Electricity + Control March 2021

FEATURES: · Control systems + automation · Drives, motors + switchgear · Measurement + instrumentation · Transformers, substations + cables

MEASUREMENT EXPERTS FOR PROCESS CONTROL

Leading-edge technology for your industrial applications

COMMENT

INDUSTRY 4.0 + IIOT

energy + information in industry

MECOSA (Pty) Ltd, sole business partner for Berthold in Southern Africa, specialises in critical measurement solutions for any process conditions. (Read more on page 3.)

The future of IoT T he Internet of Things – or the Industrial Internet of Things, or digital transforma- tion, or even 4IR – whatever you prefer to call it, is here and it’s big. Without showing my age too much, I fondly recall, as a young engineer in a Con- trol and Instrumentation Department, being terribly excited by mimic panels, 4-20 mA loops, multi-drop systems, heat-generating cabinets of whirring devices. And cabling that went on for kilometres, flashing lights and the like. Then the internet began to emerge and folk set about using it in the control environ- ment, trying to figure out how signals could be guaranteed to arrive at the designated receiver, and then how the intelligence of the system could be decentralised – allow- ing some decisions to be made in the field, and so on. PLCs were big, and computers began to infiltrate the plant progressively. Then we moved to industrial wireless communications – and I recall some of the angst accompanying that. And so it goes. Now our industries, our offices, even our homes bristle with super-smart devic- es that communicate seamlessly and truly empower control of the plant – whatever the plant may be. Even the car can be started remotely, if that works for you... What this emphasises is the prolifera- tion of data on any site – and the contin- ued importance of recognising that data without analysis is not particularly useful. We still need to extract the information from the data to make it of value to the related processes.

However, what the Internet of Things has done, of course, is bash down some of the barriers between the office and the plant, between plants separated by provincial boundaries, and even between internation- al locations. And dare we admit it – between our homes and our workplaces – the indus- tries in which we work. It has also meant that many of the issues and solutions, which once seemed relevant only to manufacturing or process plants, are now being used to manage commercial and business environments – with even your own smart device purporting to explain to you, quite often I might add, how efficient or effective you have been. The blurring of the lines between our per- sonal lives and our business lives has been profoundly influenced by this new normal – and the capacity to monitor and man- age many facilities, and indeed industries, remotely, is really pointing us to the next major developments. These developments will see the world of work change dramat- ically again – frankly, as we may not have imagined it could. The fact is, though, we will muddle through this as a species – and no doubt emerge stronger yet – in an age when smart devices will quite genuinely be a real exten- sion of ourselves, when our brains and our computers are tightly linked, and when we will be an integral part of the very process we aim to control. Interesting times ahead I think!

Editor: Leigh Darroll Design & Layout: Darryl James Advertising Manager: Heidi Jandrell Circulation: Karen Smith Editorial Technical Director: Ian Jandrell Publisher: Karen Grant Deputy Publisher: Wilhelm du Plessis

Audited circulation: Quarter 3 (July-September) 2020 Total print and e-editions: 7741

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Electricity+Control is supported by

Ian Jandrell PrEng IntPE(SA), BSc(Eng) GDE PhD, FSAAE FSAIEE SMIEEE

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

CONTENTS

INDUSTRY 4.0 + IIOT

Features

CONTROL SYSTEMS + AUTOMATION 4 Taking standardised electrical designs into new markets Eplan Software & Service

7 New textile recycling plant, Sundsvall, Sweden Valmet

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9 Products + services

DRIVES, MOTORS + SWITCHGEAR 13 Beyond the VSD: Making motors run efficiently Tony Young, CP Automation

15 Products + services

MEASUREMENT + INSTRUMENTATION 19 Smart sensors and IoT are changing logistics Michael Bozek, Pepperl+Fuchs

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21 Products + services

TRANSFORMERS, SUBSTATIONS + CABLES 24 EMI diagnostics: Isolated phase bus Michael Narbrook, Doble Engineering Company

26 Products + services

Regulars 1 Comment

The future of IoT

19

3 Cover article The measurement experts for process control

29 Reskilling, upskilling + training Young innovators in science and engineering

30 Engineering the future Engineers Without Borders design challenge

31 Cybersecurity Stepping up OT network protection

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32 Write @ the back Cleaner jet fuel from non-recyclable plastics

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COVER ARTICLE

The measurement experts for process control

C ritical measurement solutions for any process conditions are our speciality. Wherever measuring conditions are extreme and conventional measuring technologies fail, our non-contact radiometric systems are the answer. Simple, yet sophisticated principle Radiometric measurements are based on the principle of attenuation. The source emits gamma radiation that penetrates both the vessel and its contents, and is subsequently detected by the detector. If there is no material in the radiation path, the intensity of the radiation remains almost the same. However, if the radiation has to penetrate matter, it is attenuated. The attenuation increases with increasing density of the penetrated material. Since this principle applies to almost every radiometric measurement, it can be used to determine not only the density of the material in the vessel, but also its level, or to perform a limit switch task. Level measurement for industrial processes In the process industry, precise systems for level and level switch measurement are fundamental and make an important contribution to the safety and high quality of production and logistics processes. Level measurements for extreme process conditions can be done easily with the help of radiometric measurement technology. Invented by Berthold, this technology has been providing reliable measurements for more than 70 years. It is most often applied in the measurement of liquids and solids in process tanks, storage tanks or silos. However, there are areas where level measurements are not feasible or attainable with conventional measurement technology due to the extreme boundary conditions, or they are possible only with very high installation or maintenance costs. This is the case, for example, in environments with high pressures or high temperatures or with aggressive or abrasive media. Contactless and yet perfect Radiometric measurements are usually the last option considered for level measurement in process control, as the use of radiometry involves a certain amount of work, including regulatory approvals. However, with proper compliance with regulations, this technique offers many clear advantages. It provides highly reproducible and reliable measurements. The systems are characterised

by wear-free and maintenance-free operation, and they are easy to set up: only a single calibration is required during initial commissioning. The advantages extend over their lifetime in each application, starting with the simple installation, which also allows for easy retrofitting to existing vessels, in the smooth handling and operation, and through the systems’ long, reliable and safe use. With its diverse product portfolio, specialised knowledge, and 70 years of experience, Berthold develops suitable solutions together with its customers for new, unique process tasks in a wide variety of industries and applications. Berthold stands for expertise, quality and reliability. It offers its customers the most effective solutions on the market. MECOSA (Pty) Ltd is the sole business partner for Berthold in Southern Africa and has cooperated with Berthold for more than 30 years.

Based on the principle of attenuation, radiometric measurement tracks the intensity of radiation between the source and a detector.

For more information contact MECOSA. Tel: +27 (0)11 257 6100 e-mail: measure@mecosa.co.za Visit: www.mecosa.co.za or: www.berthold.com/pc

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Taking standardised electrical designs into new markets Schaeffler Sondermaschinenbau, a company focused on construction of specialised machinery, is standardising its electrical designs across its numerous operating locations – and relying on Eplan Platform to do this.

A s a specialised machinery compa- ny with 1 700 employees working at 13 locations, Schaeffler ranks among the big players in the field of ma- chine building. What’s unusual about it, however, is that until now the company has been serving (almost) only one customer – which indicates that this must be a client with a major international brand. And that is indeed the case. Specialised machinery construction Schaeffler Sondermaschinenbau develops customised machines and plant systems for the entire corporate group: the Schaeffler Group has around 84 200 em­ ployees across 170 locations worldwide and a turnover of €14.4 billion (2019). For this integrated, globally active automotive

Schaeffler Sondermaschinenbau handles around 4 500 projects annually – every one of them is complex and mechatronic, many with robotic components.

and industry supplier, Schaeffler Sondermaschinenbau focuses on assembly systems and testing technology for production lines. Overall, the special-purpose machine division realises most of the in-house production equipment required by the corporate group. Among recent highlights are the development and realisation of complex assembly and testing lines for automotive hybrid modules and for the new electric axle drive systems. And these are just two of

around 4 500 projects that this Schaeffler division handles annually.

Manufacturing expertise The depth of development in production technology has a long tradition at the company. In 1960, brothers Dr Georg and Dr Wilhelm Schaeffler initiated a Department for Production Equipment, which still contributes to the company’s success today. As a Tier 1 supplier for the automotive industry, Schaeffler develops and manufactures very complex products such as roll stabilisers, 48 V drive systems and electric axle modules, all of which are produced to the highest quality standards and under intense cost pressures. A high level of manufacturing expertise is a major advantage here. Around 60% of Schaeffler Sondermaschinenbau’s 1 700 employees around the globe work in development and design for individually customised production solutions. Software is also playing an increasingly important role. IT production solutions are programmed for almost all automated assembly technology projects and the know-how goes much deeper. For instance, the developers created an app for condition monitoring to increase productivity and system availability in demanding production environments.

Eplan Key User Sascha Jäger at the company facility in Bühl, Germany

Stefan Vietz, Electrical Design Engineer at the company site in Erlangen, Germany.

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At a glance  Overall, the special-purpose machine division realises most of the in-house production equipment required by the Schaeffler Group.  In opening up to new markets, a high level of manufacturing expertise is a major advantage and software is playing an increasingly important role.  With the standardisation of electrical design software at its various sites the company is developing a common, harmonised infrastructure, which will enable its design teams to collaborate worldwide.

cation assignment are normed, and device management has also been standardised. And it goes almost without saying that every component is stored in the ERP system with all its relevant data. To simplify the design, the team created macros for fre- quently used devices with a clear goal in mind. Each device is assigned a data set that is as comprehensive as possible. This makes manufacturing easi- er. The maxim: “Whoever needs data – whatever type is required – should get it.” This is taking place against the background that, in the future, more external customers will be requesting data, for instance for preliminary acceptance of systems. Standardisation on the device level also leads to components that can be interconnected with a minimum of effort. So if, for example, a customer chooses a controller or an electric motor from another manufacturer, it’s not a problem. Jäger says, “The devices are simply swapped out and all the data of the new components is used.”

The new standard: tablets with Eplan eView support the commissioning technicians. Opening to external clients Until quite recently, Schaeffler Sondermaschinenbau designed and realised almost exclusively in-house projects for the corporate group – and had plenty of to do, as the 4 500 projects annually demonstrate. Now the division is making its know-how accessible to external customers. Director Bernd Wollenick says, “We’re opening up new fields of activity and customer target groups.” The focus is on assembly and testing systems as well as processing machines for grinding and honing in combination with product knowledge in the areas of robotics, vision and handling systems, and production IT. Standardising electrical designs This opening up to customers outside the group was just one of the factors driving the standardisation of the electrical design software at the various company sites. For instance, operations in Erlangen and Bühl in Germany, and Taicang in China, each had developed in their own way. These locations – and others as well – work with Eplan Platform, but use it differently. The goal is to overlay a globally standardised electrical design based on Eplan. A project team of key users is responsible for the task. Stefan Vietz, an electrical design engineer in Erlangen says: “We’re developing a common, harmonised infrastructure on Eplan Platform, which will enable us to collaborate worldwide. It allows us to use our capacities in the best possible way and increase the flexibility at the development sites.” Code-compliant templates, data-enriched macros During the standardisation process, the team oriented itself to global codes and norms, particularly EN 81346: structuring principles and reference designations for industrial systems, installations and equipment and industrial products. Sascha Jäger, Eplan Key User in Bühl says: “We devel- oped code-compliant templates that every employee can understand, including everyone in manufacturing.” Basic information such as equipment identification and plant/lo-

The three-dimensional control cabinet design with Eplan Pro Panel is already being used at some locations.

3D designs for control cabinets In Bühl, Germany, Schaeffler is already using Eplan Pro Panel to create three-dimensional designs of the control cabinets for the production systems. In future, Pro Panel will be used worldwide since its advantages for the company are clear. Jäger gives an example: “If the designer places a frequency inverter onto a mounting panel, the drilling pattern is automatically stored and the data can be transferred to a Perforex system as a DXF file. This saves time in both design and production.” So end-to-end data continuity is addressed – and when Rittal enclosures are

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Jäger explains: “The production department or the commissioning technician can call up the schematics on a tablet computer and use a jump command to view the details directly. This means users no longer need to print out the schematics and the latest data is always at hand.” Vietzhighlights additional advantagesof EplaneView: “The commissioning technician can use the redlining function to directly mark where any on-site changes have been made. And three or four commissioning technicians can work on a system at the same time and always have the same documentation status in front of them. This also facilitates communication with the programmers – and not only during commissioning.” On the right track Two years after theproject’s start, the key users do not yet think they have reached their goals, but they are definitely on the right track. Major steps towards standardisation have been completed. Schaeffler Sondermaschinenbau has already positioned itself on the external market, and the first systems have been delivered to customers outside of the Schaeffler Group. □ new multi-turn IO-Link encoders also detect the number of revolutions when de-energised – without any addi- tional battery or mechanical gears. This saves users the need for battery changes and regular maintenance. The encoders allow simple and uniform data processing with the help of the IO-Link smart sensor profile (SSP) which defines the data semantics of the IO‑Link information model in detail and uniformly, irrespective of vendor. The data storage functionality of the IO-Link encoders enables users to replace faulty devices without any additional effort as the IO-Link master provides the new encoder with all the necessary device parameters, so there is no need for additional parameter setting. The new encoders once more underline Turck’s posi- tion as a full range supplier of IO-Link devices and mas- ters. Turck can offer comprehensive IIoT solutions, from the sensor to the cloud – and back again. For more information contact Brandon Topham at Turck Banner. Tel: +27 (0)11 453 2468 Email: brandon.topham@turckbanner.co.za Visit: www.turckbanner.co.za For more information visit: www.eplan.de or www.eplan.co.za

The benefits of eView: the production department or commissioning engineer can call up the schematics on a tablet computer and use the jump command to view details directly. used, this is reflected not just in the enclosure layout, but also in the climate controls with Rittal Therm. Next steps: automated routing and eView The next planned steps include transferring the data from Pro Panel to external wire fabricators. Vietz comments: “We then receive labelled wires with conductor end sleeves or finished wire sets. This also saves time and is very efficient, especially for projects using the American UL standard.” Right now the key users are testing the use of Eplan eView as support, for instance, during commissioning. Turck has expanded its comprehensive portfolio of encoders and is now also offering encoders with an IO-Link interface in the Efficiency and Industrial Lines. IO-Link models are thus now available in the other two categories in addition to the contactless QR24 encoders of the Premium Line. The new encoders support with COM3 the latest and fastest IO-Link interface on the market, with a transfer rate of 230.4 Kbit/s, enabling a considerable improvement for control circuits. The encoders incorporate integrated temperature sensors and can route already pre-processed position data to IO-Link masters if required. With smart data, the devices support the implementation of IIoT solutions, such as for predictive maintenance. Their interlocked bear- CONTROL SYSTEMS + AUTOMATION : PRODUCTS + SERVICES New encoders with IO-Link interface

Encoders with an IO-Link interface are now available in the Efficiency and Industrial Lines.

ings make the encoders particularly robust against vibration or impact to the shaft. The energy harvest- ing technology ensures continuous operation with zero maintenance since the

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New textile recycling plant, Sundsvall, Sweden Valmet, a leading global developer and supplier of process technologies, automation and services for the pulp, paper and energy industries has been selected by Renewcell as the main equipment supplier for the Sundsvall textile recycling plant.

T he two companies recently signed a contract which calls for Valmet to deliver the main equipment for Renewcell’s planned 60 000 metric tonne capacity textile recycling plant to be developed at Ortviken industrial site in Sundsvall, Sweden. This is a major milestone in the establishment of the first of its kind commercial-scale textile recycling plant in the world. Renewcell’s new Ortviken plant is scheduled to begin operations in the first half of 2022. Patrik Lundström, CEO of Renewcell, comments: “We went through a rigorous selection process and we are confident that Valmet is the best possible long-term partner for Renewcell in our mission to change the global fashion industry. With a trusted supplier like Valmet providing the core equipment, we reduce project risk and gain a committed partner with industry-leading expertise. We look forward to working closely with Valmet to put together a top- of-the-line textile recycling plant concept that can be rolled out not only at Ortviken but worldwide.” Bertel Karlstedt, President, Pulp and Energy business line at Valmet, notes, “Sustainable textile recycling is well aligned with Valmet’s mission of converting renewable resources into sustainable results. I’m very proud that Renewcell selected Valmet as the key supplier for this ground-breaking plant. Our teams have been working well together in developing these solutions and I’m delighted to see this outcome. This is an important project and will be a key reference in this new business area; we look forward to continuing cooperation with Renewcell.” Industrial scale textile-to-pulp plant Through its patented process, Renewcell is able to upcycle cellulosic textile waste, such as discarded cotton and viscose clothes, transforming it into a dissolving pulp product called Circulose ® , which is produced from 100% recycled textiles. In 2018 Renewcell opened a demonstration plant in Kristinehamn, Sweden, which can produce up to 4 500 tonnes of Circulose ® per year. The new Ortviken plant will have a capacity of 60 000 tonnes per year with a possibility to increase the capacity in future. Lundström says, “By replacing virgin textile fibres like cotton with fibres produced from Circulose ® , fashion brands can reduce the climate and environmental impact caused

by raw material extraction and fashion waste generation significantly. We have been recognised for our work to make fashion more sustainable. Most recently, Circulose ® was included as one of TIME Magazine’s 100 Best Inventions 2020.” Vice President of the Fibre Processing business unit at Valmet, Rickard Andersson, flags the project as “an excellent example of how we can use Valmet’s expertise in bio, pulp and paper technology in textile recycling.”

A Circulose ® coaster. The recycled material is used in various products, including merchandise hang tags and cards.

[Photo: Alexander Donka]

Sheets of Circulose ® baled and palleted for onward production.

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machine equipment installation, commissioning and tech- nical support. A major part of the technology is designed and produced in Sundsvall, Sweden and in Tampere and Jyväskylä, Finland. The pulp drying and baling equipment however, is second-hand equipment, originally delivered by Valmet to another customer and now being dismantled in France and shipped to Sweden with the required technical support and installation to be supplied by Valmet at the Renewcell site. □ Valmet is a leading global developer and supplier of process technologies, automation and services for the pulp, paper and energy industries. Its technologies extend across pulp mills, tissue, board and paper production lines, as well as power plants for bioenergy production. Advanced services and automation solutions are designed to improve the reliability and performance of its customers’ processes and enhance the effective use of raw materials and energy. Headquartered in Espoo, Finland, the company operates around the world, with offices located to enable its teams to work close to customers internationally.

At a glance 

Renewcell transforms discarded cotton and viscose clothes into a dissolving pulp product, produced from 100% recycled textiles.  With this first of its kind commercial-scale textile recycling plant the aim is to develop a plant concept that can be rolled out at Ortviken and worldwide.  Valmet will supply process equipment commonly used in large scale state- of-the-art dissolving pulp plants, adapted and tailored for this project.

Renewcell was founded in 2012 by innovators from Stockholm’s KTH Royal Institute of Technology. The company provides an alternative raw material for textile production that replaces resource intensive materials such as cotton or petroleum-based materials such as polyester. For the new plant, Valmet will supply process equipment for stock preparation, bleaching and drying commonly used in large scale state-of-the-art dissolving pulp plants, tailored for this project. The delivery contract includes He explains that in a project like this, Valmet is not only a technology provider. “This is a joint journey. During the past year we have worked with Renewcell to fine tune the technology for textile recycling. We have used Valmet’s pilot machines at our Swedish and Finnish R&D centres to do test runs in turning recycled textile raw material into dissolving pulp sheets.”

For more information visit: www.valmet.com

CONTROL SYSTEMS + AUTOMATION : PRODUCTS + SERVICES

Streamling control cabinet manufacturing

In industrial control cabinet manufacturing, processes still feature multiple-manual steps. Phoenix Contact offers a solution in the form of the

ClipX WIRE assist assistance system from the ClipX product family, which is designed to optimise processes along the entire value-added chain. The software-supported system guides users through the process of semi-automated conductor processing, controls the relevant output devices, and provides the necessary information based on CAE data. The modular design of the workbench gives the user the freedom to arrange their workstation as desired, which together with the electrically adjustable height enables customised ergonomics for the application. In addition to the optimal reaching distances that are achieved, the assistance system’s mobility also reduces walking distances. This can shorten the processing time and increase efficiency in control cabinet manufacturing. For more information contact Phoenix Contact SA. Tel: +27 (0)11 801 8200 Visit: www.phoenixcontact.com

The ClipX WIRE assist assistance system supports efficient conductor processing in control cabinet manufacturing.

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Managing plant operations from a distance

Restrictions relating to the pandemic are affecting many economic sectors. But one thing is certain: production processes must continue, or restart, and interrupted new projects must be resumed as soon as possible. Plants have to be maintained regularly, commissioned, optimised or quickly converted to the production of alternative products, even though technicians cannot be on site in person. In addition, employees need to go through thorough training to be able to carry out and maintain processes and workflows safely. Current travel and contact restrictions require efficient and secure solutions for engineering, commissioning, operations, service and maintenance from a distance – in short: individually adapted home-office solutions for everyday industrial production tasks. Secure remote access The ‘new normal’ affects both service personnel and programmers. Travel restrictions continue to have a negative impact on the commissioning of new plants as well as the maintenance and adaptation of existing ones. One solution for these restrictions is offered, for example, by the Siemens management platform Sinema Remote Connect, in combination with Scalance industrial routers. This allows simple, secure remote access to machines and plants and can be set up and managed from almost anywhere in the world. Virtual cooperation on a secure platform The common Remote Service platform (cRSP) from Siemens goes a step further. Via this platform, remote access can be set up to meet the most complex requirements. Challenging engineering, commissioning and maintenance tasks can be carried out conveniently on automation systems from a distance. For example, Sipix SD (Siemens Process Industry Expert Service Devices) for remote-assisted collaboration can be used to instruct and guide on-site service technicians via video. Virtual cooperation via the web For years, Siemens has been pursuing a secure web-based approach to the central remote control and monitoring of globally distributed plants with the established Simatic PCS 7 process control system, which provides secured access to local HMI functions as well as to current production data. This approach is also well suited to managing and optimising unmanned plants remotely. Global cooperation between various project teams working on the same engineering project via the web is an integral part of the architecture of the fully web- based Simatic PCS neo process control system. The system provides for the necessary transparency and consistency of engineering data, ensuring conflicts can be avoided automatically. Plant operators and

maintenance teams have device-independent access to the complete plant information anywhere in the world. Installed on a tablet or laptop, it enables them to bring the control system with them to the plant. Virtual commissioning and operator training The simulation and virtual commissioning of automation systems are also playing an increasingly important role. For this purpose, Siemens Digital Industries offers scalable solutions that can overcome impending project delaysdue tocontact restrictions. Basedon thedigital twin of a real automation system, the Simit simulation platform allows the simulation, testing and optimisation of a plant’s behaviour on a PC, and the virtual commissioning of more complex software if required. Projects can thus be developed in the home office, so delays and the number of contacts in real-life commissioning can be minimised. The digital twin can also be used for location- independent, low-contact training outside the plants. Comos, the software solution for holistic plant project management, also plays a major role: Comos Walkinside enables the 3D Virtual Reality visualisation of plants still under construction. It is ideal for providing the future maintenance and operations teams with realistic training on the virtual model – much like a computer game. With these digital remote applications, Siemens supports manufacturers and operators in various ways to maintain the availability and productivity of their machines and plants at the highest level. This capability will continue to be of prime importance for industrial production under the new normal conditions. For more information contact Siemens Digital Industries. Visit: www.siemens.com

Sipix uses the cRSP platform to provide on-site service technicians with remote audio-visual support from experts.

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The right tools to take mining digital

face Drilling, enabling customers to scale up mining automa- tion at their own pace. The AutoMine ® Underground product family includes AutoMine ® Tele-Remote, AutoMine ® Lite, AutoMine ® Multi- Lite, and AutoMine ® Fleet. AutoMine ® Surface Drilling is an automation solution available for a wide range of Sandvik’s iSeries top hammer, down-the-hole and rotary drills. “One of the biggest differentiating factors is that Sandvik is a mining equipment/mining process and digital solutions pro- vider,” says Karthikeyan. “This expertise in technical, industrial and digital domains enables it to deliver solutions that outper- form peers’ products to the market.” Riku Pulli, President, Rock Drills and Technologies Division, Sandvik Mining and Rock Solutions, says: “We are continually developing technologies that benefit our customers’ operations and this award points to the success that Sandvik has achieved with its automation solutions over the years.” tal tools, including tools to monitor equipment health and manage processes. Its AutoMine ® automation offering operates on 59 mining sites globally, and its OptiMine ® suite of digital solutions is active on 66 connected sites. The ‘My Sandvik’ customer portal, a web-based digital hub, serves 214 sites and its Newtrax technology in wire- less IoT connectivity is operating on 115 sites. “Monitoring equipment health through My Sandvik Digital Services Solutions allows users to draw down telemetry data from their equipment in real time,” says McCoy. “The data is automatically compiled into the re- quired report format for quick analysis and response. “The next aspect to be addressed is the management of the process being monitored,” he says. This is where Sandvik’s Task Management and Scheduler – part of its Optimine ® suite of digital solutions – can be applied. McCoy explains that this allows a tablet to be fitted to an item of equipment so an underground operator can accept tasks and provide real-time progress reports on those tasks. “The more advanced the equipment, the more data can be extracted and communicated auto- matically without operator intervention.” The solutions allow for data to be recorded on equip- ment’s key operations – such as the weight of loads in a loader bucket. Telemetry on the equipment gives valua- ble insights into the equipment’s availability and perfor- mance – so management can respond. “When starting the digital journey, the focus must be on improving current operations,” says McCoy. “This means getting work started on time, for instance, before moving onto optimisation efforts. Most digital implemen- tations will battle if the starting point is trying to increase productivity before getting the basics right.” For more information contact Sandvik Mining and Rock Technology. Visit: www.sandvik.com

The astute application of digital tools is the key to continually improving efficiencies on underground mines, according to Niel McCoy, Business Line Manager for Automation and Digitalisation at Sandvik Mining and Rock Solutions. McCoy says the choice of digital tools needs to be based on each operation’s key performance indicators (KPIs) – because the solutions that are implemented will be focused on monitoring and managing those KPIs. He recommends a phased approach to introducing digital tools to a mining operation. “The starting point is always machine telemetry and basic production or productivity reporting,” he says. “From there, the solutions can be expanded.” Sandvik Mining and Rock Solutions has extensive global experience in designing and implementing digi-

Sandvik OptiMine ® is a powerful suite of digital tools for analysing and optimising mining production and processes.

Global recognition in product leadership Simon Andrews, Managing Director at Sandvik Mining and Rock Solutions, recently announced that Sandvik AutoMine ® and OptiMine ® had been recognised with the 2020 Global Autonomous Mining Solutions Product Leadership Award from Frost & Sullivan. Frost & Sullivan Best Practices Awards recognise companies in various regional and global markets where they demonstrate outstanding achievement and superior performance in areas such as leadership, technological innovation, customer service and strategic product development. ”Sandvik is the only mining equipment and solutions company that received an award in our 2020 Class of Top 50 Digital Best Practitioners across the Industrial and Energy Space,” says Rohit Karthikeyan, Industry Analyst at Frost & Sullivan. The AutoMine ® system is an innovative automation solution that comprises AutoMine ® Underground and AutoMine ® Sur-

For more information visit: www.sandvik.com

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CONTROL SYSTEMS + AUTOMATION : PRODUCTS + SERVICES

Integrated solutions to automate water networks

As South Africa – and the world at large – face growing concerns regarding human and environmental health, conversations about our most precious resource – water – should be front and centre in tackling the challenges ahead. Recognising the importance of water, and the need for responsible and sustainable management of this resource, the focus should be on how to do more with less, as our water sources become increasingly limited. “Water management needs to be more efficient than ever before,” says Quintin Mccutcheon, Digital Transformation Leader at Schneider Electric South Africa. “For water network managers, this means you need to create a water supply that is highly resilient, efficient and sustainable.” Water management is a complicated industry characterised by wide geographical networks, underground infrastructure and fluctuating network demands. “Add to this South Africa’s challenges of aging infrastructure and skills shortages, and it becomes clear why the country lost an estimated 1.1 million litres of water in 2019,” says Mccutcheon. To create resilient, efficient and sustainable water supplies requires automatic management of these potentially fragile, difficult to access, widely distributed water networks. The goal is to establish a system that responds reliably to changing flow and pressure

demands at all points across the entire network. Digital tools can help manage water supply networks by giving operators more visibility into the system, better insights, and improved control. Mccutcheon explains how Schneider Electric’s EcoStruxure integrated solutions can improve South Africa’s water management industry. “With EcoStruxure Control Expert – Asset Link, we can put critical business

insights into the hands of network managers and operators more easily than before. EcoStruxure can connect an application down to field devices and take full advantage of digital hydraulic modelling to monitor pressure, flow, quality and other variables across the water network. This allows operators in control rooms to connect to field devices easily, to monitor a dynamic, real-time view of the network. In this way, it also gives them the ability to predict future network behaviour and service disruptions.” Built-in integration of control and supervisory systems makes automating water networks much faster and easier, and it helps implement changes more quickly and accurately down the road.

Quintin Mccutcheon, Digital Transformation Leader at Schneider Electric South Africa.

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CONTROL SYSTEMS + AUTOMATION : PRODUCTS + SERVICES

Cutting-edge automation in global distribution centre

Mouser Electronics Inc., industry leader in new product introductions, has added new automation technology to its continually expanding warehouse to keep hundreds of thousands of global customers supplied with the right products at the right time. Mouser’s massive distribution centre, located on the 78-acre campus of its corporate headquarters in Texas, USA, handles a vast inventory of more than 1 million unique SKUs (stock-keeping units) for products from over 1 100 manufacturer brands. In recent years, the distributor has made substantial investments in state-of-the-art automated equipment to process orders with exceptional efficiency and accuracy. Today Mouser employees operate 55 vertical lift modules (VLMs), the most at any company in North America. The VLMs – essentially giant vertical filing cabinets, complete with shelves and an automated elevator – store tens of thousands of electronic components. The VLMs deliver the parts directly to the employee workstation, significantly improving efficiency and floor space usage. Mouser has also recently invested in several I-Pack machines – sophisticated automated packing and boxing systems that each can process up to 14 orders a minute. The use of I-Pack delivers several operational advantages – reducing time, materials and ‘air’ waste (valuable space on trucks and aeroplanes), and brings benefits in terms of sustainability. The automated process results in less use of bubble wrap, equating to the reduction of more than 1.5 million square feet of the material each year. Additionally, Mouser is in the process of adding the OPEX Perfect Pick system, and further warehouse automation advances are under way with the recent completion of a new 125 000 square-foot addition to the distribution centre. “Advances in automation are having a transformative effect on many areas of industry and warehousing and logistics are seeing this too,” says Pete Shopp, Mouser Electronics’ Senior Vice President of Business Operations. “Across a broad range of activities such “Municipalities that are looking to reduce costs and improve operations will find that digitalising their water networks yields new ways to reduce costs and optimise operations,” says Mccutcheon. He reports that using an integrated water network management system offers many benefits which will improve and maintain high levels of water supply services. These include: - Adapting to demand in real-time to maintain optimal water pressure and improving reliability for consumers, while minimising leakages in the network - Improving the efficiency of pump operations which increases operational sustainability and Continued from page 11

reduces operating costs, resulting in less frequent rate increases - Identifying issues before they happen so operators can proactively inform customers of potential issues before customers encounter them on their own. “All these factors help today’s water supply utilities to increase efficiency, use less energy, avoid leakages and breakdowns, and supply and treat the ever-increasing amounts of water needed to match population growth trends,” says Mccutcheon. Investments in state-of-the-art automated equipment at its massive distribution centre enable Mouser Electronics to process orders with exceptional efficiency and accuracy. as picking, packing, and loading pallets, robotics is enhancing our operations. Assisted by IoT technologies, wireless systems and digital tablets, our 1 000-plus warehouse employees are working more efficiently now than ever before. “Because we deliver single quantities of components, we will always rely on employees for the special handling that those small orders require. Our adoption of start-of- the-art automation acts primarily as a means of boosting efficiency, productivity, accuracy and speed,” says Shopp. “These new systems can also be a positive driver of more sustainable operations and improved customer satisfaction, too. “Processing tens of thousands of orders weekly, most within 15 minutes, and with our commitment to customer service, Mouser employees are handling the technological advancements with great success,” Shopp says. For more information visit: www.mouser.com

For more information visit: www.se.com

12 Electricity + Control MARCH 2021

DRIVES, MOTORS + SWITCHGEAR

Beyond the VSD: Making motors run efficiently Motor efficiency is often overlooked completely when industrial companies are addressing energy saving and the associated reductions in operating expenditure.With a focus on chemical companies, TonyYoung, Director of CP Automation, a UK based specialist in the service and supply of drives, controls and resistors, presents top tips for ensuring the motors in a plant run as efficiently as possible.

A complex cost-saving game Electricity costs are rising as global demand continues to grow, making it imperative for industrial companies to con- tain electrical usage. Those companies that do invest time and money in energy reduction seldom go beyond fitting variable speed drives (VSDs), or tackling tariffs to save on price per kilowatt hour. However, there are a host of ad- ditional measures that can be addressed with very little capital expenditure and they all result in long-term profit by reducing overhead costs. Highly complex plants, like chemical plants, face sig- nificant technical challenges: from the integration of many different energy sources to maintaining a wide array of en- ergy conversion systems, and the need to use by-product energy effectively. For example, hydrogen is created as a by-product from the manufacturing of chemicals like chlo- rine. This can be captured and transported for use else- where, or used to help power the chemical plant itself. Choose the right motor upfront One of the first steps should always be to ensure you are fitting the right size of motor for the respective application in the first instance, whether this is for pumps, fans or com- pressors. A good provider of motors, controls or VSDs will always offer an audit first, which will help you achieve this. Design engineers tend to over specify ‘for tomorrow’, but for plant and maintenance professionals this just means higher energy bills. Furthermore, if you plan to add a VSD now or later as a retrofit product, ensure that the motor is VSD rated to start with, otherwise any retrofit project will involve replacing the motor as well. Over specification also raises maintenance bills. I have seen countless motors, which are doing an easy job like water pumping for example, specified at a much higher ca- pacity than required. Sometimes this is to the point that the motor installed costs twice as much as one that could do the same job effectively. I have also known motors to be sent in for an overhaul with problems on parts of the motor that are not being used at all. When the situation is reported to the customer, they

Beyond fitting VSDs, there are a number of other steps plant engineers can take to ensure motors run efficiently and reduce energy usage. are completely unaware of it because it’s a problem with functionality they did not need in the first place! As a clear analogy: you wouldn’t buy a mini bus for a family of four. Keep it simple if you can The less complex the motor, the better. From a repair per- spective, if you can use a standard energy-efficient motor, which you can switch on and have spin at the right speed with no bells or whistles, then use it. It will be cheaper to install, there will be less to go wrong and if something does go wrong, the repair will likely be easier and cheaper. Choosing a high efficiency motor is not always a given in every application, particularly if someone in the buying chain is looking at only the initial capital expenditure of the application and not the equipment’s long-term running costs. However, with the European Union’s Ecodesign Directive in place we should see fewer end users specifying low efficiency equipment. In addition, opting for simplicity is not always possible. In some instances there is the need for a timing device or soft

Electricity + Control MARCH 2021

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DRIVES, MOTORS + SWITCHGEAR

Soft starts are also increasingly common on pump ap- plications and they dramatically reduce the energy used when starting a motor. They are also common on convey- ors, where the smooth start prevents objects from falling. As an alternative to a motor starter resistor or a VSD, they can be more profitable, but only if the application is as- sessed correctly in the first instance and the device is sized appropriately. Move away from mass production Inevitably it’s important to address the availability of the motor at short notice in the event of a replacement being required. Of course, if spares are kept in stock this may not be necessary and so, ironically, the harder to get hold of mo- tors are sometimes the best option. This is not because they are scarce, but rather because they are not mass produced and are normally of higher quality. Consequently, while a re- placement may not always be easy, a repair often is. In this context, when choosing the service provider to do the repair, always go to a specialist. If you select a compa- ny that has not carved out a niche in, say, servo motors, you will likely find that they will simply subcontract the repair to a specialist; increasing the bill in the process. Another factor to consider is the environment in which the motor is going to be used. Chemical engineering is a harsh environment, from inorganic industrial plants to ex- plosives. Go for a more complex drive that can be boxed away. Regulations for the industry may demand this any- way, but the added bonus is that the motor and drive are protected from ingress and damage. Just implementing a few of these tips will result in a re- duced energy expenditure on running motors, and in all likelihood other associated equipment. If you implement all of them, you will find it much more effective than trying to negotiate a lower kilowatt hour price for electricity. □

At a glance  As a first step, fitting the right size of motor for the respective application will deliver ongoing savings in operating costs.  Timing devices offer a cost-effective way of saving energy on non- continuous use applications.  Availability of the motor at short notice is an important consideration, but harder to get hold of motors are sometimes the best option.

start to alter the speed. Equally, it may be that an extremely high precision motor is needed for a particular application. Timing devices can be hugely underused in the chemi- cal industry yet they are a very cost-effective way of saving energy on non-continuous use applications. Often, pumps and ventilators run constantly, even if there are times of day when there is no need for them to do so. By not running a motor unnecessarily, you are not only saving energy but also extending the life of the system. For example, the hydraulic pumping efficiency of cooling sys- tems will experience less degradation over time and remain optimally efficient for longer. It comes down to how much flow capacity is possible with a given amount of energy.

The less complex the motor the better, but simplicity is not always top priority.

For more information visit: www.cpaltd.net

DRIVES, MOTORS + SWITCHGEAR : PRODUCTS + SERVICES

480 V version in servodrive and motor pairing

The Rockwell Automation Kinetix 5100 servo drive and Kinetix TLP servo motor standalone motion solution is now available in

offering for flexible, standalone machines. Using the Kinetix 5100 servo drive, OEMs can create a motorised or automated system that can help speed up changeovers. Additionally, with built-in safe torque off, users can remove motor torque without removing power from an entire machine. This allows a machine to restart faster after it has reached a safe state. Dual-port Ethernet/IP also supports device-level ring (DLR) topologies. For more information contact Rockwell Automation. Email: mjunius@ra.rockwell.com Visit: www.rockwellautomation.com

480 V for use in a wider range of OEM applications – in packaging, converting, print and web, machine and assembly,

and life sciences.The Kinetix 5100 servo system meets growing demand for more product variety by providing a market-competitive motion-control

The new servo drive and servo motor standalone motion solution extend potential OEM applications.

14 Electricity + Control MARCH 2021