Electricity + Control November 2017

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

COMMENT

ON THE COVER

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

Looking forward to year-end?

I t cannot escape one that the year is rap- idly drawing to a close. Do we look for- ward to that, or do we view it with some trepidation? Avoiding, as always, the topics that have no place in a technical magazine, we should reflect for a while on the uncertain- ty created by policy and politics right now. As soon as politics begins to impact ad- versely, and significantly, on our industry, we need to sit up and take notice. As a courtesy, I will not analyse this fur- ther - save to say that policy makers can have a profound impact on the economy - and that is essentially their job. But we need to reflect on how best to ensure that the impact is always positive in intention. Impact we have. It is just the direction of the vector that needs work! In another context, I was recently consid- ering some of the positive developments in school Science education. I penned a very critical analysis of where we are, in this regard, as a country and it was sug- gested to me that I was being overly criti- cal. But I disagree. Recognising progress is very important and there has been progress in many aspects of our economy and our society. My grumble is that we are doing far, far worse than we should be and I have be- come increasingly impatient with the rate of progress.

It was exactly this aspect of the improve- ments in basic education that led to my rather critical assessment. Let us never lose sight of the fact that it takes your closest friend to tell you the hard truths! A true friend will honestly tell it to you like it is and I feel an obligation to be critical where I know it is a hard truth - yet a necessary one to hear. This must guide our criticism of what we see impacting our industry. Equally, we need to recognise progress where it is happening. Criticism, if well intended, can assist us in achieving the levels of excel- lence that this nation deserves. For too long we have settled for ‘good enough’ or ‘couldn’t quite get there’. Every one of our readers, I know, strives for excellence. That which frustrates the achievement of excellence should be identified, addressed, and routed out.

ABB ’s new generation drive – the ACQ580 – will assist designers, OEMs and EPC professionals to secure water and wastewater flow in municipal utilities, industrial wastewater facilities, desalination plants and irrigation environments. Read more on page 21. 10/16/2017 3:03:55PM www.electricityandcontrolmagazine.co.za ECNOV2017 cover.indd 1

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CONTENTS

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Features

Control systems + automation 4 Protecting Critical Infrastructure in Africa in a Converging Environment Goran Novkovic, Valiver 8 Intelligent Approach to Africa’s Mobility Revolution Kevin Pillay, Siemens Africa

10 Round UP

Drives, motors +switchgear 14 A Morning at Shaw Controls in Joburg South Crown Publications visits ...

18 Round UP

Plant maintenance, test + measurement 24 Performance of 500 kWp PV Plant – One Year After Jaco Bergh, Brand Engineering 26 Natural Ester Fluids: New Tool for Operational Gains Information provided by Cargill Industrial Specialities (Cargill)

29 Round UP

Temperature measurement 32 Heat Tracing – Choosing the Right System Giles Maynard, eltherm South Africa 33 Temperature Controllers Embrace the Era of AI Information provided by Omron 34 Precise Temperature Control assures High Quality Steel Information provided by Mecosa

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35 Round UP

24

Regulars

1 Comment 21 Cover Article 36 Light+Current 38 New Faces & Places 39 Social Engineers 40 Not to be missed 40 Brain Block 40 Write @ the back

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Protecting Critical Infrastructure in Africa In a Converging IT/OT Environment

Goran Novkovic, Valiver

of critical infrastructure, placing national security, economy, public safety and health at risk … like never before. Due to the increasing pressures from external and internal threats, organisations responsible for critical infrastructure need to have a consistent and iterative approach to identifying, assessing, and managing cybersecurity risks. This approach is necessary regardless of size of the or- ganisation, threat exposure, or cybersecurity so- phistication today. Operational Technology (OT) and Industrial Control Systems (ICSs) are the fundamental components of national critical infrastructure in any country. Most sectors rely on ICSs to ensure process con- trol and safety, which ensure continuity of nation- al critical functions. Key industry sectors such as energy, water/wastewater, telecommunication, OT and ICS – fundamental components of national critical infrastructure

W e hear about cybersecurity incidents on a daily basis, but how relevant are these incidents to your organisation? Cybersecurity incidents are happening globally; do you think that they are just too far from you? If you are an organisation that manages critical infra- structure, these cybersecurity incidents are more relevant than you may think. National and economic security of Africa, South Africa in particular, depends on reliable function- ing of critical infrastructure. Cybersecurity threats exploit the increased complexity and connectivity As industrial cybersecurity attacks con- tinue to increase in frequency and so- phistication, we need to do everything to stay protected.

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public and private organisations and other entities with a role in securing the national infrastructure. Members of each critical infrastructure sector perform functions that are supported by IT and OT including ICSs. The OT and IT are increasingly advanced, pervasive and connected. This reliance on technology, communication, and the intercon- nectivity of IT and ICS has changed and expanded the potential vulnerabilities and increased poten- tial risks to operations. While IT/OT convergence offers many benefits, it also increases the connec- tivity and criticality of these systems and creates a greater need for ICS adaptability, resilience, safety, and security. Nowadays, industrial organisations globally take safety seriously and have reduced cybersecurity risks for people. But as the world rapidly connects devices and machines, it is time to assess cybersecurity weaknesses as the first step toward ensuring better protection of people, information, technology, and facilities. Safety must be job one! Securing OT, ICS and IT environments Securing an OT and ICS environment is signifi- cantly different from securing a traditional IT en- vironment. What we are securing is different, and how we are securing it is different. Although some characteristics are similar, ICS has characteris- tics that differ from traditional IT systems. Many of these differences come from the fact that ICS has a direct effect on the physical world. Some of these characteristics include significant risk to the health and safety of human lives and serious damage to the environment, as well as serious is- sues such as production losses, negative impact to a national economy, and compromise of pro-

transportation, oil and gas and chemical, all rely on ICSs to supervise and control their key process- es. As industries lean towards pervasive process automation and maintenance-free operations, the role of ICSs in these sectors is even greater. Digital transformation changed the ICS envi- ronment from proprietary and isolated systems to open architectures and standard technologies. This move towards connecting ICS and IT environ- ments (IT/OT convergence) results in an increased attack surface exposing the critical functions to higher cybersecurity risks. The priority of ICS se- curity results from the great impact on national critical functions. The interconnection of critical Infrastructure across the continent, or a particu- lar country, may result in a cascading effect in the case of a successful cybersecurity attack. With new, open technologies and communication pro- tocols, ICSs are increasingly vulnerable to attack, disruption and damage. Nowadays, organisations are facing increased IT/ OT convergence and operational models that often require remote network access. The critical infra- structure demands high quality, real-time informa- tion to make more accurate business decisions. With Fourth Industrial Revolution (Industry 4.0) and Industrial Internet of Things (IIoT) that promise new opportunities for cost savings and operational improvements, ICS and IT systems will be com- pletely interconnected. The result of this dynamic change in the industry is that availability, reliabili- ty, integrity, safety and security of ICSs, networks and devices can no longer be taken for granted. As ICSs are adopting IT solutions to promote corporate connectivity and remote access capa- bilities, and are being designed and implemented using IT standard computers, Operating Systems (OSs) and network protocols, they are starting to resemble IT systems. This integration supports new operational capabilities, but it provides sig- nificantly less isolation for ICSs from the outside world than predecessor systems, creating a great- er need to secure these systems. A rapidly increas- ing number of incidents in the ICS domain, many of which are confirmed or believed to result from cybersecurity attacks, reveals the vulnerability and fragility of this area and highlights the importance of continuous improvement of ICS cybersecurity. The critical infrastructure community includes ICS cybersecurity in the converging IT/ OT environment

Take Note!

Operational Technology and Industrial Control Systems (ICSs) are the fundamental compo- nents of national criti- cal infrastructure in any country. With Industry 4.0 and IIoT – and the promise of new opportunities for cost savings and oper- ational improvements, ICS and IT systems will be completely intercon- nected. The result of this dynam- ic change in the industry is that availability, reli- ability, integrity, safety and security of ICSs, networks and devices can no longer be taken for granted.

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prietary information. ICSs have unique performance and reliability requirements and often use op- erating systems and applications that may be considered uncon- ventional to typical IT personnel. Furthermore, the goals of safety and efficiency sometimes conflict with security in the design and op- eration of ICSs.

Cybersecurity threats are placing national security, economy, public safety and health at risk … like never before.

Attack on IT – attack on OT An attack on IT could lead to information theft, but an attack on OT could affect the physical world (people, technology, environment, facilities). It is a serious distinction. IT cybersecurity focuses on

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digital information protection, while OT cybersecu- rity focuses on people and physical asset protec- tion. ICS is cyber-physical, often directly affecting the real world. This means that risk calculations include potential impacts in scope and at scales greater than in information only environments, in- cluding but not limited to loss of lives, ecological damage, intellectual property theft and revenue losses. While security solutions have been designed to deal with these security issues in typical IT sys- tems, special precautions must be taken when introducing these same solutions to ICS environ- ments. In some cases, new security solutions are needed that are tailored to the ICS environment. The traditional IT priorities of information Confi- dentiality, Integrity and Availability (CIA Triad) are shifted in ICS to system Availability, Integrity and Confidentiality (AIC Triad). To deliver cybersecuri- ty solutions specific for ICS requires an industrial mindset, purpose-built technology and specific OT security expertise. To the extent that cybersecurity events can disrupt public safety and security, ICS cybersecurity is quickly emerging as a top national priority. Cybersecurity solutions must be implemented in a way that maintains system integrity during normal operations, as well as during a cybersecu- rity attack. Many organisations recognise cyber- security challenges, but need help defining a road

map to protect critical infrastructure and valuable assets. They need an approach that draws on the success of others through manageable cyberse- curity processes and measurable improvements. One of the major constraints to protecting ICSs is a misunderstanding of the difference between IT and OT. It remains a fuzzy area in terms of how these two overlap, where they diverge, and who, with regard to internal security teams, is responsi- ble for securing what. ICS cybersecurity is a rela- tively young and very specific field. Protecting crit- ical infrastructure in Africa (South Africa) must be based on proven cybersecurity practices to exploit opportunities through a better understanding of similarities and differences in the IT and OT world, organisational cybersecurity risks that will lead to establishing cybersecurity governance, developing cybersecurity framework, and building effective cybersecurity programs. Conclusion Organisations must recognise that establishing a successful and sustainable cybersecurity pro- grams is a significant effort, but it can be and it must be done. The importance of protecting crit- ical infrastructure goes beyond one organisation, country or continent, and this will only become more evident with Industry 4.0 and Internet of Things (IoT and IIoT) as the trend of interconnect- ed systems continues to expand in the future.

abbreviations AIC – Availability, Integrity, Confidentiality CIA – Confidentiality, Integ- rity, Availability ICS – Industrial Control System IIoT – Industrial Internet of Things IT – Information Technology OS – Operational Systems OT – Operational Technology

Goran Novkovic, MSc, ITIL, CQA, CSQE, PMP, APM, Peng, is Cybersecurity Program Manager at Valiver. Goran is focused on protecting critical infrastructure and he is helping organisations to establish ICS cybersecurity governance and develop effective ICS cybersecurity programs from scratch. He is promoting cybersecurity for critical infrastructure and manufacturing through public-speaking, blogs and articles. Email: goran@valiver.com

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Intelligent Approach to Africa’s Mobility Revolution Kevin Pillay, Siemens Africa

T he need and demand for intelligent mobility in Africa has nev- er been greater – World Economic Forum competitiveness data reveals that only three African countries feature in the top 50 globally for quality of roads, quality of rail and quality of ports infrastructure respectively. World Bank data also indicates that the Sub-Saharan African railway network has declined to 59,634 km today, down from 65,661 km in 1980 with only about 70% of the railway network in operational state. At face value, it seems as though the continent faces insur- mountable transport challenges. But the reality is that we are al- ready setting the wheels in motion to create interconnected, more modern and efficient African transport networks that keep econo- mies on the move, rather than hindering them. This development will not happen overnight, and will be realised one step at a time. Intelligent traffic systems In many African cities traffic infrastructure is plagued by unreliable power supply. Road infrastructure cannot handle peak traffic (i.e. faulty traffic lights), not because of technology but because of the lack of proper technological investment.The challenge is partly that

tems affect a country’s ability to attract and maintain investment. So where do we begin? The adoption of Intelligent Traffic Systems (ITSs) will keep Af- rica’s busiest cities as fast-moving investment destinations. ITSs include deployment of smart sensor systems with intelligent algo- rithms to automatically adapt to improve traffic flow. Two-way communication can be enabled by running fibre be- tween traffic junctions and a central control centre to gather infor- mation from intelligent networked systems, sensors and cameras at every junction. This allows traffic lights to be adjusted according to demand. Nigeria’s Edo State government recently announced its inten- tion to upgrade to a technologically-advanced ITS that provides re- al-time traffic information in Benin City. As part of the integrated solution, motorists and commuters will be informed about travel times, weather conditions and traffic jams on radio or online. With all traffic management systems automated and digitalised, tech- nology like Automatic Number Plate Recognition (ANPR) cameras can be utilised to efficiently enforce traffic rules. Average Speed Over Distance (ASOD) technology captures the

these traffic systems have grown in an uncoordinated way, with lots of different suppliers and systems cobbled together. Inefficiencies in these transport sys-

time when a specific vehicle enters and exits the ASOD zone. The journey time is compared against the distance travelled and authorities are automat- ically notified if the prescribed speed limit was ex- ceeded. This improves the safety of drivers, passen- gers and pedestrians. It also minimises the risk of corruption, while promoting best practice among traffic enforcement officers who are exposed to a new skillset when trained in operating these new systems.

A well-integrated intelligent multi- modal transport network reduces traffic congestion and CO 2 emissions.

Automated rail infrastructure Another effective means of reducing congestion on overburdened and under maintained roads in Africa is through greater investment in upgrading passenger rail networks. Some of the world’s cities with the most advanced transport networks feature fast, efficient, safe and clean rail mobility networks powered by Siemens, and African cities can benefit from expertise in centralised traffic man- agement and automation systems, including train control systems with minimum line side equipment linked to modern control cen- tres. A clear case in point is the Gauteng Nerve Centre (GNC) in South Africa. The 3 400 m 2 state-of-the art control centre for cen- tralised rail traffic management in South Africa’s economic hub of Gauteng accommodates 35 train control operators in one place, and constantly monitors Gauteng’s rail traffic where over 600 trains carry more than 500 000 commuters on a daily basis. The GNC boasts world-class automation capabilities and can immediately respond to any operating failures, accidents and oth- er incidents, thereby enabling greater efficiencies in rail operations and train safety, while offering a more reliable service through higher infrastructure utilisation. Siemens’ proven railway capabil- ities are set be bolstered further, following the mobility business’

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concepts that include electric bus rapid transport and ferries, to name a few. Intelligent and integrat- ed traffic systems are part of the future of transport in the world’s advanced cities. If Africa seizes the opportunity, many of its cities will be on that list, and the continent’s citizens will reap the rewards. That is the way forward.

recent announcement of its intention to merge with French railway engineering specialist Alstom.

Take Note!

It seems as though Africa is facing insurmountable transport challenges. The reality is that we are setting the wheels in motion to create in- terconnected, modern and efficient transport networks. These transport net- works will keep econo- mies on the move!

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Environmental sustainability Transportation is the world’s second-biggest pro- ducer of greenhouse gases. In 2015 motor vehicles, trains, ships, and planes emitted 7,5 billion tonnes of CO 2 into the atmosphere, accounting for almost a quarter of all CO 2 emissions worldwide. Today transportation-related emissions are al- ready about 60% higher than in 1990. One of the reasons for this is the dramatic increase in the num- ber of vehicles in developing countries and emerg- ing markets. According to forecasts, transportation-related CO 2 emissions will increase by another 67% be- tween now and 2050. Conclusion If Africa truly wants to unleash its full potential, then sufficient funds must be responsibly invested in upgrading existing transport and logistics infra- structure like road, rail and ports, in addition to new

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Kevin Pillay – Vice President for Mobility at Siemens Africa. Enquiries: Keshin Govender Tel: +27 (0) 11 652 2000

Email: keshin.govender@siemens.com Web: www.twitter.com/siemens_press

CONTROL SYSTEMS + AUTOMATION

7-colour Indicator lights Banner Engineering , a leading provider of technology for pro- cess and industrial automation, has introduced K30L2 and K50L2 seven-colour indicator lights for use in any application requiring high-visibility status indication. K30L2 and K50L2 indicators utilise RGB LED technology to sup- port seven colours in a single indicator using just three inputs. Col- ours include red, green, blue, yellow, cyan, magenta, and white. This versatility makes it possible to standardise on a single model of indicator, reducing replacement stock requirements and simpli- fying ordering. Designed to provide clear, unambiguous indication of status, K30L2 and K50L2 indicators shine bold and bright for easy, at-a-glance visual management. An optional audible alarm available on K50L2 models provides a distinct, loud notification of a change in status. Protected by a rugged IP66, IP67, and IP69K polycarbonate hous- ing, K30L2 and K50L2 indicators withstand impact and high-pres- sure, high-temperature washdown, ensuring reliable performance in challenging environments. Models constructed from FDA-grade SCADA and industrial automation supplier, Adroit Technologies, has signed a partnership agreement with SqwidNet, the licenced SIG- FOX IoT network operator in South Africa. SIGFOX is the leading provider of global IoT connectivity with network deployments in 36 countries at present. Their proposition comprises low-cost, long- range, low-power modules and devices that serve up IoT data in a se- cure and cost-efficient manner to application and service providers. The partnership opens up excellent opportunities for IIoT appli- cation and service providers to use the cloud-based SCADA and in- dustrial-automation platforms offered by Adroit Technologies. Data from sensors and devices can now be seamlessly served up to the Adroit-hosted platform environment via the SIGFOX network. “As the IIoT evolves, we are noticing that customers are looking at the application of IIoT technologies across a wider range of use

materials are available for use in food and beverage applications. These second-generation in- dicators are based on the indus-

try-proven first generation of K30 and K50 series LED indicators. They offer similarly low levels of power consumption and require little or no maintenance over a very long operational life. In addition, K30L2 and

K50L2 indicators have a clear, uncomplicated wiring plan that ena- bles quick, hassle-free installation and allows users to consolidate controller outputs. K50L2 indicators are also available in models with IO-Link com- munication, which enables full control of colour, flashing, dimming, and advanced animations like rotation, strobing, 2-colour display, 2-colour rotation, 2-colour flashing, and chase. Enquiries: BrandonTopham.Tel. +27 (0) 11 453 2468 or email brandon.topham@retautomation.com cases, including utility management, manufacturing, and inventory and asset management,” says Dave Wibberley, Managing Direc- tor of AdroitTechnologies . “We see SIGFOX technology as much more compelling from a scalability, simplicity, cost, and ease-of-in- tegration perspective than traditional telemetry options. This is par- ticularly relevant when it comes to smaller projects’ requirements. SqwidNet already covers all of the eight major metros in South Africa, and they cover 64% of the population nationally. They have demonstrated to us their willingness to drive enablement and inno- vation in the industry through their ecosystem of global module-, device-, platform-, and application-development partners. Their ex- ceptional technical and commercial support has enabled us to build interfaces to the SIGFOX back end, and develop a number of trials based on data from sensors and connected devices on the Sqwid- Net network."

Adroit and SqwidNet sign IIoT partnership

The demonstrations of these scenarios can be viewed at the AdroitTechnologies premises. Adroit Technologies is in the process of be- coming a certified SIGFOX partner for devices and for their SCADA platform. Enquiries:Tel. +27 (0) 11 658 8100 or email info@adroit.co.za

Chetan Goshalia (SqwidNet), Reshaad Sha (SqwidNet), Dave Wibberley (Adroit Technologies), Johan Nieuwenhuizen (Adroit Technologies) and Grant Joyce (Adroit Technologies).

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Launch of open architecture industrial computers and thin clients

Many manufacturers struggle with unreliable human machine in- terface (HMI) applications that use obsolete operating systems. With the new family of Allen-Bradley VersaView 5000 industrial computers, thin clients and monitors from Rockwell Automation , manufacturers can modernise their standalone or distributed HMI applications to support smart manufacturing. “The VersaView 5000 portfolio is our latest open architecture HMI or industrial com-

puter offering,” said Christo Buys, Business Manager for Control Systems, Rockwell Automation sub-Saharan Africa. “An open archi- tecture design gives manufacturers greater freedom to install the software that fits their needs.The portfolio also includes our largest ever full-HD screen size, which can display more information and replicate control room displays on the plant floor for more efficient data sharing.” The VersaView 5000 portfolio, part of the Rockwell Automa- tion scalable compute offerings, includes five products: VersaView 5400 display and non-display computers; VersaView 5200 display and non-display thin clients; and VersaView 5100 monitors. The dis- play options include an edge-to-edge glass display, a new 22-inch widescreen option, full HD and 10-point multi-touch capabilities to help improve operator productivity. When combined with FactoryTalk View Site Edition software from Rockwell Automation in distributed applications, the VersaV- iew 5400 industrial computers can provide cost-effective com- pliance with 21 CFR Part 11. The software stores, processes and transmits electronic records and signatures to show which employ- ees have made changes. This is critical for highly regulated indus- tries like life sciences. Enquiries: Christo Buys.Tel. +27 (0) 11 654 9700 or email cbuys@ra.rockwell.com

Low-profile strip lights

WLS15 is perfect for use on mobile equip- ment and other battery regulated applica- tions. The space-saving design of the WLS15 enables installation in confined areas and very tight spaces. It has a slim 15 mm profile that will not obstruct sight lines or disrupt the work environment. The ability to cascade lights together combined with flexible mounting options, such as endcap mounting holes, snap clips, and a wide range of available brackets, simplify instal- lation and wiring and make it easy to de- ploy and power one or multiple lights with- in a short amount of time.

Banner Engineering , a leading provider of technology for process and industrial auto- mation, today announced the release of the WLS15, a professional grade LED strip light that makes it easy and very cost-effective to illuminate machines, work spaces, and mobile equipment for improved efficiency, productivity, and safety. Featuring high-efficiency LEDs and a dif- fuse window, the WLS15 provides bright, even illumination with no hot spots. It uses a fraction of the energy of many compara- ble light fixtures and operates within the 12 V dc and 24 Vdc ranges. The low power consumption and slow current draw of the

Enquiries: BrandonTopham. Tel. +27 (0) 11 453 2468 or email brandon.topham@retautomation.com

Powerful standard and safety PLC in one unit Modern vehicles and mobile machines need very powerful control electronics to process the high number of input and output signals. That is why the new third generation ecomatController was de- veloped. It has two independent, internal PLCs; one of them will be certified as a safety controller. In addition to its multifunctional inputs and outputs with diagnostic capabilities, the unit features two Ethernet ports and four CAN interfaces. The CAN interfaces support all important bus protocols (CANopen, CANopen Safety and J1939) as well as the transparent and pre-processed data ex- change. The control functions are easily integrated into the application program thanks to CODESYS programming (version 3.5). Enquiries:Tel. +27 (0) 12 450 0400 or email info.za@ifm.com

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Encoder ensures absolute accuracy Absolute encoders are considered ideal for applications where a power outage requires machinery to reorient without having to reconfigure any of its settings. This, according to Gerry Bryant, managing director of sensor solutions specialist Countapulse Controls, is because an absolute encoder is suited to applications where positional information is required periodically and not continuously. “When power is restored, the system master or controller will identify the position as soon as the en- coder starts relaying information again,” he explains. Generally, absolute rotary encoders are used as these offer absolute accuracy in determining the posi- tion of an object, but as can be seen from the scenario described above this is not sufficient. The encoder can- not simply collect feedback data. It needs to be sent somewhere in a language that can be interpreted by the system. Bryant explains that absolute encoders use binary coding which can be translated into many differ- ent protocols. Countapulse Controls is the official southern Afri- can distributor for the Hengstler ACURO range of abso- lute encoders. These quality sensors have found favour in applications where both speed and position are re- quired, and where there is no room for error. Using a static reference point, the Hengstler abso- lute encoder will determine the speed or position of an object and can be configured to measure, monitor and control the linear movement and/or acceleration. Innovative engineering has resulted in an absolute encoder that has optimised functionality while being easy to operate. Designed as a modular system, the absolute encoder can be configured to allow the correct variant for an application taking factors such as motor feedback and automation into account. The Hengstler ACURO is equipped with an open BiSS sensor interface allowing for optimal integration into any system. Johannesburg-based, Countapulse Controls has an in-depth understanding of the application of absolute rotary encoders and is able to assist the market in se- lection of the best fit solution for a given application. Enquiries: Gerry Bryant.Tel. +27 (0) 11 615 7556 or email bryant@countapulse.co.za

Commitment to packaging Exhibiting at one of the leading packaging exhibi- tions, ProPak Cape, SMC hopes to further cement

its place as the leading provider of solutions for the industry. ‘More than pneumatics’, SMC offers electric solutions as well as niche solutions such as its range of ionisers, chillers and dryers. Having been exposed to food processing and packaging manufacturing en- vironments around the world, SMC understands that static all too often plays a significant role in machine and production downtime. As such, SMC devel- oped its range of ionisers to complement its existing offerings and to offer significant benefits to its customers. Brian Abbott, Product Manager at SMC Pneumatics notes that SMC will be showcasing its ioniser range at ProPak Cape and elaborates on the issues associated with static: “If ignored or man- aged incorrectly, static can contribute to downtime which leads to a loss of income and low levels of productivity. Issues such as products clinging to each other, plastic sheets not separating properly, possible damage to electrical products as well as fire hazards caused by a spark in a sensitive environment, are all associated with unwanted but unavoidable charge of electricity”. According to Abbott, there are three different types of ionisers available depending on the application and the environment; SMC offers a bar type ioniser (IZS40/41/42), a fan type ioniser (IZF10/21/31) and a nozzle type ion- iser (IZN10). “The unique thing about SMC’s ionisers is that they can be ordered with a sensor. The sensor is a feedback device that is able to detect if a positive or negative charge exists at the source. The charge, measured as a voltage, is communicated back to the ioniser which in turn generates ions to balance it out.. An option without a sensor is also available. In this case, the unit will generate alternate charge which ‘bombards’ the applica- tion with positive and negative ions until it neutralises the application. This, even though less energy efficient, is still a very effective solution.” Enquiries: Email marketing@smcpneumatics.co.za Programmable Multi-Axis Controllers OMRON and OMRON's Delta Tau Data Systems, Inc. (hereinafter ‘DT’) have worked together to develop the PMAC controllers with global leading motion control technology from DT. PMAC achieves sophisticated fine-tuning control, including high-speed synchronous control of various Factory Automation (FA) devices, thanks to built-in EtherCAT connectivity which is used for production lines and equipment all over the world. Its development environment allows users to program their own motion algorithms and motion control functions, such as trajectory calculation and position compensation, in C and original pro- gramming languages. Builders of semiconductor manufacturing equipment and machining tools are concentrating resources on development of innovative and competitive core technology. In these circumstances, machine builders are increasingly requiring globally available controllers whose long-term supply stability and quality are guaranteed and which can be used as alternatives to board controllers that are costly to develop basic functions and maintain.More- over, manufacturers who develop manufacturing equipment with robots are expecting robust and reliable controllers that can execute customised motion control, mainly in emerging countries. OMRON offers two types of PMAC pro- grammable multi-axis controllers that meet user needs.OMRON brings innova- tion to manufacturing sites through automation with integrated, intelligent and interactive concepts. OMRON is working on manufacturing innovation with manufacturers by combining global leading DT's motion control technologies with OMRON's control technologies to realise new integrated automation. Enquiries:Tel. +27 (0) 11 579 2600 or email info.sa@eu.omron.com

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Proven, scaled platform to enable digital transformation

The rich, domain-specific functionality of the Industrial Software Platform enables business excellence: in engineering, operations, asset management and in enabling people. The rich information management, business process knowledge and decision support capability available across the modules of the platform specific to industry problems allow companies to upgrade competencies, re- tain rich operational experience and develop the next generation workforce. EcoStruxure innovation at every level EcoStruxure is our open, interoperable, IoT-enabled system archi- tecture and platform. It delivers enhanced value around safety, re- liability, efficiency, sustainability and connectivity. EcoStruxure lev- erages advancements in IoT, mobility, sensing, cloud, analytics and cybersecurity to deliver innovation at every level. This includes con- nected products, edge control, and apps, analytics and services. Enquiries: Visit www.schneider-electric.co.za

Schneider Electric ’s new EcoStruxure Industrial Software Platform offers IoT-enabled, plug-and-play, open architecture, which delivers end-to-end solutions in six domains of expertise – power, IT, build- ing, machine, plant and grid – for four end markets, building, data centre, industry and infrastructure. EcoStruxure is driving digital transformation for Schneider Electric’s clients globally, enabling them to be competitive in today’s digital economy. This integrated, modular software suite delivers rich functionality to address opera- tional and business imperatives across the value chain in the indus- trial and infrastructure markets. EcoStruxure Industrial Software Platform offers a proven solution capability for engineering, plan- ning and operations, asset performance and control and informa- tion management. With over 2 million software licences deployed at 100 000+ sites worldwide, processing 10+ trillion daily transac- tions spanning 20+ billion operating parameters, the Industrial Soft- ware Platform operates at the scale necessary to support complex and mission critical industrial operations.

It is hardware and systems agnostic and can be deployed in a scaled, modular fashion. This enables companies to protect their investments in systems and technology, while upgrading their technology footprint to support digital transfor- mation. Supported by the largest industrial soft- ware ecosystem, including over 4 200 systems integrators and 5 700 certified developers world- wide, customers can rest assured that global delivery and software support standards are con- sistently deployed at the highest quality at every location. It offers a wide range of commercial options (Subscription, SaaS, Perpetual) and deployment flexibility (on premise, cloud-based) for all its available functionality. This enables the lowest to- tal cost of ownership without compromising risk, data security and performance requirements.

MCCs in production at Shaw Controls.

A Morning at Shaw Controls in Joburg South Crown Publications visits ...

Representatives from Crown Publications recently visited Shaw Controls in the in- dustrial area South of Johannesburg. Walking through the various sections of the plant, wearing hard hats, goggles, ear plugs and big shoes, we felt that industrious, engineering vibe as well as the great enthusiasm and pride in every person on the work floor. Technically, to be honest, we all needed a bit of help which we received from our hosts – Kirk Moss and Tyrone Willemse. A good morning it was!

Shaw Controls, an ISO 9001 Bureau Veritas certified local manufacturing facility, has over 30 years’ experience as a manufacturer of quality Motor Control Centres (MCCs), Distribution Boards (DBs), Medium Voltage (MV) switchgear, control desks, PLC and instrumentation enclosures, portable and containerised substations, E-houses and various other electrical enclosures. Focused on providing world class electrical solutions, the company has the necessary skills and expertise to manufacture electrical and control panels for all types of applications. Both standard and custom engineered products are produced at its extensive manufacturing facility south of Johannesburg. Electrical and control panel solutions incorporate WEG products as well as those from leading suppliers in the switchgear industry.

T he trend in industry, for projects in distant locations, is for the electrical supplier to sup- ply the complete power distribution solution rather than for the client to build one from scratch. In many projects, especially in Africa where mines are situated in remote areas, it is cheaper for the client to purchase an already fabricated substation or E-house (Electrical-house), or Motor Control Centre (MCC). Instead of being built out of bricks and mortar on site, the E-house or MCC build is carried out at the supplier’s workshops, where it gets fabricated from steel, and is manufactured as a turnkey solution with the client overseeing and supervising the process. Finally, the unit is test- ed with the client present. It sounds ideal… but a simple process, it is not. E-houses Speed of installation and cost-effectiveness on a number of fronts make Shaw Controls’ innovative E-houses a popular choice for contractors and oth- er users. An E-house is a prefabricated power dis- tribution mobile substation that is deployed to site as a fully assembled and integrated unit. These are

designed, engineered and manufactured by Shaw Controls – part of the ZestWEG Group – at their fa- cility in Johannesburg.The extensive facility of over 12 000 m 2 is manned by a team of skilled technical personnel and having the whole construction take place in one facility makes it easier for customers to do quality and functional checks in one place. This ensures that the final power distribution solu- tion is delivered as a ‘plug-and-play’ to site. The construction of an E-house as a single source Orig- inal Equipment Manufacturer (OEM) supply option removes the difficulties associated with managing multi-disciplinary contractors on site. No complex civil infrastructure A major advantage of an E-house over a brick- and-mortar substation is that it can be installed and commissioned without the need to establish a complex civil infrastructure. This saves on the costs of planning and managing civil works – es- pecially in remote areas where the cost of civil and infrastructure construction tends to be high- er. There is a cost advantage when dealing with a single supplier – which will free up many hours

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abbreviations

DB – Distribution Board E-house – Electrical-house FAT

DRIVES, MOTORS + SWITCHGEAR

– Factory Acceptance Test

– General Assembly

GA

– Human Machine Interface

HMI

– Low Voltage

LV

– Motor Control Centre

MCC

– Module Case Circuit Breaker – Manufacturing Resource Planning

MCCB

MRP

– Medium Voltage

MV

– Original Equipment Manufacturer

OEM PCP PLC VSD

– Product Cost Planning

Beyond the advantage related to setting up and commissioning the E-house, are the portability and self-contained nature of this electrical power solution. While

of project management and allow for a seamless process from design through to fabrication, with all these activities undertaken at one location. This means a smaller team for the project engineer or consultant managing the project, leading to better productivity and resultant cost savings. A further cost advantage is achieved by the time saved through combining all the related disciplines when engineering and producing the E-house. When constructing a brick-and-mortar substation, the structure is first completed before a number of separate elements – mostly prepared off-site by a number of different suppliers – have then to be integrated into the building. This undertaking is complex and involves nu- merous sub-contractors – so it is open to human error. With an E-house, on the other hand, this integration is carefully coordinated at the facility of the OEM, where any teething problems can be immediately addressed. The cost-saving factors are making E-houses an increasingly attractive choice, as the economic climate places further pressure on project costing and forces contractors to look for ways to achieve savings in project expenditure. There is also a weather-related risk which the E-house avoids; rain and other poor weather con- ditions frequently delay construction time of built projects, particularly in regions with high rainfall. Being built off-site obviates these challenges and ensures on-time project completion.

– Programmable Logic Controller

– Variable Speed Drive

it can be easily installed on site – with just a sim- ple foundation – it can also be re-located without difficulty; this is particularly useful if the project expands and a substation is required to move to another working area. Modular design The modular design gives a great deal of flexibility while reducing the overall footprint of the struc- ture. On most sites, space is an important factor to consider, and the E-house allows the best possible use of the available space. The internal configura- tion of the E-house – which is usually equipped with MV switchgear, LV switchgear, transformers, instrumentation and auxiliary equipment – can be upgraded when necessary. In applications where required, multi E-houses can be used, again lev- eraging on the flexibility that this option provides. An E-house is a perfect interim solution where electrical power needs to be provided prior to the balance of the operational infrastructure. As a scal- able solution, it minimises project lead times and reduces on-site construction requirements. Motor Control Centres MCCs are in modern practice a factory assembly of several motor starters. A combination starter is

Shaw Controls has an established reputation for engineering and manufacturing quality bespoke

containerised solutions at its Johannesburg facility.

Kirk Moss (electrical engineer) has been with Zest WEG Group since 1996 – the last two years at Shaw Controls. He was involved in electrical motors and VSDs and more recently, he is in charge of the MV section of Shaw Controls. Tyrone Willemse has been with the Zest WEG Group for five years. He started as an electrical supervisor on the floor, then went into Sales engineering, and more recently, Business engineering.

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NOVEMBER 2017

15

DRIVES, MOTORS + SWITCHGEAR

Cost Planning (PCP) system that was recently introduced to Shaw Controls to drive down lead times and increase efficiencies. The mechanical process consists of complete design and fabrication from raw material to final complete product. The design office employs a team of full time designers proficient in Solid Works software. They issue approved-for-manufac- turing drawings to the floor. The mechanical pro- cess further includes bending, punching and weld- ing as well as a seven-stage acid dip and powder coating process. A state-of-the-art gasket machine applies the gaskets to relevant joints and doors of the panels. This automated process has dra- matically improved the quality and precision. The panels are then assembled and all busbar work is completed. The electrical process boasts an in-house ded- icated engineering and drawing office that assists the manufacturing workshop from a technical per- spective. The electrical manufacturing process in- cludes wiring of chassis, wiring of doors, busbar terminations, earthing terminations and communi- cation wiring. If the MCC panels are going into a fabricated E-House structure, final assembly will take place. Shaw Controls will mechanically and electrically custom design either a containerised or prefab- ricated electrical house substation solution to house the MCCs and other associated electrical equipment. In the case of E-House fabrication ad- ditional design analysis is often performed such as structural stress, loading, thermal models and seismic loads.

a single enclosure containing the motor starter, fuses or circuit breaker, and a device for discon- necting power. Other devices associated with the motor, such as pushbuttons and indicator lights may also be included. These usually comprise in- coming Air Circuit Breakers, main horizontal and vertical busbars, outgoing starter modules with MCCB/ Switch Fuse Unit, overload relays, contrac- tors, etc. with adequate space for connection of cable and are easily extendable on either side and have excellent short circuit withstand performance of busbars comprising bolted/ riveted modular construction. MCCs are delivered as panels, DBs, control desks, PLC panels and instrumentation control panels. LV panels are available with ratings up to 4 000 A. Shaw’s packaged solutions are often built into shipping containers which deliver compact, versatile and easy to handle switchgear for many project applications. The benefits are significant and include availability on site, up-front reductions in building and installation costs. Stages in the manufacture of MCCs and E-houses The main components in the manufacturing pro- cess; mechanical and electrical as well as final as- sembly in the case of E-House or Containerised Solutions are all performed completely in-house as part of Shaw Controls’ integrated solution offer- ing. All material is ordered through the company’s automatic purchasing system as part of the Man- ufacturing Resource Planning (MRP) and Product

Take Note!

Speed of installation and cost-effectiveness make Shaw Controls’ innova- tive E-houses a popular choice for contractors and other users. MCCs are in modern practice a factory as- sembly of several motor starters. Time spent on a guided tour of the ‘workshop floor’ gives a better un- derstanding and appreci- ation for the innovation that goes into the pro- duction processes.

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MCCs in production at Shaw Controls with Vincent Mvubu.

CNC operation at Shaw Controls with Godfrey Mthabani.

Metal preparation including degreasing, descaling and passivating underway with Victor Zakele Maduna.

Application of IP protection to a panel door by Obed Shezi.

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