Electricity + Control March 2019

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

Our team of experts … … is expecting you …

The system-integrated solution for explosion protection requirements: PC-based control

EtherCAT I/Os: high-end measurement technology with low channel costs

… at the Ticketpro Dome, Booth D11 – D12 …

… on 4 – 6 June.

TwinCAT Vision seamlessly integrates machine vision into automation technology

TwinSAFE controllers: Modularity and scalability on all levels

www.beckhoff.co.za Beckhoff will exhibit innovations in all technology areas at Africa Automation Fair 2019. As an expert in industrial PC design & in-house manufacture, ultra-compact IPCs will be on display, along with One Cable Automation, where users can reduce installation and material costs significantly with the OCT and EtherCAT P technologies. Beckhoff’s extensive range of explosion-proof components providing comprehensive solutions for barrier-free system integration right into Zone 0/20, upcoming TwinCAT Vision as well as TwinCAT HMI and the new TwinSAFE controllers for more efficient implementation of distributed safety applications will be shown along with extremely accurate, fast and robust EtherCAT measurement modules and solutions for Industry 4.0 and lloT and the evolutionary EtherCAT G.

Beckhoff Automation (Pty) Ltd Randburg 2169, South Africa Phone: +27 (0)11 795 2898 info@beckhoff.co.za

We look forward to seeing you at the Ticketpro Dome, Booth D11 – D12!

COMMENT

ON THE COVER

FEATURES: · Drives,motors+ switchgear · Energymanagement+ environmental engineering · Hazardous areas+ safety · Industry 4.0+ Industrial Internet of Things (IIoT) · Plantmaintenance, test+measurement · Temperaturemeasurement

Maintenance cannot be ignored

I f it ain’t broke, don’t fix it. One so often hears this charming mantra. And I get it, OK! If systems are working, and things are fine, why rattle the cages? My concern is that I very often encoun- ter this catch phrase being used where it has no place at all ... in the context of a system that must not be allowed to break. And that, of course, is the problem: Sure, it ain’t broke right now – but if you do leave it alone it sure as heck will be ‘broke’ some time in the future. And oh my, will it be broken! Ensuring we avoid this takes a planned process. So there is surely no need to make any comment about maintenance, is there? I have no doubt that readers of Electricity+Control plan and manage their maintenance schemes carefully and pro- ficiently. I do worry, however, that maintenance is one of the first things to suffer on so many of our plants – some seemingly more visible (and in the public eye) than others. And, as you have no doubt realised, I mean that it is during those moments when times become a bit tough. One sure-fire way to protect the bottom line is to stop the spending. And, very of- ten, stable systems give the impression that we should not meddle with that which is working. We all use the ‘don’t fix it if it ain’t broke’ mantra, time and time again. Stable systems lull the powers that be into complacency. The argument is easily made that, surely, we can cut down on maintenance spend. But here is the problem: as soon as routine maintenance is reduced, unex- pected and unscheduled events begin to creep in. And then the trouble starts.

How often have you encountered a situation where, because the system is now beginning to behave badly, short-cuts and work-arounds begin to be found? And people do these things because, in their minds, they are necessary to ensure that productivity is unaffected. There is something disturbing in how we drive productivity – and how we re- ward productivity. Many people I fear are motivated more by keeping the lights on (shall we say), than recognising when we are actually damaging the system – and then stopping the plant. You can run the engine with little or no oil – in fact for a fairly lengthy period of time – but there will come that moment when it says ‘no more’. Maintenance, of course, is the subtle art of never getting to the point where you need to stop the plant unexpectedly. The requirement is to plan and manage main- tenance and refurbishment so there are no surprises. This is not rocket science: it is a well documented, tried and tested method of preserving your critical assets and keep- ing them functioning at their best. I must say, that as I look about the in- dustrial landscape of late, I have a niggling feeling that, just perhaps, we may have dropped a ball or two in this regard. Maybe I am wrong, but let the lesson be that none of us allows that to happen in our own spheres of influence.

EC_Mar 2019 cover.indd 1 2/26/2019 8:20:29AM www.electricityandcontrolmagazine.co.za

Schneider Electric 's Easergy P3 is described as the latest innovation in medium-voltage protection relay ... (Read more on page 15).

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CONTENTS

18

Features

DRIVES, MOTORS + SWITCHGEAR 4 Advancing motor drive solutions Supplied by Control Techniques

7 Round UP

ENERGY MANAGEMENT + ENVIRONMENTAL ENGINEERING 10 Green for growth: why green manufacturing is crucial for a low-carbon future Jean-Pascal Tricoire, Schneider Electric

13 Round UP

HAZARDOUS AREAS + SAFETY 18 New generation of safety controllers Dr Martin Früchtl, Safety Technology, Beckhoff Automation 22 K-class fluid and the prevention of fire in transformers Roberto Ignacio da Silva, Cargill (BR)

25 Round UP

INDUSTRY 4.0 + INDUSTRIAL INTERNET OF THINGS (IIOT) 26 Edge computing: the next wave of data centre modernisation Dave Laurello, Stratus Technologies, a Rockwell Automation Encompass Partner

26

28 Round UP

PLANT MAINTENANCE, TEST + MEASUREMENT 32 Inspecting steam systems to maintain optimum efficiencies Supplied by Comtest

34 Round UP

TEMPERATURE MEASUREMENT 36 Round UP

32

Regulars

1 Comment 15 Cover article 40 Write @ the back

2 Electricity + Control

MARCH 2019

DRIVES, MOTORS + SWITCHGEAR

Advancing motor drive solutions

This article looks at the challenges companies face in the implementation, operation, maintenance and upgrade of drive control systems for a variety of market applica- tions with different selection criteria. The upheaval in factory automation with the Industrial Internet of Things (IIoT) or Industry 4.0 is considered, as is its impact on the selection of drives.

Take Note!

1. Different motor types suit different applications. 2. Eachmotor type needs spe- cific drive characteristics and feedback processing for optimal performance. 1 2

D rives for ac motors have become an indus- try in themselves with various types offer- ing control of speed, torque and positional accuracy from sub-kilowatt power levels to mega- watts.The ac power sources might be from 200Vac to industrial 690 Vac, three-phase. While motors controlled can be induction, permanent magnet or servo-controlled types in common applications, ad- ditional applications emerge because of the value the drive gives. For example, entertainment theatre equipment is increasingly automated with preci- sion control of curtains, floors, scenery and light- ing. Full-featured drives enable remote controlled and programmable positioning and movement for smooth transitions. Communications back to the controller report on loading and performance. Motors are chosen for intended application. Induction types might be used when wide speed range is not a factor, cost is important and efficien- cy is not critical although this does lead to higher operating costs. Permanent magnet motors are more efficient and more expensive than induction motors but give lower operating costs and can give quicker payback. They are smaller than induc- tion motors for the same rating and can approach the positional accuracy of servomotors if feedback is applied. Closed-loop servomotors are relatively expensive but can provide optimum accuracy to +/-0.001% of base speed at rated torque, current and voltage. With their smaller rotors giving low inertia and fast dynamic response, they can reach high speeds with high peak torque and accelera- tion. They can be 25% to 50% smaller than other

motor types while typically achieving over 85% efficiency.

Induction, permanent magnet and servo motors from the Control Techniques range.

The motor type chosen for an application depends on the motor load. For example, an induction mo- tor might be used in constant torque/speed appli- cations such as conveyors and a permanent mag- net type for liquid pumping with wide and variable speeds. A servomotor would find its niche in ro- botics where fast acceleration to a precise position is necessary. Each motor type needs specific drive characteris- tics and feedback processing, if used. This, if the drive programming is optimal, results in optimal functional performance. Modern drives can form part of Industry 4.0, which combines automation with communication in real time to optimise pro- duction processes and save energy, improve prod- uct quality and provide operational flexibility. In the extreme instance, the system becomes self-learn- ing and removes the variabilities of human inter- vention. Using motor drives – opportunities and challenges

4 Electricity + Control

MARCH 2019

DRIVES, MOTORS + SWITCHGEAR

The priority could simply be small size relative to performance. This often goes hand in hand with the need for good thermal performance so that re- liability is not compromised by high packing and power density of the drive electronics and their cabinets leading to thermal stress. All users’ priorities interact and change with time, with factors such as lifetime cost less easy to quantify and factor-in. Although energy saving might be the issue today, a user might plan to im- plement IIoT with a view to further process cost savings. The user might then realise that size-effi- cient drives and motors give better floor usage and more throughput and economies of scale, again helping with cost and energy savings. Ideally the final choice of a drive should cover all the require- ments, either built-in or by simple expansion of ca- pability through modular construction. Drives with a built-in PLC can be considered, saving costs and improving performance, typically running application programs many times faster than external PLCs or motion controllers. Also, with the right drive architecture, scalability in pow- er output could be achieved with families of drives that share common interfaces and programming/ communication protocols for easy upgrade. Drive selection also involves consideration of what tomorrow’s requirements might be; visionary users that anticipate IIoT with its data sharing pos- sibilities might appreciate comprehensive control and monitoring features that allow predictive main- tenance and autonomous process optimisation, again saving costs and energy while improving the end user’s experience. Use of ‘open’ languag- es and protocols would give a range of benefits including optimised performance, increased sys- tem development speed, choice of components, future-proofing and security of knowing that engi- neers can always be recruited with knowledge of the open technologies. The drive should meet current and anticipated statutory requirements for performance and safety

Industry 4 or the Industrial Internet of Things (IIoT).

To get the best value from equipment, users now need to have the technical know- how to configure the drive and integrate it into a wider IT network.

As part of this, drives can be connected to a net- work, typically by Ethernet, so control and monitor- ing can be dynamic allowing for ‘on-the-fly’ adjust- ments and continuous monitoring of parameters that might indicate process variations. Energy can be saved and loads levelled for financial benefit. An issue with automation though is the physi- cal space taken up. A monetary value of potential productivity can be attributed to each square me- tre of a factory floor so equipment size is impor- tant. Also, to get the best value from equipment, users now need to have the technical know-how to configure the drive and integrate it into a wider IT network. The installer is a ‘drives’ engineer with skills in programming and knowledge of the mul- titude of external safety and EMC specifications that the drive has to meet for proper installation and operation. In this case, support from the drive manufacturer is key. Equally important is an under- standing of network security issues to ensure the drive’s programming cannot be unintentionally al- tered or its analysis data intercepted. Selecting a drive A good starting point for drive selection is one that can be configured for different motor types and sizes. Different users may have different priorities though. Energy efficiency of the process is often high on the list because of the power consumed and controlled by large motors. It has been stat- ed that electric motors account for about 45% of global energy consumption [1] so for many users, drives that can optimise process energy efficiency may be the first choice. For others, flexibility might be key and scalable drives that can be expanded in capability with optional modules would be at- tractive. Achieving the benefits of IIoT could also be important in which case connectivity needs to be considered with flexibility in support of different networking standards.

Electricity + Control

MARCH 2019

5

DRIVES, MOTORS + SWITCHGEAR

motion control applications, supporting PC-tool connection for commissioning and monitoring. All drives have a wide range of communications and expansion options and can be seamlessly paired with servo motors from the Control Tech- niques Dynamics ranges such as the Unimotor HD type with its 255 Nm peak torque and 1000 to 6000 rpm range. Size matters The Digitax HD series is one of the smallest drives available on the market for the functionality provid- ed. While meeting high levels of efficiency within the drive power stages, some heat is still generated by the drive which, given the high packing density, has to be effectively removed. Control Techniques has developed and patented its UltraFlow TM tech- nology which effectively dissipates heat directly outside of the cabinet for cooler internal tempera- tures. This can lead to a reduced cabinet size by up to 50% with the option to stack cabinets without the need for large air channels in between. In developing the Digitax HD series, Control Techniques drew on research carried out with its customers to identify the key features needed for a drive. These were: Speed and precision of motion; Reduced cabinet size; Ease of selection; Cost/price; Scalability; Class leading reliability; and Reduced installation time. Application examples are available that prove the attraction of the drive’s speed, response, versatility, simplicity and cost benefits whether from process energy savings or hardware reduction. Summary Motor drive specifiers have much to consider from the practical considerations of performance and size through to the life time costs of acquisition, maintenance, repair and upgrade.When upcoming changes are factored in such as Industry 4.0 auto- mation, a drive that is best-in-class performance, flexible, scalable and rich in communication op- tions is the right solution. This article was supplied by Control Techniques, part of the Nidec group.

by meeting standards such as IEC 61800-5-1 and UL508C for electrical safety and by incorporating such features as a Safe Torque Off (STO) control input for mechanical safety, preventing unexpect- ed motor rotation in the event of an emergency. Features like this should meet the requirements of Safety Integrity Levels (SIL) as defined in IEC 61508 Functional Safety of Electrical/Electronic/ Programmable Electronic Safety-related Systems. Digitax HD servo drive family Control Techniques, a UK-based Nidec group com- pany, has launched the Digitax HD family, a series of drives targeting servo motor applications with high axis count.

The Digitax HD servo drive from Control Techniques.

The Digitax HD family is optimised for high dynamic applications with a 62,5 μs current loop response, 250 μs position and speed loop response and up to 16 kHz switching frequency. The drive can operate with full servo control plus open-loop permanent magnet and induction motor control and with dif- ferent functionality levels. Motor loads can be from 0.25 kW to 7.5 kW, 1 A to 16 A with 48 A peak with torque ratings of 0. 7 Nm to 51 Nm, 153 Nm peak. The drive operates from 200 Vac or 400 Vac and is just 40 mm wide, fitting in a cabinet depth of 200 mm. Users will be familiar with the set-up of the drive as the Digitax HD series is compatible with existing design tools and is programmable with IEC 6131 standard languages. As well as a ‘base’ unit, versions are available with SI-Ethernet for centralised and decentralised motion control, an- other with full stand-alone capability without the need for an external controller, and a 2-port Eth- erCAT version for easy integration into centralised

Reference [1]. www.iea.org

6 Electricity + Control

MARCH 2019

DRIVES, MOTORS + SWITCHGEAR

Aluzinc provides for longer life motor control centres

difference, which is the powder coating of steel panels complicates the earthing re- quirement on an MCC, as the paint layer insulates the panel and prevents conduc- tivity. “This means technicians and install- ers must take special care to ensure that proper contact is made between the unit and the earth connection,” he says. For instance, the use of star washers must be strictly enforced among installa- tion staff. Alternatively, certain areas of the MCCs can be left unpainted to allow for earth connections. Kohler points out, however, that this raises the concern that it only takes a small oversight and the earthing will not be fully effective.The use of Aluzinc eliminates this issue as there is no longer a paint layer between the earth connection and MCC panel. There is also the possibility of painted parts being scratched or damaged during transport and installation. When this oc- curs, it leads to the time-consuming task of their being returned to the factory for repeat powder-coating, further delaying installation and commissioning. Addition-

The replacement of steel by Aluzinc in the manufacture of Shaw Controls motor control centres (MCCs) provides a range of benefits to customers, according to the company’s Senior Manager Opera- tions, Anderson Kohler. “Traditionally, we used only steel for our MCCs and steel needs to be pow- der-coated to protect it from corrosion,” says Kohler. “This made completing our products a long process, one that the use of Aluzinc can now simplify and speed up.” The usual process of preparing the MCC panels includes welding, grinding and pre-washing before the powder-coat- ing painting process can take place. These phases can now be bypassed by using Aluzinc, a material that effective- ly resists corrosion without a protective coating being applied. Aluzinc comprises 55% aluminium, 43,5% zinc and 1,5% silicon and offers an extended lifespan. Manufacturers of the product guarantee it will last for about 35 years before any major maintenance is required. Kohler explains another point of

ally, if there is a need for re-welding, the process of grinding and pre-washing has to be repeated before painting again. Kohler highlights that the corrosion-re- sistant properties of Aluzinc allow parts to be kept in stock, ready for quick assem- bly, whereas this is not possible with mild steel due to its potential corrosion. “By introducing the use of Aluzinc in the manufacture of our MCCs, we can reduce the lead time on components by as much as two to three weeks. This is a time-sav- ing that we can pass on to our customers, delivering more quickly,” he says. Part of the ZestWEG Group, Shaw Con- trols has over 30 years’ experience as a manufacturer of quality MCCs, distribution boards, medium voltage (MV) switchgear, control desks, PLC and instrumentation enclosures, portable and containerised substations, E-houses and various other electrical enclosures. The company’s Rob- ertsham facility is ISO 9001 accredited. Enquiries: ZestWEG Group, Africa. Tel +27 (0)11 723 6000 or email marketing@zestweg.com

round up DRIVES, MOTORS + SWITCHGEAR

Drive system for automotive assembly-line extension

desired transport speed, existing space restrictions and specific ambient conditions of the application. The MOVIPRO ® SDC provides a solution for both horizontal and vertical trolley/skillet applications. It integrates all necessary functions and allows for decentralised installation of up to 15 kW. The solution is characterised by its robust design, especially in terms of reliability and precise positioning requirements. With its modular, standardised design and freely configurable software components, this decentralised drive and positioning control sys- tem facilitates the integration of numerous functions while reduc- ing the complexity of the machine or system. At the Port Elizabeth plant, SEW-Eurodrive was required to replace an existing MOVITRANS ® system, installed originally in 2006, in order to accommodate the addition of a further four skil- lets to the existing line. This was done to upgrade the technology to the latest iteration developed by the research and development department in Germany. The MOVIPRO ® SDC provides wireless communication for the MOVITRANS ® system, based on WiFi routers. Adding to the complexity of the solution required was the fact that the 30 dif- ferent stations along the assembly line had different height re- quirements. “This meant we had to design a height table into the system,” La Cock points out. SEW-Eurodrive’s scope of work on this project included com-

The MOVITRANS ® contactless energy transfer system from SEW-Eurodrive (Pty) Ltd., together with its MOVIPRO ® SDC de- centralised drive, position and application controller, played a key role in the recent assembly-line extension at a major automotive manufacturer in Port Elizabeth. The main advantage of the MOVITRANS ® system is that it is based on contactless energy transfer. In this system, electrical energy is transferred without contact from a fixed conductor to one or more mobile users. The electromagnetic connection is made via an air gap and, because it is not subject to wear, the system has the added benefit of being maintenance-free. In ad- dition, this type of power supply is emission-free and therefore environmentally friendly. Electronics Support Technician at SEW-Eurodrive, Juandré La Cock, elaborates: “MOVITRANS ® is the ideal supply system for mobile applications and has been tested according to BGV B11. It is particularly suitable, for example, for equipment that has to cover long distances at high speeds or if maintenance-free operation is required. It is also suited for applications in sensitive environments where outside contaminants must be excluded, and in wet and damp environments.” Wherever a trolley or skillet conveyor system is in use, as in an automotive assembly line, a custom-designed drive system is required to correspond to the required load-bearing capacity,

missioning the extension of the as- sembly line and ensuring that the entire plant was up-to-date with the latest technology. This involved reset- ting all of the MOVIPROs ® , replacing and extending the Leaky WiFi cable, and then replacing the MOVITRANS ® system with the latest version. La Cock adds that, since the original in- stallation, the entire system has func- tioned flawlessly. While SEW-Eurodrive Maxolu- tion® has developed products and solutions specifically for the automo- tive industry, the system supplied for this project has been customised specifically for the automotive manu- facturer. “This demonstrates our flexi- bility in being able to adapt to specific client requirements and how we en- sure our long-standing clients remain up-to-date with the latest develop- ments,” La Cock concludes. Enquiries: visit SEW-Eurodrive (Pty) Ltd https://www.sew-eurod- rive.co.za/home.html

A trolley or skillet conveyor system for an automotive assembly line.

8 Electricity + Control

MARCH 2019

DRIVES, MOTORS + SWITCHGEAR

Soft starters for three-phase motors

time. A backlit LCD icon language-neutral display is incorporated on the fascia for quick and easy configuration and visualisation of all measurements and status parameters. Alarms and text can be displayed in any of six languages. Icons indicate default application set-up in use, while graphic bars indi- cate the motor and internal thyristor temperatures, and an alpha- numeric display shows texts and measurements as well as the current status of the starter. Input and output functions are pre-configured to the most common settings, but can easily be overridden to adapt the soft starter to specific application needs. The ADXL series incorpo- rates two counters dedicated to count the number of start-ups and motor operating hours, to set possible thresholds to activate an alarm for potential maintenance purposes. The soft starters are supplied pre-configured out-of-the-box for most common applications, such as centrifugal pumps, fire-fight- ing pumps, conveyer belts, fans, mixers, and general purpose. This makes set-up easy. Selecting the required application automatically updates the parameter programming to the requested application. Programming can be done on the front four-button controls, together with the icon display, or via a front-mounted optical port that can be configured to connect to a computer via USB or WiFi using optional accessories, or simply via NFC (Near Field Commu- nication), using compatible smartphone or tablets, even with the starter turned off. All ADXL series soft starters are equipped to receive a dedi- cated RS485 Modbus communication card, allowing for constant monitoring of all starter measurements, or to connect to an op- tional remote keypad with display to view the measurements, or to perform the set-up on the front of the enclosure. Enquiries: Karen Zotter at ElectroMechanica. Tel. +27 (0)11 249 5000, or email karenz@em.co.za

Soft starters offer the advantage of limiting the inrush current, in turn improving overall stability of the power supply and reducing transient voltage drops, which may affect other loads in a network. They are ideal for applications demanding high-performance in terms of control and protection during motor start-up and operation. Soft starters can avoid pressure surges and prevent water ham- mering (typically a big problem) in pump applications. Conveyor belt systems can be started smoothly, avoiding jerk and stress on drive components. Fans or other systems with belt drives can be started slowly, and avoid belt slipping. The new ADXL series from Lovato, distributed in South Africa by ElectroMechanica (EM), comprises compact soft starters for three-phase motors from 7,5 kW to 160 kW, in four frame sizes. EM Product Manager, Jaap Grobler, says the series allows for control of starting, stopping, monitoring, and protection, with integrated functionality for a highly efficient starting solution. A bypass facility is provided on all sizes. This operates when the start-up function has completed, thus reducing power losses and saving energy. A wide operational voltage range of 208 Vac to 600 Vac, a com- pact design, and advanced functionality make the ADXL series an efficient solution for applications in diverse industries. Two-phase control during motor starting and stopping, com- bined with torque control during operation, provide optimised ramping characteristics. This ensures smooth start and stop func- tionality for all applications, increasing the lifespan of connected motors and power transmission devices. Kick-start functionality delivers high torque only during the initial starting period, enabling motors to be started when initial torque is insufficient to over- come friction. The ADXL series is equipped with built-in electronic overload protection to protect the motor from overheating. No additional overload device is required, which saves space and installation

Electricity + Control

MARCH 2019

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ENERGY MANAGEMENT + ENVIRONMENTAL ENGINEERING

Green for growth: Why green manufacturing is crucial for a low-carbon future

By Jean-Pascal Tricoire, Schneider Electric

Climate change is indisputable, as is its impact on our planet’s invaluable but finite re- sources. Indeed, this is one of the most pressing paradoxes of our time: How do we strive for industrial growth while also being mindful of the traditional environmental impact of productivity?

1. Economic growth can and must be decoupled from environmental degrada- tion. Take Note! 1

W e must find the right balance. Everyone feels this urgency.The world is on a fast track to consume four Earths’ worth of resources by 2050. [1] A recent United Nations re- port also warned that CO 2 emissions must be cut nearly in half by 2030 to safeguard the planet from additional threats of climate change. [2] Take note: this is just 10 brief years away. Without a doubt, the time for change is now. Green manufacturing, an emerging industrial trend with an achievable, long-term future for sustaina- bility, addresses these environmental challenges at a systemic level. It answers the call to action. What is green manufacturing? In short, green manufacturing is primarily about changing business and manufacturing practices, as well as the mindset of stakeholders, to mitigate the industrial impact on climate change and oth- er environmental concerns. Green is not a hollow word. There are tangible ways to drive sustainable practices: within manufacturing facilities, across the supply chain, and through the customer base. The Fourth Industrial Revolution and Industrial Internet of Things (IIOT) present new opportunities to unlock process innovations to develop sustain- able, environmentally-friendly materials; decarbon- ise energy; tap digital innovation for doing more with less; and extend the life cycle of goods within a ‘zero waste to landfill’ framework.

What are the results? • Reduced use of natural resources and energy. • A lower carbon footprint worldwide. • Technology advances that optimise efficiency, resilience and sustainability across the full man- ufacturing life cycle, including the supply chain. • The building of a strong foundation for a global circular economy. Develop new materials There is significant potential to substitute carbon-in- tensive materials for less carbon-intensive ones. In the buildings sector at large, for example, it is possible to use timber or pozzolan-based concrete instead of Portland cement to mitigate pollution. It also is possible to improve materials processing systems. For instance, in addition to using greener electronic materials such as innovative bio materials, electronics companies now can incorporate green packaging. A case in point is wheat straw packaging, which can lead to a 40% saving in energy and a 90% reduction in water required for production. [3] Companies can – and should – adopt eco-label- ling to let consumers and end-users know where they stand. In Schneider Electric’s case, we use a Green label and tool for transparency on regu- latory compliance, product environmental profiles and end-of-product-life instructions. In the coming years across manufacturing segments, look for blockchain advances to improve green traceability.

10 Electricity + Control

MARCH 2019

ENERGY MANAGEMENT + ENVIRONMENTAL ENGINEERING

Circular economy system diagram. (Image: Ellen MacArthur Foundation)

Decarbonise energy The huge payoff of a green manufacturing position is energy savings. Here, environmental and busi- ness benefits go hand in hand. We see a bright future for decarbonising energy. The latest Ener- gy Transitions Commission (ETC) report Mission Possible declares that reaching net-zero CO 2 emis- sions by mid-century is a very real vision. This goal can be achieved largely by the decarbonisation of power and the electrification of processes. The cost of decarbonisation also can be reduced sig- nificantly by constraining demand growth for car- bon-intensive transport (through greater logistics efficiency and modal shift). With digitalised process innovation, even en- ergy-demanding industries such as concrete production can push towards more efficient, cli- mate-friendly practices. China National Building Materials Group is a model in this regard, cutting energy use by 10%. Deliver digital innovation Thanks to IIoT technology and the development of smart connected devices, manufacturers can prioritise resource efficiency projects alongside productivity goals. Connected assets throughout a facility can yield insights into real-time and his-

torical energy use, enabling industrial enterprises to streamline energy and resources from a bot- tom-line perspective. And when energy is among a company’s top expenses, this view of it is critical. Producing high-performance materials at Saint- Gobain’s plants, for example, requires massive amounts of power. Through digital innovation, Saint-Gobain has a realistic goal of curbing energy use and, in turn, cutting carbon emissions by 20% by 2025. Green growth is possible. To do our part for the global resources land- scape, Schneider Electric implements solutions across the life cycle of its own products to improve usage and extend their lives. Schneider’s Smart Factory Program applies the company’s own EcoStruxure™ solutions across its global supply chain to drive operational and energy efficiencies. These systems also enable us to quantify the CO 2 emissions of clients to further reduce global emis- sions numbers. Our aim is to avoid the release of 100 million tons of CO 2 emissions between 2018 and 2020. Drive a circular economy But make no mistake: green manufacturing is about more than leveraging high-tech materials production and pushing for energy-efficient practic-

Green is not a hollow word. There are tangible ways to drive sustainable

practices within manufacturing facilities.

Electricity + Control

MARCH 2019

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ENERGY MANAGEMENT + ENVIRONMENTAL ENGINEERING

es. It requires a fundamental change in the journey of goods. We know the traditional manufacturing journey is linear: a straight path from cradle to land- fill in which products are made, used and thrown away. Sometimes, they are never even brought to market. It’s time to reshape the status quo . The green manufacturing journey, by contrast, is circular. It moves beyond the 3R approach of ‘reduce, reuse, recycle’ towards a 5R approach: ‘repair, reuse, refurbish, re-manufacture, and recy- cle’ thereby driving optimised use of the resources and an extended life of products. Achieving “zero waste to landfill” is possible. Schneider itself has committed to recovering 100% of its industrial waste at its 200 manufactur- ing sites by 2030. In addition to the environmen- tal payoff, our circular business models have also resulted in 12% circular revenues and continued growth. And Whirlpool, a global appliance manu- facturer, is on target to realise a three-year savings of $1 million through enhanced recycling practices. Collaborating for the greater good When it comes to making meaningful change, we are all in it together. An extended enterprise ap- proach is essential. We can look to Shanghai as a model here. Aside from businesses, Shanghai is bringing together government and educational stakeholders to advance green manufacturing as a municipal priority. Shanghai is pursuing a strategic combination of R&D investments, partnerships with universities, local and multi-national company collaborations, and innovation hubs to set ardent sustainability targets and – more importantly – take collabora- tive steps to achieve them. Shanghai also offers a deep talent pool, municipal commitment to green growth, private and public infrastructure for inno- vation ecosystems, and a strong foundation to de- velop next-era, sustainable manufacturing excel- lence. These measures have rapidly transformed the city into a green manufacturing hub we all can look to as a model. Adapting for the future Let me be clear: green manufacturing is simply good business. It offers revolutionary advances in

productivity and efficiency without the downsides of waste or pollution. Economic growth can and must be decoupled from environmental degrada- tion. The true power of green manufacturing will reveal itself when the entire industry begins to detach one from the other, thus accelerating the planet toward a low-carbon reality. This green mis- sion is possible. This is an edited version of the post by Schneider Electric Chairman and CEO, Jean-PascalTricoire, on the company’s website. With permission from Schneider Electric. References [1] Business Council for Sustainable Develop- ment, “CEO Guide to the Circular Economy,” June 2017 http://docs.wbcsd.org/2017/06/ CEO_Guide_to_CE.pdf [2] From 2010 levels. UN Intergovernmental Panel on Climate Change, “Summary for Policymak- ers of IPCC Special Report on Global Warm- ing of 1.5°C approved by governments,” Oc- tober 2018 https://ipcc.ch/news_and_events/ pr_181008_P48_spm.shtml [3] World Economic Forum White Paper, “Driving the Sustainability of Production Systems with Fourth Industrial Revolution Innovation,” Jan- uary 2018, http://www3.weforum.org/docs/ WEF_39558_White_Paper_Driving_the_Sus- tainability_of_Production_Systems_4IR.pdf

Jean-Pascal Tricoire joined Schneider Elec- tric in 1986. He was appointed President and Chief Executive Officer in 2006 and named Chairman and CEO in April 2013. His career at Schneider Electric has devel- oped largely outside France in operational functions in Italy, China, South Africa and USA. Jean-Pascal has been President of the France-China Committee since 2009. He holds a degree in Electronic Engineering and an MBA.

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ENERGY MANAGEMENT + ENVIRONMENTAL ENGINEERING round up

Kathu 100 MW concentrated solar power plant newly operational

Kathu will provide clean and reliable energy to 179 000 homes in the local John Taolo Gaetsewe District Municipality, the Northern Cape and South Africa as a whole. In addition, it is estimated that Kathu Solar Park will save six million tons of CO 2 over 20 years. It is also set to foster further local economic development through several projects, such as the trust estab- lished for the benefit of the communities in the Northern Cape and sourcing of services from local entrepreneurs. The KSP shareholders, which are led by Engie (48,5%), in- clude a group of South African investors comprising SIOC Community Development Trust, Investec Bank, Lereko Metier Sustainable Capital Fund and its co-investors: FMO, the Dutch development bank and DEG, the German investment and de- velopment company, and the Public Investment Corporation. The main contractor (EPC) is Liciastar– a Spanish consortium of SENER and Acciona working with the Kelebogile Trust. In South Africa, Engie has interests in a wind farm (94 MW, Aurora), two solar photovoltaic parks (21 MW) and two thermal power peaking plants (670 MW, Avon and 335 MW, Dedisa). Engie also owns Thermaire Investments (Pty) Ltd. and Ampair (Pty) Ltd., leaders in the HVAC installation and maintenance sec- tor in the South African market. Enquiries: visit www.Engie-Africa.com

Global energy and services group Engie recently announced that at end January 2019 it had achieved commercial operation for the 100 MW Kathu Solar Park in South Africa. This state- of-the-art plant is a greenfield concentrated solar power (CSP) project using parabolic trough technology and equipped with a molten salt storage system that allows for 4.5 hours of thermal energy storage. This provides for reliable electricity in the ab- sence of solar radiation and during peak demand. As a 100 MW project, Kathu Solar Park is one of South Af- rica’s largest renewable energy projects. The Kathu site covers approximately 4.5 km², with 384 000 mirrors. Kathu is the first CSP development for ENGIE. The solar park was given the go-ahead under Round 3.5 of South Africa’s Renewable Energy Independent Power Producer Procurement Programme (REIPPP), the competitive tender pro- cess that was launched to facilitate private sector investment in renewable energy generation. Pursuant to the REIPPP pro- curement programme, Kathu Solar Park signed a 20-year power purchase agreement (PPA) with the off-taker/buyer. Isabelle Kocher, CEO of Engie, says: “The completion of Kathu shows our continued commitment to economic and environmen- tally friendly development in South Africa. Kathu, with its molten salt storage design, offers a clean solution to overcome the inter- mittency of renewable energies. We are proud to contribute to the country's renewable energy goals and look forward to contin- uing the projects initiated with local communities, making Kathu a genuine driver of regional economic development.”

The 100 MW Kathu concentrated solar power plant is now operational in the Northern Cape.

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Grid-tied solar plant supplements energy supply

solar and other renewable energies and represent a compelling case, in terms of economics and sustainability, for their use.” Hanonox specialises in solar power solutions as well as sup- plying diesel generators and static UPS solutions. It handles lead- ing technologies and incorporates technical expertise to provide the best turnkey solution for particular power problems – aiming to minimise downtime and increase productivity, profit and secu- rity for its customers. Enquiries: Hanonox.Tel. +27 (0)10 312 5790 or email info@hanonox.co.za

Hanonox, a turnkey power solutions company, recently complet- ed a 182 kWp grid-tied solar project for financial services provider, MHA Management Holdings, in Johannesburg. Hanonox’s tech- nical and design teams undertook the entire project – from modi- fying the existing carport structure to allow for panel mounting, to installing and commissioning the system in January 2019. Consisting of innovative 27.6 kW SolarEdge inverters and Tri- na 270 solar panels, the system is connected to the main elec- tric power feed for the building. Generating about 874 800 kilo- watt-hours of electricity annually, it will offset nearly two-thirds of the firm’s electricity costs. Nathan Bergemann, director of Hanonox, says, “In the MHA Management Holdings project we have realised our mission of delivering true turnkey renewable energy solutions. Companies like MHA recognise the financial and environmental benefits of

Solar panels are mounted on the existing carport roofs at the office premises and supply solar power to supplement the main electric power.

Expanding beyond rental power new name echoes the strategic direction the company has taken.” Moving beyond its traditional scope of providing only temporary power solutions, Altaaqa Global Energy Services now of- fers power plants on flexible short-, medi- um- and long-term contracts with tailored project-financing arrangements, including the option of build-operate-own-transfer (BOOT). In addition, the company delivers cost-efficient, bespoke multi-megawatt power plants comprising a wider range of power generation systems, including reciprocating engines, turbines and hybrid

technologies, capable of running on die- sel, gas or HFO (heavy fuel oil). “We aim to be more than just a tech- nology provider and to serve our clients as a strategic power partner,” said Shepherd. Majid Zahid, Group President, Energy at Zahid Group, a global industry conglomer- ate and Altaaqa Global’s parent company, added: “With this rebrand, we are not only redefining who we are, but we are also driving change and taking a leadership role in shaping the future of the energy indus- try.” Enquiries: Jerome Sanchez, email Jsanchez@altaaqaglobal.com

Altaaqa Global Caterpillar Rental Pow- er, a global provider of temporary power services, recently announced a major re- branding. The company will from now be known as Altaaqa Global Energy Services. James Shepherd, Chief Executive Of- ficer, said: “The global energy landscape has changed and the requirements of the sectors we serve – such as mining, manu- facturing, cement and utilities – are chang- ing too. In order to cater to their demands and reflect the change in the company’s business proposition, providing longer- term projects as an integrated renewable and reciprocating solution provider, the

14 Electricity + Control

MARCH 2019

COVER ARTICLE

FEATURES: · Drives,motors+ switchgear · Energymanagement+ environmental engineering · Hazardous areas+ safety · Industry 4.0+ Industrial Internet of Things (IIoT) · Plantmaintenance, test+measurement · Temperaturemeasurement

Schneider Electric South Africa launches new Easergy P3 protection relay

EC_Mar2019 cover.indd 1

2/26/2019 8:20:29AM

E asergy P3 is described as the latest innovation in medium-voltage protection relay, designed to handle the challenges of modern electrical protection and distribution network management with power and flexibility. Schneider Electric, global specialist in energy management and automation, has announced the launch of Easergy P3 protection relay in An- glophone Africa. With the latest protection and modern digital communication capabilities, it is a major step forward in operational efficiency for

MV equipment protection and control devices. In addition, Easergy P3 is made to enable Schneider Electric’s EcoStruxure™ Power architecture and Smart Grid solution for end users. “We know that in the dynamic world of energy, there is growing demand for more efficient, fast delivery and easy-to-use products. These custom- er needs are addressed with the Schneider Elec- tric innovation that comes with the digitised Easer- gy P3 protection relay,” said Brighton Mwarehwa, Marketing Director for Power Systems at Schnei- der Electric Anglophone Africa.

“Today’s distribution systems are becoming more and more digitised and decentralised to meet customers’ require- ments. Furthermore, safety, reliability and efficiency are becoming increasingly criti- cal and complex to realise,” he added. “The Easergy P3 is designed to meet custom- ers’ expectations and provide simplicity, efficiency and more productivity.”

Enquiries: Schneider Electric SA, Tel: +27 (0)11 254 6400 www.schneider-electric.com or email sahar.javdani@se.com

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round up ENERGY MANAGEMENT + ENVIRONMENTAL ENGINEERING

Saving energy in agri-industry

operating for 4 000 hours per year at 91% efficiency, will consume about R93 800 worth of energy, still using old- er control methods of valves that can be throttled to reduce the output of water volume and/or pressure. The same water volume and/or pressure could be achieved using a VSD to reduce the motor speed, while simultaneously further reducing the energy used, when compared to running the motor direct online from a power source. If a 10% reduction in oper-

In the agricultural sector, operating an irrigation system can be ex- pensive, with one of the primary cost factors being the cost of energy. There are ways to reduce costs and achieve savings on energy by leveraging available technology. Selecting an appropriate electric motor and variable speed drive combination can reduce owning and operating costs while provid- ing reliable performance, and WEG IE3 Top Premium Efficiency motors and WEG Variable Speed Drives (VSDs), from Zest WEG Group, can assist with this. As a supplier with a solid track record in irrigation applications, Zest WEG Group highlights an example of how energy costs can be reduced. In a pivot pump application which operates for 4 000 hours in a single year – relative to two planting cycles – it was pos- sible to do a comparison between a standard efficiency IE1 motor (91% efficiency) and a premium efficiency WEG IE3 motor. WEG IE3 Top Premium Efficiency motors offer maximum in- gress protection with a higher winding insulation system to in- crease motor life expectancy as well as efficiencies of up to 96.6%. The benefits can be seen when compared against IE1 standard efficiency motors. Using a 22 kW 2 Pole at 75% of full load IE1 motor with an efficiency of 91%, measured against a WEG IE3 motor with 93% efficiency, estimated savings amount to a cou- ple of thousand rand per year (per motor), at the current tariff. However, much higher savings can be realised by using a WEG VSD in combination with a WEG motor. An IE1 electric motor, again

The combination of higher efficiency WEG electric motors and WEG VSDs can demonstrate real reductions in energy consumption.

ational speed using the VSD is assumed, further savings of 22% to 27% could be achieved; based on the affinity law princi- ple of hydraulics. The Zest WEG Group is available for consultation on energy-sav- ing solutions for irrigation and many other industrial applications. Enquiries: ZestWEG Group Africa.Tel. +27 (0)11 723 6000, or email marketing@zestweg.com