Electricity + Control March 2018

FEATURES: • Drives, motors + switchgear • Temperature measurement • Industry 4.0 + Industrial Internet of Things (IIoT) • Plant maintenance, test + measurement • Hazardous areas + safety • Energy management + environmental engineering

COMMENT

ON THE COVER

Does belief match the capacity to do?

task of law-making, and establishing poli- cy that genuinely enables the economy to achieve its goals. The most recent SONA set a tone which is suggestive (if not blatantly prescriptive) of a sea change in the way the country is to move ahead; and the most recent Budget Speech (while pragmatic given the circum- stances) was indicative of just how much trouble we find ourselves in. Frightening! We know that there are a few options when frightened.The first is to imagine that the problem does not exist (I think we may have become pretty good at that, in some areas); the second is to run away (we see this all the time); and the third is to face up to the danger and defend ourselves. (In the case of the third mentioned, one requires the policy and the leadership capacity to pull it off.) What we are beginning to see at a macro level, and from the recent dis- cussions I have had with colleagues in our industry locally and in neighbouring coun- tries, is that we may be entering a phase when belief is matched by the capacity to actually do. Much yet remains to be dealt with – and dealt with decisively – before many will develop sufficient confidence to bet on us again.

Recently, I corresponded with a colleague in Zimbabwe and we discussed some industrial projects that are beginning to emerge. We reflected that this emer- gence may well be due to the changes that are taking place in the country. We identified a link between implied stability and security, and the flow of resources into specific areas – some of which may have been neglected for a while. The present time in South Africa has been described as a time of hope, change, new- ness – and the like. I have a palpable sense that industry is almost beginning to believe that a growth rate of 3%may not be fiction after all. Actually, we need to achieve even higher than that if we are going to make any impact on the challenges we face. The frank version, of course, reminds us that we have decoupled ourselves from our peers as regards economic growth as the country faces an enormous challenge to regain growth, regain employment, and build the confidence of investors. Those of you who follow Face Value will know that I have been privileged to speak to a wide range of fascinating and successful people − from young entre- preneurs to seasoned business people. Watch the videos and you may share my sense that folk are no longer simply going through the motions; they are convinced that we can make a tangible difference, and that we can succeed. Something else that is emerging is the fact that we are – at last – dealing with the ‘wrongs’ in our midst. Success requires a policy environ- ment that is conducive to this objective. It is astounding to hear that policy is to be reconsidered in some cases. Politicians are at their best when they stick to their

FEATURES: • Drives,motors+ switchgear • Temperaturemeasurement • Industry4.0+ Industrial Internet of Things (IIoT) • Plantmaintenance, test+measurement • Hazardous areas+ safety • Energymanagement+ environmental engineering

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CONTENTS

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Features

Drives, motors + switchgear 4 Reduce Costs By Fixing Electrical and Motor Problems In Factories Information provided by Fluke Corporation 8 A Visit to JB Switchgear Solutions, We talk to Managing Director, Johan Basson 10 Round UP Temperature measurement 18 System Draws Power from Daily Temperature Swings … David L. Chandler, MIT News Office 20 Round UP Industry 4.0 + Industrial Internet of Things (IIoT) 24 Sigfox Partnership, IIoT and Smart Cities Dave Wibberley, Adroit Technologies 26 Future-proof Industrial Networks Michael Bowne, PI North America 28 Autonomous Food Robots Move with the Times Victor Marques, Omron Electronics 29 Round UP Plant maintenance, test + measurement 34 Advancing the Rotating Machine Industry to 4.0 Kegan Smith, PREI Instrumentation 36 Using Fuel Catalysts to Improve Efficiency of Plant and Equipment John Alexander, Eco Catalyst Reformers 39 Round UP Hazardous areas + safety 42 Ready for the Real Thing: Fire Simulation System Supports Firefighter Training Ralf Stachelhaus, Beckhoff Automation 45 Round UP Energy management + environmental engineering 46 Sustainable Energy and Electrifying the Trans- port Sector Carel Snyman, Energy Consultant 49 Round UP

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46

Regulars

1 Comment 31 Cover Article

50 Light + Current 50 Faces + Places 51 Social Engineers 52 Not to be Missed 52 List of Advertisers 52 Write @ the Back

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Reduce Costs By Fixing Electrical and Motor Problems In Factories

Information provided by Fluke Corporation

Virtually all energy waste ends up as heat, and the higher the temperature the greater the waste and the greater the chance of equipment failures.

Take Note!

Predictive maintenance should give time to schedule repairs before failures. Detecting and correct- ing failing connections avoids shutdowns, dan- gerous machine condi- tions and fires. Prioritise repairs first by safety risk, criticality of the equipment and temperature rise.

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N ew electrical components begin to deteri- orate as soon as they are installed – with fatigue, age, vibration and environmental conditions helping loosen and corrode electrical connections. Simple faults can bring down an en- tire production line. Even simply replacing a fuse can take half an hour. Lost production alone can in some industries costs as much as US$1 000 per minute, and elsewhere failure in even a rela- tively small component can mean losing a whole production batch. Motors making billions of revolutions over their lifetime are particularly susceptible. There are sev- eral main reasons for overheating: poor cooling, too many stops/starts, overload and overvoltage, and poor power quality – particularly unbalance and distortion. Even a small voltage unbalance can cause excessive motor current, which eventually returns on the low-resistance neutral connector of your power system, and that can itself increase the risk of fire. Best practice maintenance All these problems can be detected early by a reg- ular predictive maintenance round. Detecting and correcting failing connections avoids shutdowns, dangerous machine conditions and fires. Visual in- spection is not enough, though. Thermal analysis shows operating temperatures, and therefore en- ergy waste if those are above design values. That energy waste has a cause and, where this is not immediately obvious, other instruments can track

it down. Maintenance is all about best practice (with the most important aspect being safety). The exact order of actions will depend on what equip- ment and instruments you have, but we outline the procedures in the rough order you will need them. First comes the data gathering and then deciding on your plan of attack. With experience, you can decide on normal operating temperature ranges with an upper limit as an ‘alarm’. Prioritise repairs first by safety risk, criticality of the equip- ment, and temperature rise. After you have done the repairs you check they have worked and that all the updated information is in the system. Good system design and commissioning are crit- ical, since faults like under-sized conductors and components, and loose connections can often cause later failures. Motors should not be run above the design temperature or other maximum ratings. Every increase of 10°C on a motor’s wind- ings above its design operating temperature cuts the life of its windings’ insulation by 50%, even if the overheating is only temporary. Thermal imagers do not eliminate the need for conventional inspection and testing to check for electrical safety – that should be done every five years or less. And bear in mind that a device’s tem- perature – even its relative temperature – may not always be the best indicator of how close it is to failure. Other factors include changes in ambient What to look for and what you will need Thermal imager as a front-line tool

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temperatures and mechanical or electrical loads, visual indications, the criticality of components, histories of similar components and measure- ments from other tests. Thermography is best as part of a comprehensive condition monitoring and predictive maintenance program. Go for a structured approach Predictive maintenance should give time to sched- ule repairs before you get failures. Particularly if the technician doing the inspecting will not be do- ing the repairs, documentation needs to be com- plete, with both thermal and digital images of all key equipment. Past experience of plant person- nel is helpful, with any recent changes to electri- cal systems that might be causing problems. Ser- vicers need to know the basic operation and heat flow characteristics of machinery, and understand heat related failure mechanisms. They should ob- serve the machinery during start-up, operation and cool down. When inspecting, the system should preferably be under ‘worst case’ or peak loads, but at least 40% loading (according to NFPA 70B). Check the motor operating temperatures and cur- rents on the nameplate. If you have to inspect with low loads, then note all temperature differences, even if only small. Wherever possible, enclosures should be opened to show the circuits (but only by author- ised and qualified personnel using the appropriate Personal Protective Equipment – particularly the testimony starting at 11:45). If that is not possi- ble, look for slightly raised surface temperatures of cabinets, since they usually mean much higher temperatures inside. Look for hot spots and differ- ent temperatures in similar units operating under similar conditions. Be aware, though, that winds or air currents can sometimes reduce surface tem- peratures and mask issues. Shiny connections and contacts can reflect infrared energy from nearby objects, which can interfere with temperature measurement. Dirty equipment can also interfere with accuracy. Unbalanced loads, overloads, bad or undersized connections, and harmonic imbalance can all create a similar pattern – you need to measure the electri- cal load to diagnose the problem. A cool circuit or leg might similarly signal a failed component. Instruments – choose with care Readings need to be accurate and repeatable, and instruments must be safe, reliable and robust. Ini-

tial capital costs are less important than how much an instrument will save over its lifetime. Quality and robustness are worth paying extra for. And yes with Fluke’s reputation for reliability ‘we would say that wouldn’t we’, but if you drop an instrument and it alters subsequent readings that will send you looking for faults that are not there or, worse, not send you looking for faults that are there. Imminent failure is a red alert Treat imminent failure of any piece of critical equip- ment as a red alert. NETA (InterNational Electrical Testing Association) guidelines recommend imme- diate repairs of components unexpectedly 40°C or more above ambient, and similar components under similar conditions where temperature differ- ences exceed 15°C (27°F). Thermal mirrors (like a clean 3 mm aluminium sheet) can show temper- atures of hard to reach equipment like motors or gearboxes mounted on the top of a machine. This will show comparative readings rather than true temperature readings, though. Thermal-analysis based predictive maintenance saves downtime and money. Many faults involve positive feedback effects that quickly lead to failures: overheated components for example further reducing the in- sulation resistance of wires, contamination further corroding connections, and vibrating components further loosening connections. When a piece of equipment fails the first im- pulse is to get a production line up and running again, but you still need to try to find what caused the failure. Visual inspection should look for clues

Maintenance is all about best practice … with the most important aspect being safety.

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DRIVES, MOTORS + SWITCHGEAR

like discoloration or charring, and you’ll need to work fromwhat measurements you can take.With- out thermal analysis, you have much less to go on, though. It can highlight many potential problems, and even though infrared cameras only measure the exterior surface temperature, that indicates the internal temperature. Other instruments are often needed to determine the precise cause of failure. Measuring insulation resistance For new installations, insulation testers are invalu- able for proof tests of wiring errors and insulation damage. The tester generates a known dc voltage of say 1 kV and measures the leakage current from the conductor through the insulation to calculate the resistance. It detects potentially catastrophic phase-to-phase or phase-to-ground faults on start- up. An initial insulation resistance value of some- times 1 000 M Ω plus at start of life can drop rapidly with over-temperature, and it should be regularly checked. Before doing ANY insulation resistance testing, you MUST isolate any electronic controls and other devices from the circuit under test. What to look for – thermal imagers Unless you will be inspecting small, complicated components or have very heat sensitive applica- tions, you very likely do not need the top models.

High resolution screens and images look nicer and are more impressive, but they add to the price. You will however need enough accuracy, adjust- able emissivity (to allow for how well the object under view emits the heat), and level control and span control. Thermal imagers also need sharp au- to-focusing (out of focus images can be up to 20°C in error) with auto-blending of infra-red and visual images to pinpoint the exact problem. Voice anno- tation frees you from having to take written notes. For basic imagers, the user manual and some form of interactive training will often be enough. Medium to high end imagers are more complicat- ed and should include at least two days of good in-person training. Software should let you docu- ment your measurements easily. Check whether software is included in the price, whether future updates are free of charge, and whether you have to buy licences for multiple team members. Ba- sic instrument specs of course need to be good enough to show faults. The Fluke Ti400 for exam- ple measures -20°C to +1 200°C with an accuracy of 2° or 2% depending on temperature and ther- mal sensitivity of ≤ 0.05 °C. It has a 320 x 240 detector and 640 x 480 display. Some larger motors have in-built insulation meters. Alternatively, an insulation resistance tester with combined multi-meter can perform most tests you need to troubleshoot and maintain cables, switch- gear, generators and motors. Insulation multi-me- ters take basic supply measurements and contact temperatures. An extra safety feature is to detect live circuits; another is to automatically discharge the residual voltage after the test. The Fluke 1587 performs insulation tests up to 1 kV and adds an RMS digital multimeter. It combines them with capacitance, diode and continuity tests and tem- perature measurements. There is a low-pass filter for work on VSDs. What to look for – vibration meters Vibration meters should cover a wide frequency range (up to 20 kHz will cover most applications). Accuracy of measured frequency is particularly What to look for – Insulation resistance meters

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Vibration at rotating fre- quency often points to rotor problems. Bent shafts and poor couplings often ap- pear at double the rotating frequency. Higher multiples can depend on the number of balls in a bearing, and the number of stator slots, rotor bars or fan blades. You therefore need to know exactly how many of each there are. The diameter of the ball bearings, and the circumference of the inner and outer races will also af-

important because it is the frequency that will suggest a fault cause. Readings from probes can depend on how hard they are pressed and at which angle, and the meter should compensate for this. Different severity levels (like good, satis- factory, unsatisfactory, unacceptable) help prior- itise repairs. Entry-level instruments like Fluke’s 805 measure overall vibration as well as specific variables like bearing condition and temperature. More advanced, the 810 asks for basic machine information. It then identifies the root cause, its location, and how severe it is. It identifies and lo- cates bearing faults, misalignment, unbalance and looseness. Repair recommendations advise tech- nicians on corrective action. A laser tachometer measures accurate machine running speeds. Rewinding: Be careful when interpreting read- ings that are different – these may be down to dif- ferences in temperature and humidity because re- sistance decreases as temperature and humidity increase. Insulation resistance doubles for every 10°C decrease in temperature, so measure both temperature (with the thermal imager) and humid- ity. Vibration analysis is a key element of predictive maintenance. Vibration analysers should show the vibration spectrum of the three axes (prefera- bly simultaneously), at each end of the motor and equipment being driven. Three sweeps are need- ed with single-axis instruments, since some faults produce vibration in a single axis only. Vibration equipment is relatively expensive and should not miss faults because the operator does not have time to do a thorough analysis. The individual frequencies in a motor’s vibration signature are often multiples of the rotation speed and often themselves point to defective bearings, bent shafts or loose components. Check the mul- tiples of the rotation speed – not the nameplate speed but the actual running speed, which can be lower. That is important because high frequencies can divide down to be the exact number of stator slots or rotor bars. Vibration analysis for bearings and misalignment

fect the frequency, depending on where the fault is. Any sizeable change in amplitude over the pre- vious maintenance reading should be investigated. Attacking structural waste Everything so far has been aimed at reducing ‘avoidable waste’ through good maintenance. When upgrading equipment, companies need to reduce ‘structural waste’ for their next equipment generation, which means routinely using ‘real’ costs (including the price of energy) when mak- ing their decisions. Old equipment can consume so much more power than new high-efficiency models that early replacement may be justified in reduced kWh consumption alone. With energy efficiency, the repayment time or Return on In- vestment is the critical measure. Examining HVAC systems and building insulation is a topic in itself, and that alone can repay initial capital costs of a thermal imager within a few months.

• The full article can be found on E+C Spot On.

Information provided by Fluke Corporation represented locally by Comtest. Enquiries: Tel. +27 (0) 10 595 1821 or email sales@comtest.co.za

Electricity + Control

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A Visit to JB Switchgear Solutions

JB Switchgear Solutions is a manufacturer of a comprehensive range of electrical switchgear systems. Forty years in the industry, Managing Director, Johan Basson, is a senior member of the SAIEE and serves on various technical committees of the SABS. The company’s symbol – the Eagle – represents Vision, Focus, Strength and Intelligence – attributes which permeate through this company. We spent a couple of hours with Johan – followed by a tour of the factory.

A lways a hard worker with goals and ambi- tion, Johan Basson has built a company of people who themselves are hard workers, with goals and ambition. This is what is encouraged in JB Switchgear Solutions. SO passionate is Johan about development in the industry, that he came out of retirement to set up JB Switchgear Solutions … ‘with a vision to prove that in South Africa we have the competence, skills and capabilities to real- ise the potential that lies locked up in this country’. As an employer, what is your vision? Over the last five years, especially, for business- men and industrialists, the operating environment has become difficult because of the economic, political and unemployment challenges that we have in this country. I hope to leave behind em- powered young (previously disadvantaged) people, who are educated and confident enough to reach

cess; success that encompasses personal growth, community growth and country growth. Each of us asks at some time in our lives: What difference can I make as an individual? Well, one person can- not change the world, but one person can change the world for somebody. It starts with small steps which eventually lead to the ultimate objective. We have a powerful Enterprise Development Pro- gramme with the aim of growing industrial and commercial power and knowledge. We employ around 100 people. Forty to 45% of the people in this company are candidates that we have select- ed from our Enterprise Development Programme. We train and assist them financially to build their own businesses and then we use them to do our business. The skills that they learn include technical skills – an area in which in this country we are lag- ging. In the last 20 years there hasn’t been as much training as there should have been from industry. In the past, big parastatals and companies like Eskom, Sasol and Iscor had huge training programmes. Consider the fact that the average age of a qualified artisan today is 57 years… old ‘grey beards’. We are simply not training sufficient artisans. At JB Switchgear Solutions we train a number of artisans… including women. Historically wom- en were not well represented in engineering dis- ciplines. It was unusual for a woman to become Explain your Enterprise Development Programme

Take Note!

Over the last five years the operating envi- ronment has become difficult because of the economic, political and unemployment challeng- es that we have in South Africa. In South Africa we have the competence, skills and capabilities to real- ise the potential that lies locked up in this country. One of key aspects of this company’s offering is technical compliance with National and Inter- national standards.

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the ideals to which they aspire. To do this at the same time as we are servicing the needs of our customers, we create a platform for our employees to grow and develop careers that can take them forward into suc- Recognition rewards – wherein good performance and initiative are rewarded: Mduduzi Hlekwayo, Lerato Mothibe, Johan Basson, Sam Ngwenya and Jason Mann.

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an engineer, electrician or hold any other technical position. This has changed and we have six wom- en who have either University or Technicon qual- ifications who we are training in engineering dis- ciplines such as testing, MCC design, estimation, project management – a host of disciplines. And this is going very well. If you put something in place that works well – it generates more enthusiasm and growth and it feeds on itself. Knowledge is power, after all. If you empower people, they blossom. Our trainees are so receptive; they want to gain knowledge and skills. In addition, they take back this positive ex- perience into their communities. If you have 100 employees – each individual is part of a structure that supports three or four people at home. So as an employer, you are actually looking after 400 or 500 people. The knowledge that one is playing a role in nation building is very rewarding. Tell us about the technical side of your business We started off by concentrating primarily on elec- trical distribution and motor control. However, the trend over the last 10 years has been on the ‘To- tal Solution’. To avoid multiple interfaces, end-us- ers, project houses and consultants request total solutions. We provide all aspects of electrical turn- key solutions – MCCs (Fixed, De-mountable and Withdrawable) Containerised and pre-fabricated modular substations, Equipment for renewable energy projects, Floor-standing heavy duty distri- bution boards, Distribution boards, kiosks and pil- lar boxes, PLC and marshalling panels, VSDs and softstarters, Remote I/O boxes, 19” rack panels, Control desks, Special enclosures, Standard enclo- sures, Custom control panels, Field isolators and junction boxes, Electrical spares and equipment. Sixty percent of what we do today is solution provision. We don’t do everything ourselves – we partner with OEMs and we can do this because we are independent and flexible. What competition do you have? There are a reasonably large number of competitors – JB Switchgear is probably positioned as one of the top three in our field of business. We are very strong in the Mining, Metals and Minerals (MMM) sector. This is traditionally where we have moved and where we do most of our business. Other in- dustry sectors, water treatment for example, have become popular as we all know that water is the country’s next big crisis. Water reticulation, water treatment, dams and boreholes – these areas are becoming increasingly important for us.We are also

active in other industries – automotive, cement, power generation, petrochemical; whilst approx- imately 75% of our business comes from MMM – the actual growth is coming from other sectors. Do you do business out of South Africa? Possibly 60% of our work is destined for sites out- side the country’s borders. We have done projects all over the world… we are currently working on a large project for an Australian mining company – Mount Pleasant. All the boards and the switchgear for the project are being manufactured in South Af- rica – because we’re competitively priced. African countries that we have worked in include DRC, Mali, Ghana, Botswana, Sierra Leone, Zimbabwe, Zam- bia… we have done projects all over the continent. What makes JBSS stand out from the rest? One of key aspects of our offering is technical com- pliance with National and International standards. In doing work for international markets, such as the Australians, we found that the focus on safe- ty features on equipment is very strong. In South Africa, this is an area that has not really enjoyed as much attention from local manufacturers; however customers are becoming more critical and selec- tive as to what they will accept and the situation is changing. If you look at high level or visibility projects when you’re dealing with big international companies – there is no compromise on safety and performance. I am, personally involved in technical committees, working groups, SABS and industry associations to ensure that we are up to date with the latest trends, developments and standards. And we offer advice and guidance to customers, consultants and project houses when required. Most exciting project Every project is exciting in one way or another and usually includes a wide variety of disciplines and products. A very successful and satisfying pro- ject was providing a total solution for a new dia- mond mine in Lesotho, Liqhobong. Access to the site was difficult as it was high up in the Lesotho Mountains. The mine was commissioned ahead of schedule and it all came together very well. Finally … I have two points to make in my ‘Recipe for success’: • You need to be a good listener. The best sales- man is the person who listens best. Your cus- tomer knows what he wants. • If you make a promise – you must keep it … whatever it takes.

One person cannot change the world, but one person can change the world for somebody.

Johan Basson. Managing Director, JB Switchgear Solutions.

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DRIVES, MOTORS + SWITCHGEAR

Gearless conveyor drive for wider range of motors

In July 2017, the pilot project of this solution was installed in col- laboration with Lausitz Energie Bergbau AG (LEAG) in the open-pit lignite mine Jänschwalde, located close to Cottbus, Germany. The new gearless solution was installed on a high capacity (15 000 t/h) discharge conveyor of a bucket chain excavator in parallel with the existing geared drive. Both drives connect to the same pulley shaft to allow for exact benchmarking. The gearless solution has per- formed better in regard to dynamic accuracy and overall efficiency than the existing traditional solution. Enquiries: Visit www.abb.com

Fast-track project MJM Electrical in Phalaborwa recently requested JB Switch- gear to assist with the design, manufacturing and supply of a new 525 V Pit Dewatering Motor Control Centre (MCC) for Foskor’s operations. The existing MCC was damaged during blasting operations, and so it was critically urgent to get a new MCC manufactured without any delay. The new MCC Other advantages include a considerable reduction in the drive sys- tem’s footprint, so it can be installed in smaller spaces, less weight, and a reduction in the instrumentation required to operate the system. The gearless drive design is also more energy efficient, requiring less power, and operates more quietly, thus reducing noise emissions. ABB ’s innovative gearless conveyor drive is available for use on a wider range of conveyor systems. Already proven on larger motors, the newest drive is designed for medium power range motors (1 to 3 MW per motor) to make this technology economically feasible for a broader range of conveyor systems, including the use on mobile equipment in mining operations. The new solution can be applied for both greenfield and brownfield systems, and significantly de- creases the cost threshold for gearless conveyor technology. Fewer parts and new motor technology increase the reliability and efficiency of the overall conveyor system. A permanent mag- net motor specifically designed for mining applications is a core element of this system that contributes to its reliability and ability to perform in the most challenging environments. The gearless conveyor drive system eliminates the gearbox from the drive. This reduces the number of main wear parts, so less maintenance is needed, and lengthens the lifespan of the equipment. The expected lifespan for the drive train increases by more than 10 years when compared to traditional geared systems, to a projected in service life of 25 years.

Any label you need, you find it at BRADY! Durable label constructions and identification solutions can resist ex- treme temperatures, chemicals, pressure or friction. These tested la- bels enable more workplace safety, better troubleshooting, complete traceability and other identification advantages in challenging applica- tions and environments. Get the durable labelling guide and choose your label! Even complex surfaces in challenging industrial environments can be durably identified with a professional identification label. We use

consisted of a 1 000 Amp incomer and three 350 kW DOL pump starters, two of them duty pumps, and one standby. Everything is mounted on a skid and moved around the pit as re- quired. The purpose of the MCC is to keep the pit clear of water build-up during mining operations, espe- cially during the rainy sea- son. JB Switchgear built the new MCC in a record time of just two weeks, ahead of the December shutdown period. Enquiries: Johan Basson.Tel. +27 (0) 11 027 5804 or email info@jbswitchgear.co.za

material science, expertise and worldwide experience in a great number of industries to develop identification labels that stick on clean, rough, oily and powdered surfaces, and that remain legible when exposed to extreme tem- peratures, chemicals, abrasion and pressure. Just like standard

labels, custom labels can also be printed or finalised at any location. Install the firmware update on your custom capable Brady label print- er, load the custom label rolls, manually or automatically add the spe- cific information your label should display, print and identify. Our durable identification labels guide book supports industries in choosing the ideal label for their identification needs. It shows what is possible in the world of labelling and presents solutions that enable companies to easily design and print their own, trusted identification labels. Enquiries: Email robert_kubis@bradycorp.com

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DRIVES, MOTORS + SWITCHGEAR

Chillers and heat pumps – tailor-made for the mid-capacity segment

through a wider operating envelope. Says Neil Cameron, Johnson Controls Area Gen- eral Manager, Building Efficiency – Africa: “The new YORK Amichi Series Air Cooled Scroll DC Inverter Chillers (YMAA model) and Heat Pumps (YMPA model) is being launched locally and in Europe to meet growing demand in the chiller/heap pump mid-capacity segment. "With high levels of efficiency and per- formance and the smallest footprint across the widest capacity range on the market, it will provide an excellent fit as a solution for new builds, technology refreshes and retrofits in manufacturing and commercial facilities.” This solution competes with increasing- ly popular HVAC Variable Refrigerable Flow (VRF) solutions. The VRF solutions have a lower price tag but are more complex to install. The Amichi range brings high per- formance beyond typical chiller efficiency levels, as well as advanced controls. The Amichi range meets or exceeds the requirements for the Ecodesign regulations for heat pumps, comfort chillers and process chillers through an optimised combination of

YORK efficiency-enhancing technologies. The series comes standard with integrated Smart Equipment technology that allows the equipment to connect seamlessly to a build- ing control systems where smart enabled equipment self-identify and interoperate. Enquiries:Tel. +27 (0) 11 921 7141

Johnson Controls is launching its Amichi Series of Chillers and Heat Pumps into the South African market. With capacities of 45 kW up to 260 kW it’s the perfect fit for the local mid capacity segment – it marries the price benefit of a scroll chiller with the increased control a direct current (dc) inverter offers for better performance

Neil Cameron, Johnson Controls Area General Manager, Building Efficiency – Africa

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DRIVES, MOTORS + SWITCHGEAR

High-speed induction motor rotor refurbished

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ACTOM division LH Marthinusen (LHM) , a leading repairer of transformers and large rotating machines and manufacturer of specialised transformers, recently conducted extensive refur- bishment of a rotor from a 8 800 kW high-speed 6 000 rpm in- duction motor used in a power generation application. The ageing motor, which drives a pump feeding water to a boiler in the power plant, was brought in for assessment at LHM’s main repair facility in Denver, Johannesburg, earlier last year after it had failed. Full non-destructive tests were carried out on all the rotor’s components and it was found that the insulation had degraded, requiring a total rewind. The original mica-based insulation was replaced by more mod- ern, efficient and durable Nomex-based material. Additionally the rotor’s winding heads were compressed with resiglass binders to isolate the damper from the excitation winding whereupon the damper winding arrangement was refitted. The fan hub assemblies were replaced by new manufactured units as the original assemblies were found to have minute cracks. The original fan assemblies were first 3D-scanned and new units were manufactured from the scanned data using five-axis machining technology. In order to establish the integrity of the rotor body structure a complete Finite Element Analysis (FEA) was undertaken. Finally the rotor underwent a high-speed bal- ancing test to confirm its operational integrity. The contract was completed late last year. Throughout the refurbishment process the high precision de- sign specifications had to be adhered to ensure complete integ- rity of the finished product. All the tests, encompassing the initial non-destructive test with subsequent balancing and FEA procedures were essential to ensure that the repairs and refurbishments conducted, con- formed to the close tolerances required for this high speed ap- plication. Enquiries: Boris Breganski. Email borisb@lhm.co.za

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DRIVES, MOTORS + SWITCHGEAR

In-house 12 dynamic ton balancing service

The largest balancing machine in Zambia was recently successful- ly commissioned at Marthinusen & Coutts ’ Zambian operation in Kitwe. The fully upgraded 12 ton Schenck machine is capable of bal- ancing rotors up to 12 tons at operating speeds up to 3 300 r/min, 5,5 metres in length and with diameters of up to 2,2 metres. Careful planning and execution by Marthinusen & Coutts, a division of ACTOM, ensured that the machine was successfully installed, calibrated and commissioned. The local M&C team re- ceived training to ensure optimum operation of the machine. The in-house ability to precision balance rotors to very high ac-

curacy is a valuable service to customers in the region, and it will no longer be necessary to transport large components across bor- der to South Africa for this work to be done. This local dynamic balancing service also expedites the repair process, reducing de- livery time, and avoiding the risks associated with long distance transportation. All this translates into a bottom line cost reduction for customers because of the quicker turnaround times. The service will prove to be invaluable to customers and OEMs operating in the Copperbelt region, and underpins Marthinusen & Coutts Zambia’s position as the leading electro-mechanical repair

facility in the region. Over a period of four years Marthi- nusen & Coutts Zambia has successfully upgraded its test facilities which can now accommodate both ac and dc motors. The facility also boasts a temper- ature-controlled burnout oven, curing ovens and Vac- uum Pressure Impregnation (VPI) tank. Furthermore, winding verification ensures that stators and rotors are wound to international and OEM specifications. Further upgrades have also been implemented to the mechanical repair shop, which also offers machining, milling and submerged arc welding. Enquiries: Richard Botton.Tel. +27 (0) 11 607 1700 or email richardb@mandc.co.za

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DRIVES, MOTORS + SWITCHGEAR

Partnerships key for world-class Gamsberg Zinc project

“We’ve worked with Zest WEG Group for many years, and appre- ciate their professionalism, quality of service and reliable schedul- ing,” he says. “We have therefore placed a number of the contracts for this important and fast track venture through Zest WEG Group companies.” Scope of supply As a group of specialist electrical companies, Zest WEG Group’s scope of supply covers two main spheres - the water-related pack- age which focuses on the upgrading of the municipal supply sta- tion providing water to the Gamsberg site, and the package for the mine’s zinc concentration plant and related processes. In this process, Zest WEG Group supplied a number of non-standard products – providing the mechanical and design en- gineering necessary to ensure that the non-standard specifications could be met, including the redundancy requirements to ensure optimal plant uptime. Showcase “The Gamsberg plant is a showcase for WEG motors and includes four different MV motor ranges that were fit-for-purpose in their different applications,” says Kirk Moss, manager - medium voltage business at Zest WEG Group Company, Shaw Controls. “These in- cluded our newW50 line, the HGF line, large slip-ring motors from our M line, and our W22 line of low voltage IE3 motors; meeting the range of requirements demonstrated Zest WEG Group’s versa- tility in terms of the multiple MV and LV motor offering.” Energy efficiency across all aspects of the project Energy efficiency is a key driver in the project design, with high efficiency W22 WEG IE3 motors being specified across the site. To streamline and facilitate the implementation of this focus, Zest WEG Group was tasked by ELB Engineering Services to coordinate with all the original equipment manufacturers that would use mo- tors to drive their equipment. This is to ensure that the principle of energy efficiency is fully applied across all aspects of the project scope. “Importantly, we are supplying all the LV motors for the plant, ensuring the project will save considerably on its energy cost by complying with the IE3 energy efficiency standard,” says Moss. “These motor are also IP66 rated with Class H insulation, which enhances the IE3 specification by providing higher ingress protec- tion and accommodating a higher temperature rise.” According to Shaw Controls business development manager Tyrone Willemse, the MV Mill package being supplied for the plant comprises two large 6,5 MW WEG motors – MAF 11 kV slip ring units – specified for the ball and semi-autogenous (SAG) mills. “The jaw crushers will be fitted with proven, robust 11 kV 400 kW motors fromWEG’s HGF line,” says Willemse. “We were also requested to supply the distribution transformers on the plant. Zest WEG Group’s contribution to the upgrading of the water supply facility involved the provision of eight 3,3 kV 550 kW medi- um voltage (MV) motors as well as its locally designed and manu- factured transformers to provide power to the pump stations.

At Vedanta Resources’ Gamsberg mine in the Northern Cape, Zest WEG Group is working closely with lead contractor ELB Engineer- ing Services as a preferred supplier to standardise on its range of transformers and motors across a number of on-site applications. The Gamsberg project is South Africa’s largest current green- fields mining project, and will exploit one of the world’s largest zinc deposits. It is being developed at a capital cost of US$400 M and is expected to produce 250 000 tonnes a year of zinc metal in concentrate. “This is a very exciting project for South Africa, especially as we haven’t seen a new mine being developed in the country for many years,” says Dr Stephen Meijers, chief executive at ELB Engineer- ing Services. Water and power ELB Engineering Services’ first package of work was the provision of water from the Orange River to the process plant, through an upgraded pump station and a pipeline of about 40 kilometres. The second package is the supply of power from the existing Eskom switching yard via overhead lines to the mine, and the third is the process plant itself covering all aspects from run-of-mine tip through to final product, including process dams and balance of plant. “First product is expected through the plant by the middle of 2018, with the civil works being largely completed by the end of the second quarter of 2017,” says Dr Meijers. Extreme temperatures Extreme temperatures on site – down to −10ºC at night in winter and up to between 45 and 50º in summer during the day – have affected the design and the construction methodology, he says. This has meant making optimal use of the cooler hours in summer, even pre-manufacturing as much as possible at night before placing during daylight hours. Dr Meijers is a strong believer in partnerships, with much of the project technology being applied through exclusive partnerships with preferred suppliers.

Enquiries: +27 (0) 11 723 6000 or email marketing@zestweg.com

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DRIVES, MOTORS + SWITCHGEAR

Oil Lab helps avoid transformer failure Testing transformer oil is a key function end-users should build into their maintenance programmes, as it speaks volumes about the con- dition of the transformer itself, according to Ronaldo Bertoldi, engi- neering manager at WEGTransformers Africa . As one of the largest manufacturers of transformers in South Af- rica, WEG Transformers Africa has a state-of-the-art oil laboratory at its production facility in Heidelberg, Gauteng, and offers an extensive range of services to transformer owners. “The dissolved gas analysis (DGA) test is one of the most impor- tant for a customer to conduct,” says Bertoldi, “as it provides the first available indication of malfunction within a transformer unit.” Bertoldi highlights that the DGA indicates the internal condition of the unit, and identifies degradation taking place. It is therefore essen- tial for effective monitoring and trend analysis. The laboratory is able to perform a range of important routine tests, starting from the ‘kV’ test which passes current through the oil to test its insulative properties. The water test would then measure the parts per million of water in the oil; as a conductor of electricity, high levels of water become both damaging and dangerous to the transformer’s continued operation. “It is also important to measure the amount of cellulose in the oil, as this is an indication of the extent to which the paper around the winding is degrading and turning to sludge,” Bertoldi says. “Judging by how much cellulose is in the oil, a prediction on the life expectancy of the transformer can be provided.” Even the simple oil colour test has a useful function in showing oil quality, indicating that further investigation may be necessary to keep the transformer well maintained. “All test results are kept in our extensive database, which allows a history of the trend analysis to be available to each of our customers,” Bertoldi says. “We use these figures daily in developing trends for

a particular customer or even a particular trans- former unit.” Access to regular oil test results makes it easier for custom- ers to identify poten- tial problems arising in their transformers, and to take corrective ac- tion to avoid expensive damage or unplanned downtime. Enquiries: Tel. +27 (0) 11 723 6000 or email marketing@ zestweg.com

Oil samples loaded for automated analysis process.

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