Electricity + Control November 2018

FEATURES: · Drives + motors + switchgear · Energy management + Environmental Engineering · IIoT + Industry 4.0 · Plant maintenance, test + measurement · Temperature measurement + Instrumentation

COMMENT

ON THE COVER

Technology ... the great growling engine of change

I was recently invited to say a few words at the opening of a conference about the Fourth Industrial Revolution – as if oth- ers have not already said enough. But it is worth noting that people view this revolu- tion, and what it means, in very different ways, and in many quarters the angst is profound. Preceding industrial revolutions were about steam, electricity, IT – all terri- fying in their own ways. Steam and mechanisation were pro- found. The industrial revolution in England saw manufacturing change forever. Between 1811 and 1816, a band of English workers, inspired by a fellow called Ludd, actively destroyed machinery, which they believed threatened their jobs. They became known as the Luddites, and were distressed by the mechanical chang- es they saw in industry. From the mechanical genesis grew the electric motor – and the next big revolu- tion – the rise of electrical machinery and, in fact, the emergence of a new branch of engineering – electrical engineering. But what a revolution! From steam, belts and mechanical linkages – we sud- denly had a way of generating and trans- porting massive amounts of energy over huge distances and running rotating ma- chines – many of which simply coupled back into legacy mechncial systems. There were decades – almost a centu- ry – between these fundamental changes, these revolutions. At least our forebears had time to reflect – to retread – and to advise their children to consider some of the new and exciting opportunities that were emerging. Then, just the other day, last centu- ry mind you, we were experiencing the emergence of IT– the Third Industrial Rev- olution, that digital revolution.

These three revolutions were funda- mental. They certainly threatened people’s job security – and they changed the way the world works. But I am not sure they could be described as being ‘sudden’ – we saw them coming and were able to adapt, to ed- ucate and train – to capitalise on, and meet the needs that the revolutions offered. I have a sense that, slowly, each sub- sequent revolution has clicked up a little – from the level of the most basic manual labour, to more complex and detailed ac- tivities. And each one was based on tech- nologies that required an increasing level of education to allow people to actively engage with them. For all that, each subsequent genera- tion has simply absorbed what it sees as if it always was. The technological develop- ments we are witnessing today are unlike any time before, and the speed of change is far more rapid than we experienced dur- ing the Digital Revolution. Make no mis- take, the new changes have the ability to do great things for humanity. But the angst we see is because, for the first time really, almost no aspect of human endeavour will be left unaffected. Learn how to harness this revolution as quickly as you can. The Fourth Industrial Revolution is not just about the technol- ogy we will be working with now and in the future. It is about how we as humans learn to work with the technology in ways that do not take away our humanity.

FEATURES: · Drives+motors+ switchgear · Energymanagement+ Environmental Engineering · IIoT+ Industry 4.0 · Plantmaintenance, test+measurement · Temperaturemeasurement+ Instrumentation

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CONTENTS

5

Features

DRIVES + MOTORS + SWITCHGEAR 4 Suiting up for switchgear: Gabriel Paoletti, Eaton

6 Motor control centres and how they work: Johan Basson, JB Switchgear

7 Round Up

ENERGY MANAGEMENT + ENVIRONMENTAL ENGINEERING 10 Advancing power generation with pumps and turbines: Annett Kriel, KSB Pumps and Valves

14 Round Up

IIOT + INDUSTRY 4.0 20 Next generation healthcare in Africa: Ruckus Networks 22 Digitalisation – the evolutionary approach: Peter Middleton

24 Exploring new real-time communication technologies for industrial automation: Dr. Guido Beckmann and Thomas Rettig, Beckhoff Automation

10

28 Round Up

PLANT MAINTENANCE, TEST + MEASUREMENT 30 The next evolution of plant safety: John McCormick, Fossil Operations

32 Preventative maintenance for instrumentation

34 Round Up

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30

TEMPERATURE MEASUREMENT + INSTRUMENTATION 36 Sensors and remote monitoring enable smarter renewa- bles: John TA Miller and Doug Young, Black & Veatch

40 Round Up

Regulars

1

Comment

19 43 44 44 44

Cover Article

Engineering the Future

Write @ the back

Events

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2 Electricity + Control

NOVEMBER 2018

DRIVES + MOTORS + SWITCHGEAR

Suiting up for switchgear Planning ahead to understand and prevent failures

Gabriel Paoletti, Eaton

Switchgear is a critical part of every utility's power distribution system; and, as such, any malfunction can be catastrophic. Utilities can take these power system compo- nents for granted, mistakenly believing that the switchgear will continue to run with- out any attention or maintenance.

Take Note!

1. Prior to beginning switch- gear maintenance tasks, utilities should complete a required arc flash study. 2. Additionally, all circuit breakers and electrical switching devices should be labelled. 3. The facility should also have an up-to-date elec- trical single line diagram. 1 3 2

S witchgear malfunctions can, however, spell immediate disaster in several ways. One concern is with the time required to repair or replace the switchgear following a fail- ure. Downtime from outages can be extensive. A switchgear assembly contains the copper bus, connections and control wiring of the individual circuit breakers. So while a spare can replace an individual circuit breaker in 30 minutes, it can take weeks to repair or replace the entire switchgear assembly. A switchgear failure can also prevent power flow completely. Should a switchgear malfunction cause damage to the outgoing or incoming cables that are connected, this damage can result in ad- ditional equipment, labour and, most importantly, additional time to repair or replace. This article explores some common causes of switchgear malfunctions and provides recommen- dations on the core preventative measures utili- ties can take to avoid unexpected setbacks from equipment failure. To avoid downtime, these basic steps must always be addressed before exploring or investing in any new maintenance automation technologies. Attend to environmental conditions Through a recent analysis of IEEE reported fail- ure data and customer surveys, it was discovered that preventable causes account for over 50% of all switchgear failures. These findings were first summarised in the paper, Past, Present and Fu- ture Maintenance Practices: Monitoring of Elec- trical Equipment Failure Indicators and Alarming , presented at the 2015 IEEE IAS Pulp and Paper Industry Committee Technical Conference in Mil- waukee, Wisconsin.

The most common switchgear failures can be split into three general categories that are all environ- mental in nature: 1. Humidity and internal arcing. 2. Dust and surface contamination. 3. Mismanaged heating resulting from either overloaded equipment or deteriorated connec- tion points or electrical contact areas. The good news is that implementing a simple maintenance program can control all these com- mon causes. A few additional causes, such as a lightning strike, operator error or rodent damage, might seem unavoidable. But these also can sometimes be ad- dressed beforehand by routine maintenance. For example, monthly inspections would help ensure that no unexpected openings exist in which rodents could enter the location to destroy the switchgear. Regular switchgear testing and inspection can go a long way. For some tasks, it's important to en- sure that factory trained or independently certified individuals complete the switchgear maintenance. Quality vendors typically provide these services and can advise on a plan specific to the site. For some tasks, it is important to ensure that factory trained or independently certified individu- als complete the switchgear maintenance. Prior to beginning switchgear maintenance tasks, utilities should complete a required arc flash study and label all circuit breakers and electrical switching devices. Next, the facility should have an up-to-date electrical single line diagram. Without these two items, the operation, maintenance and Safety checks, preplanning for switchgear maintenance

Personnel safety must always be considered and prioritised.

4 Electricity + Control

NOVEMBER 2018

DRIVES + MOTORS + SWITCHGEAR

for potential overhead water leaks. The second tier is an annual opening and closing of all circuit break- ers as well as inspection of all cubicles. The failure of a circuit breaker to properly interrupt a fault can lead to a complete switchgear failure. Some circuit breakers are not exercised (opened and closed) for many years during typical operations, which could result in deteriorated lubrication of moving parts and possible wedding together of overheated contacts. These inspection would most probably occur during a weekend maintenance period. Simply operating a circuit breaker is a form of maintenance. In preparation of this, an infrared (or heat-sensing survey) should be completed. In this instance, a trained person observes the electrical equipment front circuit breakers and rear live-bus with an infrared camera to detect any loose, cor- roded or deteriorated equipment. To properly complete these inspections, rear doors or covers must be removed, which is risky. To enhance safety, it is often recommended that infrared windows be installed during a planned maintenance outage to make sure that these critical inspections can continue to be completed without opening any doors or covers. The third and critical aspect of a robust switch- gear maintenance program is a complete shut- down of equipment to conduct a detailed cleaning of the entire switchgear assembly. Simulated load testing of circuit breakers or relays or both, which control the trip circuit of a circuit breaker, should also occur at this time. This type of maintenance is typically performed every three to five years, but timing depends on equipment age, usage and en- vironmental conditions. Beyond these standard approaches are many op- portunities to leverage new technologies to perform remote monitoring of internal switchgear tempera- tures, the build-up of dust, floor water or humidity. The application of these technologies, however, requires that utilities first consider the proper rou- tine maintenance requirements for their electrical systems.Without that solid foundation in place, you can only hope that a failure does not occur.

trouble-shooting of equipment can put individuals at significant risk. Personnel safety must always be considered and prioritised. There have been cases where an entire sub- station shut down because the internal circuit breakers did not interrupt a downstream fault in the proper time period. To avoid this scenario, a routine switchgear maintenance program should always include the following: • Simulated load testing to help ensure that the circuit breakers will operate properly under a fault condition (versus failing to interrupt the fault, which creates the potential for complete switchgear failure and shutdown.) • Testing of circuit breakers and relays for proper tripping-times to support a properly coordinated electrical distribution system. If a feeder circuit breaker is feeding a fault, it should operate be- fore the main circuit breaker operates. • Proper settings of all circuit breakers, relays (and fuse sizes) as determined by a coordi- nation study. Such a study provides updated equipment settings. In addition, it provides arc flash findings and their impact on safety. The study, therefore, should be completed prior to each maintenance period. An update of the sys- tem short-circuit study, coordination study and arc flash study can be completed as one task. Three-tier approach to preventative maintenance Utilities should practice a three-tier approach to switchgear maintenance that assures the equip- ment room is in good repair, regular maintenance tasks are addressed and critical load testing be- comes less frequent. The first tier of this plan assures that employ- ees complete weekly inspections of the switch- gear rooms to help ensure that no water leaks exist; that the gear is not exposed to the outside atmospheric conditions or humidity; and that the room is generally clean, with easy, open access to all equipment and exit doors. A floor water sen- sor can be added if there are reasons to monitor

Gabriel Paoletti is the technical application engineering manager, Electrical Engineering Services and Systems Division at Eaton.

Electricity + Control

NOVEMBER 2018

5

4

round up DRIVES + MOTORS + SWITCHGEAR

In the final of FOUR tutorials, Johan Basson of JB Switchgear, advises:

Motor control centres and how they work

circuit. Motor control centres have been around since the 1950s, when they were first used by the car manufacturing industry, which needed many electric motors. Today, they’re found in numerous commercial and industrial applications, specifical- ly where there are multiple, remotely controlled loads linked to a central control point. Modern MCCs offer a host of benefits, including: • Reduced downtime – standardised sections mean a simpler design, so operators require less operational training. Plug-in units can be easily swapped out for maintenance or replace- ment, and the inherent isolation of MCC units means they can safely be serviced individually, within legislated guidelines, without switching off adjacent units. • Quicker, cheaper installation – MCCs have their own factory-wired and tested units and pow- er buses, so field wiring and testing are mini- mised. • Flexibility – MCCs can be easily expanded by adding new units and sections. • Saves on space – much more compact than mounting individual devices. JB Switchgear is known in the industry for de- signing and manufacturing high quality switchgear solutions that meet the latest national and interna- tional safety and performance standards. We offer a comprehensive range of fixed, de-mountable and withdrawable motor control centres.

Think about what happens when you switch on your kettle in the morning. Apart from the encour- aging noises it makes, indicating that coffee is not far away, all kinds of clever things are going in in- side the kettle’s electrical circuitry. Every electric motor has a controller, and these controllers differ in complexity and number of fea- tures depending on the job they need to do. In the case of your kettle, the controller is the on/off switch, and you manually operate it so that your kettle can perform its very important task. Now imagine you had to make a thousand cups of coffee, and needed to switch on 500 kettles all at the same time. Not easy. In fact, pretty impos- sible. This is why motor control centres are such vital pieces of equipment, controlling everything through a centralised system. In its simplest application, a motor control cen- tre (MCC) is a panel that works as a motor start- er for several automated or semi-automated ma- chines. Comprising one or more enclosed sections with a common power bus, an MCC can include variable frequency drives, programmable con- trollers and metering. Essentially, they are a type of electrical 'filing cabinet,' with 'drawers' full of lighting contactors, combination starters and other electrical control and distribution products. Each section, or motor controller, of the cabinet has a built-in safety mechanism to protect the mo- tor. These can be solid-state overload protection re- lays, fuses or a circuit breaker, and there is usually a disconnecting switch as well to isolate the motor

Take Note!

1. Motorcontrolcentreswere first used by the car manu- facturing industry. 2. Today they are found in numerous commercial and industrial applications.

1

2

Every controller differs in complexity and number of features, depending on the job they need to do.

JB Switchgear Solutions is a leading manufac- turer of a comprehensive range of electrical switchgear systems. Enquiries: Email johanb@jbswitchgear.co.za

6 Electricity + Control

NOVEMBER 2018

round up

DRIVES + MOTORS + SWITCHGEAR

First-rate drive solutions

unit size remains unchanged.Advantages of large oversized output bearings include quick assembly, large bore capacities, high radial load capacity and extended service life. Modular NORD Drivesys- tems are easy to expand or upgrade, using a minimum of different types and sizes of components. Local assembly enables prompt delivery of drive systems and the ready-availability of spare parts. Included in BMG’s NORD range are drives for torques from 10 Nm to over 250 kNm, electric motors in the power range from 0,12 kW to 1 000 kW and frequency inverters with the required power electronics up to 160 kW. Inverter solutions are available for conventional control cabinet installations, as well as for decen- tralised, fully-integrated drive units. Enquiries: Derrick Louw.Tel. +27 (0) 11 620 1820 or email derrickl@bmgworld.net

NORD Drivesystems, designed by German precision engineers, Getriebebau Nord and assembled locally by BMG, encompass optimum drive configurations to ensure optimum performance of mechanical speed control for specific applications, in almost every industry. “NORD drive solutions, which meet stringent local and interna- tional quality standards, are known for reliability, energy-efficiency, low noise levels, extended service life and reduced maintenance,” says Derrick Louw, NORD product specialist, Electromechanical Division, BMG. “The modular drive systems incorporate advanced drive technology and special design features to meet the exact requirements of every operation. In the processing sector, for example, NORD Drivesystems are engineered with reinforced bearings and increased bearing spacing, especially for agitators, pumps and mixers used in process plants. “Reinforced and larger output shaft bearings allow the gear unit to absorb high radial and axial bearing loads that occur during the agitating process. An important benefit of this design is the extended service life of the gear units.” To enhance efficiency, an agitator version (VL2 bearing) with increased bearing spacing and reinforced bearings, as well was a drywell version (VL3) with an additional oil drip plate and leakage or oil sensors, are available from BMG. The bearing spacing of VL2 and VL3 versions is increased with attachments, while the gear

round up

DRIVES + MOTORS + SWITCHGEAR

SEW clinches major order for West African mine

“Based on the enquiries received, we work in conjunction with the specific project house or OEM to offer a complete solution for their mining clients. Our products essentially allow them to com- plete their portion of the work in hand,” Meid explains. Such col- laboration between suppliers and related companies is a growing trend in response to a tough business environment, and clients’ need to reduce costs by installing the latest technology. The Projects Department liaises closely with its clients so that they can best meet their own technical requirements and time con- straints. “Our project management in this regard is critical, from the time the order enters our system, to the point where the prod- uct is finally delivered,” Marquez says. “Once this stage is reached, other departments such as Field Service become involved. “We specialise in integrated solutions. A lot of clients regard SEW as a gear unit supplier, but we offer a host of ancillary servic- es that can add significant value, reduce risk and downtime, and improve efficiency.” It is for this reason that the Projects Department remains in a growth phase, with the bulk of SEW’s project work being secured in the rest of Africa at present. In this regard, it also works closely with the Exports Department, headed up by Marcio Sicchiero, to realise additional opportunities on the continent. In terms of main products, the M-Series industrial gear units (with the ‘M’ indicating ‘modular’) are ideal to meet the highest demands for quality, reliability, and performance. The product range has been optimised for a range of drive characteristics, allowing for simple ma- chine design by easily adding options and mounting parts. A long service life is guaranteed owing to highly efficient lubri- cation and sealing, which also cuts down on maintenance require- ments. Easy mounting and installation are facilitated by advanced features such as EBD (Extended Bearing Distance) and an axial thrust bearing arrangement on the output shaft. Looking to the future, Meid concludes that SEW is well on its way to being perceived as a sole solutions provider for its clients. “This gives us the added possibility of integrating some of our latest elec- tronics products in future. While our mechanical product remains remain our core focus, particularly given the harsh operating environ- ment in Africa, combined with the lack of technical skills, SEW has always been sufficiently forward thinking to make sure our clients have access to the latest technology and developments.” Enquiries: Jana Klut. Email jklut@sew.co.za

Having an in-house Projects Department to focus on the specific requirements of project houses, OEMs, and other tender-related project activity is starting to bear fruit for drive and automation spe- cialist SEW-EURODRIVE South Africa, which has clinched a major order for five M-Series industrial gear units for a mining operation in West Africa. The Projects Department, headed by Andreas Meid, with Pat Marquez as Project Sales Coordinator and BrettWeinmann in charge of Project Sales Development, oversaw the entire project from re- ceipt of the initial order to successful installation and commissioning at the mine, and back-up service and technical assistance. It is this capability to offer complete solutions packages, as op- posed to standalone products, in addition to the necessary after- market support, that has resulted in SEW’s Projects Department showing consistent growth year-on-year. “We pride ourselves on our on-time delivery in particular, which is a clear differentiator for us in a highly competitive market,” says Meid. “We are committed to supplying high-quality products, and continuously improving our customer service offering.” The Projects Department has a drawing office, and a mechanical engineer to compile any calculations that are needed. Its core func- tion is to respond to queries from project houses or OEMs for spe- cific project work. It focuses mainly on Greenfield projects related to conveyors, agitators and mixers in mineral-processing applications.

Andreas Meid, Head of Department – Engineering, SEW Eurodrive.

8 Electricity + Control

NOVEMBER 2018

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DRIVES + MOTORS + SWITCHGEAR

Versatile condition monitoring system

Parameters that can be measured include velocity and enve- lope, and temperature. Known as the MTN/5032, the microcontroller-based system has an easy-to-navigate 18,5 cm colour touch screen that ena- bles users to set alarm thresholds and delays either individually or across all channels. Data sampling periods, ranges and accu- racy levels are also easily set. The channels are configured to customer specifications and offer 12 bit sampling, with an input range of 25 mm/s for veloc- ity and 10 g for envelope g. Temperature channels, which can be used to monitor bearings or gearbox oil, for example, can monitor up to 120°C. AC output data for each channel is accessible via door-mount- ed BNC connectors for easy analysis, while Modbus and remote PC monitoring are available as options.The stainless steel enclo- sure provides IP66 ingress protection. “The versatility of our MTN/5032 makes it ideal for monitor- ing a wide range of rotating machinery, including industrial, pow- er, water, mining and marine applications,” says Andy Anthony, Monitran’s managing director. Enquiries: Instrotech.Tel. +27 (0) 10 595 1831 or email sales@instrotech.co.za

The latest Monitran condition monitoring system, which mon- itors and logs vibration on as many as 32 channels, is available from Instrotech.

Electricity + Control

NOVEMBER 2018

9

ENERGY MANAGEMENT + ENVIRONMENTAL ENGINEERING

Advancing power generation with pumps and turbines

Annett Kriel, KSB Pumps and Valves

A technical team serving the requirements of the Drakenstein Municipality in the Western Cape has designed one of the country’s largest pump and turbine stations to be used for water reticulation to the nearby town of Paarl in dry periods, and as turbines to generate electricity for the city during the remainder of the year.

Take Note!

The water comes from the Wemmershoek Dam and is gravity-fed to the city regions via the main reservoir. For one month per year during the driest month the pumps need to be switched on to pump 400 litres per second upstream to Paarl.

1

2

T he City’s engineer for water operations, Hein Henning, says the city was faced with the dilemma of having to pump water to its neighbour for just one month a year. For the rest of

the year the pump station would be dormant and need hundreds of thousands of Rand’s mainte- nance due to possible corrosion, perishing, lubrica- tion and bearing damage to the idle infrastructure. Instead, the progressive municipality chose to innovate and rather generate an income while si- multaneously reducing the requirement for main- tenance by effectively allowing the pumps to run backwards against the pressure of water from its elevated Leliefontein reservoir and generate elec- tricity for the region’s electrical grid. Generating power The commissioning of the pump and turbine (PaT) station effectively brings online one of the largest projects of its kind in South Africa, able to gener- ate 57 kW (all mechanical & electrical efficiencies Kiewiet Viljoen, projects director for Hidro-Tech systems (Pty) Ltd with Drakenstein Municipality engineer for water operations, Hein Henning, alongside the KSB pumps that are being used as turbines in the wet season.

10 Electricity + Control

NOVEMBER 2018

Leliefontein pump and turbine station (PaT).

ENERGY MANAGEMENT + ENVIRONMENTAL ENGINEERING

KSB Pumps and Valves to procure three KSB ETA200-40 pumps to meet and exceed the require- ments of the tender. These not only perform bril- liantly as pumps, but in turbine mode have a better than 80% efficiency even considering hydraulic and electrical losses. This speaks volumes for the overall efficiency and design of the pumps,” says Viljoen. Technology integration Electrical systems integrator, Brian Cooper, of Hi- dro-Tech systems Pty (Ltd), says despite the rel- ative simplicity of the mechanical design, it does require complex integration of controls to deal with the hydraulic force and convert the electricity generated into a useable form. This required pump speeds to be controlled via a variable speed drive to prevent overspeed as well as convert the wave produced to a pure 50 hz wave form that is com- patible with the city’s power grid. “Thereafter the system is designed with full PLC control which can be managed on site via Human Machine Interface (HMI) or can be ac- cessed remotely via computer or a mobile device to give users infinite control and monitoring of the site wherever and whenever required. The indus- trial network also provides automated control of the entire system including controls of the three

taken into account) with three turbines, which is enough to power the entire region’s water infra- structure of treatment plants, pumphouses, offic- es and other infrastructure for an entire year. “The water comes from the City of CapeTown's Wemmershoek Dam and is gravity-fed to our city regions via our main reservoir. For one month of the year during the driest month the pumps need to be switched on to pump 400 litres per second upstream to Paarl whereafter the pumps would usually be switched off. “However, the higher elevation of the reservoir allows us to rotate the pumps backwards to act as small turbines for the rest of the year which is able to generate electricity at more than an 80% efficiency. Unlike turbines however, the pumps are standard stock items from the supplier, KSB Pumps and Valves and does not require special- ised support and servicing. What’s more, the pumps are durable enough to allow us to design the infrastructure with a 40-year lifespan. “With this long lifespan in mind, we decided to make use of KSB pumps as we already have a num- ber of these installed throughout our municipality and are aware of their reliability. They also have a longstanding track record of support to our munici- pality, and many other municipalities and water utili- ties throughout South Africa,” says Henning. Upgraded pump station Before commissioning the project, the munici- pality had spelled out its requirement to replace its existing 96 litre-per-second pump station and discussed the ability to generate electricity in the off-season with consulting engineers, Aurecon. Having designed and planned a solution, the main contract was awarded to Hidro-Tech systems (Pty) Ltd for mechanical and electrical work. Kiewiet Viljoen, projects director for Hidro-Tech systems (Pty) Ltd, said the primary role of the pro- ject was to develop an efficient and reliable boost- er pump station to ensure uninterrupted water supply to nearby Wellington. Only once that need had been fully met could the project managers consider its secondary role to generate power in off-peak season. “We therefore knewwe needed a technologically savvy and reliable service provider and approached

The commissioning of the PaT effectively brings online one of the largest projects of its kind in South Africa.

Electrical systems integrator, Brian Cooper at the main control HMI.

Electricity + Control

NOVEMBER 2018

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ENERGY MANAGEMENT + ENVIRONMENTAL ENGINEERING

pumps, valves, level indicators, flow meters and other parameters that are critical to the systems efficient operation to either pump water or gener- ate electricity. “In addition to providing seamless control of the system, it also ensures redundancy in all operating conditions and provides emergency measures in the event of failures of any part of the system, including valve controls, bypassing of the system or parameter changes as required to rectify any problems incurred". Solution provider KSB Pumps and Valves specialist, Stefano Testi, applauded the project, saying its success paves the way for numerous similar projects throughout the Southern African region, wherever there is a reliable supply of water at a high enough elevation to drive the PaT. “It is particularly useful in areas that would oth- erwise require the installation of pressure reduc- ing valves to deal with water from high elevations, as a PaT can fulfill the same requirement while generating electricity for nearby infrastructure or communities, especially rural ones.

“KSB internationally is a leader in the supply of PaT solutions and we have a wide range of pumps that are suitable for this purpose. With growing pressure on the country’s power generating infra- structure, it pays for local authorities, farmers and landowners with access to water to investigate the installation of PaT systems as a cost effective and reliable source of electricity that is not reliant on wind or sun to drive it,” Testi adds. Project success Following the commissioning of the pump station and turbines the system has begun operating at full capacity and the Drakenstein municipality has started reaping the rewards of its forward-looking water management systems. “We are pleased with the outcome and com- mend everybody involved in the project for their innovation and dedication to building a system that can be used as a blueprint by other munici- palities around the country and across the globe. It has been a brilliant project with lots of challeng- es and innovation; the end result being the de- livery of a highly successful project,” concludes Henning.

KSB Pumps and Valves branches and dealer manager for South Afri- ca, Francois Naude with regional sales manager (Sub-Sahara Africa), David Jones.

Enquiries: KSB Pumps and Valves, Annett Kriel, Tel: (011) 876 5600, Fax: (011) 822 1746, Email: Annett. Kriel@ksb.com, or visit www.ksbpumps. co.za

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round up ENERGY MANAGEMENT + ENVIRONMENTAL ENGINEERING

Cummins announces appointment of new MD

the ground up, the New Entities Execu- tion and Facilities Management function in January 2014, which included the first Cummins Project Management Office in support of the region. Her professional ex- perience garnered at a global level, togeth- er with wisdom gained working in Africa and within local teams have equipped her with a deep understanding of the industry both locally and internationally. Commenting on her new role, she said: “I am honoured and humbled to take up the challenge of my new role. I’ll be working together with my dynamic team to create effective and efficient partner- ships to continue to grow our position in the marketplace and further enhance the business performance during this exciting time of growth on the African continent. It is my vision to add value, innovation and excellent propositions for our customers through our highly visible and credible Cummins brand.” Ms Njoroge enjoys interacting with diverse and multitalented stakeholders and is passionate about problem solving and bringing different perspectives to the table. She holds a Bachelor’s degree in Management Information Systems and Business Administration from Winona State University and an MBA from Ball State University in the United States of America. She is also a 2013 Global Leader- ship Development Program graduate and a 2015 High Performance Team graduate

and has attained Six Sigma Green Belt and Sponsor Certifications. She was born and raised in Kenya, and is particularly excited about giving back to the African continent. During her personal time, she is an ardent traveller, thrill sports enthusiast and enjoys entertaining. Cummins Southern Africa is well posi- tioned to achieve its ambitions and deliv- er the highest levels of legendary sales, service and support to its customers with Ms Njoroge’s demonstrated track record of leadership and performance enhance- ments. Under her guidance and with her strong understanding of the industry, the company is well set to achieve its goals. Enquiries: Siboni Tsabedze. Email. Senetisiwe.tsabedze@cummins.com

Cummins Southern Africa is pleased to announce the appointment of Ms Racheal Njoroge as Managing Director for Cum- mins Southern Africa as of 1 September 2018. Ms Njoroge is responsible for the leadership, operations and strategic direc- tion for Cummins’ distribution business in South Africa, Angola, Botswana, Lesotho, Madagascar, Malawi, Mauritius, Mozam- bique, Namibia, Swaziland, Zambia and Zimbabwe. Ms Njoroge has enjoyed a 12-year jour- ney at Cummins and has been a pivotal member of the Cummins Southern Afri- ca executive leadership team since 2017. Most recently, she successfully managed the operations division as its Operations Director and was responsible for leading a centralised function, delivering on op- erational efficiency improvements and compliance, whilst also leading the Cross Border entities of Lesotho, Madagascar, Malawi, Mauritius, Mozambique, Namib- ia, Swaziland and Zimbabwe as General Manager. Ms Njoroge joined Cummins as a summer intern in Columbus, Indiana in 2006, and was quickly promoted to Business Systems Analyst. In 2009, her strong leadership and strategy orientation earned her the role of global IT Strategy and Planning Leader also based in Colum- bus, USA. In 2011, she relocated to South Africa as the Africa IT Leader where she built the IT organisation as a key business enabler. She moved on to establish, from

SMEC Africa at Future Energy East Africa Conference SMEC Africa participated in the Future Energy East Africa Conference held in Nairo- bi’s Kenyatta International Conference Centre from 12-13 September. The conference is the largest such regional event and provides a platform for pub- lic and private stakeholders to engage in discussions around the future of the East African energy sector. The conference was attended by over 1 600 visitors and boasted 68 exhibitors. Future Energy East Africa has been running for 20 years and was attended by visitors from South Africa, Rwanda, Uganda, Mozambique, Tanzania, Ethiopia and Kenya. “Future Energy was a strategic event for us to attend”, stated Dinesh Bhaga, SMEC South Africa Business Development Manager -- Power & Energy. “At least a third of visitors we met with were not previously known to us. We have made many valuable contacts which will help us unlock multi-disciplinary consulting opportunities for SMEC in the renewable and traditional power generation sectors”. Enquiries: Dinesh Bhaga.Tel. +27 (0) 11 369 0600 or email dinesh.bhaga@smec.com

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DEHN introduces the dream team The goal of the DEHN AFRICA Technical Team is to offer a range of technical support in lightning and surge protection products, as well as to undertake site assessments and produce designs of lightning pro- tection systems. In achieving this goal, the Technical Team, which has been rounded out with recent appointments of additional resources, has gathered together a select group of impassioned engineers who offer a valuable combined skills-set. Tatenda Gora, sales engineer, says, “DEHN Africa offers products within a very niche engineering sector, and so the technical support and engineering services that we offer, including consulting, is critical. The DEHN Technical Team is responsible for providing engineering and technical support in lightning protection, surge protection, earthing and safety equipment. This includes designs, customer support and product specification.Through this suite of service offerings, we add value to the day-to-day activities of the company. “The team has been in existence since 2014, when we realised that there was a need for technical support in the lightning and surge pro- tection products that DEHN offers. After this, the need for site assess- ments and designs of lightning protection systems arose, and the team began to grow from there.” The team is headed up by technical director Hano Oelofse, assisted by Ivan Grobbelaar, senior engineer. Oelofse’s responsibilities include the management of the team, risk assessments, training, consulting and mentoring, just to mention a few. “The DEHN AFRICA Technical Team brings together a group of young, enthusiastic and intelligent engineers who are competitive in the lightning protection and engineering field. Our combined technical expertise includes both industrial and academic backgrounds. Our de- signs are professional in both engineering and presentation, offering detail that can be understood by the layman in the field of lightning protection,” concludes Gora. Enquiries: Hano Oelofse. Tel. +27 11 704 1487 or email Hano.oelofse@dehn-africa.com

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Integrated solutions key to growing Africa’s power generation

A recent project was to provide a 12,5 MW continuous power diesel generation facility ― to be potentially expanded to 20 MW to a graphite mine in Mozambique. The complete integrated solu- tion included containerised power generators, an ‘electrical house’ (E-house) with medium voltage board and control room, with gener- ator synchronisation and plant control system. Also provided were all the supporting ancillary systems including the fuel and oil systems, the cooling system, and the air filtration and pressurisation system. “The majority of the main power plant equipment was sourced within the Zest WEG Group,” says Gerrard, “while the plant instal- lation was also conducted by our construction company within the group.” Reflecting its diverse expertise in engaging with various ener- gy resources, the Zest WEG Group designed and commissioned several 380 kW containerised biogas generators, complete with radiator cooling systems, synchronisation switchgear and heat re- covery systems, at two different sites for a public sector custom- er in South Africa. This integrated solution also included step-up transformers, medium voltage integration switchgear, a container- ised control room and plant auxiliary distribution board as well as the electrical installation of all equipment supplied. It also developed, installed and commissioned a steam turbo generator set solution for a large KwaZulu-Natal customer, using a 48 MW multi-extraction, condensing steam turbine, complete with a 57 MVA, 11 kV two pole generator. Ancillary equipment included the condensing system, lubrication oil system, turbine control panel, generator protection and synchronisation panel and battery systems and chargers. As part of the project, the Zest WEG Group provided a long term service contract for a five year period, and was required to guaran- tee 98% availability of the system throughout the warranty period. Enquiries:Tel. +27 (0) 11 723 6000 or email marketing@zestweg.com

As African countries work to develop their power generation capaci- ty in the most cost effective ways, the key will be to find integrated solutions that attract investment throughout the value chain. According to Alastair Gerrard, integrated solutions executive at Zest WEG Group, the energy sector on the continent is seeing a growing number of power-related projects funded by recognised lenders and financiers. The African Development Bank, for exam- ple, has committed to fund $12 billion for energy development in Africa over the next five years. “Energy investment needs to target the whole value chain, in- cluding local content and supplier development as well as local skills development and the building of manufacturing capabilities,” says Gerrard. “This focus will lead to improved skill levels and more self-sustainable economies, which can contribute towards the projected return-on-investment in the projects themselves; the approach will also promote further investment on the continent.” He emphasised that project developers in the public and private sector therefore need to partner with companies that understand these requirements and have the capability to provide cost effec- tive and reliable power generation solutions. Such innovation is particularly important in an environment where electrical infrastructure is not always available or well-main- tained. These factors often preclude the development of large scale power generation projects. The energy opportunities that are presented therefore require extensive analysis, in which the needs must be clearly understood, and all constraints and challenges un- packed before the most appropriate technologies are selected. “In this context, solutions must be carefully customised to suit the need, and may require a combination of different re- sources to fuel a power plant, making up a hybrid power gen- eration solution such as diesel combined with solar,” he says. “These hybrid systems then need to be supported by the right electrical infrastructure.”

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Siemens launches one of a kind Distributed Energy System The challenges currently facing Africa’s en- ergy sector are urging private businesses, communities and educational institutions to curtail their dependence on the tradi- tional, centralised model of linear power generation and delivery, and to identify ef- ficient power generation solutions. cess energy is then stored in a 140KWh SIESTORAGE installation with the entire system monitored, visualised and con- trolled via the IoT (Internet of Things) ener- gy platform, MONET.

Combining efforts from local and global Siemens experts, this is the first Siemens DES solution of its kind in Africa and is in line with the company’s goal to achieve carbon neutrality by 2030 through energy efficiency, decentralised energy systems, and the purchasing of clean electricity. The project provides a showcase to current and prospective customers on a proven Siemens solution that will help them save energy, cut costs, lower carbon emissions and to ensure uninterrupted power. “Microgrids and Distributed Ener- gy Systems are the ideal solution for Afri- ca because they’re designed for a specific purpose, be it communities or industry,” CEO, Siemens Southern and Eastern Af- rica, Sabine Dall’Omo says. “But it also means you can have diverse power sup-

Siemens launched a one of a kind, end- to-end Distributed Energy System (DES) as a solution to tackle Africa’s energy transition, at its headquarters in Midrand, Johannesburg. The launch took place after an interactive discussion between Sabine Dall’Omo, Siemens CEO for Southern and Eastern Africa and media partner CNBC Africa as well key industry players, around the role that Distributed Energy Systems plays in Africa's energy transition. The system is built around a 1 MW PV-solar plant strategically positioned throughout the Siemens Park campus that takes full advantage of the African sun. Captured solar power is then integrated into the SICAM Microgrid controller. Ex-

plies, such as solar or wind during the day, then switch over to other forms of gener- ation like biomass when the conditions for renewables are poor.” The SICAM 8000 Microgrid Controller is the intelligence behind the system that stabilises the Siemens campus grid in case of an outage and allows for cost- op- timised energy consumption. It took home the “Digital Solution of the Year” award at the Africa Utility Week (AUW) Industry Gala Awards. Enquiries: Keshin Govender.

Tel. +27 (0) 11 652 2412 or email keshin.govender@siemens.com

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‘Home ground’ renewable projects for Raubex Infra

The company constructs overhead power lines, with the relat- ed design and construction elements, as well as MV cable instal- lation, splicing, termination and testing. On the high voltage side, Raubex Infra collaborates with consultants and subcontractors to offer design and engineering services, while also constructing substations, switching stations and overhead lines up to 132 kV. “We are well equipped to carry out the civils construction work on these renewable energy projects, including bulk earthworks, roads, storm water management, wind turbine foundations, crane hardstands, pre-assembly areas, inverter footings or bases and step-up transformer plinths including the placement of inverters and transformers” says Deacon. “Our teams are also highly ex- perienced in constructing the various buildings required on these sites, as well as the associated concrete works.” Enquiries: Dirk Lourens.Tel. +27 (0) 51 406 2000 or email dirk.l@raubex.com

Renewable energy infrastructure specialist Raubex Infra is looking forward to the rollout of public-private solar and wind energy pro- jects this year and is excited about Energy Minister Jeff Radebe’s announcement of a fifth bid window to be launched in November. “Our work in the renewable energy sector has always been a core business area for us,” says Charles Deacon, operations direc- tor for renewable energy at Raubex Infra. “We have been a major role player in the government’s Renewable Energy Independent Power Producers Procurement Programme (REIPPPP), working with a number of solar and wind projects varying in size from 5 MW to 150 MW.” In the field of solar energy, Deacon highlights that the company has been involved in both photovoltaic (PV) energy generation and concentrated solar plants, contributing to electrical and civil con- struction aspects. “On the PV projects, for instance, our electrical construction scope on the low voltage side has included the interconnection of PV modules as well as DC cabling and connections from com- biners to inverters,” he says. “On AC works, we provide cabling and connections, as well as installing inverters, transformers, ring main units (RMUs) lighting, security and surveillance equipment. We also test and commission and issue a certificate of compli- ance in terms of the SANS 10142-1 (LV) and SANS 10142-2 (MV) standards.” In a recent contract for a solar field park in the Northern Cape, the company provided foundations for the CSP mirror arrays in- volving 28,000 concrete piles and 3,000 m3 of concrete footing. It also installed electrical, instrumentation and control elements of the project, including excavation of cable trenches, laying of low voltage (LV), medium voltage (MV) and fibre optic cables, and cable terminations. Earthworks have also made up a large part of Raubex Infra’s contribution to certain solar projects, where the requirement has been for large areas of land to be levelled before construction can begin.

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