Electricity + Control May 2018

FEATURES: • Sensors, switches + transducers • Analytical instrumentation • Cyber security • Drives, motors + switchgear • Energy management + environmental engineering • Power Quality, standby + back-up

COMMENT

ON THE COVER

FEATURES: • Sensors, switches+ transducers • Analytical instrumentation • Cyber security • Drives,motors+ switchgear • Energymanagement+ environmental engineering • PowerQuality, standby+ back-up

Change in Electricity+Control

C hange, as they say, is not always easy. This month in Electricity+Control, I need to acknowledge a change. And that change is the retirement of our current ed- itor, Wendy Izgorsek. Wendy has been at the helm of the maga- zine for ten years. It has been an absolute privilege to work with her and to watch the magazine take on a fresh look, feel and vibe. I wish Wendy every happiness in her retirement, which – if I knowWendy – will not entail sipping tea on her veran- da, or at least not for long. Fiona Mosca is taking over Wendy’s posi- tion as editor of Electricity+Control. She has a degree in publishing, a diploma in public relations and communications, and 13 years’ experience in both print and digital publishing. We welcome Fiona to Crown Publications. Speaking of change, it seems to be in the air. It is impossible to see any items of news that do not speak to seismic devel- opments on this continent. Much of this is happening beyond the borders of South Africa – but change, I suspect, becomes a captivating theme. When we speak of change, the opportu- nity it brings should always override the fear that some may feel. My own sense, from interacting with many people from within our industry over the past month in a variety of forums, is that the dust seems to be settling, and the noise filtering is just beginning to work. That being the case, we need to reflect on the status of all infrastructure at our plants. Is it in order? Does it need refur- Wendy will take up a new challenge, in a new direction. And so it should be.

bishment? What should we be doing? Do we have the confidence to take action?

The truth of the matter is that much of the infrastructure in the public eye is in dire need of attention. This cannot be ignored … just driving around, one be- comes increasingly embarrassed by what one sees. Yet it seems there are also are- as within our control that are in a similar predicament. This implies the need to be decisive and to take decisive action – be- fore that infrastructure is in such a state of disrepair that it needs to be decommis- sioned. Such a situation can arise suddenly, and although it is often the topic of jokes and jibes, it can pose real risks to organisa- tions and their people. I continue to find it intriguing that, in some instances, a lack of proper maintenance results in health and safety risks, and yet no one seems to notice. All too often my engagement on matters is only after things have gone most horribly wrong. As we enter this time of change, we should reflect on where we are and what needs to be attended to ... and attend to it. Before we regret the delays.

ECMay2018 cover.indd 1 5/2/2018 9:16:43AM www.electricityandcontrolmagazine.co.za

Established well over 60 years ago, Countapulse Controls offers reliable, efficient and application appropriate sensing, control and motion detection solutions. Read more on page 7.

Magazine Team

Editor: Design & Layout: Advertising Managers:

Wendy Izgorsek Adél JvR Bothma Helen Couvaras Heidi Jandrell Karen Smith Karen Grant Wilhelm du Plessis Ian Jandrell

Circulation: Publisher: Deputy Publisher: Editorial Technical Director:

Circulation

Quarter 4 (Oct - Dec 2017) Total print circulation: 4 563

Contact

Published monthly by:

Crown Publications cc Cnr Theunis and Sovereign Sts, Bedford Gardens PO Box 140, Bedfordview 2008 Tandym Print

Printed by:

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

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+27 (0) 11 622 4770 e-mail: ec@crown.co.za admin@crown.co.za www.crown.co.za

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The views expressed in this publication are not necessarily those of thepublisher, theeditor,SAAEs,SAEE, CESA, IESSAor theCopperDevelopmentAssociationAfrica

CONTENTS

4

Features

Sensors, switches + transducers 4 More to Selecting Sensor Technology than Meets the Eye Gerry Bryant, Countapulse Controls 8 Round UP Analytical instrumentation 10 The Heartbeat of a Plant’s Processes: Self-diagnostics and Predictive Maintenance Information provided by Endress+Hauser 12 Round UP Cyber security 16 Easy Way to Achieve the Optimum Control Panel Carolyn Meuschel, Siemens 18 Deception Technology Comes of Age Information provid- ed by Attivo Networks at Networks Unlimited 20 Maturity Self-assessment: Industry 4.0 Michael Grant, DataProphet 22 Harmonised PLC Use Through Single Interface Increases Plant Performance Dirk Mottmann, Umeå Energi 23 Round UP Drives, motors + switchgear 26 Preventative Maintenance Prolongs MCC Lifespan Pat McLaughlin, Boulting Technology 28 JBSS TUTORIAL 1: Get the Control you need with Custom Control Panels Johan Basson, JB Switchgear Solutions 29 Round UP Energy management + environmental engineering 34 Windfarm Layouts: Reduce CO 2 Emissions – Improve Energy Yield Klaus Vogstad, WindFarmDesign 36 Round UP Power Quality, standby + back-up 38 Halting Harmful Harmonics: Active and Passive Filtering Techniques for Harmonic Mitigation John Mitchell, CP Automation 40 Action Needed to Reduce Lightning Fatalities in South Africa Information provided by ELPA (Earthing Lightning Protection Association) 42 Round UP

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40

Regulars

1 Comment 7 Cover Article 44 Light+Current 46 CESA News 47 Social Engineers 48 Events 48 Advertisers 48 Write @ the Back

2 Electricity + Control

MAY 2018

More to Selecting Sensor Technology than Meets the Eye

Gerry Bryant, Countapulse Controls

Sensors are a critical component in the operation of engineering devices and essentially have the function of converting a stimulus into a measured signal.

Take Note!

The risk level associated with purchasing sensing devices on price alone is simply too great. Selecting an incorrect or inappropriate sensor can result in minor malfunc- tions to complete disrup- tion of a production line. It is critical that the right sensor is selected for the right job.

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T hese sophisticated devices are engineered to detect or measure a property or a con- dition and record, indicate or otherwise re- spond to this information, according to the defi- nition of the word sensor. The stimulus can be mechanical, thermal, electromagnetic, acoustic or chemical, and while typically the measured signal is electrical it could also be optic, hydraulic and pneumatic. Sensing technology has developed at an ac- celerated pace for the past twenty years, and will continue to do so for years to come. Networks of sensors measure and record everything and sen- sor-enabled devices communicate with one anoth- er through the IoT.

Vast advances in sensor technology The vast advances made in sensors technology have largely made these devices more widely used and an integral part of the world’s digital eco- system. And in the context of the global market- place access to sensors has become much easier. Yet while it may, on the surface, seem that it has become simpler to source such equipment, this is often not the case. Without an in-depth understanding of the appli- cation of sensing technology it is almost impossi- ble to select the correct sensor for an application. Selecting an incorrect or inappropriate sensor can result in anything fromminor malfunctions in an op- eration to complete disruption of a production line.

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MAY 2018

In addition to these measuring distance sensors, miniaturised sensors, such as photoelectric sensors and light diffuse sensors, are preferred for use in shuttles. This is due to the limited available space.

SENSORS, SWITCHES + TRANSDUCERS

Adding to this scenario is the ready availability of these products from international online sources, where a buyer chasing short term savings can buy just about anything. In these instances, an individu- al would select a sensor from the photograph and brief description which appears on their screen and not have any method of verifying that the sensor in question is suited for the application at hand. Both of these scenarios have created problems not only in indus- try, but also for original equipment manufacturers of sensing equip- ment and their distributors worldwide. Information shared between players in this market show an increase in situations where incorrect devices have been retrofitted with major and even catastrophic dam- age being caused during operation or where technical support for devices is not readily available. Reputable suppliers This would suggest that it is preferable for end users to deal with reputable suppliers that are able to provide optimum levels of techni- cal support at any stage. It also points to need to further educate the market as to why it so important to use appropriate sensing technol- ogy for a given application. Given the strained state of the economy, particularly in South Africa, the risk level associated with purchasing sensing devices on price alone is simply too great. It is critical that the right sensor is selected for the right job. As an example, if you want to detect either position or speed of bottles on a conveyor belt, a non-polarised photo cell would not be the correct sensor choice. This is because the reflective properties of glass make detection difficult and therefore render this data provided by this type of sensor inaccurate. It is essential that a polarised photo electric sensor is used for this particular application. Further challenges can be in experienced in bottling and packaging applications depending on the materials used for labelling on the bot- tles as well as the packaging or shrink wrap used on the pallet. It is essential to take these factors into account when specifying a sensor for a bottling plant. There are sensors that have been specifically de- veloped to accurately detect printing on different coloured surfaces, and using these would ensure accurate detection. A shaft encoder, also known as a rotary encoder, is an electro-me- chanical device that converts the angular position or motion of an axle of shaft to an analogue or digital signal. Two main types of shaft encoders exist – absolute encoders and incremental (relative) encod- ers and it is essential that the correct encoder is used to achieve the required end result. Incremental encoders operate by generating a series of pulses during movement, and must always come back to a reference point. Absolute encoders are more sophisticated and provide a unique code for each shaft position. These encoders are available as either single channel or multiple channel devices depending on the application. A single-turn encoder can verify position with a single channel of the encoder shaft which makes these devices ideal for short travel scenarios. In contrast, the multiple channel encoders are suitable for more complex and longer positioning applications. Shaft encoders are used extensively on cut-to-length lines where it is essential to accurately control the required desired length. In

The Leuze RK46C-VarOS retro-reflective photoelectric sensor is ideal for packaging systems and intralogistics where it will detect objects with various sizes and shapes.

Leuze offers a wide range of laser Class 1 sensors and the advantage of these devices is that the laser radiation emitted by these sensors does not pose a hazard to the human eye.

The Leuze DDLS 500 photoelectric sensor enables the transparent, contact- and wear free transmission of data over distances of up to 120 metres in 100 Mbit/s real-time.

Electricity + Control

MAY 2018

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SENSORS, SWITCHES + TRANSDUCERS

The Leuze LSIS 422i reads up to 99 barcodes per image in any format.

Leuze LSC 200 stations with Leuze CML 700i Series light curtains con- tain an integrated web visualisation system.

these applications, a conventional single channel shaft encoder would suffice. However, in applica- tions where excessive vibration is encountered a single channel shaft encoder would be subject to spurious counts and would therefore not deliver the correct accuracy. In this instance a three chan- nel phase shifted shaft encoder would be the cor- rect choice. Fit-for-purpose sensing equipment One can see from the example above that it is not as simple as it would seem when selecting a re- placement sensor. In the example above, the orig- inal single channel encoder may have been part of the original equipment supplied and it was not envisaged that this equipment would operate un- der conditions of excessive vibration. Yet over time it would have become apparent that the encoder was not operating accurately and a sensor special- ist who assessed the application would have been able to advise that it needed replacing. An inex- perienced individual would probably have replaced like encoder with like, and the problem would have continued.

The need to use fit-for-purpose sensing equipment applies to even the simplest of applications, and also relates to the material of construction of a sensor. Installing a sensor made from a perfectly acceptable material in an application for which it is not meant can have dire results. As an example, the correct selection of a prox- imity switch can be of importance when the envi- ronment in which it will operate is taken into ac- count. A conventional proximity switch is generally in a nickel plated brass housing which for certain applications would not be acceptable due to the environmental application. In applications where aggressive materials are present a proximity switch with a Teflon or Hasteloy housing would be more appropriate, thereby ensuring optimum per- formance and longevity of the sensor. Conclusion Staying abreast of sensing technology is the re- sponsibility of the original equipment manufac- turers that produce these sophisticated devices, and this knowledge needs to be transferred to the official distributors of these sensors. Coupled with the knowledge of the latest state-of-the art sensing technology and underpinned by years of in-depth experience in the field, reputable suppli- ers of sensing technology are able to accurately assess individual end user requirements and rec- ommend a fit-for-purpose solution.

Without an in-depth understanding of the application of sensing technology it is almost impossible to select the correct sensor for an application.

Gerry Bryant is the Managing Director of Countapulse Controls. Enquiries: Tel. +27 (0) 11 615 7556 or email bryant@ countapulse.co.za Visit www.countapulse.co.za

6 Electricity + Control

MAY 2018

COVER ARTICLE

FEATURES: • Sensors, switches+ transducers • Analytical instrumentation • Cyber security • Drives,motors+ switchgear • Energymanagement+ environmental engineering • PowerQuality, standby+ back-up

Sensing Solutions Specialist at the Top of the Game

ECMay2018 cover.indd 1

5/2/2018 9:16:43AM

T he importance of being able to rely on a reputa- ble sensing technology supplier cannot be un- derestimated. This is the opinion of Gerry Bryant, managing director of leading sensing solutions supplier, Countapulse Controls . “This is especially true given the massive strides made in this sector over the past few decades, and it is important to establish a sound relationship with a company that is able to offer the depth of knowl- edge, technical expertise and experience to ensure that you get the right sensor for the job,” Bryant says. Countapulse Controls was established well over 60 years ago, and it is what customers get when they work with this company that really makes the difference. The company offers reliable, efficient and ap- plication appropriate sensing, control and motion detection solutions. And its success has been built on a solid foundation of local applications knowl- edge across a broad range of industry sectors. This is a critical differentiator as there are nu- merous factors that need to be considered when selecting sensing devices, and these include op- erational parameters, the range of the sensor, the speed of the automatic process, the background conditions and type of product, auxiliary equip- ment, the circuits within the process and the sen- sor’s materials of construction. When assessing a customer’s application, it is necessary to look beyond a single problem area; a far more structured approach is required to obtain a general overview of the specific requirements. Sensors must be selected specifically for the op- erating parameters of individual applications to ensure that absolute accuracy and optimum per- formance are achieved. It is simply not sufficient to match a sensor to a model number hoping that it will achieve what is required. Failure to understand the full capabilities of a specific device could result in the selection of a far costlier sensor, when a more cost effective option would suffice in a particular application. “For years, our customers have benefitted from the in-depth technical expertise that resides within

our team, and this has enabled us to assess indi- vidual customer applications and recommend fit- for-purpose solutions in even the most demanding environments,” Bryant says. Countapulse Controls represents some of the most advanced counting, sensing and motion tech- nology available internationally, and this includes well-known brands such as Leuze, Hengstler, EGE, Pulsotronic, Secatec and ABP. With the backing of these globally renowned German sensor manufac- turers, customers are assured of absolute accura- cy and optimum performance. Significantly, staying abreast of technology has also allowed Countapulse Controls to assist cus- tomers in locating suitable alternatives where its own product offering does not exactly match the operational parameters. Focused on a strong customer service ethic, Jo- hannesburg-based Countapulse Controls offers sol- id engineering and technical support throughout the country with representation in Cape Town, Durban, East London, Port Elizabeth and Windhoek. Coun- tapulse Controls also offers customers 24/7 access to immediate technical support and information, through its technical advisory service hotline which can be reached on +27 (0) 66 148 5287. “By involving a specialist supplier such as Coun- tapulse Controls it is often possible to provide a far more cost efficient and operation related solution which could in the end result in significant cost savings,” Bryant concludes.

Enquiries: Gerry Bryant.Tel. +27 (0) 11 615 7556 or email bryant@countapulse.co.za

Electricity + Control

MAY 2018

7

round up

SENSORS, SWITCHES + TRANSDUCERS

Non-contact temperature measurement Available from ifm electronic , this product is suitable for the precise temperature meas- urement of particularly hot objects or objects which are difficult to access, e.g. in the steel, plastics or glass industries. The measured value is provided via the analogue output. In ad- dition, a switching output and an IO-Link interface are provided. Integrated LED pilot light: The pilot light shows the user the exact position and size of the measuring segment. The green light is visible very well even on glowing surfaces. Besides a low current consump- tion, the LED is distinguished by a virtually unlimited lifetime. Batch-related programming: Thanks to the integrated IO-Link communication interface, the parameters can be dynami- cally adjusted to the application from the control room. Local parameter setting on the unit is not necessary, but can optionally be done via the buttons and the display. Enquiries:Tel. +27 (0) 12 450 0400 or email info.za@ifm.com

Torque transducers on test rig test advanced powertrain

heavy duty buses and trucks, as well as motorsport vehicles and off highway ma- chinery. Its high efficiency electric motor and power electronics technology delivers class-leading electrified powertrains and propulsion systems. In order to test and characterise the high performance electric motors used in electric and hybrid powertrains, AVID Technology designed and built a special purpose test rig. Central to the design of the test rig is an innovative wireless rotary torque measurement device from Sensor Technology. These non-contact surface wave acoustic (SAW) transducers offer sig- nificant advantages compared with strain gauges, magnetic torque sensors and op- tical devices that might be fitted to a con- ventional dynamometer for motor charac- terisation. Sensor Technology SAW-based devices are non-contact, robust and highly accu- rate. TorqSense torque sensors use two tiny SAW devices made of ceramic piezo- electric material containing frequency res-

A draft clean air policy has been introduced in the UK, along with the announcement that sales of petrol-only and diesel-only vehicles will be banned from 2040, bring- ing the role of hybrid and electric vehicles to the fore. In evolutionary terms, these technologies are still in their infancy, and this is where Instrotech (South Africa) is pleased to represent AVIDTechnology. The company develops powertrain im- provement solutions for a wide range of electric and hybrid vehicle applications, in- cluding high performance passenger cars,

onating combs. These are glued onto the drive shaft at 90 degrees to one another. As the torque increases the combs expand or contract proportionally to the torque be- ing applied. In effect the combs act similar- ly to strain gauges but measure changes in resonant frequency. The adjacent RF pick- up emits radio waves towards the SAWs, which are then reflected back. The change in frequency of the reflected waves iden- tifies the current torque. This arrangement means there is no need to supply power to the SAWs, so the sensor is non-contact and wireless. AVID Technology sales director Jordan Taylor explains: “The TorqSense transducer was chosen as it allowed us to use a fixed pedestal load motor and eliminate friction- al losses and parallax errors from the load installation in the measurements. This al- lows AVID to produce very accurate perfor- mance characterisation results compared to a conventional motor dynamometer.” Enquiries:Tel. +27 (0) 10 595 1831 or email sales@instrotech.co.za

One sensing range for all metals ifm ’s ‘Kplus’ sensors have the same sensing range for all types of metals. They are for ex- ample perfectly suited for the detection of aluminum, where conventional sensors show a considerably reduced sensing range. The high switching frequencies enable the monitoring of fast changing switching states. The resistant stainless steel sleeve allows reliable use in oil and coolant applications. The wide temperature range as well as the high protection ratings enable universal use of the new ‘Kplus’ sensors. ‘Kplus’ sensors are suitable for welding robots and welding machines. Strong magnetic fields occur during welding. The new ‘Kplus’ sensor technology reliably prevents incorrect switching. The sensor housing and the fixing nuts have a non-stick coating to prevent weld slag from sticking. Enquiries: Email info.za@ifm.com

8 Electricity + Control

MAY 2018

round up

SENSORS, SWITCHES + TRANSDUCERS

New vibration switch protects critical assets

As part of the recently introduced RC range of vibration sen- sors, R&C Instrumentation has launched a new compact vi- bration switch, designed to protect machinery against unex- pected shutdown and repair costs. The RC-429 automatically trips in the event of excessive vibration levels, allowing crit- ical systems to be shut down before damage can occur. The RC-429 is one of the most compact vibration switches on the market, enabling the continuous monitor- ing and protection of assets in tight spaces. It is designed to transmit a 4-20 mA signal, features an adjustable false trigger delay of up to one minute to prevent error trips, which may occur at machine start up, and is overload pro- tected to a maximum shock of 100 g. The RC-429, which features a MEMS (Micro-Electro-Mechanical System) ac- celerometer integrated onto the I.C. (Integrated Circuit) mi-

crochip, is exceptionally quick and simple to set up, with the maximum RMS velocity set point and response delay time easily adjustable using two rotating setup dials. It is sealed to IP67 and designed to perform reliably within a temperature range of -25 to +80ºC, making it ideal for use in a range of sectors, from building services, pulp and paper, mining, and metals, to utilities, automotive, water, and pharmaceutical. Minimising machine downtime and maintenance costs are essential for the productivity and profitability of manufac- turers. The RC-429 provides a simple, cost effective method of continuous monitoring for protecting motors, generators, engines, pumps and fans, ensuring greater machine availabil- ity and increased output. Enquiries:Tel. +27 (0) 86 111 4217 or email info@randci.co.za

Solexy RX antenna coupler In mining applications there is equipment used to transport product, people and sup- plies. There is also equipment that is used for excavating and removing material during tunnelling, and in the mining process of re- moving coal from the mine. By utilising the Solexy RX antenna coupler in combination with a radio installed in an Exd box on the equipment, the system will broadcast data regarding the machine’s engines critical data for predictive maintenance purposes. Some advantages: • It does not take up any space inside the housing • It allows the use of standard passive an- tennas The radios installed in the Exd enclosure must get the signal out of the explosion proof box.The Solexy RX antenna coupler provides an explosion proof connection and an intrinsi- cally safe barrier to insure there is no external spark ignition from the control enclosure. By using the Solexy heavy-duty flexible antenna (The Noodle) damage to an antenna is elim- inated. This helps to prevent machine break- down and blocking of the mineshaft. Enquiries: BrandonTopham. Email brandon.topham@retautomation.com • No seal gland is required • Shock resistant antenna

Muting reinvented Smart Process Gating, introduced by Leuze and available from Countapulse Controls, has made muting processes more economical as well as simpler and safer. Gerry Bryant, managing director of Countapulse Controls , explains that in intralogis- tics as well as in the automotive and packaging industries, material locks often need to be safeguarded against unauthorised access by means of safety sensors. Previously, muting processes with muting sensors were required to clearly identi- fy when transported goods were approaching a protective field. These muting sensors were then to bridge the passing of these goods through the protective field at the cor- rect moment. The Leuze Smart Process Gating method has completely eliminated the need for sig- nal-emitting sensors making this a far simpler and more reliable solution in these appli- sensing solution has eliminat- ed the risk of misalignment or damage to the sensors, and in addition because it is so simple to install there is a reduction in capital input costs. There is also a considerable reduction in maintenance and servicing requirements which also reduces costs. Increased reliability and sensing accuracy is a major advantage of the Leuze Smart Process Grating solution, and this will increase not only productivity but also safety in an operation. In the case of typical intralogistics applications, the height of the protective device is entirely dependent on the safety-related requirements and this sensing meth- odology does not require synchronisation beams to be taken into consideration, again saving on cost and increasing reliability. With the Leuze Smart Process Gating solution, the first muting signal comes from the process controller (PLC), while the second muting signal is generated by the pro- tective field itself. Smart Process Gating requires a detailed knowledge of the process so that the necessary control signals are made available in the expected time window. Enquiries: Gerry Bryant.Tel. +27 (0) 11 615 7556 or email bryant@countapulse.co.za cations. This solution is based on the Leuze MLC safety light curtains and this means that conveyor systems can be made more compact. This configuration of the

Electricity + Control

MAY 2018

9

ANALYTICAL INSTRUMENTATION

The Heartbeat of a Plant’s Processes Self-diagnostics and Predictive Maintenance

Information provided by Endress+Hauser

Take Note!

The advantages of in- struments with self-di- agnostics are evident. Plants run more cost-ef- fectively and safely without interruption. You are always in con- trol of your measuring point and verification efforts are significantly reduced.

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Imagine a production process where devices can diagnose themselves: They would realise when something is wrong or unusual and send an alarm?

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W hen, for example, excessive build-up occurs in silos and tanks the devices with this capability would just signal the need to clean a process. An Endress+Hauser (further referred to as ‘the company’) customer in the Copper Mining industry, experienced the ad- vantages of self-diagnostics. It is as if your field measurement device has a heartbeat: It will react like an additional member of your workforce with spe- cialist knowledge to steer the pro-

The advantages of instruments with self-diagnos- tics are evident: Plants run more cost-effectively and safely without any interruptions. You are al- ways in control of your measuring point, and veri- fication efforts are significantly reduced with doc- umented in-situ verification. A simple, predefined procedure guides the person responsible for main- tenance through the verification procedure and, at the end, the verification results are documented in an unambiguous manner.The SIL test according to the safety manual and documentation saves time and reduces costs, too. An automatically gener- ated verification protocol supports the evidence demanded by regulations, laws or plant standards. The data acquired through self-diagnostics fa- cilitates trend recognition for predictive mainte- nance. A combination of instrument and process parameters provides all the important information for the next steps in maintenance or targeted pro- cess optimisation. It is a prerequisite to finding the right strategy for predictive maintenance. The challenge at the Copper Mine The Copper Mine wanted to test a smart sensor. There were two clear objectives for their changes in level measurement: to increase production by higher ROM bin capacities and to reduce mainte- nance costs. To do so, the Copper Mine wanted to use the maximum fill heights of a ROM bin used to store unprocessed copper ore. To accommo- date this increase in fill heights, the existing radar level sensor had to be relocated to a new position, where it would unavoidably get covered in dirt. The danger was that the strength of the measuring sig- nal emitted and received by radar level transmit- ters – a critical factor for precise measurements

Micropilot FMR6x radar level transmitters.

cess in an effective way so that you avoid costly downtime. You just run the plant and the processes and do not have to spend time check- ing how the instruments are working. The devices would tell you directly if a problem occurs. Processes that can take their own pulse are already a real-

ity with Heartbeat Technology in many level, flow, temperature and analytical instruments. Since 2012, self-diagnostics has been stand- ard in several of the company’s flow devices, and the portfolio has just been expanded to include level, temperature and analytical de- vices. Instruments with Heartbeat Technology excel by permanent process diagnostics and extensive in-situ diagnostic functions. Processes are no longer interrupt- ed if verification is needed; it

happens directly in the measuring point with- out any dismantling.

10 Electricity + Control

MAY 2018

ANALYTICAL INSTRUMENTATION

Overview of Heartbeat Technology.

– would diminish. Under these conditions conven- tional radar and ultrasonic level transmitters would need to be regularly cleaned, sometimes as often as every hour. It would be time-consuming for the maintenance personnel and the ROM bin would be stopped, which leads to costly downtime. The copper mine wanted to avoid expensive mechanical changes and decided to use the com- pany’s Micropilot FMR67 radar level transmitter with Heartbeat Technology. This function monitors the extent of dirt build-up, and reports it back to the control room to alert the personnel of the need to clean the transmitter. The FMR67 also features a PTFE horn protector that reduces the rate of build-up. This means cleaning is required less fre- quently. The Copper Mine reached its objectives with the Heartbeat Technology devices. Conclusion Heartbeat Technology, as the company calls the intelligence, tracks the performance of the device to ensure it is not adversely affected by abrasion, corrosion or sticky build-up at the copper mine. Standardised and clear diagnostic messages are sent regarding what needs to be done to maintain the plant economically and as a matter of priority. As the devices run their own diagnostics, proof tests are only necessary in maximum extended cycles. Furthermore, the automatically generated protocols provided by Heartbeat Technology with- out process interruption support the documenta-

tion according to international standards request- ed by institutions. For future-orientated predictive maintenance the instruments offer parameters to monitor the performance for process optimisation. Heartbeat Technology is accompanied by two wiz- ards for easy commissioning of foam- or build-up detection.

Imagine a production process where devices can diagnose themselves!

Enquiries: Dhiren Naidoo. Industry Manager, Primaries & Metal, Endress+Hauser. Email dhiren.naidoo@za.endress.com

Electricity + Control

MAY 2018

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round up

ANALYTICAL INSTRUMENTATION

NEW Radiometric Density System

diverse operator interfaces. Operators ben- efit from the new simplified user-friendly interface where calibration is as simple as possible. Only two-points – a low and a high density, e.g. air and water – have to be acquired by the customer. Advanced self-diagnostics and monitoring features ensure a safe function of the system. Operators also benefit from the new service functionalities like data logging, which can be accessed either remotely through Ethernet connection or through the USB port at the front panel of the sys- tem. MECOSA is the sole agent for Berthold Technologies in South Africa. Enquiries:Tel. +27 (0) 11 257 6100 or email measure@mecosa.co.za

The measuring system DuoSeries stands out by a particularly excellent performance with high accuracy and repeatability. De- pending on customers' needs, the trans- mitter output can be configured for units of specific gravity (SGU), ‘pounds per gallon’ (PPG), or a calculated ‘pounds proppant added’ (PPA).The DuoSeries density meas- uring easily connects to the FracSENS LB 6770 detector and links directly to the cus- tomer control system. No calibration or dif- ficult math has to be implemented in the data system. The density gauge is used to translate the measured count rate into the specified output values either in low pres- sure or in high pressure applications. The density transmitter is a state-of- the-art control unit with robust 3,5” TFT touch panel, powerful Dual Core CPU, and

DuoSeries LB 475 is the new radiometric density system from Berthold especially designed for the cementing and hydraulic fracturing industry.

TorqSense … for caps that fit

Strict international rules apply to the manufacture and packaging of pharmaceutical products and require that the correct environment is maintained within the bottle following capping. Regulation USP 671 provides a guide to the torque range to be used for screw type containers with varying closure diameters. By ensuring that bot- tle caps are successfully applied to the bottles within the required torque tolerances, the integrity of the product is maintained. Sen- sor Technology Ltd, which makesTorqSense, has worked with many

OEMs to develop high precision, high speed capping machines for use in pharmaceutical plants and a range of other applications. One of these, Cap Coder, an Oxfordshire neighbour of SensorTechnology, incorporates TorqSense units in its CC1440 and CC1440T Bench top Cap Coder machines, both of which are used by the Almac Group. TorqSense is wireless and does not need to physically contact the bottle caps or shaft of the torque head it is monitoring. Sensing is achieved through a radio frequency link.

Attached to the surface of the transducer shaft are two Surface Acoustic Wave (SAW) devices, when torque is applied to the shaft the SAWs react to the applied strain and change their out- put. The SAW devices are in- terrogated wirelessly using an RF couple, which passes the SAW data to and from the electronics inside the body of the transducer. “All you have to do is set up a TorqSense transducer in the capping machine and turn it on,” explains Mark Ingham of SensorTechnology . Enquiries: Tel. +27 (0) 10 595 1831 or email sales@instrotech.co.za

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ANALYTICAL INSTRUMENTATION round up

Wireless technology revolutionises service and maintenance in process industry With the new wireless concept − INOR Goes Wireless − INOR introduces a completely new way of configuring and monitoring transmitters. By integrating the wireless technologies NFC and Bluetooth, INOR enables communication with the transmitter via a smartphone or tablet without removing the device from the process. The transmitter can easily be configured through the in- tuitive interface of the ‘INOR Connect’ app. The new app offers, previously launched and highly appreciated products such as IPAQ 202 and IPAQ 330. With technologies like NFC and Bluetooth, we are developing and driving the process industry towards digitisa- tion and a wireless future," says Benny Björkander, CEO of INOR. MECOSA is the sole agent for INOR Process AB in South Africa. Enquiries:Tel. +27 (0) 11 257 6100 or email measure@mecosa.co.za

among other things, a feature that makes it possible to quickly copy a configuration to multiple transmitters. There is also a monitoring feature to fa- cilitate troubleshooting. The new concept is launched together with the IPAQ 530, the first temperature transmitter with built- in NFC and with support for Bluetooth via the ICON-BT modem. It is also equipped with the latest HART 7 version for extend- ed diagnostics. The IPAQ 530 is a modern, universal transmitter available both in head and rail mounting versions, and with ATEX and IECEx approval. It is designed to meet the highest standards of flexibility, accuracy and reliability. “The IPAQ 530 is our latest step in INOR's new industrial platform with

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round up ANALYTICAL INSTRUMENTATION

Goodbye to the Manometer Needle Instrotech is offering Keller’s electronic ECO 2 manometer – an instru- ment that can perform all standard measuring jobs at an exceptional- ly low price. Compared to its mechanical predecessors. Keller’s digital technology offers high resolution, excellent repeatability at very similar prices. The ECO 2’s dual display updates twice every second, showing the measured value and the minimum or maximum value attained. As a special feature, the ECO 2 has a Zero Tare feature, allowing the user to set the zero to any pressure, so that the manometer will then always show deviations from the Zero Tare value as the actual value. The user-friendly two-key operating system provides access to the entire range of functions: the stored MAX/MIN can be erased and reset to zero, or the device can be switched to continuous mode. In continuous operating mode, the battery has capacity for up to 1 000 hours. The ECO 2 electronic manometer has a standard automatic switch-off time of about 15 minutes

High performance in applications with limited mounting space WIKA’ s model FLC-FC cone flow meter is an advanced application of differential pressure technology. Its char- acterisation of the flow profile enables reliable measure- ment even under the most difficult conditions. Thanks to its design, the cone flow meter is ideally suited for applications with limited mounting space. It offers a wide and stable turndown and, at the same time, a high ac- curacy and repeatability. The FLC-FC cone flow meter is produced in accordance with the ISO 5167 reference standard. Part 5 of this standard covers the topics of in- stallation and operating conditions and gives further infor- mation for calculating the flow rate and its uncertainties. • Low maintenance effort: The conical primary ele- ment has been designed so that its edges are pro- tected from particles in the medium. Therefore, the cone flow meter has a very long service life, even in applications with abrasive media • Short upstream and downstream pipes possible: The optimised flow profile prevents asymmetric flow effects and enables operation with very short upstream and downstream pipes Enquiries:WIKA Instruments.Tel. +27 11 621 0000 or email sales.za@wika.com

after the last key function, this extends the battery life where continuous operation is not required. The easy- to-handle ECO 2 is available with two practice-based measuring ranges of -1…30 bar and 0…300 bar in the compensated temperature range from 0 to 50°C, the economically priced standard manometer offer typical overall accuracy of 0,5% FS (Full Scale). Enquiries:Tel. +27 (0) 10 595 1831 or email sales@instrotech.co.za

WIKA?

CYBER SECURITY

Easy Way to Achieve the Optimum Control Panel Carolin Meuschel, Siemens

The focal issue with Integrated Control Panels is to leverage potential in control panel engineering and especially in their electrical design.

Take Note!

Those involved in the engineering and manu- facture of control panels have to deal with dead- line and cost pressure on a daily basis. Control cabinet design- ers and builders are being forced to become more efficient to as- sert themselves against global competition. In this context, digital- isation not only consti- tutes a challenge but also provides a great many opportunities.

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W hat are the main concerns of designers and manufacturers of industrial control panels? What are the current challeng- es facing electrical designers? And how can we as a component manufacturer support our customers on their path to the perfect control panel? Siemens has been asking itself these questions and is now making a major addition to its industrial control panel portfolio with ‘Integrated Control Panels’. 'Integrated Control Panels' was presented to the general public for the first time at Hannover Messe 2017. The focal issue with these products is to leverage potential in control panel engineering and especially in their electrical design. One key factor here is the optimisation of the engineering process. Furthermore, those engaged in configur- ing control panels can rely on Siemens' practical know-how, for example when applying new stand- ards, guidelines and technologies in their day-to- day work. Drawing upon its extensive and coordi- nated product and system portfolio for industrial control panels, the technology company is able to put together a holistic support package for the specific challenges in control panel building. Considering the ubiquitous discussions on dig- italisation and Industrie 4.0, some of the issues that Siemens addresses with Integrated Control

Panels may seem rather unspectacular at first glance: heat rise verification, short-circuits and short-circuit strength or the starting of motors are some of the basics considered in designing control panels. However, these are also the questions that preoccupy the people on the shop floor every day. There are enough reasons why some aspects of configuration have become long-running issues. New technologies and functionalities in control panels repeatedly necessitate new solutions. At the same time, standards and guidelines are often amended, adjusted and regularly reissued. These amendments sometimes have a considerable im- pact on the engineering and construction of con- trol panels. In addition to national and international technical standards, the respective legislation and relevant guidelines also need to be considered. Just one example: could any panel builder have an- ticipated that the gradual increase in drive efficien- cy demanded by the EU since 2015 would have a direct impact on control equipment? Vast specialist knowledge of internation- al standardisation The experts from Integrated Control Panels keep a close eye on any developments concerning stand- ards and are therefore able to give timely notifi-

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Figure 1: The Way. Siemens accompanies its customers on the path to the ideal control panel with a multitude of prod- ucts and services.

Figure 2: The Know-how. Comprehensive information directly from the device manufacturer – either in direct dialogue or in the form of training courses and printed documents – speeds up the overall engineering process.

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CYBER SECURITY

Figure 3: The TIA Selec- tion Tool. Software-based support tools such as the TIA Selection Tool from Siemens make the every- day procedures involved in panel building simpler and much more efficient.

companies can profit even more by using appro- priate tools that already have configuration know- how on board. The best example from Siemens is the Simaris planning tools. SIMARIS design and SIMARIS curves enable users to quickly and ef- fectively design a selective solution according to the recognised rules of technology and applicable standards (VDE, IEC). Suitable components and distribution systems are selected automatically. Simaris design supports users in network calcu- lation and dimensioning for example, whereas Simaris curves provides a convenient means of creating characteristic tripping curves as well as characteristic cut-off current and let-through ener- gy curves. Siemens also provides a powerful cal- culation tool by the name of Simaris therm for heat rise verification in the control panel. Among other things, this tool helps to meet documentation re- quirements arising from standards and guidelines. And then there are selection tools to make day- to-day work easier for users. These include Sizer for drives, TIA Selection Tool for many automation components, and product configurators. Based on technical characteristics or specific applications, products can be selected in a targeted fashion, thereby saving time and, in many cases, providing a better solution. Quick access to product data, im- ages, 2D/3D models, dimension drawings and im- portant documents speeds up engineering. Even availability can be checked here at an early stage, which saves valuable time in day-to-day work and ensures that commissioning deadlines are met. Conclusion The holistic approach of Integrated Control Panels comprises finding specific solutions for specific challenges, whereby Siemens experts can call upon many years of experience and know-how, sound data and tools as well as a coordinated product and system portfolio.

cation of any relevant changes. But they do more than merely pass on information. In workshops, guides and other publications, Siemens custom- ers can learn about tips and tricks that can help them to implement any changes to standards and legislation. The new edition of the DIN EN 60204-1 standard concerning electrical equipment for ma- chinery, which is expected shortly, is already on the agenda. Siemens also keeps its users up to date regarding changes on the North American market (UL and CSA standardisation). That is im- portant because receiving relevant information quickly can be essential for competitiveness in a demanding market environment like machinery production and especially in panel building. Utilising the benefits of digitalisation Those involved in the engineering and manufacture of control panels have to deal with deadline and cost pressure on a daily basis. And then there is the fact that no two orders are alike. Individualisation is constantly gaining ground. Control cabinet design- ers and builders are being forced to become more efficient to assert themselves against global compe- tition. In this context, digitalisation not only consti- tutes a challenge but also provides a great many op- portunities. A supply of reliable data at all times and in every working environment is an essential pre- condition in digital processes. That is why Siemens now not only provides its product data via its own tools but also supplies platforms run by partners from the CAE field, such as Eplan or WSCAD, by means of a regular exchange of data. And that is not all: the company is also developing more and more interfaces for its own tools such as the TIA Portal and the TIA Selection Tool to enable a standardised exchange of data during the engineering process. Engineering tools speed up the job Data is the basis for getting digitalisation off to a successful start. However, when dimensioning and calculating aspects of control panel design,

There are enough reasons for some aspects of configuration to have become long-running issues.

Carolin Meuschel. Email Carolin.Meuschel@siemens.com

Acknowledgement Images courtesy Siemens.

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