in which up to 200 tons are processed daily. Saves time and money The Swissmill team is convinced that working without level measuring technology would be quite different. “When a holiday is coming up and the bakeries need more flour, we can start produc- tion a week earlier thanks to our reliable stocktak- ing. Previously, we had to work special shifts to compensate for bottlenecks,” says Keller. Swissmill recognises VEGA as a problem solv- er and VEGA sensors are a set standard for level measurement at the factory.

Enquiries: Chantal Groom. VEGA Controls SA Tel: +27 (0) 11 795 3249 or email: chantal.groom@vega.com

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FLOW MEASUREMENT + INSTRUMENTATION round up

Pocket-sized flow measuring technology

In industrial process measurement and automation, demand is steadily rising for simple, reliable and maintenance-free measuring instruments in a pocket-sized format. The new Picomag from En- dress+Hauser fulfils such requirements, making no compromises. Not only does it measure the flow of electrically conductive fluids, but also their process temperature. In addition, Picomag offers cus- tomers easy commissioning with Bluetooth using its SmartBlue App, as well as seam- less system integration thanks to IO-Link technology. This makes Picomag absolutely ready for Industry 4.0. Due to its compact design, Picomag can be installed flawlessly into any pipe up to 50 millimetres (2") in diameter, even in confined spaces. For this purpose, there are various process connection adapters available, such as NPT-thread, R-thread, internal thread, Tri-Clamp or Victaulic. Picomag is a cost- optimissed solution for applications where the focus is on high repeatability (±0,2% o.f.s.) and thus reliable measured values – e.g. for correctly measuring water flows (max. 750 l/min, 198 gal/min) or for minimising energy costs in utility applications. Picomag is suitable for process temper- atures between –10 to +70°C (14 to 158°F) as well as for process pressures up to 16 bar (232 psi). The robust Picomag housing made of stainless steel (IP65/67) is available in two designs. Left: DN 15 (½"), DN 20 (¾"), DN 25 (1"); Right: DN 50 (2"). Clear display with diagnostics field The large and user-friendly display allows an instant local process reading of flow, temperature and totaliser values. Errors occurring during operations, e.g. a partial pipe filling or an exceeded temper- Whether it is for quantity measurement or process monitoring of cooling, heating or process water:

ature limit, are displayed via diagnostic symbols in accordance with NAMUR recommendation NE 107. The screen rotates automatical- ly depending on the installation position (horizontal, vertical). This guarantees optimal readability at any time. And last but not least, configuration parameters can be called up and monitored by simply knocking on the device. Wireless configuration and commissioning via Bluetooth With Bluetooth connection, it is possible to carry out wireless con- figuration or data retrieval over a distance of 10 meters – even at installation sites which are difficult to access. The free-of-charge SmartBlue App from Endress+Hauser provides the user with quick and easy navigation through all device and diagnostic functions. The SmartBlue App is available for Android and iOS. Optimal system integration with IO-Link technology Another highlight of the Picomag is the digital data transmission to process control systems via IO-Link technology. This commu- nication standard has been established for 10 years and can be combined with all conventional fieldbus systems. Thus, it offers maximum flexibility of installation into existing system infrastruc- tures. The IO-Link master as an interface allows users to have com- prehensive data access through the control room. Other advan- tages of the IO-Link technology include the automatic transfer of parameters after a device replacement as well as low wiring effort as compared to conventional wiring. Ultimately the Picomag is ideally equipped to handle the future requirements of process automation. Enquiries: Frans van den Berg.Tel. +27 (0) 11) 262 8000 or email frans.vandenberg@za.endress.com

SCAN TO WATCH VIDEO

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