Electricity + Control July 2019

FEATURES: · Industry 4.0 + IIoT · Energy management + environmental engineering

· Control valves + actuators · Flow measurement + instrumentation · Drives, motors + switchgear

COMMENT

ON THE COVER

FEATURES: · Industry 4.0+ IIoT · Energymanagement+ environmental engineering

· Control valves+ actuators · Flowmeasurement+ instrumentation · Drives,motors+ switchgear

There is hope

W e have just heard that the South African GDP fell by 3.2% – the largest quarterly fall since 2009, when you will recall the global economy hit a bit of a snag… But hot on top of that, we hear that the manufacturing sector has actually shown growth in output of over 4.5% year on year. There is hope. It may not be much – but it is something. Obviously growth after contraction is not always as rosy a situation as one might desire, but nevertheless, there is growth. The word is not commonly used in the context of either our industry, or our economy! The GDP fall of 3.2% was larger than that anticipated by some, but was generally in line with expectations after a torrid decade in the economy – which stuttered along at best, lurching as it were from one crisis to the next (and often, it would seem, self-inflicted crises). All of this means very little, of course, if so much of the uncertainty still clouding the economy is not deftly dispelled. But let’s stick with the ‘there is hope’ slogan for a while … In amongst all of this varied news, a highlight was the running of the Africa Automation Fair. The fair is timed to allow some of the latest technologies and solutions from the Hannover Fair to be highlighted in South Africa – and by extension southern Africa – timing which I think is important. I remain firmly convinced that we must generally be early adopters if we are serious about competing internationally. While I was simply not able to get there, many of my spies were! And I was actually quite encouraged by the feedback I received.

In general it does seem that the spirit was positive and the exhibitors were bullish. Perhaps not surprising given the conclusion of yet another peaceful election here, but nevertheless, a sense that some of the weight was lifting seemed evident. Although there were differing views, with some exhibitors being quite critical, there seems to have been a fairly significant proportion who felt that the people visiting the fair were the ‘right’ people – serious attenders with real challenges and real budgets. Again – a very positive indicator to my mind. Crown Publications was also there and I received equally encouraging feedback from our staff. In particular, it remains clear that the content of the magazines is sought after, and in fact desired by far more people than those currently on our database. We are working hard to attend to this need. I also received excellent feedback from the Editor of Electricity+Control , Leigh Darroll, who was able to conduct a number of formal interviews with some of the exhibitors. These interviews are published in this issue, and I would encourage you to reflect on what emerges from them. Clearly, it is not technology alone that drives our industry. And it is not technology alone that defines its success.

energy + information in industry

EC July 2019 cover.indd 1

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Aberdare Cables , a long-established South African manufacturer of low and medium voltage electric cables, recently announced its new range of high voltage cables. (Read more on page 11).

Editor: Design & Layout: Advertising Managers:

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Bi-monthly Newsletter

Online Edition

CONTENTS

Features

INDUSTRY 4.0 + IIoT 4 4IR – the next steps for industry in South Africa Leigh Darroll, Electricity + Control 8 Cost-efficient production with 18 synchronous NC axes Beckhoff Automation

10 Round UP

ENERGY MANAGEMENT + ENVIRONMENTAL ENGINEERING 16 Distributed generation – a fresh approach to South Africa’s power supply Seydou Kane, Eaton South Africa 18 Natural gas as an energy source for industry Laetitia Jansen van Vuuren, Energas Technologies

20 Round UP

CONTROL VALVES + ACTUATORS 26 Water loss savings – a new approach Peter Telle, Ultra Control Valves

8

28 Round UP

FLOW MEASUREMENT + INSTRUMENTATION 29 Round UP

DRIVES, MOTORS + SWITCHGEAR 32 Understanding the terminology in IEC 61439 Johan Basson, JB Switchgear Solutions

18

34 Round UP

28

Regulars

1 Comment 11 Cover article 38 Cyber security 39 Write @ the back

2 Electricity + Control

JULY 2019

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INDUSTRY 4.0 + INDUSTRIAL INTERNET OF THINGS (IIOT)

4IR – the next steps for industry in South Africa

Africa Automation Fair, which was staged from 4 to 6 June in Johannesburg, provided a platform for a host of players involved in Industry 4.0, the Industrial Internet of Things (IIoT) and what is broadly termed the 4 th Industrial Revolution (4IR), to come together and share new technologies, new systems and services, new ideas and new opportunities. Electricity + Control had the chance to meet with and interview two leading players in industrial automation, digitalisation and IIoT to explore their views on 4IR, what it means for industry in South Africa, where we stand now and what are the next steps.

Siemens Digital Industries

Take Note!

1. Industry 4.0 and the IIoT are essentially aimed at driving improvements – across industries – in production flexibility, quality, safety and time to market. 2. The digitalisation of in- dustry means we can look at and link the whole value chain digitally: from product concept, through production process to distribution. 2

Ralf Leinen, Senior Vice President, Digital industries, Southern and Eastern Africa

A ccording to Leinen, Industry 4.0 and the Industrial Internet of Things (IIoT) are essentially aimed at driving improvements – across industries – in production flexibility, quality, safety and time to market. “We are looking at the same business principles as applied 30 years ago, when the industrial auto- mation journey began,” Leinen says. “The big differ- ence today is that the pace of technological change is much faster. And the digitalisation of industry enables a much wider, generally more complex but essentially more inclusive network of interconnec- tivity. This means we can look at and link the whole value chain digitally: from product concept, through production process to distribution.” Leinen has been with Siemens for 30 years, having joined the group from university where he did his research thesis on one of the company’s original drive systems. Hence he has witnessed the technological evolution from machine and plant automation to the digitisation of information and the ongoing rollout of digital transformation and integration across all aspects of industry. Next steps In South Africa, Siemens is especially strong in the mining, automotive, oil & gas, agriculture and food & beverage and food processing industries.

The company’s approach is to work with its customers to implement the digital transformation process where and as far as suits each customer’s present needs. Leinen highlights, for example, the advantage of plant engineering technologies that enable a digital twin of a plant to be created in design. This simulated process plant, a bottling plant, for example, can then be commissioned and tested virtually for comparative performance using variable inputs before the design is finalised and implemented. Based on the product concept, production requirements, process requirements and related inputs, production can be optimised. He also emphasises that optimisation is a recurring cycle, encompassing the whole value chain, so that once the digital network is in place, sensors feed information back to plant management and maintenance teams. Edge computing links real-time operational information from the plant floor into the operations monitoring network. Operational adjustments for energy savings, for example, or other modifications can be made where opportunities are indicated and this information is incorporated into the digital twin so that it remains a true replica of the built plant. With its software portfolio, Siemens is the only automation company that supports the digital

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Skills development A critical aspect of implementing new technologies is ensuring that they are understood and well used. For this reason Siemens invests substantially in upskilling its teams internally and in training customers. Typically, following design development and implementation, and in cases of retrofitting newer technologies to existing plant and industrial opera- tions, Siemens provides training, maintenance and support services. In-house and in working with cus- tomers it includes engineering upskilling so that new technologies and continuing innovations are shared and understood. In addition, technologies like virtual reality and augmented reality can be used to share knowledge and skills with remote sites. Universities and universities of technology need to be part of the programme. Leinen says tertiary education institutions are generally keen to embrace 4IR and the new skills it needs. This has opened up opportunities for partnerships like the Digital Mining Incubator that Siemens launched with the University of theWitwatersrand at the end of 2018. Leinen describes it as an interactive learning fo- rum where ideas and possibilities are discussed, explored and tested with customers, academics, students and Siemens’ own engineers and experts. For South Africa, he says, there needs to be genuine investment in the localisation of technology and the development of digital talent to enable a strong, future-oriented workforce. “It is essential for the country to move with technological developments if we are to participate and compete in the global economy. And it has to happen now,” Leinen says. “Although Industry 4.0 or 4IR is itself an unfolding process, we need to join the revolution, otherwise, in 30 years’ time, South African industry will no longer be relevant in the global marketplace.”

twin along the entire value chain – for products, production and entire systems. It also offers customers a key advantage in that it provides both the hardware and software for con- nected industries. It has been in the plant automa- tion sector from the start, as one of the early devel- opers of programmable logic controllers (following the original Modicon plc which came to the market in 1958). Hence it has an understanding of how industrial processes have changed and can change. “As a group Siemens strives to lead the market through innovation,” Leinen says. “That innovation is driven by customers’ requirements and technology enablers.” The group operates globally with different regional hubs responsible for their geographical markets. Leinen points out the advantages this offers in terms of local insights and market knowledge in the different regions. “It also enables us to be close to our customers and to ensure fast response times,” he adds. From its South African office, Siemens reaches into Africa. FromLeinen’s perspective, “Siemens, as a leader in digital industries, has an obligation to existing and new customers to keep pace with change, innovate ahead of the market where opportunities exist, build our own capacity and resources and share our knowledge and skills with our customers. “With our portfolio of products we support cus- tomers to achieve greater productivity and flexibility.” He says the company has seen in South African industry a willingness to change. “A lot of organisations are ready to change, it’s a question of how to make it real.” He adds that it’s important to acknowledge that as much as local industry feels possibly anxious about embarking on the digital transformation process – all industry players, globally, are at one point or another on the same learning curve that Industry 4.0 and the IIoT present.

… all industry players, globally, are at one point or another on the same learning curve that Industry 4.0 and the IIoT present.

Ralf Leinen, Siemens Digital Industries.

Siemens at Africa Automation Fair 2019.

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INDUSTRY 4.0 + INDUSTRIAL INTERNET OF THINGS (IIOT)

Rockwell Automation

Take Note!

1. South Africa needs to adopt the new technol- ogies now, in order to stay relevant and competitive globally. 2. Industry 4.0 and the IIoT have the potential to stimulate the South African economy and boost growth. 2

Henry Craukamp, Managing Director, South and Sub Saharan Africa, and Christo Buys, Business Manager Control Systems, Sub Saharan Africa

C raukamp made the same point that it is critical for South Africa to adopt the new technologies now, in order to stay relevant and competitive globally. He also emphasises that, as we all know, it is essential to grow the South African economy and, in his view, Industry 4.0 and the IIoT have the potential to do that. “We need to start today to build the future,” he says. Industry recognises this imperative – the big question usually is –What do we do next? Craukamp says it’s important to recognise the transition to Industry 4.0/IIoT as a journey. Different solutions apply in different industry operations and related business models. “It represents an evolution of technology and we need to move with it,” he says. “In many cases, the data exists. Digitalisation enables us to bring it together in a meaningful way to drive greater productivity, improved efficiencies and better products. Industry can reduce production costs and advance competitive quality. “We have seen technology impacting on industry operations over the past 30 years,” he says. “Now the pace of technological change is accelerating. It’s like comparing the original Nokia 2110, a breakthrough when it was launched in 1994, and the latest iPhone 10, which offers far greater capabilities and is much faster and smarter. The same applies with the technologies emerging in Industry 4.0 and the IIoT. Another point is that while technology is changing fast and its life expectancy is relatively short, its potential for adaptability is relatively high. “In the context of Industry 4.0, no single technology is going to suit all industrial operations. Each company has its own processes, its own culture and it’s important to respect that and work with it,” he says. Rockwell Automation operates as a business partner working with its customers to provide technology and industry expertise. It has the advantage of owning the technologies it brings to the market and it has the in-house expertise to

support customers through the implementation process and beyond. As a consulting partner it guides customers to maximise current investments and build technology infrastructure. It supports them on their journey through progressive phases, connecting data and insights to enable optimisation. The company also provides further services including training, skills development and customer support. Rockwell’s expertise is focused in certain industry sectors, specifically: mining, metals, oil & gas and food & beverages, as well as discrete industries like the automotive industry and tyre manufacturing. Craukamp highlights that the international corporation’s Global Centre of Excellence in mining is in South Africa. He also emphasises that the company develops and produces systems and equipment internally, at its premises in Randburg, Johannesburg, and executes at end-user sites. “As a manufacturer itself, Rockwell Automation in SA is using its own systems and technologies to drive internal performance. We are on the journey, part of the evolutionary process. This supports the credibility of our systems in the market and means we can demonstrate proof of concept and key performance outcomes to our customers.” Christo Buys points out that it’s important to see this as an ongoing journey. “There is no end goal. On reaching the first goals of productivity improvements, we can circle back with our customers to re-optimise the plant and/ or processes from information and data gathered, as we do in our own operations. It is not a straight- line journey,” says Buys. Rockwell Automation works with a range of recognised international partners to access proven expertise in respective specialised fields of technology. Technology partners include, for example, Cisco, Endress + Hauser, Microsoft, Stratus Technologies and many others. Each

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brings unique benefits to the Rockwell offering. It operates on open standards, aiming for the best in class in each segment. Government support Craukamp says President Ramaphosa and the South African government have recognised the imperative of embracing Industry 4.0 or 4IR. The question is how best we do this and make it work to the country’s benefit. The term 4IR has become something of a catchphrase and it means different things to different people. Craukamp puts it into context. “If we look back in history, the first industrial revolution was driven by steam, the second by electricity, the third by the plc, and now we are in the fourth industrial revolution, which is driven by digitalisation.” Rockwell Automation is determined to be involved in the Presidential Commission on 4IR, which has been set up as a discussion forum to draw on the insights and guidance of academia, industry leaders, private sector players and government to guide South Africa forward on this learning journey. He notes that at this stage it is a fledgling forum, but he believes it can make a valuable contribution going forward. Craukamp says technological advances and digital transformation in industry can support, among other things, government’s drive to boost economic growth by increasing beneficiation at home so that as a country South Africa reaps the benefits of exporting finished products as

opposed to raw materials and commodities. It has the potential to advance South African industry to a stronger competitive platform. Skills sets He says it’s clear that the younger generation, having grown up with digital technologies, are and can be early adopters of these technologies in industry and other sectors of the economy. He cautions however, that there is something of a dilemma in SA in terms of skills. “We need to look at reapplying existing skills and upskilling the existing workforce. We also need to recognise this as a journey of continuous learning.” Among the key challenges currently are: to educate and inform local industry, to clarify the concept of 4IR, and to develop a shared understanding of its potential. Concluding, Craukamp emphasises again that South African industry needs to move forward or we will fall behind as a country, increasingly reliant on imports rather than producing goods that can compete globally. He views Industry 4.0 as an opportunity rather than a threat and highlights again its potential to stimulate economic growth. Acknowledging that it is critical to address labour concerns, he says Germany and other countries have faced similar resistance in some areas – yet studies show that the digital transition creates new jobs and other economic spinoffs, overriding job losses. As with any revolution, new opportunities, skills and services emerge to drive industry forward and meet the needs of the new economy.

It’s important to recognise the transition to

Industry 4.0/IIoT as a journey. Different solutions apply in different industry operations and related business models.

Henry Craukamp, Rockwell Automation.

Rockwell Automation at Africa Automation Fair 2019.

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INDUSTRY 4.0 + INDUSTRIAL INTERNET OF THINGS (IIOT)

Cost-efficient production with 18 synchronous NC axes

Swedish equipment manufacturer Ecmec AB developed a high-tech machine for a supplier to the automobile industry – the machine can complete several process steps simultaneously without having to remount the part being worked on. It reduces the previous processing and conversion times by more than a third and, with its reduced footprint, requires less shop floor space. Beckhoff supplies TwinCAT 3 automation software for the Ecmec machine’s PLC and NC operations as well as the main spindle and forward-feed drives.

The machining centre is designed for high- volume production of up to 200 000 parts per year and performs its functions and processing steps simultaneously within the same cycle. Take Note!

1

F ounded in 1983 and located in the Swedish city of Växjö, Ecmec AB produces hydraulic and mechanical fixtures, accessories for robot grippers and customised machines for assembly, parts handling andmachining operations. The most recent is the newly developed Ecmec SPM (special purpose machine) machining centre, which integrates and simultaneously executes all steps for processing up to 200 000 pressure die castings per year for the automotive industry. From drawing board to delivery When equipment manufacturers design a customer-specific machine, they must keep an eye

we looked for a partner who could supply control and drive components designed to meet customer requirements.” The challenges were considerable. Parts that were previously made on two machine tools with three to five axes had to be processed by a single machine operating 18 NC axes simultaneously. Two main spindles are designed as four-axis units, such that they can move freely along the X, Y and Z axes as well as rotate and tilt. Another threemain spindles move as three-axis units, supplemented by an addi- tional one-axis main spindle.With this configuration, workpieces can be machined on all sides without having to be remounted. A tool changer with four different tools makes the design even more flexible. “The Ecmec SPM employs a totally different set of processing methods compared to traditional machines and does everything much faster,” says Eklund. “It processes the workpieces about 33 percent faster than conventional machines and has a smaller machine footprint.” Precise motion control “Addressing all 18 axes simultaneously requires a fast and powerful control system. This is where Beckhoff came into play,” says Eklund. “To avoid interface problems, we looked for a solution from a single source and Beckhoff was able to meet all the customer specifications.” The flexible

on component costs as well as d eve l o pme n t expenses. So the time from first draft to de- livery should be as short as possible. Daniel Eklund, CEO of Ecmec, says, “As we don’t build a machine of this magni- tude every day,

In the Ecmec SPM machine, the synchronised spindles move along 18 axes to cut the metal parts with exceptional precision, and the synchronised cutting spindles process the metal simultaneously. Picture: Ecmec, Sweden

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INDUSTRY 4.0 + INDUSTRIAL INTERNET OF THINGS (IIOT)

Single source control and drive components

hardware design was another reason for the decision to use Beckhoff technology, because it made a big difference for the project group. “We ran through various alternatives, but the NC I software modules from Beckhoff represented the best option. The system is very powerful and easy to operate, which we truly appreciate. It is a prime example of German engineering,” says Eklund. At the core of the machine is TwinCAT 3 NC I software, which controls the six mechanical spindles simultaneously. The numbers of axes and channels were adjusted to meet the application’s requirements with respective option packages. As a highly scalable system, PC-based control also provides the most appropriate hardware platform for this application. The TwinCAT real-time kernel and the ultra-fast system communication over EtherCAT are ideal for high-precision motion control. Eklund comments: “This platform provided fast control properties and a much faster response time than the PLCs we used in the past. This was one of the main reasons we selected PC- based control technology from Beckhoff.” In addition, the TwinCAT development environment provides numerous features that make the designer’s work easier. For example, Ecmec’s programmers developed their own control and machine software on the basis of TwinCAT 3. They also opted to use the syntax with G- and M-codes as defined in the DIN 66025 standard, which makes it easier for the machine operators to change setups for new workpieces. These and other features enabled Ecmec to develop the high- performance machine in a short timeframe.

“All operating steps are

The Ecmec SPM is controlled and operated via a C6930 control cabinet industrial PC with a custom-designed CP3921 multi-touch control panel featuring push-button extensions. The user interface isTwinCAT HMI for NC processing, which is easily programmable based on standards such as .NET. The axes and I/O channels are configured via TwinCAT Engineering with NC I functions. The two main spindles are equipped with AM8000-series servomotors with speeds of up to 11 000 rpm. The other four spindles ensure a high degree of processing efficiency for downstream processing steps as well. The maximum feed rate is 30 m/min, and the maximum acceleration rate is 0.2 g. The six main spindles and 12 servomotors are controlled by Beckhoff AX5000 Servo Drives for exceptionally fast and dynamic positioning. In addition, one cable technology (OCT) saves a significant amount of installation space. To protect the operators and avoid equipment collisions, all servo drives are equipped with AX5805 TwinSAFE cards. The machine also uses TwinSAFE terminals and the EL6900 TwinSAFE Logic terminal with certified safety function modules and Safety over EtherCAT (FSoE).

executed in a single unit. Multiple steps are synchronised, which saves processing time,”

Acknowledgements to Beckhoff Automation for the information supplied.

The customer-specific CP3921 multi-touch control panel provides excellent machine operability. Picture: Ecmec, Sweden

Ecmec CEO Daniel Eklund. Picture: Ecmec, Sweden

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round up

INDUSTRY 4.0 + INDUSTRIAL INTERNET OF THINGS (IIOT)

Precise distance measurement and positioning

positioning on production or assembly lines that move large components such as engines or vehicles. The distance of these objects can be measured to a specific reference point with optimum accuracy. Countapulse Controls offers a 24/7 technical hotline to assist customers with selection of the most appropriate sensor for any application, or to deal with any troubleshooting requirements. Enquiries: Countapulse Controls. Tel: +27 (0) 11 615-7556 or visit: www.countapulse.co.za

with machine software. This is important as, based on the real-time values obtained, production processes can be constantly adapted and optimised. In quality assurance applications, particularly during the assembly process, the completeness or alignment of individual components must be ensured. The Leuze ODSL range of optical distance sensors uses extremely high resolution to define and check all reference points. The sensors function reliably even where objects include plastic and metal housings. Another application is in machining processes where raw material needs to be fed into the machine without interruption. This means the stack height on the load carrier must be constantly monitored. Using a combination of Leuze optical distance sensors with different resolutions and ranges, it is possible to measure the height of differently stacked objects. The large operating range on Leuze optical distance sensors, up to 65 m, as well as the focused laser sensing mechanism, make it easy to monitor While the MOVIDRIVE ® B Drive Inverter and MOVIAXIS ® Multi-Axis Servo Inverter have been available for some time, the MOVI-C ® modular automation system sets SEW-EURODRIVE on the path to Industry 4.0. “This requires products that are open and flexible,” says Maleka. “Our focus is to provide our customers with a modular and fully customisable solution.” On display at the fair was a high- speed pick-and-place solution, including a tracking function, which can be used in a range of industries. This represents just one of the new technologies that SEW- EURODRIVE is developing, with a three- to four-year window period, responding to customers’ needs and industry trends. “Our main focus at the exhibition was on energy-efficiency,” says Maleka. Three segment conveyors, each about 1.5 m in length, featured IE2, IE3 and IE4 motors, with the different energy consumption and relative efficiencies displayed on a screen. The MOVIGEAR ® mechatronic

Precision monitoring and accurate measurement of distances are essential for the smooth running of intralogistics and production operations. According to Gerry Bryant, Managing Director of Countapulse Controls, optical distance sensors are generally used for this purpose and fulfil several different functions. As a specialist sensing solutions provider, Countapulse Controls offers a comprehensive range of optical distance sensors that can pinpoint measurement and position of any object over long or short distances and facilitate quality assurance. “Leuze optical distances sensors are based on various measurement operating principles, including triangulation measurement, propagation time measure- ment and phase measurement,” Bryant says. “They enable reproducible distance measurements in the range of tenths of a millimetre, over distances of more than 60 metres.” With production operations moving to Industry 4.0, the measurement data can be transferred with IO-Link and evaluated At the recent Africa Automation Fair SEW-EURODRIVE presented visitors with a preview of its MOVI-C ® modular automation system. This represents the next generation of automation technology from Germany and will be phased in gradually by SEW-EURODRIVE in South Africa. National Sales and Marketing Manager Norman Maleka says, “The system consists of a MAXO-RPS- T-RRRRRRO-10-1300-01, including stand and polycarbonate guard, CMP motors, MOVI-C ® modular, MOVI-C ® controller, a human-machine interface (DOP), and MOVIKIT ® Robotics software. The system provides an automation solution, from planning to commissioning, operation and diagnostics software, electronic control and monitoring devices, mechanical drives and gear motors. It features open communications from PROFIBUS and Industrial Ethernet to Modbus.

Leuze Optical Distance Sensors enable accurate distance measurement.

Next generation automated drive solutions

drive system was also showcased. This technology is making inroads in the food- and-beverage industry due to its quick installation and ease of use as well as the advantages that it is easy to clean and meets strict hygiene standards, for which an optional smooth surface is available. Other energy-efficient products on display included variable speed drives and the LTP-B Eco HVAC drive, which is ideal for applications ranging from large buildings to mills. Features include an advanced ‘sleep and wake’ function that maximises energy efficiency by switching on a pump, for example, only when it is required. “Our aim is stay ahead of the technology curve,” says Maleka, “to ensure our customers always have access to the latest solutions that are flexible, adaptable and cost-effective.” Enquiries: SEW-EURODRIVE. Tel: +27 (0)11 248 7000, or visit: www.sew-eurodrive.co.za/home.html

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COVER ARTICLE

FEATURES: · Industry4.0+ IIoT · Energymanagement+ environmental engineering

· Control valves+ actuators · Flowmeasurement+ instrumentation · Drives,motors+ switchgear

New high voltage cables from Aberdare

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A berdare Cables, a leading South African manufacturer of low and medium voltage electric cables and a company that has been in the business for more than 70 years, recently announced its new range of high voltage (HV) cables. An official launch with customers is scheduled for mid-July 2019. With its parent company Hengtong Optic Electric’s funded investment, Aberdare Cables has successfully completed its HV project. This included investment in HV plant and equipment, accreditation and other costs associated with the start-up and running of the HV division. The HV cables manufacturing lines are located at the company’s Port Elizabeth factory. This industrial investment sees Aberdare Cables’ cable-manufacturing capability increasing from a current level of 33 kV to a new product offering of up to 132 kV. With the new HV manufacturing lines Aberdare Cables will be able to offer the market two types of extruded XLPE cables: - CSA (Corrugated Seamless Aluminium), and - APL (Aluminium Polyethylene Laminated). TheHV cables can bemanufacturedwith aluminium or copper conductors, as required by customers, and across the full range manufacturing capability in cable sizes up to 2 500 mm². The factory includes hi-tech cable testing facilities and a laboratory. Speaking on behalf of the Aberdare team, Mduduzi Mabaso, General Manager for the High Voltage business, said, “The mandate for our HV cable business is to establish Aberdare Cables as a competent South African high voltage cable manufacturer and turnkey solutions provider, offering our customers competitive, value for

money, quality products and service.” He added that with this investment and through strategic partnerships, the company will be able to: - Manufacture and supply HV cables and accessories - Offer innovative HV engineering and system design solutions - Construct and deliver HV system projects - Commission and test HV systems - Offer condition monitoring of HV systems as well as maintenance on installed HV cable systems. “We are excited about entering this market and look forward to expanding our capability as an electrical solutions provider,” Mabaso said. Aberdare Cables has three manufacturing sites in South Africa and customer service centres in each province as well as in Maputo, in Mozambique. The company employs 1 500 people and currently holds Level 1 B-BBEE status, with 55% Black ownership and 30% Black Women Owned.

For more information contact: Aberdare Cables.Tel: +27 (0)11 396 8000,

email: info@aberdare.co.za, or visit: www.aberdare.co.za

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round up

INDUSTRY 4.0 + INDUSTRIAL INTERNET OF THINGS (IIOT)

SC10 safety controllers for multiple safety devices

a secure connection, even in applications subject to heavy shock and vibration. The SC10 eliminates the need to buy and stock single-function safety relay modules dedicated to specific safety devices. It is fully configurable to work with a wide range of safety devices, completely replacing the functions and logic of multiple safety relay modules. The SC-XM3 external drive can be used to configure an SC10 safety controller quickly, without a PC. Using the safety controller software, the user can create and confirm a configuration, write the configuration to the SC-XM3, and insert the SC-XM3 into the micro USB port of the SC10. The configuration, network settings and passwords automatically download to the SC10.The configuration can be applied to multiple SC10 safety controllers to get machines up and running fast, or to a single SC10 for an easy swap-out in the field. SC10 Series safety controllers can be used to monitor a wide range of input devices, providing safe stop and start functions. They are typically used on smaller machines and equipment to monitor e-stop buttons, rope pulls, safety light curtains, safety interlock switches and similar safety devices. Enquiries: BrandonTopham at Turck Banner.Tel: +27 (0)11 453 2468, or email: brandon.topham@turckbanner.co.za

makes it possible to increase the number of available inputs from 10 up to 14, to accommodate additional devices. Industrial Ethernet communication protocols provide two-way communication between the SC10 and other devices, enabling advanced diagnostic capabilities. The SC10 can be configured for up to 256 virtual non-safety status outputs and up to 80 virtual non-safety inputs. This makes it possible to connect output devices like a programmable logic controller (PLC) or indicator lights as well as input devices like a manual reset without using IO terminals on the safety controller. Installation is quick and easy. No tools are required to mount the SC10 to the DIN rail and the slim design saves space in the control panel. Terminals are clearly labelled and located on the front of the device. The wire is simply inserted into the terminal and the spring clamp ensures

The SC10 series of safety controllers from Turck Banner offers a number of key benefits. The powerful software is designed to support intuitive operation. The icon- based, drag-and-drop user interface provided by Banner’s free safety controller software makes it easy to add devices to a configuration. The software automatically generates ladder logic and wiring diagrams that clearly identify terminal assignments. Users can test configurations prior to implementation using the simulation mode, reducing the risk of error. The SC10 has two six-amp relay outputs with three normally open sets of contacts, enabling the creation of independent safety zones with unique outputs for different safety functions. It has 10 inputs, including four that can be converted to outputs for more efficient terminal use. Automatic terminal optimisation (ATO)

SC10 safety controllers can be used to monitor a wide range of safety devices.

Thermal compressed-air meter

process values of compressed air in common industrial compressed-air networks can be monitored effectively via the integratedTFT display. This allows for selection between four different and individually adjustable graphic layouts. The process values can also be transmitted via IO-Link. Enquiries: ifm electronic. Tel: +27 (0)12 450 0400, or visit: www.ifm.com

The new thermal compressed-air meter from ifm electronic, to monitor compressed air in industrial use, is described as a real all-rounder. It has an integrated temperature sensor as well as a pressure sensor, enabling the user to read four process values at once: volumetric flow, pressure, temperature and total quantity, in order to optimise production. Integration of the SD compressed-air meter into the maintenance unit of existing or new installations provides additional advantages. The

The SD compressed-air meter measures volumetric flow, pressure and temperature in industrial compressed-air networks.

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round up

INDUSTRY 4.0 + INDUSTRIAL INTERNET OF THINGS (IIOT)

Siemens to acquire South African based ESTEQ

In making the announcement, Edwin Severijn, Senior Vice President, Europe Middle East and Africa for Siemens Digital Industries Software, said, “Through this acquisition, Siemens Digital Industries Software will now have a direct presence in the Southern African and UAE markets. This will enable Siemens to expand and enhance how we support and service our customers across the region. “The combination of ESTEQ’s local knowledge and Siemens’ expertise makes it easier now for manufacturing companies to tap into Siemens’ full software portfolio, to reduce cycle time and create new business opportunities.” “With ever-increasing pressure from their customers and competitors, manufacturers across the region need to rethink every aspect of their businesses,” said Ralf Leinen, Senior Vice President, Siemens Digital Industries, Southern and Eastern Africa. “With our comprehensive knowledge of the South African market, we can offer our customers the most appropriate products, solutions and services so they can become digital enterprises and take advantage of the new technology drivers across all phases of their operations.” The asset sale and purchase transaction is due for completion in the third calendar quarter of 2019.The parties have agreed not to disclose any details of the transaction. TheTest and Measurement business which formed part of the ESTEQ Group is not part of the transaction and will continue as a separate and independent business. Siemens Digital Industries Software is a leading global provider of software solutions to drive the digital transformation of industry, creating new opportunities for manufacturers to realise innovation. Siemens Digital Industries (DI) is an innovation leader in automation and digitalisation. Closely collaborating with partners and customers, DI drives digital transformation in the process and discrete industries. It provides companies with a set of products, solutions and services to integrate and digitalise the entire value chain, supporting customers to achieve greater productivity and flexibility. Enquiries: Siemens Digital Industries Software, visit www.siemens.com/plm

At the Engineering Community Conference held 12 th June at the CSIR International Convention Centre, Siemens Digital Industries Software announced that it has signed an agreement to acquire the assets of ESTEQ, a distributor of product lifecycle management, product design and simulation, and manufacturing operations software and services. ESTEQ is headquartered in Pretoria, South Africa, and has locations across the region and the United Arab Emirates (UAE), serving the aerospace & defence, transport, consumer products, energy, electronics, machinery, mining & minerals, and oil & gas industries. Siemens will incorporate ESTEQ into new software focused sales organisations in South Africa and the UAE, gaining direct presence to expand and grow the support and services to customers across the regions. Cobus Oosthuizen, CEO of ESTEQ said, “For over 25 years, ESTEQ has had a strong partnership with Siemens, developing and growing its engineering and manufacturing software and services business across the Southern African and Gulf regions. In that time, we have helped hundreds of customers, large and small, by providing technology solutions that assist them with every step of the product development and delivery process. “We are excited to join Siemens. Our customers will benefit from the existing relationships and local expertise that the ESTEQ team provides and the extended range of technologies and industry expertise that we can offer as part of Siemens.”

Edwin Severijn, Siemens Digital Industries Software, and Cobus Oosthuizen, ESTEQ, sign the agreement following the announcement at the Engineering Community Conference 2019.

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round up INDUSTRY 4.0 + INDUSTRIAL INTERNET OF THINGS (IIOT)

IIoT-enabled automation and energy management

operators to superimpose current data and virtual objects onto a cabinet, machine or plant.” “For the energy manager, EcoStruxure offers data and analytics that enable better energy management.The results are predictive, improve power quality through cost and reliability, and deliver energy optimisation. “The plant manager is concerned with the security of cyber and physical assets. This can be provided through EcoStruxure by its real-time measurement, automation and efficiency, which simplifies data acquisition via digital information for IIoT. “For the maintenance manager, reliability, up-time, redundancy management, future-proofing and asset management are key. He or she needs predictive maintenance, systems with initiative, service orientated equipment and a reduction in costs.” McCutcheon says Schneider Electric South Africa combines the group’s expertise and knowledge of the international and African markets to offer comprehensive solutions tailored to business specifics. Enquiries: Schneider Electric South Africa. Tel. +27 (0)11 245 6400, or visit: www.se.com/za

The Industrial Internet of Things (IIoT) is creating new business models and reshaping the industrial landscape. At the Africa Automation Fair held in June in Johannesburg, Schneider Electric demonstrated how its EcoStruxure platform can support clients in accelerating their companies’ digital transformation and reap the rewards. QuintinMcCutcheon, DigitalTransformation DCX+ EcoStruxure Leader International Operations, says, “EcoStruxure offers energy management and automation solutions for industrial machines and plants across Africa. Having helped thousands of customers, we have evidence of its power and capabilities. “EcoStruxure is an IIoT-enabled, plug-and-play, open, interoperable architecture and platform. It can be used in homes, buildings, data centres, infrastructure and industries. It offers innovation at every level, from connected products to edge control, and apps, analytics and services,” says McCutcheon. At its stand Schneider Electric presented automation solutions such as the Altivar Process range of products and systems, the next generation of variable speed drives designed to deliver IIoT benefits. Smart and connected, with built-in intelligence to gather data and share information to the enterprise level, Altivar Process drives can improve operational efficiency and profitability and reduce total cost of ownership. “Our automation and control products and solutions extend from programmable relays to motion controllers and interface modules, for applications from simple machines to complex process systems,” says McCutcheon. “One of the benefits of the Schneider Electric automation systems is that they are geared to provide the various role-players in key areas with specific information needed to optimise the running of automated plants. EcoStruxure Augmented Operator Advisor puts real-time information at the customers’ fingertips, whenever it is needed.The custom application improves operational efficiency with augmented reality – enabling

Extended warranty on Delta automation range

“Together with Delta, we have agreed to extend the warranty for the benefit of our clients.” The extended warranty covers all Delta products. “Delta’s range has matured over the past decade. Every product has a wide portfolio of models available to suit the end user’s needs, in terms of performance and price,” Cameron says. Delta takes pride of place in EM’s automation offering, allowing opportunities for complementary I/O products. New Delta launches this year include the AS200 and AS300 mid-range PLCs. Delta’s third-generation HMIs will also be launched, and the DOP- 100 series will replace the successful DOP-B range. The power range of the Delta servos will be increased as well and will include precision reduction gearboxes. Enquiries: ElectroMechanica.Tel: +27 (0)11 249 5000, email Karen Zotter: karenz@em.co.za or visit: www.em.co.za

TheDelta industrial automationproduct rangehasbeen represented in Southern Africa by leading supplier, ElectroMechanica (EM), for over 14 years. The strong relationship maintained over that period has been consolidated by the recent announcement that EM is

extending the current warranty period on the entire Delta range by an additional 12 months. EM Delta Product Manager, William Cameron, says, “This means that the factory warranty covers all manufacturing-related issues for a two-year period from the date of sale.

The new Delta AS200 mid-range PLC.

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ENERGY MANAGEMENT + ENVIRONMENTAL ENGINEERING

Distributed generation – a fresh approach to South Africa’s power supply

Seydou Kane, Managing Director, Eaton South Africa

Former Minister of Energy Mr Jeff Radebe, speaking at African Utility Week which was held mid-May at the CapeTown International Convention Centre, acknowledged that energy is a critical input cost in any economy, and unaffordable energy in a mineral energy industrial complex like South Africa can only frustrate the country’s industrialisation programme.

Take Note!

1. Improving grid reliability will improve business continuity, minimise business losses and improve economic growth in the country. 2. A decentralised model is much more flexible and makes it easier to employ renewables in microgrids equipped with more cost- effective battery units. 1 2

S peaking at the CEO’s Forum at the same conference, Seydou Kane, Managing Director, Eaton South Africa, highlighted that while ageing infrastructure and stability of supply remain issues of concern, improving grid reliability will improve business continuity, minimise business losses and improve economic growth in the country. At times like this, alternative energy solutions need to be considered to address the energy crisis and help alleviate the burden on the national grid, especially during peak periods. It was in March this year (2019) that Eskom once more implemented load shedding – at escalating levels. Ageing power stations, unplanned maintenance, and design flaws in the new power stations Medupi and Kusile emerged as the combination of causes that forced the utility into implementing rolling power cuts to give itself enough space to make emergency repairs to the system. Government and Eskom itself have stated that the utility is facing severe financial and structural challenges as well as logistical issues and a skills shortage that affects its ability to detect system faults early enough to prevent further crises. The ramifications of this supply instability go far beyond the inconvenience of missing a live football match or some provisions spoiling in the freezer. Among other impacts, thousands of

small businesses and micro enterprises around the country could be forced to close if electricity disruptions continue. Eskom’s issues will take some time to fix. But for the short- to medium-term, President Cyril Ramaphosa announced – in his February 2019 State of the Nation address – plans to unbundle the state power utility into three separate entities: generation, transmission and distribution. This plan is expected to bring improvements in control and accountability as well as efficiencies and stability in supply. However, unbundling is not the sole panacea for the country’s electricity woes. South Africa’s power market needs a thorough regulatory, technological and economic shift away from the current centralised system. With thousands of kilometres of infrastructure sending electricity to customers across the country, the transmission network loses as much as 40% of generated power through thermal heating. South Africa needs to move towards a decentralised model made up of localised generation-to-distribution nodes with shorter transmission lines. While power losses will still affect these nodes, the losses would be reduced significantly to as little as 15% of generated power. A decentralised model is much more flexible and makes it easier to employ renewables in microgrids equipped with more cost-effective battery units, further alleviating the burden on the

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