Electricity + Control August 2019

FEATURES: · Control systems + automation · Electrical protection + safety · Power quality, standby + back-up · Temperature measurement + instrumentation · Transformers + substations

COMMENT

ON THE COVER

Stick to the rules and we can resolve our problems

N ow obviously one must be measured, and one must never give away too much. But of late I have been sensing one or two glimmers of light in a period that has been rather dark (to say the least). The other day I visited the campus of a multinational outfit that covers multiple hectares, and got to better understand the vision they have. It reminded me of times I’ve spent in other countries that were, by all accounts, down and out. Yet, for someone not at the coalface, opportunities were obvious. Unless you were at the coalface. I do worry that we have become conditioned to be introspective and cautious – although with good reason. I am of the view that anyone can learn to play within the rules – providing the rules are clear. And, more importantly, providing the rules do not seem to keep changing. I have no doubt that much of our inability to see over the horizon is due largely to all the dust in the air, and the glare in our eyes (as they water). But establish the rules, and we can all optimise the game plan. Keep on mucking about with the rules, and there is no chance of any local team actually becoming competitive. The game is our economy, and that is our coalface. Listening to a foreign view, and speaking with folk who have seen success in emerging economies (with all the troubles one associates with those environments), provides a perspective that there may well be something better over the horizon than we imagine right now. It seems that we have been ground down to the point where few are seeing that. But it is there.

In as much as it is easy to be an armchair coach, a number of things are slowly but surely changing. We all know the challenges at Eskom, but right now an increasing number of people who can do something about it are becoming aware of the actualities of those challenges. There is value in removing the veil of secrecy around the issues that affect us all, and dispelling the view that it may all be a media attack with no basis. More and more issues are surfacing that leave us in no doubt about the problem, but at the same time, allow many who can, to begin to think through likely ways of resolving the problem. Fighting shadows is tricky; fighting a known and understood problem is that much easier. I am confident that in many areas we have allowed the problems to emerge from the shadows for all to see. And more importantly, that we have the resilience, finally, to allow that process of resolving those problems to begin. Now that is worthy of recognition. Think of that as we muddle on into calmer waters. Then, I am certain, we can begin to resurrect failing industries and struggling enterprises – and begin to be competitive as we should be as a nation. The wave is building – our challenge is (as it always is for us) to be ready when it hits.

FEATURES: · Control systems+ automation · Electrical protection+ safety · Power quality, standby+ back-up · Temperaturemeasurement+ instrumentation · Transformers+ substations

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Bi-monthly Newsletter

Online Edition

CONTENTS

Features

TRANSFORMERS + SUBSTATIONS 4 Natural ester oil transformers in South Africa Cargill South Africa

6 Round UP

4

CONTROL SYSTEMS + AUTOMATION 10 A milestone in digital transformation for materials services thyssenkrupp Materials Services

12 Robot assistance enables variable production runs Mitsubishi Electric Europe

14 Round UP

POWER QUALITY, STANDBY + BACKUP 20 UPS with integrated power supply and USB interface Felix Schulte, Phoenix Contact Power Supplies

22 Round UP

TEMPERATURE MEASUREMENT + INSTRUMENTATION 26 The advantages of non-contact temperature measurement R&C Instrumentation

28 Round UP

ELECTRICAL PROTECTION + SAFETY 30 Protecting wind power one turbine at a time DEHN Africa

12

26

32 Round UP

Regulars

1 Comment 15 Cover article 38 Cyber security 40 Write @ the back

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TRANSFORMERS + SUBSTATIONS

Natural ester oil transformers in South Africa

Cargill has pledged continued investment in the supply of FR3 ® natural ester fluids for electricity transformer applications in the South African and sub-Saharan markets through the appointment of a new Country Manager.

Take Note!

1. Natural ester oil provides a fire-safe and biodegrad- able alternative to the mineral oil typically used in power transformers. 2. As the global leader in production and supply of natural ester fluids, Cargill brings its technological expertise, research and experience to the South African market. 1 2

F or several years Cargill has supplied fire- safe and biodegradable FR3™ natural ester fluids for electricity transformer applications in the power, utilities and other industries, in South Africa and sub-Saharan Africa, through its exclusive agent,Wilec, one of this country’s largest distributors and parts suppliers to transformer manufacturers. Committing to its continued investment in this field, the company has appointed Valdir Baraldi as Country Manager for Cargill’s Bioindustrial Group in South Africa. He is based in Johannesburg to guide transformer manufacturers and end users in the application of FR3 for local markets, following

his relocation from Sao Paulo, Brazil, where he has been working for Cargill for the past 12 years. According to Baraldi, Cargill will increase its investment in South Africa to meet Eskom’s and the DTI’s goals of replacing transformer fluid, typically mineral oil, with fire-safe and biodegradable natural ester fluid for the electrical grid. “We will extend our drive to meet the needs in municipal, utilities, mining, industrial and other markets for safe and green transformer oils,” he says. “As the global leader in the production and supply of natural ester fluids and the original producer of FR3, Cargill brings its technological

An SGB power transformer filled with natural ester FR3 in operation.

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Examples of transformer installations using Cargill FR3 include: - One of the largest transformers, 420 kV / 300 MVA, at Transnet BW in Germany - Interconnection autotransformers of 420 kV / 250 MVA at Terna in Italy - 25/30 MVA compact substation transformers at Tata Power in India - Fourteen generator step-up 13.8 kV - 345 kV 100 MVA units at the US Bureau of Reclamation - 81 distribution transformers at the Kennedy Space Centre in the USA - In Brazil, Cargill’s FR3 was used in 138 kV 50 MVA transformers at the Light Olympic Village substation in Rio de Janeiro. “We look forward to developing markets for FR3 natural ester fluid in South Africa and other export markets throughout sub-Saharan Africa,” Baraldi says. Cargill employs 155 000 people across 70 countries. The company combines 153 years of experience with new technologies and insights to serve as a trusted partner for food, agriculture, financial and industrial customers in more than 125 countries. The Cargill Bioindustrial Group recognises the increasing commercial and consumer demand for renewable and sustainable products as well as the regulatory need to eliminate toxic and unsafe products. With the increasing viability of bio-based alternatives, Cargill leverages more than 60 years’ experience in agriculture-based chemistry for industrial applications. This enables it to provide customers with a more sustainable solution over fossil-based alternatives.

expertise, years of research and vast experience to the South African market,” he adds. The main benefits of replacing mineral oil with FR3 natural ester fluid include improved fire safety, extended transformer insulation life and increased load capacity. According to Baraldi, the potential reductions in installation, insurance and spillage remediation costs are also important benefits and motivators in the adoption of natural ester transformers. He also points to the many environmental benefits of using natural ester fluids. “These include biodegradability, non-toxicity in soil and water, and carbon neutrality, while at the same time increasing the reliability of the electrical grid.” Baraldi highlights that the safety factor of natural ester fluid transformers compared to mineral oils is important in overloaded, unstable electrical grids, particularly where there are illegal connections and power outages. “FR3 natural ester transformers are safer as they contain fire- safe fluids and mitigate the incidents of fires and explosions that can threaten people’s lives, their homes, the community and the environment at large. In fact, to date, we have zero fire history in FR3 fluid-filled transformers,” he says. “The replacement of mineral oil with renewable green natural ester fluids, such as FR3, is becoming a priority in many regions across the world. Worldwide, there are more than two million transformers filled with FR3 fluid in operation, with no fire records. The largest privately owned electricity company in Brazil is migrating its entire distribution network to ester filled transformers,” he adds. The motivation to change to natural ester oils is strong. “Not only do performance, environmental, financial and safety factors play a key role, but FR3 is made from a renewable resource that comprises more than 98% engineered vegetable oil, so it’s sustainable and can support local farming communities.

… FR3 is made from a renewable resource that comprises more than 98% engineered vegetable oil, so it’s sustainable and can support

local farming communities.

Valdir Baraldi, Country Manager for Cargill’s Bioindustrial Group in South Africa, showcases a transformer filled with ENVIROTEMP ® FR3 ® natural ester fluids which will be used for electricity applications across different industries. He holds two bottles – one of naturally derived FR3 ester fluid and a bottle of the soybeans, which are the source oil for this engineered fluid.

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TRANSFORMERS + SUBSTATIONS

Gas-insulated electrical substation

later. Over the decades, ABB has provided safety and reliability in power networks to address growing power challenges all over the world. As a market and technology leader in high voltage GIS technology, the group offers ratings and applications from 72.5 kV to 1 200 kV and has a global installed base of more than 35 000 bays. Its latest product developments include eco-efficient and digital capabilities. Enquiries: ABB Power Grids Division, Southern Africa.Tel +27 (0)10 202 5841 The gas-insulated Sebenza substation in Johannesburg serves as a new interconnection point for the city’s north-eastern region and the national transmission grid.

switchgear consisting of high voltage components, such as circuit breakers and disconnectors, that can be operated safely in confined spaces. It is a valuable enabler for urbanisation in cities like Johannesburg where land is scarce and costly, as it can save up to 70% of space that would be required for an air-insulated substation. Mauro Damonte, Hub Business Unit Manager, Middle East and Africa for High Voltage Products in ABB’s Power Grids division, says, “Our technology is powering one of the largest GIS installations in Africa and we are proud to support South Africa’s development and the region’s growing need for power. We are helping our customer, City Power, which provides electricity and network services to the municipality of Johannesburg, to strengthen its network and the reliability of the electricity supply.” ABB pioneered GIS technology 50 years ago and continues to drive innovations in this space. In South Africa, it supplied its first 800 kV GIS to Eskom in 1987 and that power station is still in existence 30 years

Johannesburg is the largest metropolis in South Africa and its substantial economic and population growth over the past decade have increased its need for more reliable power. As part of the solution to address this requirement, Sebenza substation will deliver 30% additional electricity into the national grid. The Sebenza substation features 38 bays of 132 kilovolt (kV) gas-insulated switchgear (GIS) from ABB, making it the largest installation of GIS at this voltage level to be commissioned in Africa. ABB also supplied 132 kV, 275 kV and 400 kV circuit breakers, surge arresters and point- on-wave controllers that remove electrical transients in the network. Operated by City Power, the municipal utility owned by the City of Johannesburg, and built by Consolidated Power Projects (CONCO), the substation will play a key role as the new interconnection point for the city’s north-eastern region and the national transmission grid. GIS is a compact metal encapsulated

Multi-level E-house for oil and gas sector

“Our expertise and experience in designing appropriate mechanical and electrical solutions using 3-D modelling software makes this kind of innovation possible,” says Richards. Using a turnkey approach allows WEG Automation Africa to construct the full solution efficiently at its dedicated E-house facility in Heidelberg, saving customers the complexity of managing multiple contractors on site. At the Heidelberg facility, the modules are trial-fitted, assembled and tested before being transported to the installation site. “As with our other E-house projects, we are able to provide quality assurance before units leave the facility, reducing the risks and costs of on-site construction and commissioning, including specialised resources,” Richards says.

WEG Automation Africa, formerly known as Shaw Controls, has designed, engineered, manufactured and supplied a fit-for-purpose E-house solution for an oil and gas sector application at a major South African port. Using a draft concept supplied by the customer, WEG Automation Africa has taken its E-house design and manufacturing capabilities to new heights. Bevan Richards, Managing Director of WEG Automation Africa, says that the company was responsible for the complete mechanical and electrical design as well as the manufacture of the E-house solution. Accommodating space constraints on site, and in what Richards says is probably in a first for South Africa, the design is a multi- level construction which will be fitted onto the available footprint. It comprises five modules, three at ground level with two above. The structure, including all electrical substation equipment, weighs about 90 tonnes. A section of the ground floor houses a medium voltage (MV) switch room with a dry-type transformer for enhanced safety, and a module fitted with three 450 kW MV variable speed drives (VSDs). The third module contains a 1 MVA generator set, sourced from Zest WEG Group’s dedicated genset manufacturing facility in Cape Town, to provide backup power. The first floor comprises one module with a low voltage motor control centre (MCC) and four freestanding low voltage (LV) VSD panels, plus a second module for control and automation. An additional E-house comprising one module for a separate LV substation has also been supplied.

Enquiries:WEG Automation Africa, ZestWEG Group: www.zestweg.com

The E-house in construction at WEG Automation Africa Heidelberg, showing ground and upper floors which house the different modules.

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TRANSFORMERS + SUBSTATIONS

Quick transformer turnaround for KZN mine

Dry-type transformers – also called cast-resin transformers – are growing in popularity as users recognise their safety benefits as well as their economy and flexibility of placement. To meet this demand, Trafo Power Solutions works in close collaboration with established and well-resourced manufacturing partners in Europe to source tailored designs that meet customers’ specifications. With its South Africa-based expertise and experience across Africa, Trafo Power Solutions provides its customers with ongoing after-sales service. Enquiries:Trafo Power Solutions, visit: www.trafo.co.za

When a mining company in KwaZulu-Natal recently experienced a transformer failure, it was hoping for a quick solution. The mine got one from dry-type transformer specialist Trafo Power Solutions, which took just five weeks to design, build and deliver a non-standard cast-resin replacement. “Once the old transformer was assessed, it was decided it would be more economical to replace the unit than to embark on major repairs,” says David Claassen, Managing Director of Trafo Power Solutions. “We were able to accommodate the customer’s specifications in our replacement design and have the unit manufactured by our European partners in just four weeks. After that, it took only a week to fly in the transformer and deliver it to the customer.” Claassen notes it is not uncommon for transformer replacements of this scale to take anything from 12 to 14 weeks, so the rapid turnaround time achieved by Trafo Power Solutions was highly valued by the customer.The mine required a 1 600 kVA dry-type DYN11 transformer that stepped 33 kV down to 550 V, with a non-standard tap setting arrangement of seven tap settings instead of the normal five. “We are always willing to step in when a user has an urgent requirement – and to propose innovative solutions that meet customers’ priority needs,” says Claassen.

Trafo Power Solutions took just five weeks to design, build and deliver a non- standard cast- resin replacement transformer to a mining operation

in KZN. It was manufactured at the TMC Transformers facility in Italy.

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round up TRANSFORMERS + SUBSTATIONS

Fast tracking substation for gold tailings recovery project

Fabrication of all MCCs and adaptations to the container were undertaken by WEG Automation Africa at its facilities in Robertsham, Johannesburg and Heidelberg, further adding to the high local content on the project. This local manufacturing capability is an integral part of Zest WEG Group’s status as a B-BBEE Level 1 contributor. Particular care was taken with on-site modifications at the plant itself. At the milling and classification MCC extension, WEG Automation Africa was required to connect to DRDGOLD’s existing MCCs. The use of joggle chambers on either side of the existing board made for best practice and greater safety. On the return water MCC, a raised plinth was added for easier cable access. Top entry cables for the slurry receiving and tailings MCC was facilitated by innovative board design. The MCCs incorporate an extensive range of WEG LV products including its air circuit breakers (ACBs) to facilitate a 50 kA fault level, moulded case circuit breakers (MCCBs), contactors, fast-acting high rapid fuses, and motor protection relays. WEG W22 LV electric motors were selected to drive the tailings facility pumps. These units are designed with an optimal cooling fin which ensures lower energy consumption. Ingress protection is to IP66 ensuring effective sealing against liquid and dust. WEG Automation Africa, formerly known as Shaw Controls, recently changed its name to align with parent company, Brazil- based WEG’s global strategy. Its local manufacturing operation has received

An important consideration was to reduce the footprint of the substation and Willemse says the free-standing VSDs allowed this. “Had the VSD configuration been a conventional design the units would have been incorporated in panels and we would have needed an additional container.” In this case, the VSDs are placed against the container wall, completely isolated from any exposed conductors. Motor Control Centres (MCCs) were also provided for modifications to the Driefontein 2 plant. The MCC for the thickener is fed by two 1 600 kVA transformers and the tailings MCC is fed by a 1 600 kVA transformer; both manufactured atWEGTransformers Africa’s Wadeville facility. Significantly, the WEG transformers have a local content of 95%, above the required 90% specification. Stuart Brown, Sales Team Leader at WEG Transformers Africa, says, “For this project, the transformers are designed to incorporate theVSD component of the load – so they are not distribution transformers as such, rather VSD-type transformers. This demonstrates the engineering flexibility that WEG Transformers Africa can offer customers in meeting specific operating parameters.” Cooling capacity had to be increased to accommodate the harmonics, and flux density is also reduced. The WEG transformers are built to SANS 780 specification, which stipulates losses even lower than the global IEC standard. Brown explains this is an important advantage and will translate, over time, to energy savings for the customer.

WEG Automation Africa and WEG Transformers Africa, part of the Zest WEG Group, assisted with the commissioning of a containerised substation and control room at DRDGOLD’s new Far West Gold Recoveries Project’s Phase 1 tailings site. The tailings recovery project will see 500 000 tonnes of material, per month, pumped from the Driefontein 5 dam through a new 2 km pipeline to the Driefontein 2 plant. Business Development Manager for projects and contracts at WEG Automation Africa, Tyrone Willemse, highlights the tight timelines in which work had to be done. The development of Phase 1 began in August 2018 with first commissioning undertaken just four months later in December 2018. In an unusual step for such a project, the electrical portion was supplied ahead of the mechanical aspects to expedite the contract. “At the tailings facility, the customer required a medium voltage (MV) substation, a low voltage (LV) substation and a control room,” Willemse says. “This was accommodated within a double- container structure, which included a room to house all free-standing variable speed drives (VSDs) and uninterruptible power supplies (UPSs).” The container was mounted on a concrete plinth with 2.5 m columns elevating the structure to allow optimal visibility from the control room. Heat losses were factored into the design to ensure the substation remains cool and the installation is fitted with a comprehensive fire detection system.

extensive investment from WEG that has seen its facilities upgraded as part of the group’s ongoing commitment to the South African economy and customers in the region. Enquiries: ZestWEG Group, visit: www.zestweg.com

WEG Automation Africa supplied the containerised

substation and control room as well as WEG motors and WEG transformers for the gold tailings recovery project.

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Sierra Leone contract for local panel builder

been supplied to sites around the globe. JB Switchgear is an ISO 9001-listed, Level 3 BEE company. Enquiries: JB Switchgear.Tel +27 (0)11 027 5804, or email: info@jbswitchgear.co.za

JB Switchgear Solutions has been awarded a contract by DRA Global for the design and manufacture of numerous containerised substations mounted on skids and destined for a rutile mine in Sierra Leone. What makes the project unique is the fact that each of the containerised substations contains an MV/LV dry-type transformer and the required LV panels, which include motor control centres, distribution boards and programmable logic controllers as well as power factor correction, uninterruptible power supply and fire suppression systems. The containers are constructed with a mid- point split between the transformer and switchgear assemblies and the completed substations are mounted onto heavy-duty skids so they can be moved around the mine site. The substations cover three main areas on the site: the booster substations, mining in-pit substation and scrubber substation. Operational voltage in this instance is 480 V/60 Hƶ with a 50 kA fault level. Incomer sizes vary from 1 250 A to 2 500 A, and variable speed drives up to 350 kW. Connections between the transformer and LV switchgear are with resin-encapsulated busbars. JB Switchgear supplied its Eagle series panels which are IEC 61439 certified. More than 30 000 tiers of this design have

Eagle series panels and variable speed drives formed part of the contract for the containerised substations.

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CONTROL SYSTEMS + AUTOMATION

A milestone in digital transformation for materials services

thyssenkrupp Materials Services continues to drive digital transformation across its operations. From early 2019, an artificial intelligence solution, supported by Microsoft’s cloud platform Azure, has been integrated into the processes of the largest materials distribution and services provider in the western world. ‘alfred’ supports ‘his’ colleagues at Materials Services in dynamically managing the global logistics network with 271 warehouse sites and more than 150 000 products and services.

1. thyssenkrupp, the biggest materials distributor and service provider in the western world, is using artificial intelligence to improve its efficiencies in processing and analysing orders and dispatching deliveries. Take Note! 1 “Joining forces with Microsoft allows us to use advanced technologies for our in-house developments… to ensure that the projects are closely linked to our core business and are technologically state-of-the-art.”

A s with his namesake – Alfred Krupp – all information comes together at alfred. As a first step, alfred will help to optimise transport routes and thus obviate the transport of thousands of tons of material per year, achieving significant savings. In addition, in future, materials will be available more quickly at the right locations. In the medium term, Materials Services will be able to make all processes along the supply chain more flexible, in order to better take into account, for example, specific customer requirements for delivery speed, pricing or material quality. Klaus Keysberg, CEO of thyssenkruppMaterials Services, summarises alfred’s strengths: "Artificial intelligence is one of the technologies that will make a decisive contribution to competitiveness in materials distribution in future. With alfred we are taking an important step towards making our processes even more efficient and optimising our value chain. At the same time, AI gives us better insight into our customers' needs so that we can

align our offerings accordingly. In the medium term, this holistic approach will also open up new business opportunities for us.” Using big data systematically With AI, the approximately 14 million order items received annually by Materials Services can be processed and analysed much more efficiently. For the first time, the materials experts are also bringing all company data together on a single platform. Using self-learning algorithms based on Microsoft Azure Machine Learning, alfred analyses all relevant information, generates important findings and supports employees with appropriate recommendations: Which materials have to be assigned to which industry? Where are materials processed? What would be the most intelligent transport route to supply the customers with materials in the best possible way? What are the needs of the individual locations? Axel Berger, Head of the Digital Transformation

Digitalisation has contributed to advanc- ing efficiencies and optimising the com- pany’s value chain, with further potential benefits to be gained in the medium- and longer- term.

One of the warehouses in the Materials Services global logistics network of 271 warehouse sites, handling more than 150 000 products.

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All information comes together at alfred, the artificial intelligence (AI) solution developed by thyssenkrupp Materials Services with the support of Microsoft’s cloud platform Azure.

thyssenkrupp Materials Services With around 480 locations – including 271 warehouse sites – in over 40 countries, thyssenkrupp Materials Services is the biggest materials distributor and service provider in the western world. The broad service spectrum offered by the materials experts enables customers to concentrate more on their individual core businesses and spans two strategic areas: global materials distribution as a one-stop shop – from steel, tubes and pipes, nonferrous metals and

Office at Materials Services, says, "The intention is very clear. With alfred we are improving our own processes so we can serve our customers around the world more efficiently." Focus on customer benefits At Materials Services, the digital transformation is aligned along the value chain and consistently placed at the service of customer benefit – directly or indirectly. Keysberg says, "From procurement through warehousing and logistics to sales, we rely on integrated digitalisation concepts. While we simplify cooperation with our suppliers in the area of procurement by means of a cloud-supported platform, for example, we create possibilities for networking internal machinery with our self-developed IIoT platform toii. toii allows us to coordinate and optimise the processes of warehousing and logistics flexibly. In sales, we offer our customers access to 150 000 products and services at 271 warehouse sites in the world's largest virtual materials warehouse." As a link between all these areas, alfred fits into the ecosystem and ensures continuous optimisation of speed and service quality through intelligent data processing with corresponding recommendations. Lifelong learning with Microsoft In the company's own Digital Transformation Office in Essen, all strands of digitalisation flow together. Here, integrated teams of IT experts,

engineers and business coordinators work under the direction of Axel Berger on various digitalisation projects that arise directly from the core business of Materials Services – including alfred. The materials experts are supported by Microsoft and its global cloud platformAzure. "Joining forces with Microsoft allows us to use advanced technologies for our in-house developments. This enables us to ensure that the projects are closely linked to our core business on the one hand, and that they are technologically state-of-the-art on the other," says Berger. Commenting on the digital transformation process at thyssenkrupp Materials Services, Ça ğ layan Arkan, Global Lead Manufacturing & Resources at Microsoft, says, "At this point in history, manufacturers need to become digital companies to lead in their industries. thyssenkrupp Materials Services is adapting digital technologies and building its own digital capabilities and portfolio to elevate its logistics business to the next level using AI services. The company is unlocking new business opportunities by merging its industry know-how with the core of AI: large volumes of relevant data as well as strong machine learning methods and algorithms.” Keysberg is confident in the synergies of the partnership. "The collaboration with Microsoft makes the implementation of projects like alfred much more efficient. Ultimately, it will enable us to apply our in-house developments more quickly, gather important insights there and develop new business models from them.”

speciality materials to plastics and raw

materials – and tailored services in the areas of materials management and supply chain

management. An extensive ‘omnichannel’

architecture offers 250 000 customers worldwide cross- channel, round- the-clock access to more than 150 000 products and services. The logistics system ensures that all requested services are integrated into customer production processes ‘just-in-time’ or ‘just-in-sequence’.

For more information contact thyssenkrupp Materials Services: www.thyssenkrupp-materials-services.com

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CONTROL SYSTEMS + AUTOMATION

Sensor manufacturer Lenord + Bauer has used robot automation to optimise its manufacturing production cycle for frequent product changeovers and various batch sizes. The robot cell has taken over monotonous manual pick-and-place tasks, releasing operators to perform more valuable work. The solution is flexible, efficient and provides integration into the company’s higher-level enterprise systems as well as providing a platform for future developments. Robot assistance enables variable production runs

Take Note!

1. High levels of customisa- tion and varying sizes of production runs presented a challenge for more tradi- tional forms of automation. 2. Compact design, a high level of precision, flexibil- ity, safety and integration with in-house systems were the main require- ments in this robotics ap- plication. 1 2

F ounded in 1965 and based in Oberhausen, Germany, Lenord + Bauer is a leading manufacturer of precision motion sensors, controllers and integrated drive technology. The company manufactures products such as compact encoders for logging speed and position in highly dynamic systems, including machine tool spindles. The products are designed to be easily tailored for different individual requirements using customised cable assemblies and connectors. This results in a wide variety of batch sizes, from single units to large-scale production runs.

The high levels of customisation and the varying sizes of production runs presented a challenge for more traditional forms of automation. For Lenord + Bauer, set-up needed to be fast and flexible otherwise the automation wouldn’t be worth doing. Engineers from the company approached Mitsubishi Electric to explore the options open to them. Ulrich Marl, Head of Business Production at Lenord + Bauer, says, “We didn‘t have a fully prepared set of requirements at that time, but Mitsubishi Electric gave us the support and advice we needed for our first foray into robotics. Besides a compact design, our main requirements included a high level of precision and flexibility, while complying with safety standards, as well as the ability to integrate with our in-house IT systems.” Fast programming, precision operation The high variability of batch sizes the company manufactures makes frequent retooling necessary. As a result Lenord + Bauer required precision operation and that re-programming should be carried out as quickly as possible. A Mitsubishi Electric RV Series articulated arm robot proved to be an appropriate choice. The six-axis robot, with a load capacity of 4.0 kg and delivering positional accuracy of ± 20 μm, now handles the required pick-and- place tasks with optimum precision. To provide a complete solution, the robot is equipped with the MELFA SafePlus safety system as well as a controller and teaching box. The teaching box enables the complete system, comprising robot

An RV Series articulated arm robot was integrated into the production process at Lenord + Bauer to enable efficient produc- tion of variable batch sizes. All images courtesy of Mitsubishi Electric Europe B.V.

Pick-and-place tasks are carried out with optimum precision.

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and controller, to be programmed intuitively by the operator in a matter of minutes. The robot cell – at just 4.0 m 2 – is very compact and, if required, can be moved using a pallet truck. The compact size is made possible by using a CR750-D controller. Like all Mitsubishi Electric robot controllers it is extremely compact and can be installed in a 19” rack. As bulky enclosures can hinder the feeding and removal of parts to and from the cell, the robot is equipped with the MELFA SafePlus safety module that allows it to operate close to the workforce. Two laser scanners on opposite corners of the square footprint frame each monitor an area 180° wide. As soon as a person or object enters this safety zone, a signal is sent to the robot controller, in real time, to reduce the speed of the robot to a pre-defined setting. If a person or object further encroaches into the safety zone, entering the operating space or collision zone of the robot, a further signal stops the robot immediately. The frame of the robot cell is also fitted with a light curtain and mirror deflector strips which send an additional signal

to the SafePlus safety system if an object is detected.

With future production requirements in mind, Lenord + Bauer wanted to integrate the solutions into its higher- level enterprise systems… as part of the continuous optimisation of production.

Connectivity for production process control With future production require- ments in mind, Lenord + Bauer wanted to integrate the solution into its higher-level enterprise systems – such as its enterprise resource planning and quality assurance systems. As part of the continuous optimisation of production, a Kanban warehouse is to be implemented for the sub- assemblies required for the manual final installation process, so a futureproof solution was important. As soon as sub-assembly stocks drop belowdefinedminimum levels, the warehouse will communicate autonomously with the robot and production will be increased accordingly. With extensive coverage of protocols, interfaces and connectors, Mitsubishi Electric robots can be integrated easily into factory control and IT networks, without additional development work. System integration was carried out by TAR Automation – part of the Lenord + Bauer corporate group. The team constructed the robot cell using a third-party panel controller. This was accommodated easily as Mitsubishi Electric robot systems work with MELSEC controllers and operate seamlessly with third-party hardware. The existing robotic application will serve as a basis for further automation and inspire developers to design new products, with the capacity for automation in mind right from the start. Examples of other potential applications include the robot taking parts directly from stacking stations, use in other production processes such as soldering or laser applications and completely safe human-robot collaboration.

Ulrich Marl, Head of Business Production at Lenord + Bauer.

Mitsubishi Electric With nearly 100 years of experience in providing reliable, high-quality products, Mitsubishi Electric Corporation is a recognised world leader in the manufacture, marketing and sales of electrical and electronic equipment used in information processing and communications, space development and satellite communications, consumer electronics, industrial technology, and in products for the energy sector, transportation and building equipment. With more than 145 000 employees the company has sales offices, research & development centres and manufacturing plants in over 30 countries around the world. Factory Automation EMEA Factory Automation EMEA, which has its European headquarters in Ratingen near Düsseldorf, Germany, is a part of Mitsubishi Electric Europe B.V., a wholly owned subsidiary of Mitsubishi Electric Corporation, Japan. Factory Automation EMEA manages sales, service and support across its network of local branches and distributors throughout the EMEA region.

The compact dimensions of Mitsubishi Electric’s CR750-D robot controller contribute to the overall size of the robot cell being just 4 m 2 .

The user can intuitively program the robot in a matter of minutes using the teaching box.

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round up

CONTROL SYSTEMS + AUTOMATION

PLC infrastructure upgrade for underground mining operations

the existing system and replacing it with the new controllers, without any loss of production time to the mine. The Becker Mining team will also carry out the commissioning of the new system.” The new enclosures have front and rear access, with a glass window on the front outer door, for clear visibility of a 17” display fitted on the inner door. With dimensions of 1800 mm height by 800 mm width by 350 mm front depth and 200 mm rear depth, the units have an IP65 rating to guard against the ingress of dust and water. Becker Mining’s PLC enclosures incorporate available technology, including Control Logix controllers, Ethernet communication, digital and analogue inputs and relay outputs, Anny bus modules, 24 Vdc output relays, Smart Guard safety relays, 24 Vdc / 12 Vdc internal and external voltage supply and fused termination for external connections (inputs, outputs, analogues, supply voltage). As well as the design and manufacture of a wide range of electrical products for hazardous and non-hazardous applications, Becker Mining South Africa offers a repair

and maintenance service to ensure total reliability of equipment in harsh operating environments. The company’s specialist services to the mining sector include ener- gy distribution, communications and auto- mation solutions, mechanical and transpor- tation systems and steel arch roof supports.

Becker Mining South Africa’s energy division has been awarded a contract to upgrade the Programmable Logic Controller (PLC) infrastructure at a leading coal producer’s underground operations. Nico de Lange, Vice President: Operations & Systems at Becker Mining South Africa, says, “This project comprises the design, manufacture and installation of 15 different PLCs, where each controller will monitor separate divisions underground. The new system will control the run and stop commands of conveyor belts and manage safety signals. All PLCs will be linked to the mine’s SCADA system, with remote access to control functions from the control room. “This advanced system, custom- designed by Becker Mining, is expected to enhance productivity, reduce energy consumption and improve safety on the mine. De Lange adds, “The controllers are currently in production at Becker Mining’s manufacturing facility in Alrode, to meet the mine’s exact specifications. Our project team will be responsible for removing

Enquiries: Nico de Lange at Becker Mining South Africa. Tel +27 (0)11 617 6300 or email: info@za.becker-mining.com

Becker Mining South Africa’s energy division has been awarded a contract to upgrade the PLC infrastructure for a leading coal producer’s underground operations.

Automated laboratory solutions for mining industry

mining. For instance, data collected from online analysers and the laboratory can be used to optimise the entire flow sheet for mining operations. Using this data to strengthen our process optimisation initiatives is an exciting prospect,” says Knudsen. The combined IMP-FLSmidth customer offering of automated laboratory solutions is now available to mining customers worldwide. As well as gaining IMP’s capabilities, FLSmidth will be bolstered by the expertise of over 130 IMP employees, including IMP’s Managing Director, Boyne Hohenstein. The IMP business will be consolidated into FLSmidth from 1 June, 2019 onwards. Enquiries: FLSmidth, www.flsmidth.com The IMP Automation team now adds automated laboratory solutions to FLSmidth’s established quality control and process optimisation services for the mining industry.

Following the approval of the competition authorities, IMP Automation Group has now officially become part of FLSmidth.With the acquisition, first announced in February, FLSmidth completes its portfolio of automated laboratory solutions for the mining industry. IMP is an established global leader in this field and its core competencies will complement the products FLSmidth offers for quality control and optimisation of the mining process. Tina Knudsen, General Manager for Sampling, Preparation and Analysis – Mining, at FLSmidth, says, “With the closing of the deal, we can start the next phase in our product evolution. The benefits of the joint portfolio are immediately available to our customers and our pipeline is strong. We are confident that our product offering, covering manual and automated sampling and laboratory solutions, will open new doors with our mining customers worldwide.” The integration of IMP will enable FLSmidth to support the expanding market for automated laboratories, which has grown as a result of high exploration activity and an increased focus on productivity, automation and digitalisation. “Together we are well positioned to create cutting-edge, competitive solutions for mining applications. IMP has created a strong business based on its innovative approach and at FLSmidth we are traditionally strong on standardisation. We also see great potential to enhance the development of our digital solutions for

14 Electricity + Control

AUGUST 2019

COVER ARTICLE

A CDC Dynamics has always strived to be a market leader in offering the widest range of products from its supply chain of global leaders. ACDC Dynamics will be introducing the Danfoss VLT ® range into its already comprehensive range of Danfoss VACON ® variable speed drives. With the introduction of the Danfoss VLT ® range of variable speed drives, ACDC Dynamics will be offering the full breadth and depth of a product range needed for any application. Whatever you need, ACDC Dynamics will always get the right drive for your application. VLT ® drives position you at the forefront of the energy-efficiency race. Outmanoeuvring other precision drives, they excel, with remarkable fit, functionality and diverse connectivity. VLT ® drives play a key role in rapid urbanisation through an uninterrupted cold chain, fresh food supply, building comfort, clean water and environmental protection. Benefit from the universally-compatible VLT ® effectiveness where ease of use unites seamlessly with high precision, synchronisation and speed. You achieve servo-like performance with rationalised elegance, free of complexity. Secure long-term economic benefits with documented low system-lifetime cost. VLT ® drives consistently deliver, whether in food and beverage, water and wastewater, HVAC, refrigeration, material handling, or textile applications. The steadfast longevity of VLT ® drives is directly attributable to world-class quality assurance placing VLT ® drives right at the sharp end. The sharp end of global resource management and factory automation. Danfoss VLT ® comes with numerous features and benefits, some are highlighted below. If you’re looking to realise untapped potential in your systems with intelligence, you know that adding more intelligence often means adding more components, sensors and complexity. Danfoss intelligent drives can act as your smartest IoT sensor without the complexity. Our intelligent drives gather data from multiple sources by leveraging internal and external sensors. They use intelligence on the edge to generate valuable insights and send actionable data to the cloud or Drives to suit any application Predictive and condition-based maintenance

on-premises system, so it can be distributed where it’s needed. Our drives work with any platform and application, enabling predictive maintenance to increase performance, efficiency and uptime while lowering complexity. Higher data security By applying intelligence close to the data source and processing data on the edge, intelligent drives increase data protection. They avoid the transmission of raw data to the cloud, on-premises data-storage or automation system, which reduces the amount of data at risk of interception or compromise. Reduced investment You can use the drive as a smart hub for external sensors, such as vibration sensors and pressure sensors, to enable condition-based monitoring and process control. As you only need one drive to create a hub, you can avoid spending on additional sensors and gateways.

FEATURES: · Control systems+ automation · Electrical protection+ safety · Power quality, standby+ back-up · Temperaturemeasurement+ instrumentation · Transformers+ substations

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For any inquiries contact: Tel. +27 (0)10 202 3300, E-mail info@acdc.co.za or visit our website www.acdc.co.za

Lower data cost Streaming and processing raw data in the cloud can be costly. Distributing intelligence and processing data on the edge means you can send pre- processed data, which reduces bandwidth and simplifies data analysis in the cloud.

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