Electricity and Control May 2020

FEATURES: · Control systems + automation · Drives, motors + switchgear · Sensors + switches · Plant maintenance, test + measurement

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FEATURES: · Control systems+ automation · Drives,motors+ switchgear · Sensors+ switches · Plantmaintenance, test+measurement

COMMENT

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Adapting to where we are… I wonder how many of you reading this have had the opportunity to return to your office, your plant, the site you were watching progress on before the shutdown. Or, for that matter, how many of you were locked down away from home.

energy + information in industry

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Editor: Leigh Darroll Design & Layout: Adél JvR Bothma Advertising Managers: Helen Couvaras, Heidi Jandrell Circulation: Karen Smith EditorialTechnical Director: Ian Jandrell Publisher: Karen Grant Deputy Publisher: Wilhelm du Plessis The OPTIMASS series of Coriolis mass flowmeters from KROHNE has been developed to conform to IEC 61508, with improvements in diagnostics, verification and functional safety. (Read more on page 3).

run your plant on a legacy system, fearing the change – until you have no option; then you find yourself wondering why it took you so long to make the change in the first place! The transition to an online economy has been remarkable. This company, and this particular magazine, are no exception. For instance, trawling the records of Electricity+Control – now in its 34 th year of publication – on January 1 st this year it had almost 1 000 online subscribers in the rest of Africa (which makes sense), and a slightly lower number than that in South Africa (where the magazine is normally posted to readers). As I write, Electricity+Control has close to 5 000 online subscribers – the largest growth in that number (over 3 000 additional subscribers) has been from within South Africa – people who are now receiving the e-Edition of the magazine. If you are not already an online subscriber, please do sign up. It will cost you nothing and can be done from wherever you are; the magazine will henceforth find its way to you! Go to: https://www.crown.co.za/electricity- control. At the bottom of the page you will see how to subscribe to Electricity+Control (or any of our nine publications). In conclusion, we recognise many of you are with companies that have continued to deliver essential products, goods and services during this very difficult period. Our commendations to you, and the efforts you are putting in. I wish you all well as, slowly, we move out of this lockdown, towards the next levels of managing this terrible, invisible enemy.

In general, the response to this disaster has been decisive and impressive. And to a large extent the issues were understood. But equally there has been some complete rubbish spoken, mind-numbingly bad advice given – in many cases by people who are in positions of trust (read: really should know better). By contrast, the response on the African continent has generally been very good indeed. It is worth reflecting on some of the good, and some of the changes emerging from our response to this pandemic. The first thing to be aware of, naturally, is that this little virus isn’t going anywhere any time soon. Until we have a vaccine to sort it out we will simply have to continue very much as we have up to now – perhaps for more than a year to come. I am sure a vaccine will be developed – but this is a process that is not based on luck or good fortune. It is a process following known methods, and until you can be sure of the results, you keep your mouth shut. Never confuse nice theories with actual proven performance. We must remain cautiously optimistic that those who can sort this out are doing so to the best of their abilities – quietly, and largely unrecognised at this time. Dare I say that things will never be the same again? For a moment, let’s consider some encouraging developments. I am sure many of you, like me, never knew how effective a virtual meeting could really be? (Or the dangers associated with leaving your video on when others would have preferred you to have turned it off (or maybe not…).) But the digital transformation this pandemic has spawned has been profound. Like a new software tool, the best way to get good at using it is to have to use it. You can

Circulation: Quarter 4 (Sep – Dec) 2019 Total print circulation: 4 857

Published monthly by: Crown Publications (Pty) Ltd Cnr Theunis and Sovereign Sts, Bedford Gardens, PO Box 140, Bedfordview 2008 Printed by: Tandym Print Telephone: +27 (0) 11 622 4770 E-mail: e-mail: ec@crown.co.za; admin@crown.co.za Website: www.crown.co.za www.electricityandcontrolmagazine.co.za

CROSS PLATFORM CONTENT INTEGRATION: * Electricity+Control Magazine * Online Edition * Bi-monthly Newsletter * Website

Publisher of the year 2018 (Trade Publications)

Electricity+Control is supported by

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

Electricity + Control MAY 2020

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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

Features

CONTROL SYSTEMS + AUTOMATION 4 The world’s first Shared Smart Factory Rob Goossens, Technologies Added 6 Advancing industrial machine control Piotr Siwek, Mitsubishi Electric Europe

7 Products + Services

DRIVES, MOTORS + SWITCHGEAR 11 Energy-optimising drives save costs Danfoss

12 Products + Services

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SENSORS + SWITCHES 18 Measuring small torque on machinery Sensor Technology

20 Products + Services

PLANT MAINTENANCE, TEST + MEASUREMENT 24 Safer gas monitors Industrial Scientific

26 Products + Services

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Regulars

1 Comment

Adapting to where we are…

3 Cover article Developments in Coriolis mass flowmeters 28 Reskilling, upskilling + training Reaching for the stars 29 Cybersecurity Malicious Trojan uncovered 30 Engineering the future After COVID-19, what will Africa look like in 2030 and 2063? 32 Write @ the back Energy savings rebate delivers billions of rand

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COVER ARTICLE

FEATURES: · Control systems+ automation · Drives,motors+ switchgear · Sensors+ switches · Plantmaintenance, test+measurement

Developments in Coriolis mass flowmeters

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L eading supplier of industrial process measurement, KROHNE, has developed its OPTIMASS series to conform to IEC 61508. This includes improvements in the devices’ diagnostics, verification and functional safety. Now available with Bluetooth ® connectivity, the upgraded version of the MFC400 VE54 ER2.1.x converter is fully developed for safety applications according to the latest IEC 61508:2010 standard. A comprehensive safety concept with proven diagnostic coverage of >96% as well as internal diagnostic test intervals of less than one minute has been developed. This allows the OPTIMASS 6400 to be used in SIL 3 applications or in continuous demand mode, the highest specified level of operation. For added security a hardware switch is incorporated to enable or disable the Bluetooth capability. Bluetooth connectivity provides for wireless on-site commissioning, device parameterisation and diagnostics, as well as validating measured values and settings or starting diagnostic functions that check the device has been installed correctly. A mobile app is also available for wireless device commissioning, diagnostics, verification and monitoring. Some of the features include performance of zero and density calibration, backup/restore settings, NE107 configuration and mapping of events to NE107 status. The ‘OPTICHECK Flow Mobile’ app is available, free of charge, from the App Store and can be used in simulation mode so customers can try it before receiving the flowmeter. Enhanced online diagnostics Enhanced diagnostic coverage of >96% is achieved by using such measurements as continuous signal monitoring, redundant references, entrained gas detection, fault detection and calibration. All measurable parameters, electronic components such as CPUs, memory and internal bus connections, as well as all sensors are monitored continuously during operation. Test simulations can also be run and the simulation measurements recorded as an output. The diagnostic information is displayed in accordance with NAMUR standard NE107 and, to facilitate identification of the problem source, all messages are sorted into status groups: sensor, configuration, electronics and process. Colour coded display and user interface The colour coded display and user interface allow for diagnostics and status messages to be shown via display,

current and/or status output, HART ® or bus interface. The backlight colour indicates device status according to NE107: grey indicating ‘operational’, blue: ‘maintenance required’, yellow: ‘out of specification’, or red: ‘failed’. Functional safety Additional novel technologies and features have been implemented to enable maximum versatility and the highest safety standards. These include the comprehensive authentication concept, configuration wizard for safe parameterisation, enhanced online diagnostics, certified partial proof test concept, and redundant storage of all device configuration data. The Toolbox data logger enables the user to understand and analyse the process conditions. Providing on- and off-line data logging, all measurement and diagnostic values can be recorded and analysed using the free of charge software. OPTICHECK, the KROHNE service tool for in-situ verification of field devices, is an essential service tool to ensure that process measuring devices are performing according to specification. OPTICHECK can carry out rapid troubleshooting with a quick scan, or a full verification. This supports reduced downtime and increased safety for operators and plant. A single OPTICHECK device can be used for all KROHNE meters in the plant without additional licensing.

The OPTIMASS series of flowmeters developed to deliver improved safety and functionality includes enhanced online diagnostics covering a range of measurements.

For more information contact Deon Rampathi at KROHNE Mobile: +27 (0)82 900 7360 or visit: www.krohne.com

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CONTROL SYSTEMS + AUTOMATION

The world’s first Shared Smart Factory

In this case study, Rob Goossens, CEO ofTechnologies Added, outlines five transformative lessons that the company learned through its first two years of operation as a shared smart factory. Beyond their value for industry broadly, these lessons, and the concept of the shared smart factory, hold particular relevance, potentially, for small industrial enterprises in South Africa looking to start production, accelerate or scale up their operations.

C reating a breakthrough business in the digital economy needs a fearless and inventive approach. It pays to be different, so businesses need to think about what they’re doing to push boundaries and stand apart. This is what we’ve tried to do at Technologies Added. As operator of the world’s first shared smart factory, we’ve continually striven to challenge conventional manufacturing models and apply a creative approach to how our factory operates. Working with Rockwell Automation to integrate its manufacturing execution system (MES) into our production facilities, we were supported in using automation software resulting in cutting-edge, Industry 4.0 innovation. A smarter model Based in Emmen, in the Netherlands, we opened the factory doors in early 2017. What sets the facility apart is our collaborative model: we host production for

multiple like-minded companies under one roof. This brings to a conventionally closed, proprietary industry, a WeWork-like model that allows the companies we work with to benefit from a ‘ready-to-use’ production model (the manufacturing equivalent of booking space on a subscription basis), shared resources and access to advanced technologies. The model allows our customers to set up configurable production lines fast, enabling ‘mass customisation’ – a flexible and highly scalable process for bringing products to market. The factory sets a new standard through the capabilities it provides, such as 3D modelling, smart robotics, digital twins and data-driven manufacturing, which our customers can use to experiment with new production models. Two years into our journey, we now have 10 companies active in the facility (in addition to our own production lines), and a further 20 companies ordering from us on a regular basis. Based on the experience of the past two years, here are some key lessons I’ve learned that may help other manufacturers seeking to adopt smarter capabilities. Lesson #1 – Make flexibility your advantage At Technologies Added, we use modular ‘flexible assembly’ capabilities to allow for multiple partners to operate simultaneously, with scope for rapid changes in what’s produced on the lines. Both major companies and start-ups use this; the former to test new lines (overcoming some of the issues they have with their legacy production facilities), and the latter to scale up production of goods that they have already validated demand for in the market. Lesson #2 – Challenge the status quo Innovation-focused companies should always look for false assumptions in both their own and their competitor’s existing business models, and probe deeply into whether a better way of operating exists. As an example, at Technologies

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At a glance ■ Technologies Added has created a collaborative environment where smaller companies can gain access to digital technologies and expertise that would otherwise be outside their reach. ■  The model allows customers to set up configurable production lines fast, using a flexible and highly scalable process to bring products to market. ■  Today’s breakout companies are built on the strength of their networks – an open, collaborative network will triumph over closed approaches.

Added we work with an established manufacturer that was considering outsourcing a new production line to a low- cost factory in a developing country. Following a full cost analysis, the customer was surprised to discover that our smart factory actually worked out as the more cost-efficient option overall, due to an ability to adopt a ‘by order’ (rather than ‘by stock’) approach to production. Digital transformation can pose challenges for a single organisation, such as meeting the expense and finding the technical expertise to compose all the technology that’s required within a private factory, and then building the skills to maximise its effectiveness. To overcome this, we’ve created a collaborative environment where smaller companies can gain capabilities that would otherwise be outside their reach. This includes not only the production technology within the facility, but also expert support in important areas such as production design, engineering, logistics and security. Lesson #4 – Don’t be afraid to experiment Businesses today have the benefit of far deeper insight into market demand, helping them to serve niches that previously would have been overlooked. We use a ‘product innovation’ process that allows for prototypes to be industrialised within a short timeframe (often just two months) and with limited costs. Our customers can use this process to get products into the market quickly and make evidenced assessments of whether a business opportunity really exists before scaling up to full production. No company can be an expert in everything. Today’s breakout companies are built on the strength of their networks. That’s why we work with Rockwell Automation to integrate its manufacturing execution system (MES) into our production facilities. Rockwell’s support helps us to use automation software to get to the cutting-edge of innovation in the manufacturing industry, and to lend the same benefits to the companies that use our facility. Sharing success As new technologies lower the traditionally high barriers to entry in manufacturing, businesses need to think differently Lesson #3 – Make the economies of scale work in your favour Lesson #5 – Find partners who can fill the gaps in your own capabilities

if they want to gain the benefits. Digital transformation offers such companies a means for tackling weak points in conventional business models that their competitors have been afraid to probe. Through our smart factory, companies have access to a partner that can help them test the limits of what’s possible. The success we’ve seen to date suggests that there’s strength in numbers, and drawing on the force of an open, collaborative network will triumph over closed approaches. We look forward to continuing our mission with the support of Rockwell Automation. Everyone’s journey to digitalisation is different, and a personalised approach is important. One experience that helped us was visiting Rockwell’s EMEA Connected Enterprise Customer Centre in Karlsruhe, Germany, where we interacted with a lot of technology and learned what The Connected Enterprise could do for us. □

For more information visit: www.rockwellautomation.com or www.technologiesadded.com

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CONTROL SYSTEMS + AUTOMATION

Advancing industrial machine control Piotr Siwek, Head of Product Marketing EMEA, Factory Automation, Mitsubishi Electric Europe B.V. considers how advanced analytics and artificial intelligence will drive development in industrial machine control. He looks at how embedding these smart technologies in controllers can deliver a new paradigm of machine operation.

A dvanced analytics and artificial intelligence are extending traditional machine control architectures with enhanced data processing, learning and decision-making capacity. They hold the potential for enabling increased availability, efficiency and reliability through predictive and prescriptive maintenance, as well as improving productivity with the ability to make autonomous decisions. It wasn’t so long ago that the potential of technologies such as model-predictive control, PID control, field-oriented control and fuzzy logic was merely hypothetical. Today, they are so deeply embedded in controller architectures that we no longer even think about them. Within that context, consider the development possibilities of advanced analytics (AA) and artificial intelligence (AI) technologies for machine control. They can drive increased machine availability, for example, by delivering more effective predictive maintenance. This brings us into the realm of Big Data analysis where AA and AI technologies enable different machine states to be recorded and analysed in real time. Recognising the current machine status, detecting potential faults on the horizon, and immediately offering recommendations for actions to be taken, they can alert the machine operator or maintenance provider to respond, or initiate autonomous remedial actions within the system. By linking that same AI technology into the wider enterprise, into the logistics chain for example, the control system could mitigate for delays in the delivery of replacement components. For instance, it could slow the

machine down slightly to increase longevity rather than stopping the production line altogether. Going further, AI can begin tomake autonomous decisions to optimise productivity. Consider, for example, how a machine is typically built to work within defined margins of capability – perhaps to allow for different loads or speeds or safety ranges. AI technology using deep learning algorithms within the controller could enable machines to be driven up to and even beyond today’s margins, significantly boosting productivity without compromising reliability or safety. We are already seeing how applying AI principles to individual machine processes can be an enabler for operational improvements. For example, Mitsubishi Electric has developed diagnostic technology based on its AI technology called Maisart. Embedded into products such as Mitsubishi Electric’s MELIPC edge computing solution, this uses machine learning to analyse collected data to generate a model of the machine’s operational states. The model can detect abnormalities in the machine’s operation in real time, enabling it to provide early warning of potential problems so that maintenance personnel can take prompt action. Another example of the use of AI is the smart predictive maintenance function of MELFA robots. The Smart Plus function can be applied to Mitsubishi Electric’s MELFA robots to analyse primary drive components precisely according to actual operating conditions and warns of failing or deteriorating parts at an early stage. This provides for reduced downtime and allows an efficient maintenance schedule to be planned. Further, during the design phase of the applications, the technology offers simulation capabilities to predict the robot’s lifetime and estimate annual maintenance costs, giving engineers the opportunity to modify the robot’s operation to extend the lifecycle. These two examples already could drive significant improvements inmachine availability and reducemaintenance costs, yet they only hint at the potential of AA and AI. □

Machine control systems can boost productivity without compromising

For more information visit: Mitsubishi Electric Europe B.V. eu3a.mitsubishielectric.com/fa

reliability or safety with the use of AI technology.

Image courtesy of Mitsubishi Electric Europe B.V.

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CONTROL SYSTEMS + AUTOMATION CONTROL SYSTEMS + AUT MATI N : PRODUCTS + SERVICES

Partnerships for integrated automation systems How can field instruments and components be easily integrated into automation systems? The answer to this question is becoming increasingly important as the digitalisation of industrial production progresses. The Endress+Hauser Open Integration partner programme unites 13 manufacturers that want to ensure the streamlined interaction of their products. Softing Industrial Automation joined the partner network at the beginning of the year. The Open Integration partners test and document the interaction of their products for typical process automation applications. Users benefit by being able to combine the best products for each application and through fast commissioning. Automation technology suppliers value the advantages of the Open Integration programme as well. For these companies, it’s important to be able to detect potential problems early and solve them before installing their products at the customer site. Jörg Reinkensmeier, Marketing Manager at Endress+Hauser, explains: “We go well beyond the established test methods in this programme by scrutinising the functionality of complete system architectures in a lab environment. We do that for specific fields of application or customer solutions. After successful completion of the tests, the reference topologies are published in the form of mutual recommendations.” All the partners are suppliers of control technology, fieldbus infrastructures, measurement technology or Open automation platform reduces engineering time With ctrlX AUTOMATION, Bosch Rexroth has introduced what it describes as the most open automation platform on the market. It has eradicated the traditional boundaries between machine control systems, IT and the Internet of Things. Centralisedanddecentralisedautomation topologies can now be created flexibly with the scalable platform. With a Linux real-time operating system, open standards, app programming technology, web-based engineering and a comprehensive IoT connection, ctrlX AUTOMATION reduces engineering time and effort by 30 to 50%.

actuator technology: Auma Riester, Bürkert, Festo, Flowserve, Hima Paul Hildebrandt, Honeywell Process Solutions, Mitsubishi Electric, Pepperl+Fuchs, Phoenix Contact, Rockwell Automation, Schneider Electric, Turck and most recently Softing Industrial Automation. Softing Industrial Automation is a network technology specialist, a leading provider of software and hardware products designed to integrate technologies and data in factory and process automation environments. “Our companies have enjoyed many years of successful cooperation, which is now manifested in our decision to join the Open Integration partner programme,” says Thomas Hilz, Vice President Strategic Accounts at Softing Industrial Automation.

For more information contact Endress+Hauser Tel: +27 (0)11 262 8000 visit www.endress.com

The Open Integration partner programme brings together manufacturers of various control and related technologies to combine the best products for specific fields of application.

These apps can be created in a various programming languages such as C++, script languages such as Python, or new graphical languages such as Blockly. This gives machine manufacturers new-found freedom. Users can choose to program in IEC 61131, PLCopen or G-Code, or in conventional high-level or internet languages. This liberates machine manufacturers from dependency on the availability of PLC specialists and proprietary systems. Configuration and commissioning of the automation components are completely web-based, eliminating the need to install software. Within minutes of switching the system on, the software is programmed. A virtual ctrlX AUTOMATION system environment is available, enabling programming without hardware. System functionalities can be extended at any time via the user’s own process functions, apps, and open source software. By reducing required engineering time and effort, ctrlX AUTOMATION significantly reduces time to market for new machines. ctrlX will be available in South Africa through Tectra Automation, a Bosch Rexroth South Africa Group company, towards the end of 2020. For more information contact Tectra Automation. Tel +27 (0)11 971 940, email: wiets.pretorius@boschrexroth.co.za, or visit: www.boschrexroth.africa

Today, mechanical engineering is centred on software development. The new ctrlX AUTOMATION platform encompasses the latest engineering software technologies and all PLC and motion tasks. Software functions are combinable in any number of ways with ready-made, customised and customisable apps.

The new ctrlX AUTOMATION open automation platform

eliminates traditional boundaries between

machine control systems, IT and IoT.

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CONTROL SYSTEMS + AUTOMATION : PRODUCTS + SERVICES

Wall mounted solution for critical IT infrastructure Big data, the Internet of Things and edge computing are altering the distributed computing landscape. In line with these changing trends, there are changes in the IT infrastructure needed to support our increasingly connected environment. “We have seen computing power move from network cabinets – infamous for their nests of tangled wires and poor labelling – to powerful, compact micro datacentres,” says Jonathan Duncan – Secure Power VP for Anglophone Africa at Schneider Electric. Responding to the call for smaller and more convenient IT closets, Schneider Electric’s latest iteration of its 6U Wall Mount unit enables convenient and easy deployment of edge computing systems. “The 6U Wall Mount is about the shape and size of an electrical panel and allows heavy edge servers to be mounted safely on the wall, out of the way,” Duncan explains. He adds that this space-saving solution, with integrated dust filter and fan ventilation, has a wide range of applications, from businesses and shops to manufacturing sites and warehouses. “This solution can be deployed almost anywhere, and offers critical computing infrastructure to remote locations.” Designed to house servers, UPSs, storage and networking equipment, the 6U Wall Mount can help in rolling out mission critical IT equipment to places where it has never existed before. Furthermore, it can reduce unanticipated business downtime with Schneider Automation in ore sampling laboratories With the general decline in ore grades in mining, FLSmidth’s market-leading expertise in mineral sampling and laboratory automation holds increasing value for mines. Martin Matthysen, Director, SPA (sampling, preparation and analysis), Sub Saharan Africa and Middle East at FLSmidth, says, “The more mines understand about the characteristics of the ore entering their process plants, the better it can be treated. But this needs technology that can sample high volumes, maintain rapid turnaround times, and deliver quality results.” Only then can plant operators respond to laboratory data in real time, which is one of the keys to effective plant optimisation. With over 30 years’ experience, FLSmidth

Electric’s additional solutions, which can provide data- centre-like resilience. These include battery backup, power protection, remote monitoring, standardised designs, redundancy, and cooling solutions. As the applications for edge computing have expanded, so has the diversity of micro datacentres available to meet end-user edge computing needs. Duncan says, “A very basic system can consist of a simple rack with a UPS to provide battery backup and power protection. Adding a simple switch and server is enough to begin the process of local data capture and data sharing. More complex micro data centres can incorporate modular designs comprising sealed solutions equipped with hyper-converged IT, ruggedised components that resist the dust and moisture of harsh environments, and built-in fire suppression and cooling technologies.” How big and complex a micro datacentre will need to be depends on the IT technology required to address the business challenge, productivity goals and local application to be supported. The 6U Wall Mount empowers customers to support critical business operations in non-IT environments. Schneider Electric has designed this solution to be easy to deploy and cater to the changing needs of businesses with the rise of edge computing. tories constructed over the past 12 years or so in the global mining industry.” FLSmidth designs solutions for exploration and ore characterisation, grade control, process plants and port shipment. The highest quality equipment is sourced and applied to a laboratory solution to achieve accurate sampling, effective sample preparation and detailed sample analysis. Each laboratory is designed to suit the customer’s particular operating conditions and goals. This requires close collaboration with the customer and a detailed examination of mined material and process demands. This ensures that the laboratory generates the analytical data that the plant operators require. “With our world-class mineral research and testing facilities, we are constantly pioneering innovations that add value to customers,” he says. “Our automated solutions also offer consistency and traceability, while improving ergonomics and eliminating hazards to laboratory personnel. “We are accredited in terms of international quality standards, and work strictly to our customers’ specifications regarding health, safety and environment,” Matthysen adds. For more information contact FLSmidth. Tel: +27 (0)10 210 4000, email flsm-za@flsmidth.com or visit: www.flsmidth.com For more information contact Schneider Electric. Tel: 27 (0)11 254 6400, or visit: www.se.com/za

The new 6U Wall Mount unit makes it easy to deploy edge computing systems conveniently and safely.

The state-of-the- art automated zinc laboratory at Vedanta's Gamsberg Mine.

has pioneered laboratory systems integration and driven automation in the laboratory environment. “Our particular expertise in laboratory automation is now recognised world- wide,” says Matthysen. “We have supplied 95% of all automated labora-

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CONTROL SYSTEMS + AUTOMATION : PRODUCTS + SERVICES

Software stack and SoM add to IE development An engineering company that specialises in industrial real- time data communication has developed two alternatives for CC-Link IE TSN products: a software stack (master/ slave) reduces in-house development time and costs for the component manufacturer, and an embedded system on module (SoM) can directly expand existing platforms. John Browett, General Manager, CLPA-Europe, explains. Founded in 1990 and based in Halle/Saale, port industrial automation GmbH is committed to industrial real- time communication in all sectors. More than 500 product and system developers worldwide use MCU middleware, libraries, cores, protocol stacks, drivers, tools and development services from port to place their products successfully on the market. Since the beginning of CANopen, the company has relied primarily on multi-protocol solutions, working in collaboration with market drivers from the European and US automation industries. Today, port focuses on the Industrial Ethernet protocols in their many forms and that is why, in June 2018, it joined the CC-Link Partner Association (CLPA) – to support its Industrial Ethernet technology CC- Link IE TSN which combines gigabit bandwidth and time- sensitive networking (TSN). “port mainly serves industrial markets such as factory automation, logistics automation, sensor technology and the process industry and our real-time communication solutions cover the whole communication chain. CC-Link IE TSN provides an interesting technology platform which enables data from sensor to interface ‘IT’ to be displayed safely, and represents an important addition to our portfolio,” says Dietmar R. Franke, CEO/CFO of port industrial automation. “We will continue to develop the company by focusing on TSN as we support the whole concept of time-sensitive networking with a variety of products.” Automated marking of terminal strips The Mark Master terminal strip marking system from the Phoenix Contact ClipX product range uses patented high- speed technology for the fast and efficient processing of marking tasks. In control cabinet manufacturing, marking terminal strips is an exacting process with a high proportion of

The product range for CC-Link IE TSN currently includes a software stack that contains the tools required to configure, manage and install the new open specification. A decisive advantage of the stack solution is its hardware independence. The stack is ported to the relevant hardware platform in a consistent format and already contains the TSN features that are supported according to IEEE standards. In addition, there are appropriate configuration and management tools. port has also developed a hardware product for CC- Link IE TSN in the form of an embedded SoM which can be used as an add-on or expansion board for existing systems. “In other words, customers who are currently using a platform that offers a serial peripheral interface (SPI) can also add CC-Link IE TSN to their platform via this interface”, says Franke. While the licensing of port’s CC-Link IE TSN stack is aimed at customers who will then be able to optimise their development effort for larger quantities, the company also wants the embedded module to offer a CC-Link IE TSN option for companies that produce very small quantities. Franke sees opportunities for the SoM alternative for mechanical engineering in particular: “This fully integrated SoMalternative is especially suitable for manufacturers who make more specific products such as certain gateways or I/Os with small annual production runs because all the customer has to take care of is the integration of the hardware. However, we also offer that as a service for the CC-Link IE TSN system.”

port has

developed a hardware product for CC-Link IE TSN in the form of an embedded SoM which can be used as an add-on or expansion board for existing systems.

For more information contact CLPA-Europe. mail: john. browett@eu.cc-link.org or visit: eu.cc-link.org

added value, and it is facing increasing cost pressure and growing demand for ever-shorter delivery times. Common sources of error include the manual installation process for marking labels and even their incorrect printing. The solution is an end-to-end digital chain and automation of the marking process. The digital core of the high-speed technology supports connection to Phoenix Contact’s Project complete engineering tool. This ensures the flow of data from engineering directly into production. The ClipX product range is part of Phoenix Contact’s Complete line system solution for the control cabinet.

For more information contact Phoenix Contact SA. Tel:+27 (0)11 801 8200,

email: info@phoenixcontact.co.za or visit: www.phoenixcontact.co.za

The Mark Master terminal strip marking system ensure accurate marking fast and efficiently.

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CONTROL SYSTEMS + AUTOMATION : PRODUCTS + SERVICES

Safe panel design in a hazardous facility By 2030, only 20% of the total number of hydrofluorocarbons (HFCs) that were sold in 2015 will be available on the market. The HFC phase-down is a crucial aspect of the EU Fluorinated greenhouse gases (F-Gas) regulation and will influence the use of refrigerants in all end-use markets, including applications in the manufacture of food and beverages. Infrastructure to support the F‑Gas phasedown – particularly the reclamation of existing refrigerants – is being developed by companies such as A-Gas, with a view to overcoming potential shortages. As a business that supplies refrigerants world-wide, A-Gas is investing substantially in reclamation and recovery. It has developed its first European refrigerant separation vessel in Eygelshoven, in the Netherlands. The new facility is designed to split mixed, reclaimed refrigerant into distinct products for re-sale and buy-back schemes, to save customers money on buying virgin refrigerant and alleviate the demand for new HFCs. CP Automation has supplied core components for the new refrigerant separation vessel. As it is a hazardous environment, effective panel design to house the control and safety components was essential. A-Gas contracted UK-based G&P Controls, to design the panels collaboratively for it. To suit the given small footprint, and recognising space was at a premium, G&P Controls had to consider the placement of equipment carefully. In addition, harmonic filters and motor chokes were to be added to reduce harmonics and the dV/dT on the motor insulation. This was important to protect the motor and the drive, which would otherwise be vulnerable to long cable distances that might lead to high voltage rises. When sourcing and building in the control and safety elements, using A-Gas’s non-standard panel design, and in sourcing the power conditioning equipment, G&P Controls consulted Phil Perkins at Routeco, with a view to using its range of Allen Bradley Powerflex drives. Perkins said: “I work with a lot of automation engineers and panel builders. We find in almost every case a project is carefully planned to ensure the panel and its contents is capable of controlling the machinery and components downstream. "However, in almost every case we also see a lack of planning when it comes to ensuring that what has been designed is not going to cause complications for the clean distribution of power on the whole site. “We find time and again, electricians are re-setting panels, and keep re-setting panels. Whole plants keep tripping out at enormous cost and hardship to the business. Components continually fail and just get replaced, with engineers or consultant engineers charging a lot to firefight but not rectifying the issues that are causing the problem. “To an automation engineer and many electrical engineers, this is a dark art, one they steer clear of if

they can. We were lucky to have a good relationship with CP Automation and the team was able to identify and resolve every issue in this area of expertise.” CP Automation supplied the components to meet specifications and helped improve the design of the system, using additional products to make it more robust. Most of the items supplied were from stock, including a Sine Tamer TVSS surge protector, harmonic filter, ac line choke, EMC filter and motor choke. John Mitchell of CP Automation commented: “Advising and supplying the safety-critical parts was simple. Although this was hardly an out-of-the-box application, as a specialist in this area it is what we do every day. We had to consider every millimetre of space in the panel and we had everything G&P Controls needed.” With all parts installed, the panel was exported from the UK to the Netherlands. A-Gas has since commissioned the first of its facilities. It will bring further separators, filling stations and storage tanks online to meet demand in Europe for new refrigerant gases in the run up to 2030 and beyond. For more information contact CP Automation. email: john.mitchell@cpaltd.net visit: www.cpaltd.net

Control panels that work, controlling machinery and components downstream and ensuring stability in power distribution site-wide.

10 Electricity + Control MAY 2020

DRIVES, MOTORS + SWITCHGEAR

Energy-optimising drives save costs

The AEL (African Explosives Ltd.) Intelligent Blasting 720 Mtpd nitric acid plant is saving some 3.6 million rand annually on operating costs, as a result of an upgrade from direct-on-line operation toVLT ® drive control of electric pumps and motors.

Greater reliability at a lower cost The nitric acid plant, in Johannesburg, South Africa, supplies other AEL divisions serving mining operations with chemicals and explosives, nationally and internationally. Its reliability has been improved by upgrading the process water cooling system, and energy consumption was reduced by 500 kWh hourly in the process. For many years, motors and pumps in the process cooling water (PCW) system operated direct-on-line. With the upgrade, AEL Intelligent Blasting sought to improve efficiency and reliability by introducing ac drive motor control. The company chose VLT ® AQUA Drive FC 202 and VLT ® HVAC Drive FC 102 drives from Danfoss, based on the drives’ ability to ensure stable operation despite unreliable mains power supply. The drives offer automatic energy optimisation and kinetic back-up features to support highly efficient and reliable plant operation. During the upgrade, there was no disruption of operations as all equipment was ‘pre-installed’ with wires run to and from the motor control centre. The final connections were made during a planned shutdown for a catalyst change out. Johan Engelbrecht, AEL Nitrates MV Electrical Engineer, says, “The drives were selected based on the kinetic back- up feature, which is valuable to us because of our unstable electricity supply and a lot of small voltage dips that cause our facilities to trip out. With this feature we can keep the plant online without any issues, so saving millions.” Fast payback time Since the upgrade, AEL Mining Services has been able to reduce the electricity consumption on the two fans by 200 kWh combined, and by another 300 kWh on the motors. The total savings on operating costs based on an average electricity charge of 85 c/kWh, amount to about R3.6 million. The payback time of only 18 months reflects the substantial improvement in process cooling water efficiency that AEL Intelligent Blasting has achieved. “Because we linked everything to our distributed control system – DCS – we were able to use the drives to reach a

At a glance ■ The drives' automatic energy optimisation and kinetic back-up features support efficient and reliable plant operation. ■ The payback period of 18 months reflects the savings achieved by improving efficiency in the process cooling water system.

sweet spot of running the pumps and fans on the cooling system so as not to drop efficiency or impact negatively on plant production or quality, while still maintaining an energy saving of around 360 kWh. This resulted in the payback period of about 18 months,” says Eben Jacobs, AEL Process and Control Engineer. □

The upgraded process cooling water system now uses VLT ® AQUA Drives controlling each of three cooling water pumps, and VLT ® HVAC Drives controlling both

the cooling tower fans.

African Explosives Limited Intelligent Blasting nitric acid plant in Johannesburg.

Application Installed drives Cooling water pumps 3 x 355 kW, 525 V ac 3 x VLT® AQUA Drive FC 202 P450K Cooling tower fans 2 x 185 kW, 525 V ac 2 x VLT® HVAC Drive FC 102 N250K Motor sizes

For more information visit: www.danfoss.com

Electricity + Control MAY 2020

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DRIVES, MOTORS + SWITCHGEAR : PRODUCTS + SERVICES

Geared motors to extend Zest WEG range With over 40 years’ experience in the African market, Zest WEG will soon be adding the WEG WG20 geared motors to its extensive range of electric motors, components and systems. “Geared motors represent a natural extension to our market leading electric motor range,” says Zest WEG National Sales Executive Johan van Niekerk. “They will also pave the way for us to expand our contribution in a number of markets.” Geared motors are used in various sectors, including packaging, food and beverages, automotive, chemicals, materials handling and recycling. It is expected that the most popular size range in the geared motors to be offered will be up to about 22 kW, although the company will be able to provide non-stocked units up to 110 kW where required. “With our extensive footprint around South Africa and other countries on the continent, we are well positioned to provide this range to new and existing markets,” says van Niekerk. “Our geared motors will

Componentry will be sourced within the global WEG group, from Austria-based gear technology specialist Watt Drive, a leader in modular motor and gear systems. The company offers a complete range of combinable drive systems for production machines and industrial manufacturing plants. Zest WEG geared motor specialist, Cas de Jager says, “To ensure quick turnaround in our assembly process, we are locally warehousing a full range of gears, flanges, housings, shafts, bearings, oil seals and other components. This improves our time to market, enabling us to respond to customer orders in as little as a day or two, rather than the weeks it would take to import a complete product.” De Jager highlights that the assembly process will prioritise market demands for quick reaction and minimal production downtime. “Every application has a different requirement in terms of a geared motor’s specification, so each unit must be designed and assembled with that customer’s specific use in mind,” he says. “The gears specified are able to adapt the speed or torque of a motor to the needs of the application.” De Jager adds that the new Zest WEG assembly facility will support the local economy and promote the development of engineering skills in the local market. Specialised training related to the WEG WG20 range will be provided to Zest WEG employees through visits to the Watt Drive factory in Austria, which will also send technical experts to South Africa to share skills. Van Niekerk says, “This aligns with our established mission to invest continuously in engineering and other skills that our economy needs to thrive in the long-term.” De Jager emphasises a number of benefits that the geared motors bring to industry. One of the key improvements enabled by modern geared motors is a high level of efficiency. Research shows that only about 1.5% of mechanical efficiency is lost per gear stage – so a two- stage gear unit would be about 97% efficient. They are also very reliable, with a robustness and durability that makes them economical to maintain, especiallywhen constructed fromhighquality components. With many customers already using WEG motors in their production plants, the geared motors from Zest WEG could provide an immediate benefit.

all carry the benefit of the high levels of service and after-market support for which Zest WEG is well-known.” He expects the WEG WG20 range to be made available in South Africa from the third quarter of 2020. The geared motors will be locally assembled at a new assembly facility at Zest WEG’s Linbro Park headquarters in Gauteng, close to the company’s existing motor workshop. A considerable investment has been made in the new facility, including hydraulic presses and assembly tooling. It will also be able to leverage ancillary services from the company’s existing technical resources.

Parallel shaft gear units are particularly suited for conveyors.

Design of the WEG WG20 range allows for easy integration of the geared motors into almost any existing system.

WEG K geared units can also be equipped with a hollow shaft, output shaft, shrink disc, torque arm and mounting flange.

The WEG WG20 was the first geared motor range to be developed completely in-house at WEG.

The WEG gear units with two-stage designs feature a large ratio range, which makes them highly efficient.

12 Electricity + Control MAY 2020

DRIVES, MOTORS + SWITCHGEAR : PRODUCTS + SERVICES

The housings can be constructed from a range of materials which affect the rigidity and weight of the overall design. An aluminium housing, for example, is much lighter than a grey cast-iron housing but delivers similar strength. For higher torques, cast iron is generally chosen due to the material being particularly torsion-resistant and able to dampen vibrations. In applications where intensive cleaning is regularly required – such as in the food and beverage sector – a smoother surface on the housing is preferred as it is easier to keep hygienic. De Jager notes that the most common types of gears used in industry today are in-line gears, and these will make up the majority of the box types for the local market. In-line gear units are the popular and reliable option for most slow-speed, high-torque applications. With its longer design, the in-line box is used where sufficient space is available. “For customers who have space constraints, the parallel shaft gear offers advantages,” he says. “With the input and output shafts being offset – but parallel – to each other, they provide a very compact, space-saving solution.” These are usually multi-stage helical gear units comprising a hollow output shaft that allows the gear to be mounted on an existing shaft. “For applications where the angle of the input and output axes is not a straight 180 degrees, bevel gear units serve this need,” he says. “In principle, any axis angle can be achieved with bevel gear wheels, but in most cases the input and output axes are at 90 degrees to each other.” Van Niekerk highlights the long established benefits Zest WEG offers customers in high service levels and ease of doing business. “Our flexibility and responsiveness to customers’ needs is what sets us apart, allowing us to introduce added lines of technology in the interests of productivity and uptime. Our branches will also have the capacity to support these geared motors with the same expertise and commitment they apply to our other products,” van Niekerk says.

For more information contact Zest WEG Group. Visit: www.zestweg.com

Zest WEG National Sales Executive, Johan van Niekerk.

Electricity + Control MAY 2020

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