Electricity + Control January 2016

FEATURES: • Control systems + automation • Drives, motors + switchgear • Earthing + lightning protection • Pressure + level measurement • Energy + enviroFiciency: Focus on Standby + back-up

COMMENT

I wish you all the best for 2016 which, I believe, will be an interesting year. Last year saw a number of events that brought into stark reality the fragility of, not just our country and continent, but our world. Wars raged; climate change continued to be a debate not just lead by the frivolous; and we were forced to scrutinise leadership at various levels on the continent. We also saw that remarkably peculiar individuals can be taken for serious presidential candidates in the largest economy on the planet! It was a fascinat- ing year and we have come through it having all learned important lessons. Would that everyone was paying attention. I am not an economist but I am concerned that the rest of the world is by no means the rosy place it appears, to the likes of us, whose currency is drift- ing on the sea according to international perception (well-founded, I might add). We need to look very carefully at the massive economies of the East and West. There are challenges, and there is a sense that it could all come tumbling down in a heartbeat. Where does that leave us? Well, not by any means on a ‘continent into which all the continents can fit’ – but on an African continent into which most of the developed (and some of the developing) world CAN fit. By land area alone, the USA, China, India, Western Europe and Japan can all be shoe-horned into our continent (Japan fitting quite nicely into Madagascar…). What cannot escape us is that, beneath the soil lie the most abundant natural resources. There are riv- ers that flow no matter what; there are people – the most critical of all resources and there is sunshine the likes of which no other continent sees. Sufficient tax revenue is raised on this continent to achieve the most ambitious goals. It takes leader- ship, political will and foresight to actively channel resources into those endeavours that can genuinely see this continent rise to be at the forefront of de- velopment and growth. Will we, this year, have the courage, the foresight and the will to make it begin to happen? Each of us can contribute to that reality. Where is the opportunity, you might ask? It is there, and it is big. It needs capital to realise it.

I am of the view that 2016 will be a watershed year – for many reasons and in many spaces. I am confident that increasingly you will see civil society standing up to be counted – inasmuch as one city can see its international credit rating rise while that of the country declines. In our interconnected and global village, civil society will work around many of the formal structures ostensibly set up to be of assistance – but more often ending up being a hindrance.

Editor: Wendy Izgorsek

Design & Layout: Adél JvR Bothma

Advertising Managers: Helen Couvaras and Heidi Jandrell

Circulation: Karen Smith

Publisher : Karen Grant

What will be your contribution to the new future… to the future of the greatest continent on the planet?

EditorialTechnical Director: Ian Jandrell

We can make this happen.

Quarter 3 (July - September 2015) Total print circulation: 4 758

Published monthly by: Crown Publications cc CnrTheunis and Sovereign Sts Bedford Gardens PO Box 140, Bedfordview 2008 Tel: (011) 622-4770; Fax: (011) 615-6108 e-mail: ec@crown.co.za admin@crown.co.za Website: www.crown.co.za Printed by:Tandym Print

Ian Jandrell Pr Eng, BSc (Eng) GDE PhD, FSAIEE SMIEEE

Electricity+Control is supported by:

The views expressed in this publication are not necessarily those of the publisher, the editor, SAAEs, SAEE, CESA, IESSA or the Copper Development Association Africa

January ‘16 Electricity+Control

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CONTENTS

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Control systems + automation 4

XTS enables compact and fast linear machine Stefan Ziegler, Beckhoff When failure is not an option Brian Roth, Antaira Technologies

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Round UP

Drives, motors + switchgear 16 Monomer and VOC-free unsaturated polyester resin… in modern impregnation machines Jaco de Beer, Tectra Automation 19 Round UP

Earthing + lightning protection 24

Lightning protection… ‘Separation Distance’ concept Trevor Manas, Pontins

28

Round UP

Pressure + level measurement 30

Optimise your thickener efficiency for maximum profitability Su-Anne Willemse, Endress+Hauser

33

Round UP

Energy+enviroFiciency: Focus on standby + back-up 36

Stabilising the power supply at Joburg’s Bara Yen-Hsaing Jason Huang, Outreach Engineering

39 42

Future of diesel-generated power Nalen Alwar, Cummins Power Generation

Round Up

FEATURES: • Control systems+ automation • Drives,motors+ switchgear • Earthing+ lightning protection • Pressure+ levelmeasurement • Energy+ enviroFiciency: Focus onStandby+ back-up

Regulars

Cover

1 Comment 13 Cover story 44 Light+Current 46 A sense of Africa 47 Social engineers 48 Clipboard

Implementation of Beckhoff ’s In- dustry 4.0 and IoT concepts comes with a wide range of requirements, particularly for machine diagnos- tics. Read more on page 13 .

Visit our innovative online technical resource for the engineering industry. www.eandcspoton.co.za

www.electricityandcontrolmagazine.co.za

CONTROL SYSTEMS + AUTOMATION

XTS enables compact and fast linear machine Stefan Ziegler, Beckhoff Automation

Filling machines with a linear process sequence are more application-friendly, user-friendly and maintenance-friendly than circular filling systems. However, the processing speed can reach limits, if very large machines are to be avoided; unless you utilise an innovative machine design which combines high filling speed with a compact design based on the eXtended Transport System (XTS), as Groninger did for their new cosmetics filling line.

F or 35 years, Groninger &Co GmbH (referred to from this point as ‘the company’) has been developing technologically advanced machinery and equipment for the pharmaceutical industry at its headquarters in Crailsheim, Germany, and for the cosmetics industry at its nearby facility in Schnelldorf. The company sees, as one of its key success factors, its in-depth industry and technology expertise. Every year, the company invests 10% of its revenue in research and development. This is also true for its cos- As an example, key demands for the fragrance filling system for a large Brazilian manufacturer were speed and flexibility, withminimum footprint. The plant is capable of filling 150 bottles of eau de toilette or fragrance per minute, which equates to 300 000 bottles per day in three shifts. The system must be able to handle bottles with a very complex seal pattern. An additional factor is that the line currently processes eight different products and has to offer adequate flexibility for future product changeovers. The biggest challenge in the cosmetics sector is the large variety of formats. In some cases, one machine handles up to a hundred different container formats. Flexibility in terms of the end products is therefore crucial. metics division, which includes filling systems for all liquid cosmetics, ranging from aqueous products, such as mouthwash, to highly viscous creams and paste-like materials, such as mascara.

Innovation potential fully utilised in space-saving bot- tle handling unit In the case of the Brazilian cosmetics manufacturer, flexibility was also a key requirement during the development process of the fragrance filling system. On the one hand, increased customer requirements in terms of system output had to be taken into account, on the other hand less space was available for the machine than originally planned. In view of these basic requirements, it was not possible to implement the company’s preferred concept of a linear machine layout, i.e. a monoblock system consisting of a clocked filling machine and a continuous sealing machine, in a conventional manner. The high output speed would have required extensive accumulating conveyors between the system components, and for that no space was available. XTS from Beckhoff made it possible to implement a highly compact bottle handling unit between the system components. By eliminating the accumulating conveyors it was possible to reduce the system length from 7,5 m, as originally envis- aged, to approximately 6 m. It is worth noting that such a significant reduction was not in itself decisive, because even an excess length of only 10 cm would make a conventional linear machine design impossible to implement. This would have resulted in disadvantages

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for implementing the filling process, which not only requires time, but plenty of expertise, and can be controlled much better in a linear process. There are definitely benefits in the linear process, both from an application and operation perspective, as well as in terms of main- tenance. By means of the XTS the linear machine was realised and the cosmetic manufacturer’s output requirements which conventionally would only have been possible with a circular filling line, were met. Software functionality not only reduces the hardware requirements XTS can replace conventional hardware through software function- ality. With the XTS, the company was able to do without space- consuming accumulating conveyors, not to mention the fact that the eXtended Transport System is, itself, very compact. A further benefit is that it can be used in any installation position. In this filling system, it is tilted by 45° relative to the conveying direction. The workpiece carrier grippers are also tilted by 45°, so that the required handling unit can be realised with minimum space requirement, using horizontal grippers for the product transport in forward direction and vertical grippers for maximum space-saving on the way back. Further significant benefits include the enhanced flexibility and quality of the product handling. In this plant, batches of 10 bottles exit the filling area. In a conventional system, this batch would enter a balancing loop, resulting in abrupt deceleration. Depending on the speed, this may lead to spilling of liquid. This situation could, of course, be handled adequately, but it would mean that a fully controllable product – i.e. the filled bottle would have to be removed from the controlled process and only returned to it afterwards during sealing. With XTS, the products can be controlled throughout, and bot- tle accumulation can be optimised, based on software functionality. Therefore, XTS makes it possible to process complicated or difficult product container batches more quickly with the same machine.

• There remains massive scope for automation at most plants. • Modern systems can be compact and cost effective. • The case study, as presented, shows space saving and significant improvements.

take note

20 straight motor modules, each 25 cm long, and semi-circles used as curve modules, as well as 30 movers with semi-circular grippers for the workpiece carriers. The result is an oval track with a length of approximately 3 m. The whole system – with a path velocity of 1,5 m/s and a maximummover acceleration of 10 m/s² – is controlled by a single C6920 control cabinet PC with a control cycle time of 2 ms. Batches of ten bottles are filled at standstill, in order to be able to meet the demanding process requirements. The fragrance contain- ers are then sealed in a rotary process, that is, a continuous process. A block of 10 elements has to be synchronised with the continuous sealing machine from standstill, within a relatively short time and a short distance of less than one metre. This is a rather demanding task, which can be optimally solved with XTS. A further aspect is that during the filling process, the ten grippers waiting for full bottles are positioned directly side by side, without a gap in between. However, when entering the sealing machine, they must have a certain, equi- distant spacing. Incidentally, this also applies to the distance of two groups of ten, between which no gap should occur. All these are ideal applications for XTS. Conclusion The XTS system at the company currently uses 30 movers, a group of 10 bottles in the filling area, a further group at the synchronisation stage in the sealingmachine, and a third group during discharge from the sealing processes or on the way back to the filling area. Future efficiency potential could capacity reserves of XTS becoming further optimised and utilised in order to save a fewmore movers and there- fore costs. Moreover, XTS enables process sequences to be mapped in such a way that the slowest sub-process could be duplicated, result- ing in a significant increase in the overall processing speed. Typical examples are complicated and therefore time-consuming sealing mechanisms or additional processing steps emerge during the ma- chine development as a result of retrospective product modifications.

30 movers on an oval track The XTS system for the cosmetics filling line consists of a total of

Links: www.groninger.de/en www.beckhoff.com/XTS

Stefan Ziegler is in marketing communications at Beckhoff Automation. Enquiries: Kenneth McPherson. Email kennethm@beckhoff.com

Contributors to this article are: Hubertus Ritzenhofen (Sales Director, Cosmetics), and Markus Regner (Technical Director), both at Groninger, with Ulrich Vogel, Beckhoff sales office Crailsheim. (Photograph courtesy Beckhoff).

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When failure is not an option Brian Roth, Antaira Technologies

Redundancy serial-to-Ethernet device servers… how they can eliminate single points of failure for networked devices while assuring data redundancy to support data transmission with dual independent host connections simultaneously. T oday, serial devices still play a major role in many applications worldwide to collect or report process data. No matter the industry, from power or utility, water, wastewater treatment, afford data to be lost by any network downtime. Building a reliable redundancy system with a primary and secondary remote host PC or Server will allow field devices to exchange data simultaneously through a dual-network infrastructure.

oil/gas or mining, transportation, factory or process control automa- tion, medical, to security, many applications are still equipped with legacy serial equipment, such as Programmable Logic Controllers (PLCs), sensors, meters, barcode scanners, display signs, security access controllers, and CNC controllers for processes, that are not yet Ethernet-ready for a TCP/IP network. In these industries, it can be challenging to connect serial devices to an Ethernet network. Serial-to-Ethernet technology has been ap- proved since the late 1990s, and represents a paradigm shift – data transmission which was previously tied to a 45-foot RS-232 serial cable can now be made available across TCP/IP Local Area Networks (LANs,) Wide Area Networks (WANs) and even the Internet. It benefits the limited transmission distance of serial-based connections and can be extended to essentially any distance with Ethernet. Serial-to-Ethernet can also benefit engineers inmany applications to centralise remote management, to easily and efficiently access, control, or monitor the status of field serial devices. As engineers start to depend on access to these islands of information, issues such as the environment, connection reliability (uptime), and accessibility become top concerns. Thinking of redundancy as a design paradigm is important, especially in mission-critical applications that cannot

With this set up, engineers will have no need to worry about any failures occurring because the primary and secondary hosts will continuously communicate with field devices.

Serial-to-Ethernet redundancy Typical Ethernet networks consist of many links between hosts and Ethernet switches, and form a tree topology with hundreds of point- to-point wired connections. Any link failure in the network could bring the entire operation to a critical halt. A redundant ring network allows a small portion of the network to be kept idle until another part of the network fails, at which point the ‘redundant’ portion is activated to maintain the flow of data. However, building a reliable redundancy system can create other challenges to engineers, due to specific hardware and the costly software development. Antaira Technologies (referred to from this point as ‘the compa- ny’) chose to embrace the redundancy needs of users and responded with several new features in our industrial redundancy device servers: STE-6104C-T, and STE-700 series, including:

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CNC – Computer Numerical Control ERPS – Ethernet Ring Protection Switching ETH – Ethernet LAN – Local Area Network MAC – Media Access Control PC – Personal Computer PLC – Programmable Logic Controller RPL – Ring Protection Link RSTP – Rapid Spanning Tree Protocol RTU – Remote Terminal Unit STP – Spanning Tree Protocol TCP/IP – Transmission Control Protocol/ Internet Protocol UDP – User Datagram Protocol USB – Universal Serial Bus WAN – Wide Area Network

• LAN Bridge Mode solutions • Provides a dual LAN port solution to allow engineers to perform daisy chaining • LAN Redundancy Mode solutions The redundancy serial device series described supports IEEE802.1D/W [1] Spanning Tree or Rapid Spanning Tree Protocols, and an open standard ITU-T G.8032/Y.1344 ERPS (Ethernet Ring Protection Switch- ing) Protocol [2] to performa single-ring redundancy network solution.

Abbreviations/Acronyms

a serial port to communicate with an application across an Ethernet IP network. The company’s serial device server series provides Vir- tual COM operation mode and TCP Socket connections to allow an application to communicate with a remote networked serial port as if it were attached locally. Types of connections to device servers: • Raw TCP Socket • User Datagram Protocol (UDP) • Serial Tunnelling (a pair connection) • Virtual COM LAN Bridge Mode solutions The STE-6104C-T and STE-700 series comes with dual 10/100Tx LAN ports that allow engineers to connect multiple serial devices in a single location through the Ethernet network. Engineers can enable LAN Bridge Mode to cascade multiple serial device servers through the second LAN port. When enabling this feature, the built-in LAN 1 and LAN 2 will use the same IP address set-up (see Figure 1 ). In many manufacturing automation applications, Ethernet-based devices are now being incorporated on the plant floor with a variety of legacy serial-based devices. By enabling LAN bridge mode, the device server can allow engineers to apply the second LAN port as a switching port to connect with the Ethernet-based device, instead of buying an additional Ethernet switch for the application (see Figure 2 ). LAN Redundancy Mode solutions LAN redundancy mode allows users to set up a single-ring redun- dancy network with all device servers. This feature uses a physical link in the network as a back-up path, and the built-in software allows devices within the ring network to transmit data to the next connec- tion link in one direction. The data transmission will be routed to the back-up path direction if the built-in software does not detect data transmission in an uplink port, eliminating any network downtime concerns. The company’s redundancy serial device server series provides two types of open standard network recovery protocols to support a redundant ring network: IEEE 802.1D/W [1] and ITU-G.8032 ERPS [2]. IEEE 802.1D SpanningTree and IEEE 802.1W Rapid SpanningTree Protocols IEEE 802.1D, Spanning Tree Protocol (STP) [1] was introduced in 1990 to protect the network from broadcast storms caused by unintended loops, and to reduce network crashes caused by failure of a single link in the network. IEEE 802.1w, Rapid Spanning Tree Protocol (RSTP)

Figure 1: Daisy Chain solution for LAN Bridge mode.

Figure 2: Ethernet Switching solution for LAN Bridge mode.

LAN Dual Subnet Mode solutions Enabling this feature will allow engineers to set up the device servers to connect to two independent networks with different IP addresses for data redundancy solutions. It involves creating a complete back- up to the Ethernet network.

Device server overview Device servers represent the segment of product also known as Serial- to-Ethernet converters, which essentially allow any serial device with

January ‘16 Electricity+Control

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is an enhanced version of STP released in 1998. Both STP and RSTP detect duplicate paths in the network and then block data from being transmitted across those duplicate paths (see Figure 3 ). The STP/ RSTP [1, 2] protocol is a typical set-up for a tree or star topology network and can be used with complicated mesh-type networks. The advantage of setting up mesh-type networks is that there is no need to worry about loops. The STP/RSTP algorithm analyses the network automatically to determine if any loops exist. If loops are

node will be responsible for unblocking the RPL to allow it to be used for forwarding, hence why it is called the protection state. Therefore, the RPL becomes the back-up link when a link failure occurs. ERPS provides a highly reliable and stable protection within the ring topol- ogy, and supports a network recovery time <50 ms (see Figure 4 ).

LAN Dual Subnet Mode solutions

discovered, the algorithm determines which links in the loops should be blocked, and the blocked loops are then reserved for use in the event that an ac- tive link is broken. Meanwhile, the STP/RSTP algorithm springs into action by activating one of the redundant links in the network. However, there is also a drawback to using STP/RSTP within an industrial network; slow recovery time. The STP protocol can take up to 30 seconds for network recovery, and RSTP can take up to three to five seconds. Since data transmission from device to device takes milliseconds, the slow recovery time of STP or RSTP protocol can run a potential risk of losing data between three to five seconds.

The STE-6104C-T and STE-700 series redundancy serial device servers provide dual independent LAN ports to set up dual- network redundancy architectures, in order to perform data redundancy for mission-critical applications. LAN dual subnet mode can be used to set up a redundant LAN between serial devices connected to the device server and the host computer. The redundant struc- ture involves using the device server’s two LAN ports to set up two independent LANs that connect the device server to the host computer. If any LAN port link fails, the other LAN link will continue transmitting packets between the serial devices and the host, with the packets passing through the device server. As a result, LAN dual subnet mode performs a zero data loss mechanism to support data redundancy applications (see Figure 5 ). Multi-host redundancy In a multi-host set-up (see Figure 6 ), serial device servers can estab- lish TCP connections to the serial port at the same time, duplicate the serial data, and transmit the data to all hosts at the same time. Ethernet data is sent on a first-in, first-out basis to the serial port when data comes into the device server from the Ethernet interface. Dual redundancy system By setting up the STE-6104C-T and STE-700 series’ LAN dual sub- net mode, the device server provides a highly redundant network structure that takes advantage of built-in dual LAN ports, dual IP ad- dresses, and dual MAC addresses. Engineers can set up two remote host PCs or servers with two independent networks to connect to the redundancy serial device server.

Ethernet Ring Protection Switching (ERPS) ITU-T G.8032/Y.1344 ERPSwas introduced in 2008 by the International Telecommunication Union (ITU). ERPS defines the Automatic Protec- tion Switching (APS) protocol and protection switching mechanisms for ETH layer Ethernet ring topologies. It was defined to protect the point-to-point, point-to-multi-point and multipoint-to multipoint connectivity within a ring network topology. The STE-6104C-T and STE-700 series supports an ERPS protocol for Ethernet layer ring networks without requiring extra managed Ethernet switches. By enabling the ERPS function, users can connect all serial device serv- ers to a ring topology network. In a ring topology, each ring node is connected to an adjacent ring node participating in the same ring using two independent links (i.e. two ways).

Figure 3: Daisy Chain Solution for LAN Bridge Mode.

Loops can be avoided by guaranteeing that traffic may flow on all but one of the ring links at any given time. This particular link is called a Ring Protection Link (RPL). A control message called an R-APS coordinates the activities of switching on/off the RPL. Under normal conditions, this link is blocked by the owner node, which is referred to as the blocking state. In case of a network failure, the RPL owner

Figure 4: ERPS Protocol for LAN Redundancy mode.

The remote redundancy system sets one host PC up as a primary host and another PC as a secondary host as a back-up system. When

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the primary IP fails, the back-up IP will take over by using a switch- ing library. However, this type of set-up will only allow the primary host IP to transmit data bi-directionally to the device server, and the secondary IP to receive data from the device server.

• Any process tends to include serial devices. • These have tended to be single points of failure. • New Ethernet-based solutions eradicate this problem, while ensuring data redundancy.

take note

Figure 5: Dual-Network Redundancy.

Data redundancy solutions in power substations Within power substations, engineers cannot afford data loss from any piece of equipment. Building reliable systems and dual-network archi- tectures for remote data acquisition and access control becomemission- critical. There are so many serial-based devices, such as protection relays, controllers, switchgears, and RTUs that require integration with major redundancy systems and networkswhich can become a challenge because traditional redundancy systems and networks require costly software development and specialised hardware. The STE-6104C-T and STE-700 series provides LAN dual subnet mode to allow engineers to set-up dual-network redundancy architectureswithout requiring a front- end redundancy systemto connect all bay level legacy serial devices and exchange data simultaneously with remote dual-host servers. Conclusion Although there is a variety of Ethernet-based or USB-based devices in the market, they are more for consumer, commercial, or enterprise type equipment that thrive only in indoor or air conditioned environ- ments. Most industrial application measurement devices are being developed by device manufacturers which means serial is prevalent in today’s automation world and applications require real-time and accurate data exchange between field serial devices and remote control management maintenance systems.

Figure 7: Dual redundancy system.

The industrial serial device server series provides high industrial grade, environmentally proven designs, plus new features that can assist in a number of mission-critical applications for data assurance and accuracy solutions. • LAN Bridge Mode: Applications can be applied as daisy chain connections, or Ethernet switching solutions • LAN Redundancy Mode: Includes STP/RSTP protocols for mesh- type topologies, and the open standard TU-T G.8032/Y.1344 ERPS protocol for ring network topology solutions, and supports a standard network recovery time <50 ms • LANDual Subnet Mode : Supports dual-network set-up to transmit serial data simultaneously to remote redundancy servers References [1] IEEE802.1D/W. Spanning Tree or Rapid Spanning Tree Protocols. IEEE 802.1D: Spanning Tree and IEEE 802.1W Rapid Spanning Tree Protocols [2] ITU-T G.8032/Y.1344. Ethernet Ring Protection Switching Protocol (ERPS).

Brian Roth has a BS degree in Electrical and Computer Engineer- ing from California Polytechnic University of Pomona. He has worked in a variety of engineering roles and is currently the Marketing Product Engineer for industrial networking devices at Antaira Technologies. Enquiries: Email james.liao@antaira.com.tw

Figure 6: Multi-Hosts redundancy.

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ROUND UP

Rail automation… right on track

ACTOM Signalling has been awarded a further contract to provide and install yard control systems for variousTransnet Freight Rail sta- tions around the country, following its earlier successful execution of contracts for semi-automated yard control systems.The latest yard control contract is for a total of 13 yards. “We view the awarding of this second project to us as affirmation of our success with the earlier project in developing a yard control system that is effective and efficient, along with our installation of the system at the various yards in a satisfactory manner and substantially on time,” commented Peter Colborne, ACTOM Signalling’s General Manager.The new project, awarded in mid-August 2015 and sched- uled for completion in December 2017, is for yard control systems for Kazerne, Natalspruit and Springs yards in Gauteng, Newcastle and Vryheid in Kwazulu-Natal, Witbank, Belfast, Nelspruit, Komatipoort and Oosbank in Mpumalanga, Phalaborwa andThabazimbi in Lim- popo and Rustenburg in North-West Province. The yard control system is a semi-automated system that replaces existing manually-operated mechanical systems in which the points’ sets have to be thrown by a yard operator on the tracks.With the new system yard operators are provided with two alternatives for operat- ing points sets, using either a trackside push-button or a Local Control Panel (LCP) that, although a remote control system, is located in a

line-of-sight position so that the operator can see the points or series of points he is controlling.The earlier project, executed between mid- 2012 and the end of last year, comprised five yard control contracts for a total of 10 stations in Gauteng, Kwazulu-Natal, Western Cape, Northern Cape and Eastern Cape. Enquiries: Peter Colborne.Tel. 011 871-6600 or email peter.colborne@actom.co.za

Reliable cyber-security management services

Based on an objective evaluation, this report attests to the adequacy and effectiveness of Yokogawa’s internal controls for its secured remote solution services providing custom- ers the assurance they need to commission these services without conducting their own audits. In addition, customers can submit such reports for evaluations of ser- vice organisation internal controls that are required under regulations such as the U.S. Sarbanes-Oxley Act (SOX), thus reducing their auditing workload. Enquiries: Christie Cronje.Tel. 011 831 6300 or email Christie.cronje@za.yokogawa.com or visit www.yokogawa.com/za

Yokogawa has received aType 1 (evaluates the adequacy of a service organisation’s internal controls) report on the internal controls that it employs in the provision of production control system secured remote solution services at its customers’ plants. This report complies with the ISAE3402 international standard and the SSAE16 U.S. standard, both of which address the adequacy and effectiveness of the internal controls at service organisations. With the growing threat of cyber-attacks, there is an urgent need to strengthen the security of plant production control systems.

In addition to control systems, Yokogawa provides comprehensive solution services that address its customers’ security needs. Yokogawa designs, constructs, andmanages various control system security solutions that make use of information systems in- frastructure.To help it improve the reliability and value of these services, and thereby ensure the stable operation of its systems, Yokogawa has obtained an ISAE3402/ SSAE16 internal controls report on the ser- vice delivery and service support processes supporting the secured remote solution ser- vices that it offers in markets outside Japan.

South Africa’s energy resources are limited and yet demand for industrial products continues to rise. Managing costs and still meeting output targets can be a fine balancing act.Talk to one of our EnergyAdvisors today and let us assist you in devising the most effective energy plan for your business. Allow us to help you manage the delicate balance between input and output

Mohlaleng_2582_E

Call our Eskom Contact Centre and request a call from an Energy Advisor on 08600 37566 . For more information go to www.eskom.co.za/idm

Eskom Holdings SOC Ltd Reg No 2002/015527/30

CONTROL SYSTEMS + AUTOMATION

ROUND UP

Focus on device data Eplan Data Portal has introduced Eplan Data Portal Professional – available locally from EPLAN Software & Service – comprising updating, enhancing and filtering functions for device data. Us- ers can start designing without having to go through the tedious process of setting up master data. Users get comprehensive functionalities to update or enrich device data, as well as sig- nificantly expanded filtering possibilities.When device data has been updated in the portal, the system alerts users as to which data is more current than that found in their local database. The advantage is that users can update their data at the push of a button, without manually searching and replacing. The portal’s new data enhancement functionality begins at the start of a project, when device data is not yet available in the device management system. Users can send lists of devices or model numbers to the Data Portal, and then they receive a shopping cart to downloadwith all the found device data. Besides supplementing commercial data, these updates also include important engineering data such as macros, documentation and production data. Another practical benefit is that once device data has been enhanced, the change is accounted for during the update routine for device data. Comprehensive filtering options such as the ability to save prefilters can be assigned to individual persons via the inte- grated rights administration. Components can be located more quickly, considerably increasing the speed of the design process. Enquiries: Johan ReynekeTel. 011 609 8294 or email Reyneke.J@eplan-software.co.za visit www.eplan-software.co.za

CONTROL SYSTEMS + AUTOMATION

ROUND UP

First contactless IO-link encoder

At the SPS IPC Drives fair Turck showcased the first fully contactless encoder which outputs its measured value via IO-Link.This makes the QR24-IOL an inexpensive alterna- tive to encoders with an analog interface. Us- ers can connect the single turn encoder with a standard M12x1 male connector. Expen- sive shielded cables become unnecessary through the use of simple three-wire cables. The combination withTurck's contactless measuring principle offers additional ben- efits.The zero point of the encoder can be se- lected as required – and can be set simply via IO-Link after mounting. It is thus no longer necessary to align the encoder optimally to its electrical connection and use correction

factors for the zero point in the controller. The measuring range, the resolution and the orientation of the signal (CW/CCW) can also be set as required via IO-Link.The absolute resolution is 0,005 degrees. The data storage function of IO-Link 1.1 enables the plug & play exchange of the QR24 in the event of any faults. All relevant encoder parameters can be stored in the IO-Link master and are automatically used on every encoder of the same type. Even em- ployees without any special training can thus replace the encoder reliably. The machine can continue running seamlessly without having to re-parameterise the device. The typical service requirement and associated

waiting times for specialist personnel be- come unnecessary. Enquiries: BrandonTopham. Email brandon.topham@retautomation.com

On the way to Industrie 4.0 Driving the Digital Enterprise

Nadcap certification and Industry 4.0 Yokogawa ’s Release 3 of the SMARTDAC+ GX/GP series paperless recorders and GM series data acquisition system includes an ad- vance reminder notification and calibration correction feature that will help customers in the heat treatment industry comply with the requirements of the National Aerospace and Defence Contractors Accreditation Program (Nadcap) and the SAE AMS2750E standard, and options that facilitate communications with a variety of indus- trial equipment, a key requirement for the Industry 4.0 initiative. In addition, the release features multi-batch capability, a dc power supply module (GM series only), and a pulse input module, and also adds support for a communications protocol used by Supervisory Control and DataAcquisition (SCADA) systems and HumanMachine Interfaces (HMIs). Recorders and data acquisition systems (data loggers) are used on production lines and at product development facilities in a variety of industries to acquire, display, and record data on temperature, voltage, current, flow rate, pressure, and other variables. Yokogawa offers a wide range of such products, and is one of the world’s top manufacturers of recorders. Since releasing the SMARTDAC+ data acquisition and control system in 2012,Yokogawa has continued to strengthen it with the release of a variety of recorders and data acquisition devices that meet specific market needs and comply with industry-specific requirements and standards. Aerospace companies often need to certify that their heat treatment and other industrial processes are Nadcap compliant. This SMARTDAC+ release includes a new option that addresses this need as well as options that facilitate connectivity with other types of industrial equipment. Enquiries: Christie Cronje.Tel. 011 831 6300 or email Christie.cronje@za.yokogawa.com

At SPS IPC Drives 2015 held in in Nuremberg from24 – 26 November 2015, Siemens exhibited its integrated portfolio of hardware, soft- ware and services for the electrification, automation and digitalisa- tion of industrial processes.The presentation focused primarily on the company’s portfolio aimed at building the Digital Enterprise, in which all value adding processes are digitally supported – across the entire product and plant life cycle. Siemens has developed a portfolio which will enable its customers from the manufacturing industry to make the transition to the Digital Enterprise – whether large-scale corporations or SMEs. “We realised the growth potential offered by digitalisation in the discrete production and process industries at a very early stage, and with the Digital Enterprise portfolio have consistently aligned our product offering towards this objective.With a range of concrete products and solutions custom- ers can begin the step-by-step transition towards Industrie 4.0”, said Klaus Helmrich, Member of the Managing Board of Siemens AG. The company’s focus on the challenges of digitalisation was reflected in the slogan chosen for the Siemens trade fair booth: On the way to Industrie 4.0 – Driving the Digital Enterprise. “We are supporting our customers in their bid to become more competitive – by reducing the time-to-market and helping them achieve faster, more flexible and more efficient production”, continued Helmrich. “The processes implemented by the discrete and process industries

vary considerably – and therefore require different solutions”, said Helmrich. “Our Digital Enterprise portfolio addresses all of these different needs cohesively along the entire length of the value chain, and that goes for all sizes of company.” Enquiries: keshin.govender@siemens.com

Klaus Helmrich, Member of the Managing Board of Siemens AG.

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COVER ARTICLE

FEATURES: • Control systems+ automation • Drives,motors+ switchgear • Earthing+ lightning protection • Pressure+ levelmeasurement • Energy+ enviroFiciency: Focus onStandby+ back-up

Beckhoff’s TwinCAT Analytics Seamless recording and analysis of data

I mplementation of Industry 4.0 and IoT concepts comes with a wide range of requirements, particularly for machine diagnostics, includ- ing online and offline condition analysis, predictive maintenance, pattern recognition, machine optimisation or long-term data archival. As a result, seamless and cycle-synchronous data acquisition becomes a prerequisite for effective analysis and correction of processing errors in the machine. For this reason, Beckhoff has developed theTwinCAT Analytics tool to serve the growing needs of Industry 4.0 applications. Processing errors in machines generally create excessive cost and lost production time. The situation becomes all the more serious if there is a lack of machine data and production parameters for analys- ing processing errors and avoiding such errors in the future.The new TwinCAT Analytics tool can be used to rectify this information deficit by storing all process-relevant data in a cycle-synchronous manner. Data is stored in a standardised process data format with data com- pression, either locally in the controller, in a cloud-based solution on a server in the company network, or in a Public Cloud, as required. Seamless data logging opens up optimisation potential TwinCAT Analytics provides a complete temporal image of the process and the production data. This offers an ideal information baseline, not only to assist in the event of an error, but also to en- able comprehensive condition analysis of the machine, among other functions. The recorded process and production data can be analysed online or offline, and machine cycles can be examined for minimum, maximum and average values of the cycle times. Total runtimes and time differences of production processes can be gleaned from cycle

counters or offline trace analyses, e.g. via ‘post-scope configuration’ in TwinCAT Scope View Professional.

Benefits for predictive maintenance Further benefits arise for predictive maintenance. Logging of data fromoperating hour counters, frequency analysis or RMS calculations, for example, enables implementation of high-performance condition monitoring. Moreover, the system facilitates limit valuemonitoring for different process data. Pattern recognition for detecting regularities and repetitions in the recorded data further improves the reliability of the process sequence. In addition to optimum support for error analysis,TwinCATAnalytics offers numerous opportunities to further machine optimisation.The status analysis provides all the information required for optimising the machine or system in terms of energy consumption or process sequence. In addition, detailed knowledge of all processes simplifies the drive configuration and it may be possible to reduce the connected load of machines based on sound measurement readings.This tool serves an increasing demand for highly flexible production down to batch size 1. In this case,TwinCAT Analytics can provide comprehen- sive production documentation for each individual workpiece. TwinCAT Analytics – four software components • The TwinCAT Analytics logger enables cyclic storage of large data quantities, storing the entire process image, including the application data • The TwinCAT Analytics workbench serves as an engineering tool for online and offline analyses of one or more machines • As a PLC library for application in the Analytics workbench, the TwinCAT Analytics library contains numerous function blocks, enabling cycle analysis, energy demand or RMS calculations, among others • TwinCAT Analytics cloud storage can house data and make it available in private or public networks via a ‘message broker’ Enquiries: Kenneth M Pherson 011 795 2898 kennethm@beckhoff.com www.beckhoff.co.za https://twitter.com/BeckhoffSA http://www.linkedin.com/company/beckhoff-automation https://www.facebook.com/beckhoff c

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CONTROL SYSTEMS + AUTOMATION

ROUND UP

Rugged LED strip lights for harsh environments

Banner Engineering has released theWLS27 LED strip light. Featuring a durable alu- minium internal structure and shatterproof, UV-stabilized, polycarbonate shell, WLS27 LED strip lights are ideal for harsh indoor and outdoor applications and resist exposure to high-pressure, high-temperature water, solvents, cutting oils and a broad range of chemicals.

ogy,” said Matt Hahn, Technical Marketing Engineer for Lighting, Banner Engineering. “The new WLS27 LED strip light provides a lighting solution for harsh environments where washdown, oils or chemicals may be present, ensuring superior performance and reliability.” To satisfy demanding environments, WLS27 LED strip lights are available in rug- ged, water resistant IP66, IP67 and IP69K construction. An internal temperature monitoring circuit protects the device in extreme conditions, ensuring the light does not overheat. Enquiries: BrandonTopham Tel. 011 453 2468 or email brandon.topham@retautomation.com or visit www.retautomation.com

Designed with the same durable, low-pro- file design and efficiency as Banner’s work light strip family,WLS27 LED strip lights are optimal for use where laminar airflow is a requirement.To satisfy diverse applications, theWLS27 is available in eight lengths from 145 mm to 1 130 mm and multiple colour illumination options, including single, dual and dimmable configurations. Colour op- tions include cool white, warm white, red, green, blue and yellow. Dual-colour models feature two colours in one light strip, which maintains the same intensity as single-color models. “With our customers continuously dis- covering new lighting applications and chal- lenges, we are constantly striving to develop dependable and advanced lighting technol-

Simple, rugged safety light screen - enhanced performance

Banner Engineering has introduced EZ-SCREEN Light Screen (LS).This rugged, easy-to-use safety light screen is optimal for machine safeguarding and built to with- stand challenging conditions found in manufacturing and packaging environments.With a lean, simple design and enhanced performance features, Banner’s EZ-SCREEN LS provides a cost-efficient light screen safety solution. The EZ-SCREEN LS features highly visible and intuitive bi-colour alignment indicators that allow for simplified setup, easy troubleshooting and streamlined installa- tion. The end-to-end sensing design of the EZ-SCREEN LS eliminates gaps in detection when mounted on top of machine work surfaces and between cascaded segments. For added ease of use, the system requires no PC soft- ware, DIP switches or other device for configuration. “The EZ-SCREEN LS incorporates the most popular functions Rockwell Automation has added new applications to its Rockwell Software Studio 5000 development environment to help engineers speed development of automation systems as they design a Con- nected Enterprise. These applications, along with the Studio 5000 Logix Designer application released in 2012, bring more function- ality together into one environment to help improve automation design productivity.The Studio 5000 environment now includes the following: • The new Studio 5000 Architect application is the central point within the Studio 5000 environment, where users can view the overall automation system; configure devices and manage the communications between the devices • The Studio 5000 Logix Designer application is the design and maintenance software for the Allen-Bradley Logix5000 family of controllers and is used to configure discrete, process, batch, motion, safety and drive control. It simplifies the design process by providing an application-centric view of code

of our previous generation light screen systems and adds new, beneficial features, all with a durable small profile and extremely simple-to-use design,” said Mike Carlson, Safety Products MarketingManager, Banner Engineering. “In creating the EZ-SCREEN LS, we focused on optimising features that deliver high-value, while eliminating those that may complicate the installation or add further main- tenance - providing our customers with a streamlined, cost-efficient safety solution.” To accommodate diverse applications, the EZ-SCREEN LS is available in three resolutions—14 mm, 23 mm and 40 mm—with a range of up to 12 metres. Sensor lengths range from 280 mm to 1 820 mm in 70 mm increments. Enquiries: RET Automation Controls BrandonTopham.Tel. 011 453 2468 or email brandon.topham@retautomation.com

Improving automation design productivity

• The new Studio 5000 View Designer application is the design and maintenance software for Allen-Bradley PanelView 5500 graphic terminals. The Studio 5000 View Designer application provides an intuitive, modern design environment that helps users build

contemporary sys- tems more easily. It enhances integration between the control system and operator interface • The new Studio 5000

ApplicationCodeMan- agerspeedsupsystem development by helping users build libraries of re-usable code that can be managed and deployed across their entire enterprise Enquiries: Christo Buys.Tel. 011 654 9700 or email cbuys@ra.rockwell.com

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CONTROL SYSTEMS + AUTOMATION

ROUND UP

Ionisers take static out of manufacturing environments Static is problematic in themanufacturing environment. Static causes dust and this in return comes with its own set of problems. From dealing with the nuisance of products clinging to each other, plastic sheets not separating property to managing possible damage to electrical products.There is also the real hazard of a possible fire which can be caused by a spark in a chemically sensi- tive environment. SMC Pneumatics is able to offer a solution to these ‘every day’ manufacturing problems by means of the three different types of ionisers available from their product range. “When working with plastics you often have an unwanted but unavoidable charge of electric- ity” explains Brian Abbott, Product Manager Pneumatics at SMC. According to Abbott, there are various options of ionisers available depending on the application and the environment. “The bar type is equipped with nozzles which generates charge and air then blows the charge onto the application.This could work in a PET environment for example. It would also be suitable for lamination and web printing.The bar type varies in length and performance options.The nozzles can be equipped with condition monitoring and therefore easy maintenance and replacement of the nozzles are not a problem.The unique thing about the SMC ioniser is that it can be ordered in a variant which is equipped with a sensor.The sensor has a feedback device which is able to determine if a positive or negative charge is required, and then it will generate accordingly.The charge relates back to a voltage so that the unit can measure the charge.This is communicated back to ioniser and ioniser will generate ions to balance out the charge. An option without a sensor is also available. In this case the unit will generate alternate charge which ‘bombards’ the application with positive and negative ions until it neutralisers the ap- plication.This would however be a less energy efficient option. Enquiries: Email sales@smcpneumatics. co.za or visit www.smcworld.com

Control system for Europe’s first hybrid-flywheel energy storage plant Yokogawa Ireland has delivered a control system for Europe’s first hybrid energy storage plant in Rhode, County Offaly, Ireland.The hybrid energy storage plant was officially launched and opened in early November 2015 by Schwungrad Energie, the owner and operator of the facility. Schwungrad Energie has developed this hybrid power storage system in collaboration with the Department of Physics and Energy at the University of Limerick, and will work with the Irish transmissions system operator to connect the plant to the power grid as a demonstration project under its Smart Grid Programme.The Rhode hybrid demo project comprises of two Beacon Power 160 kWflywheels and Hitachi Chemical valve regulated lead acid batteries of up to 240 kW.The plant will have a maximum import capacity of 400 kVA andmaximumexport capacity of 422 kVAwhen completed.The flywheel system, with very high cycling ability, can rapidly absorb short-termexcess grid energy and generate energy as needed by grid operators. Batteries can provide energy over longer durations but have more limited cycling capabilities.The hybrid flywheel will assist in disruptionmitigation, during times of unexpected demand or sudden changes in energy supply and demand. After the completion of construction, the plant will enter a test operation phase fromFebruary 2016.The Schwungrad Energie plant will be the first field test of a hybrid-flywheel energy storage system in Europe. Enquiries: Christie Cronje.Tel. 011 831 6300 or email Christie.cronje@za.yokogawa.com or visit www.yokogawa.com/za

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