Electricity + Control October 2017

113 GHz +Your Wavelength

FEATURES: · Analytical instrumentation · Control systems + automation · Cables + accessories · Earthing + lightning protection · Pressure + level measurement

COMMENT

ON THE COVER

Linking the human brain to the Internet

R ecently I learned that some local re- search had ‘gone viral’ on social me- dia. Frankly, it is really encouraging when good stuff goes viral – rather than the non- sense that generally seems to be sprayed all over the ‘subway walls’ of modern so- ciety’s social media. The work in question relates to the linking of the human brain – in real time – to the Internet, which is genuinely intriguing. Let us reflect for a moment on what we al- ready know. We can certainly measure the electromag- netic environment surrounding the brain; this has been used to do some remarka- ble things. We can measure the change in potential across the head as you shift the eyes from side to side (for instance). Controlling simple switches, managing a computer cursor – and even playing games with the mind alone – can be done. In fact, I still find it remarkable to watch someone in complete control of a computer – with no physical contact whatsoever. I am also aware that, by monitoring the electric impulses in the nervous system, you can transmit those to (even!) another person – and effectively bridge an ‘electrical’ system in the body. Incredible.These devel- opments pose several challenges; some are ethical in nature and founded in the medical discipline; others point to a future that may be different to what we imagine. As we have focused on automating and controlling processes, we wonder if there is a place for humans in the working en- vironment as machines; and, would it be good to automate all activities that pose risks to humans?

But, is there not an emerging place for the human intellect – deployed in ways we have never imagined – to engage with the world? Virtual reality is being used in a variety of ap- plications – including teaching and learning, and most recently I have noted its use in the study of fossils and early humanity. To what extent could there emerge elements of fu- ture human endeavour where it is our own brains that are doing the hard lifting without any physical contract whatsoever? The concept of remotely sensing the ‘real’ environment (such as in remote medicine) where the surgeon needs to feel the sys- tems with which he is engaging – even though it be 1 000 km away – is one thing. But imagine an environment where the link is purely based on the interaction with the brain? I have little doubt that the integration of in- telligent systems with the human brain (and no longer just the body) will be a rapidly growing area of research and development – much of it frightening, but equally exciting. The challenge we face is understanding how profoundly this will affect the world – and our role in it.

113 GHz +Your Wavelength

FEATURES: · Analytical instrumentation · Control systems+ automation · Cables+ accessories · Earthing+ lightning protection · Pressure+ levelmeasurement

Endress+Hauser: The Right Wavelength *+] 7KH EHVW ÀWWLQJ UDGDU IUHTXHQF\ IRU HDFK DSSOLFDWLRQ Read more on page 7. www.electricityandcontrolmagazine.co.za

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CONTENTS

4

Features

Analytical instrumentation 4 ‘Our Instruments are Ready for IIoT; Are Your Pro- cesses Ready?’ Susan Buitendag, Endress+Hauser 8 Round UP Control systems + automation 12 PC Worx Engineer: Adaptive Software Platform Dipl.-Ing. (FH) Frank Walde, Phoenix Contact Elec- tronics GmbH 14 Round UP • 14 The IIoT can make a major impact on Africa Bradley Hemphill, EES Live • 15 New cyber security system for oil and gas industry Davinder Harcharan, Siemens • 16 Future of manufacturing Mike Vincent, Deloitte Consulting • 18 Powering Nigeria’s global ecoconomic rise Information provided by Siemens

Cables + accessories 24 Rotating and Turning Frank Rothermund, Lapp GmbH 26 A Cable Gland with a Virtual Thread Eldon Kruger, Pratley 28 When E-Chains Carry Sensors Harald Nehring, igus 31 Round UP

Earthing + lightning protection 32 Earthing for South African Conditions Information provided by the Copper Development Association Africa (CDAA) 36 Comparison Between ac and dc in Power Trans- mission Nikhil Naidoo, Ensight Energy Solutions 40 Round UP Pressure + level measurement 42 4 Common Pressure Calibration Pain Points Information provided by Fluke Corporation 44 FTIR Spectroscopy For a Variety of Industrial Appli- cations Nenne Nordström, Gasmet Technologies

12

24

36

Regulars

7 Cover Article 52 Light+Current 54 Appointments 54 New Faces & Places 55 Social Engineers 56 Not to be missed 56 Brain Block 56 Write @ the back

42

2 Electricity + Control

OCTOBER 2017

¶2XU ,QVWUXPHQWV DUH 5HDG\ IRU ,,R7 Are Your Processes Ready? ’ 6XVDQ %XLWHQGDJ (QGUHVV +DXVHU

The concept of IIoT (Industrial Internet of Things) is electrifying the mining industry, but what is really behind it? What is the benefit for you?

Take Note!

When implementing IIoT it is not necessary to revamp your entire op- eration. Because data is pro- duced in abundance in mining operations, Big Data can assist with many challenges. Ahead in smart sen- sor development, this company’s instruments are ready for the digital evolution.

1

F irst came flint, followed by bronze, iron, gold, coal and during the last decades it was oil. The title of ‘most important’ resource has been held by many different materials during the course of our history. Now, early in the 21 st century, there is another contender. A player, that in reality is not even a substance at all: Big Data. A company such as Facebook for example, has become one of the most valuable enterprises in the world and that within a decade. However, social media is not the only beneficiary. Industri- al companies believe they can benefit from this evolution or rather, revolution, that some call IIoT, others call Digitalisation, Big Data or even Indus- try 4.0. The manufacturing industry has embraced IIoT. Digitalisation of the work place has started in this sector and the process industries are be- coming more and more interested… mining is no exception. Clients ask about the IIoT trend and what it actually means. It is no wonder, bearing

in mind that the whole mining industry is facing huge challenges because of declining ore grades and volatile commodity prices. Integration as a first step How can Big Data help mining companies master these challenges? Data is produced in abundance within a mining operation – process information from the field, inventory values, plant status and market prices, to name a few. The problem is that much of this data is stored and visible in different systems and platforms. So the first step towards IIoT has to be the in- tegration of this data to open up its real potential. Integration has to be aligned along three axes: Horizontally along the value creation in the supply chain, vertically from the field to the control level and from planning to maintenance to ensure con- sistent engineering. Let us look at the first axis. An exact forecast of consumption based on current

2

3

4 Electricity + Control

OCTOBER 2017

ANALYTICAL INSTRUMENTATION

Industry 4.0: The term ‘In- dustry 4.0’ was first used in 2011 during the Han- nover Fair in Germany. It is part of a project within the high-tech strategy of the German government that focuses on the computer- isation of manufacturing. The basic idea of the name is that the use of water and steam power mechanised production and became the first industrial revolution. The second industrial revo- lution introduced electricity and mass production. The digital revolution improved the production process with electronics and IT. Big Data: Generally speak- ing, ‘Big Data’ describes sets of data that companies produce that are so huge that traditional methods of processing do not work on them. The term implies that these data sets are stored in an unstructured way and on separate systems. Internet of Things (IoT): This term refers to the idea of connecting physical objects like buildings, ve- hicles etc. and equipping them with sensors so that they are able to collect and exchange data with each other. The Internet of Things was coined by Kevin Ashton, a British technology pioneer. Industrial Internet ofThings (IIoT): IIoT is the use of IoT technologies in manufactur- ing. Digitisation: This basically means the conversion of certain information into digi- tal data. But in recent years it has become the name of the general trend towards the usage of process data to optimise performance of companies.

optimised functionality and best efficiency of the digital mine. The reality today is often a less than streamlined or smooth operation. It is character- ised by closed system silos, missing interfaces and many manual data transfers, thus causing po- tential errors. These decoupled system silos can be con- nected to form an elegant overall system with a continuous data flow, with the company’s BPI con- cept (Business Process Integration). BPI acts as middleware beneath the sub-systems, forming a shared platform for data exchange between these systems. This is not just limited to the IT world however, by using Industrial Ethernet at field and control level, automation components can be inte- grated in the overall system. Digital communication enables advanced measurement sensor diagnostics which can form the basis of effective process condition monitor- ing and preventative maintenance measures or calibration requests which can be triggered in the ERP system. Many of the company’s smart measurement sensors can be used to monitor process condi- tions and verify measurement integrity. HEARTBEATTechnology Several examples of HEARTBEAT Technology’s benefits are used in the concentration processes in many copper and gold mines, one example in froth flotation tanks: A Promass 100 Coriolis flow meter will schedule a flocculant batch remix by measuring changes in the medium chemistry. The aim is to produce process optimisation and stabil- ity using a combination of smart sensors which monitor their own performance, indicate process anomalies and tell maintenance when things need cleaning or recalibrating. Big Data made easy In order to get close to this goal of maximum pro- cess efficiency at the lowest possible cost, intu- itive and reliable process asset management is crucial. Big Data asset management software which is manufacturer-neutral: the cloud-based asset management toolbox, called W@M (Web enabled Asset Management) has proven beneficial to man- agement, maintenance, process engineers and metallurgists in generating plant wide process improvements and providing relevant and reliable data on process wide performance.

inventory values and planned material movements is the key to reducing warehouse stocks and at the same time, improving the delivery service. Relia- ble measurement technology is the fundamental basis for this supply chain management.

Figure 1: The three axes of data integration: Along the value creation chain, from field to control level and from planning maintenance. Measurement For data communication, Endress+Hauser can plug most available fieldbus technologies directly into their smart measurement sensors. In addi- tion, the local data transmission unit, Fieldgate, with an integrated web server, allows for global data acquisition via private and public communi- cation networks. A standard internet browser is sufficient for querying inventory data. Fieldgates not only provide current measured values, but offer the possibility of monitoring de- vice stations, requesting information and sending data directly to a superordinate inventory manage- ment software system such as SupplyCare. Sup- plyCare offers convenient access to the current fill levels in tanks and silos from the comfort of your desk, and offers extensive functions for inventory management. This option can be used with an integrated e-mail function making it possible for to easily re- quest supplies quickly. With the analysis module, you can calculate and evaluate Key Performance Indicators (KPIs). Full control of your basic processes When it comes to vertical integration, intelligent networking between sub-systems of mine pro- cess, from the ERP system to operating and control level and on to field level, is essential for

Electricity + Control

OCTOBER 2017

5

ANALYTICAL INSTRUMENTATION

abbreviations BPI – Business Process Integration ERP – Enterprise Resource Planning IT – Information Technolo- gy KPI – Key Performance Indicator R&D – Research & Develop- ment

Figure 2: In flotation tanks a batch remix can be automatically scheduled by a Promass 100 Coriolis flow meter that measures changes in the mixture.

Data is produced in abundance within a mining operation.

An example is a 10% proven increase in heap leach and stripping performance in a copper mine when W@Ms powerful measurement perfor- mance capability is used to monitor variations in performance of critical measurement parameters such as acid usage, PLS output, organic to aque- ous stripping rates against pipeline breakage, filter rupture or other process imbalances.

IIoT offers: • Quick, visual and targeted access to the right data at the exact time, when it is needed • Easy to download cloud based tools – opera- tions apps for mobile smartphones and tablets • Wireless and wired connectivity to smart sen- sors and other process equipment for diagnos- tics, verification and condition monitoring Conclusion Customers are sometimes surprised, that with the first implementation of IIoT they do not have to completely revamp their whole operation. The Fourth Industrial Revolution is more a gradual evo- lution than a ‘big bang’ revolution. This company’s R&D engineers take pride in being ahead of the game in smart sensor development to ensure that instruments are ready for the digital evolution. The customer’s first step will be a small one towards IIoT in ‘digital mining’.

<>

Susan Buitendag is Industry Manager for Primaries & Metals at Endress+Hauser.

+27 (0) 11 262 8000 susan.buitendag@za.endress.com www.za.endress.com

6 Electricity + Control

OCTOBER 2017

COVER ARTICLE

The Right Wavelength *+] 7KH EHVW ÀWWLQJ UDGDU IUHTXHQF\ IRU HDFK DSSOLFDWLRQ

113 GHz +Your Wavelength

FEATURES: · Analytical instrumentation · Control systems+ automation · Cables+ accessories · Earthing+ lightning protection · Pressure+ levelmeasurement

E ndress+Hauser completes its portfolio of radar instruments with Micropilot FMR60, FMR62 and FMR67.The newMicropilot series provides the first instruments with 80 GHz technology which have already been developed according to the safety-by-design concept of IEC 61508. Further- more, they belong to the first generation of level instruments which, like many flow instruments of Endress+Hauser, support Heartbeat Technology. Dhiren Naidoo, Product Manager at En- dress+Hauser, presents the new level campaign. He realises that nobody can do anything with 113 GHz. He just added the frequencies of exist- ing instruments to demonstrate the overall com- petence of Endress+Hauser in the radar range. The new level campaign is called ‘113 GHz + Your Wavelength’. Dhiren describes the idea as such: “We are not concerned with faster, higher, further. At present, everybody is talking about the highest radar frequencies in the industry. But the real is- sue is finding the respectively fitting frequency for each application. In order to accomplish that, we have to listen very carefully to the requirements of our customers so that we can give them really good advice. The aim is to find a common Wave- length that is a common understanding.” In the area of tank gauging, Endress+Hauser launched Micropilot NMR81, the first highly accu- rate instrument with 80 GHz technology for the oil and gas industry. Now, the company is adding Micropilot FMR6x to serve other industries. Also in this case, accuracy is at stake but first and foremost safety and the provision of sim- pler processes for customers. For the first time, an 80 GHz process radar is available which pursues the safety-to-design concept, thus making the life of customers much eas- ier in terms of safety. In addition, the product offers a wide selection of ex-approvals. Im- proved focusing of the radar signal as well as dynamic algorithms provide reliable, stable measurements with a measuring range of up to 125 metres and an increased meas- uring accuracy of ± 1. The measurement is unaffected by baffles or obstacles at the tank

walls. Due to the innovative antenna design, build- up and condensate do not impair the measuring re- sult either. The interactive commissioning software makes this task fast and easy. Heartbeat Technology Instruments with their own pulse beat, Heart- beat Technology, have been only available at En- dress+Hauser in flow instrumentation thus far. The preconditions for predictive maintenance and documented verification have already been creat- ed in the new Micropilot. This means that every measuring point can be verified and documented in assembled condition and without any interrup- tions. A simple, pre-defined procedure leads the maintenance staff through the verification and doc- uments the verification results in an unambiguous manner. The guided SIL proof test according to the safety manual and included documentation also save time and costs. An automatically generated test protocol supports the evidence concerning regulations, laws and standards. The monitoring area of Heartbeat Technology provides instrument and process data, thus facilitating trend recogni- tion for predictive maintenance. The aim is always the optimisation of processes in a targeted man- ner. Therefore, a combination of instrument and process parameters provides all important details for a respective analysis.

Enquiries: Dhiren Naidoo

Tel: +27 (0) 11 262 8000 Email: dhiren.naidoo@ za.endress.com

Electricity + Control

OCTOBER 2017

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round up

ANALYTICAL INSTRUMENTATION

Redefining mid-range oscilloscopes TEKTRONIX, represented locally by Comtest , has introduced the new 5 Series MSO mixed signal oscilloscope. To bet- ter meet modern electronics design challenges, the 5 Se- ries MSO redefines the midrange oscilloscope with a host of innovations including the industry’s first FlexChannelTM technology that allows 4, 6 or 8 analogue channels and up to 64 digital channels, integrated protocol analysis and signal generator, a new 12-bit signal acquisition system, a massive high-definition capacitive touch display, and a highly intuitive Direct Access user interface. As embedded systems used in everything from smart watches to hybrid vehicles become more sophisticated, en- gineers developing these systems require more from their go-to test and measurement solution – the oscilloscope. To effectively and efficiently characterise and debug these more complex systems, designers need to look at a much larger number and wider variety of signals than in the past. At the same time, usability and fast time-to-insight are critical to staying on time and budget. “The world of embedded electronics is expanding rapidly, driven by an insatiable demand for more electronics content in military, automotive, consumer and industrial products and systems, as well as, leading edge power technologies,” said ChrisWitt, vice president and general manager, Time Domain Business Unit at Tektronix. “Enabling our customers to keep pace required a completely new oscilloscope platform. The 5 Series MSO is the culmination of the largest single platform development effort in Tektronix’ history and delivers signifi- cant new innovations that will benefit our customers daily.” Advantages: • FlexChannels – More channels and digital channels when needed • Largest screen, capacitive touch, advanced UI • 12-bit ADC, new High Res mode = industry leading verti- cal resolution • Optional Windows OS • Flexible options, field upgrades Enquiries:Tel. +27 (0) 10 595 1821 or email sales@comtest.co.za

Encoder with three separate measuring systems

Sensor specialist FSG presents the new special magnetic encoder series MH680-III-MU-G which provides maximum reliability through multiple redundancy. The single-turn encoder is equipped with three electrically isolated Hall measuring systems to meet even the most demanding requirements in safety-related applications, i.e. in cases where redundant signals for monitoring do not suffice or additional signal outputs are needed to visualize the process. The device enclosures are manufactured from Hart-Coat alumini- um and provide corrosion, shock and vibration resistance. Thanks to their wide temperature range of -30°C to +80°C and IP67 ingress protection they are suitable for even the most demanding environ- ments. The new encoder features a resolution of

14 bit and covers a measuring range of 0 − 360°. Signal output is provided per channel via a 4-20 mA current inter- face. FSG provides each channel with its own membrane keypad

for signal setting, therefore allow- ing for independent calibration of every signal output. Mecosa is the sole agent for FSG Fern- steuergeräte in South Africa. Enquiries: Tel. +27 (0) 11 257 6100 or email measure@mecosa.co.za

Real-time laser beam analysis Slight changes in the beam profile of high-power laser systems can cause severe consequences. The Beam Waist Analyser Monitor (BWA-MON) by Haas Laser Technologies provides users with contin- uous real-time data covering the entire laser beam profile. Mistakes are detected as they happen and can be fixed before damage occurs. The BWA-MON is the only monitoring system without any moving parts. It uses an identical reflection of the actual beam to determine characteristics like beam waist and size, M-squared or thermal lens- ing. Working at 50 Hz, the system allows for several measurements per second. Thanks to its modular build, the BWA-MON can easily be adapted to the needs of any specific application. In Europe, Haas Laser Technologies products are exclusively sold by Laser Compo- nents. Enquiries: Email presse@lasercomponents.com

8 Electricity + Control

OCTOBER 2017

round up

ANALYTICAL INSTRUMENTATION

Driving IIoT forward Endress+Hauser is driving IIoT forward through innovative prod- ucts and solutions as well as by working with partners. This dedica- tion has been proven twice – winning the Digital Champion Award and presenting a new digital platform at the German Digital Sum- mit. The advantages of digitalisation in the process industry can already be seen clearly. Increased networking opens up new op- portunities in process optimisation and increases plant efficiency. Digital Champion 2017 With Memosens, Endress+Hauser introduced a pioneering sensor technology for liquid analysis in various industries such as chemical, power and energy, food and beverage and waterand& wastewater over 10 years ago. Memosens sensors measure the pH-value in liquids, for example, and transform it into a digital signal while still in the sensor. The data is then passed on via a contactless system and provides extremely accurate, reproducible and reliable measure- ment results. Furthermore, the technology combines high process and data security with simple handling: it can withstand corrosion and moisture, can be calibrated in the laboratory and enables pre- dictive maintenance. Endress+Hauser’s Memosens was presented with the Digital Champion Award in the category Digital Products and Services in June 2017.

At the Digital Summit Endress+Hauser demonstrated its commitment through its work with partners: the company created a platform through which data can be exchanged together with BASF, SAP, Pepperl+Fuchs and SAMSON. This was presented for the first time at the Digital Summit of the German Federal Ministry for Economic Affairs and Technology in June 2017. Enquiries: Email suanne.willemse@za.endress.com Visit http://bit.ly/IIoT_Endress_Hauser A platform for Industry 4.0 in chemistry: together with BASF, SAP, Pepperl+Fuchs and SAMSON, Endress+Hauser presented the opportunities of digitalisation to Chancellor Angela Merkel.

An IRThermometer that takes heat, dust, water… And a 3 m drop!

• Hi and Lo alarms for rapid display of measurements outside set limits • The 62 MAX+ has dual rotating lasers to help identify area to be measured. The measurement area is the spot between the dots (62 MAX and 64 MAX have one) Enquiries:Tel. +27 (0) 10 595 1821 or email sales@comtest.co.za

± 1°C or ± 1% of reading whichever is greater with 20:1 distance to spot ratio (64MAX) • Flashlight (64MAX) and large, easy-to- read backlit LCD display for easy view- ing even in dark environments • IP54 rated for extra protection against airborne contaminants • Set time and desired interval between measurements and Auto Capture will capture spot temperatures unattended (64MAX) • 99 data point logging (64 MAX) • Displays the minimum, maximum or average temperature, or the difference between two measurements

Fluke, represented locally by Comtest , has just launched the Fluke 64 MAX IR thermometer with internal memory, un- attended monitoring, improved accuracy, increased battery life, as well as the pre- cision needed to do the job accurately. Designed and tested to survive a three metre drop, this lightweight, compact in- frared thermometer works in the harshest of environments and even when unattend- ed. Applications include industrial mainte- nance, electrical and HVAC industries. The Fluke 64 MAX IR features: • Precise laser technology for more accu- rate and repeatable measurements • Temperature accuracy of up to t 0°C:

Measure residual chlorine without chemical reagents

cost makes the Q46H your best choice for chlorine monitor- ing applications in potable water, wastewater, cooling water, or high purity water systems • Automatic pH Compensation: For free chlorine monitoring un- der widely varying pH conditions, automatic pH compensation may be added to maintain the highest measurement accuracy at pH levels up to 9,5 • Dual Chlorine/pH Monitoring: Even when pH correction is not re- quired, adding a pH sensor to the system converts the monitor to a dual analyser, providing 4-20 mA outputs for both chlorine and pH Enquiries: Email shelaghw@nz.co.za

ATI ’s monitors provide long term accuracy and reliability for your chlorine monitoring needs and are economical to purchase and economical to maintain. ATI’s Residual Chlorine Monitor helps you achieve optimal disinfection and minimal chlorine dosing by meas- uring residual chlorine on-line. A unique advantage of the system is that no chemical reagent is required. This substantially reduces the running costs of chemicals and servicing. • Free or Combined Chlorine: Q46H monitors are factory set for either Free or Combined Chlorine measurement, but can easily be converted from one to the other in the field • Economical Operation: Reagent-less operation and low parts

Electricity + Control

OCTOBER 2017

9

Launch of turbidimeters Prei Instrumentation proudly introduces the Hach TU5 Series family of turbidimeters for drinking and high purity water turbidity measure- ment, for online as well as laboratory use. Not only does Hach use the latest ISO standard (DIN EN ISO 7027) for laser technology Nephlerometric measurement, but Hach has de- veloped a newstandard, HachMethod 10258which has been approved and adopted by the USEPA as a standard for the measurement of Tur- bidity.The HachTU5 Series of turbidimeters uses groundbreaking 360º x 90º detection technology employing a patented optical design that sees more of your sample than any other turbidity meter, delivering the best low level precision and sensitivity while minimising variability from test to test. The turbidimeter measures turbidity by directing a laser into a sample to scatter off suspended particles.The light that is scattered at 90º from the incident beam is reflected through a conical mirror in a 360º ring around the sample before it is captured by a de- tector.The amount of light scattered is proportional to the turbidity of the sample. If the turbidity of the sample is negligible, little light will be scattered and detected by the photocell and the turbidity reading will be low. High turbidity, on the other hand, will cause a high level of light scattering and result in a high reading. Prognosys monitors

your TU5 series online instrument, proactively alerting you to main- tenance needs before your measurement becomes questionable. A Hach Service Agreement protects your investment and helps ensure that you stay in compliance and on budget. Prei Instrumentation is the South African distributor for Hach online liquid analysis equipment. Hach has been the market leader in turbidity measurement since Clifford Hach introduced the first Continuous Read turbidimeter in 1957. Enquiries: Email steve.herbst@prei.co.za

Optic principle.

360º x 90º detection technology.

Accurate echo

sor emits an ultrasonic pulse train and receives the echoes reflected. The electronics evaluates the echo time of the pulses and determines the level. The compact evaluating electronics is mounted on the unit. For remote transmission, a norm signal out- put and for monitoring purposes, a relay contact is available. For programming and for local dis- play, the units may be delivered with an optional pluggable programming unit with LCD display. The sensors have a total beam angle of 5°-7° at -3 dB. This ensures a reliable measurement in nar- row silos with uneven side walls as well as in pro- cess tanks with various protruding objects. Further- more, as a result of the narrow beam angle − the emitted ultrasonic signals focus and penetrate gases, vapour and foam. Enquiries:Tel. +27 (0) 10 595 1831 or email sales@instrotech.co.za

KOBOLD, represented locally by Instrotech , has on offer an ultrasonic level meter, model NUS-4, to be used for non-contact, continuous level and volume measurement in vessels or for flow measurement in open channels. Level measurement technology based on the non-contacting ultrasonic principle is especially suited for sticky or abrasive media and applications where, for any reason, no physical contact can be es- tablished to the surface of the material to be meas- ured. Such reasons may include corrosive attack by the process medium against the measuring device material (acids), possible contamination (sewage) or particles of the process medium adhering to the measuring device (adhesive materials). The ultrasonic level metering technology is based on the principle of measuring the time required for the ultrasound pulses to make a round trip from the sensor to the level to be measured and back.The sen-

10 Electricity + Control

OCTOBER 2017

3& :RU[ (QJLQHHU Adaptive Software Platform

abbreviations

FBD – Function Block Diagram IT – Information Technology LD – Ladder Diagram SDK – Software Development Kit SFC – Sequential Function Chart ST – Structured Text

'LSO ,QJ )+ )UDQN :DOGH 3KRHQL[ &RQWDFW (OHFWURQLFV *PE+

PC Worx Engineer tailors the functional scope to requirements, ensuring added cost-effectiveness.

T he PC Worx Engineer adaptive engineering software by Phoenix Contact – PLCnextTech- nology – is a cornerstone of the solution. This tool combines the most important functions of an automation solution and systematically expands capabilities for simultaneous project development. Additionally, PCWorx Engineer tailors the functional scope to requirements, ensuring added cost-effec- tiveness. IEC 61131-3 [1] has been the international standard for programming in the field of automation for decades. Tools from a variety of manufacturers reflect the structure of this standard and allow the user to easily develop application-specific automa- tion solutions. Compared to older solutions, today’s solutions have become significantly more complex with the integration of technologies such as func- tional safety, visualisation concepts or different pro- gramming languages outside of IEC 61131-3 [1]. As a result, project teams have to manage and master an increasing number of disciplines. This means that different programmers usually work simulta- neously on the same project or project task, and often in different disciplines. The team members then merge the different project results together into the master project at defined intervals. To do this, they often use common version control tools such as Subversion or GIT. Clear assignment of permissions With conventional automation tools, projects are stored in folder structures according to the hierar- chy described in IEC 61131 [1] and are transferred to version control tools in this format. In such tools, rights can be assigned to individual objects. How- ever, changes to an object that is visible to a user usually result in modifications in all folder struc- tures. The user is unable to track these changes. For one, this goes against the principle of privilege separation. Second, even tools like GIT cannot of- fer reliable protection against manipulation in such cases. Furthermore, it is possible for competing versions to be saved with different changes (see Figure 1 ).

Take Note!

Actions

This company ensures that users pay only for the services they need to implement an auto- mation project. The basic version of PC Worx Engineer can open all projects. Its flexibility makes it possible for users to fo- cus on the project rather than the software.

Project X

1

State Welding Coating

IEC 61131-3

Time

Version 1

Function block Main task Welding task Coating task Function

Copying Version 1 to systemA Copying Version1 to systemB

Modifying

Modifying

2

Visu

Copying themodified version to the server

Welding Coating Overall operation

Version 2

Conflict

Copying themodified version to the server

Version3

3

Version 3 (modify by )

overwrites Version 2 (modified by )

Is this acceptable?

Figure 1: Points of conflict in a conventional folder structure.

To solve these fundamental problems, the com- pany developers have borrowed an approach used by the military. In the military, geographical areas of responsibility are strictly assigned to specific command posts. This structure ensures quick re- sponse times in each area of responsibility, thanks to defined authorisations. Fewer communication interfaces make operations more efficient, and by restricting responsibility to one person, misunder- standings are prevented, thereby minimising the likelihood of errors. So how is this approach implemented in the new PC Worx Engineer software? The project manager assigns developers responsibilities for individual applications in the usual way. PC Worx Engineer creates the folder structure of the project based on the assigned responsibilities. If a devel- oper makes changes to the program, the software only makes the changes in that developer’s area of the folder structure. The other parts of the master project remain untouched. While this procedure is not discernible to the user, this type of folder structure allows for clear separation of privileges. All privileges, from the folder level (IT administrator) to the develop- ment tool level (project manager), can be easily and clearly assigned using this method (see Fig- ure 2 ).

The editors in PCWorx Engineer provide users with so-called inplace actions. These buttons always appear in a context-sensitive manner when a defined action is possible on an object, and are placed graphically directly next to the object. Searching for actions in toolbars becomes entirely obsolete and editing code and graphics becomes much more efficient.

12 Electricity + Control

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CONTROL SYSTEMS + AUTOMATION

Faster programming thanks to assistance function PC Worx Engineer sup- ports the familiar Win- dows drag-and-drop func- tion throughout the entire system. The new role picker functionality makes programming even easier because the programmer is only offered those ob- jects that can actually be used for the current task. This eliminates the need to look for suitable mod- ules in a catalogue or for variables in a table (see Figure 3 ).

to create areas of responsibility. Th designed the licence model based on the same concept. The de- velopment team wanted to create a clear and fair model for licences and enable users to quickly be- gin using PCWorx Engineer. Unlike other solutions on the market, this engineering tool is available free of charge. The free version includes essential functions for creating a simple automation solu- tion. These functions include the mandatory IEC 61131-3 [1] editor with Structured Text (ST), Func- tion Block Diagram (FBD), Ladder Diagram (LD) and Sequential Function Chart (SFC) languages, as well as the integrated eHMI editor, which provides basic functions for web visualisation. The licence model includes all the necessary functions for configur- ing and diagnosing peripheral components. Using function add-ins, additional functions can be ena- bled depending on user requirements and prefer- ences. More features will be added in the future, including safety functions and extended eHMI fea- tures such as alarming and trending, as well as the programming languages SFC+ (sequential func- tion charts) and C#. Many users are excited by the possibility of using the C# function add-in to cre- ate programs and functions in high-level language, for example in Microsoft Visual Studio, and import them into PCWorx Engineer. In this way, commu- nication tasks can be implemented more elegantly than with conventional IEC 61131 [1] languages. Conclusion The company’s aim is to ensure that users only have to pay for the services they actually need in order to implement their automation project. Therefore, even the basic version of PC Worx En- gineer can open all projects, including those creat- ed using function add-ins. The project can then be loaded onto the controller on site and diagnosed. However, no changes can be made outside of the standard functions. PC Worx Engineer is there- fore not just another new IEC 61131-3 [1] tool. It perfectly adapts to changing requirements in the world of automation. Thanks to its extendibility and flexibility, users can now focus on the pro- ject instead of the software itself. Reference [1] IEC 61131-3. 2003 (second edition). Pro- grammable controllers – Part 3: Program- ming languages.

Projectmanager sepa- rates into responsibilities.

Project X

Visu specialist Visu

Welding

Coating

IEC 61131-3

IEC 61131-3

Functionblock MainTask WeldingTask Function

Functionblock Coating task Function

Overalloperation

Visu

Coating

Visu

Welding

IT admin

Figure 3: The role picker function simplifies object selection.

Figure 2: Consistent structure from the folder level to the project level.

Task-specific assignment of elements Furthermore, if the project team would like to use a version control tool such as GIT, the software can individually sign the folder structure, which has been created according to clearly defined responsibilities. The interaction of these mechanisms ensures that unauthorised access can be detected at every level and that access permissions are reliably implement- ed.The company uses the these features in the built- in Safety Editor of the PCWorx Engineer.This means that the user does not have to ensure privilege sepa- ration across different software tools. As a result, the safety programmer can switch from the Safety Edi- tor to the IEC 61131 [1] editor just as easily switch- ing between tabs in a browser. PC Worx Engineer provides intelligent system filters based on areas of responsibility.These filters make the software easier to use by providing developers with only those ele- ments they need for their particular task. For exam- ple, developers of visualisation solutions would only see the eHMI toolbox and electrode holder special- ists would only have access to program organisation- al units. Eliminating unnecessary functions reduces complexity and minimises the risk of errors. Easy activation of additional functions The idea of allowing users to access only those are- as necessary for their tasks inspired the developers

Faster implementation of automation

projects with fewer errors.

<>

Dipl.-Ing. (FH) Frank Walde, Competence Centre Automationworx, Phoenix Contact Electronics GmbH, Bad Pyrmont, Germany.

Andre Kemp

+27 (0) 11 801 8200 andrek@phoenixcontact.co.za

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The IoT can make a major impact on Africa %UDGOH\ +HPSKLOO ((6 /LYH

tinent’s unique business challenges and socioeconomic conditions must be addressed. An American or European strategy may not be the best fit for the local environment. There are, for example, some unique barriers to adoption in Af- rica, such as effective connectivity. In order for the IoT to work effectively it relies on high speed internet connections and this in- creases demands on available resources, such as bandwidth and network capacity. It is necessary to analyse the digital skills, infra- structure and technology required to connect so many devices and evaluate the data obtained. There is however potential across the continent for using Big Data Analytics in significant new ways. Research by global scien- tific research body, ResearchGate, on IoT deployment in Africa, re- veals that the introduction of Big Data Analytics means that the Contain cost and new technology Another barrier or challenge in Africa is the need to contain the cost of devices and new technolo- gy. A positive development here, also according to ResearchGate, is the decline of sensor and bandwidth prices and decrease in the cost of processing in the past ten years. Ubiquitous wireless networks, such as Wi-Fi, too have become cheaper and more accessible. The availability of power to supply most devices that require automation has been a concern for the continent, but alternative technologies for energy harvesting and ultra-low power devices have been beneficial to IoT. Cyber security The sharing of content and data across multiple platforms is in- tegral to IoT. As this initiative gains pace around the world, it be- comes increasingly important that this information is secure. Pri- oritising cyber security is essential to successful digital transformation. Conclusion IoT can be facilitated and the transition made easier through collaboration and the formation of strategic alli- ances. Key players, such as government, regulatory au- thorities, mobile operators, the private sector and other stakeholders, need to work together to optimise the potential of IoT. This will ensure a shared, integrated, inclusive digital environment facilitating socio-economic development. The IoT and the global technological revolution, the Fourth Industrial Revolution, are profoundly transforming client interactions. abundance of data which is generated daily by the various connected ‘things’ in the IoT network can be processed faster and better.

The Internet of Things (IoT), which bridges the digital and physi- cal world, is already making its mark in Africa as smart connected devices are being deployed and the use of connected hardware emerges. However, it has the potential to make a far more signifi- cant impact on the region, as long as circumstances specific to the continent are taken into consideration.

Sub-Saharan Africa – world’s fastest growing mobile region

The global association for the mobile telecoms industry, Groupe Speciale Mobile Association (GSMA), states that Sub-Saharan Af- rica has in recent years been the world’s fastest-growing mobile region in terms of both mobile subscribers and mobile connec- tions. It predicts that the number of individual mobile subscribers in Sub-Saharan Africa is set to surpass the half billion mark by 2020 as mobile services become more affordable and accessible.

The Internet of Things has the potential to make D IDU PRUH VLJQLÀFDQW impact in Africa.

However, the IoT, which has a stagger- ing reach globally and is driving companies the world over to redefine their business processes, can make a far more significant impact on Africa and facilitate major digital transformation.The IoT can be further devel-

oped in Africa to provide a range of innovative new services and solutions to people across the continent, and to gather data and gain insights to bolster efficiency and productivity. It can make a marked impact on numerous industries, as diverse as security, energy, finance and healthcare, and contribute significantly to the economy and wellbeing of the continent’s people. Unique African context He emphasises however that when adopting IoT it is vital that is- sues and circumstances specific to Africa are carefully considered and defined within their unique context, before devising and im- plementing an appropriate strategy and course of action. The con-

Bradley Hemphill is the Managing Director of EES Live. Enquiries: Visit www.eeslive.com

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CONTROL SYSTEMS + AUTOMATION

New cyber security system for oil and gas industry 'DYLQGHU +DUFKDUDQ 6LHPHQV

APE is an x86-based computer designed to occupy a single-line module slot in a RUG- GEDCOM RX1500 device. The APE is able to host a variety of cyber security solutions including Next Generation Firewalls and identity based cloaking solutions. With the addition of the SNOK Network Anom- aly Detection solution, the RUGGEDCOM RX1500 adds another critical layer to its security appliance capability. This solution is compatible with new and legacy ICS net- works, designed and specifically tailored to operate in SCADA environments with plug-and-play simplicity. In addition, it re- quires no changes in the existing network topology or hardware and can be seam- lessly dropped into the existing infrastruc- ture thus preserving current investment. Uniquely, the SNOK platform has virtually no operational load or other impacts on the ICS or SCADA networks and does not re- quire signature updates. How it works SNOK works quietly behind the scenes, us- ing software agents to collect deep low-lev- el information that, analysed over time, can identify anomalous behaviour patterns in the network or any of its devices that might indicate a low-and-slow cyber threat before an actual attack and disruption can occur. SNOK then alerts a compromised ICS net- work’s operators to the attack. It also pro- vides sufficient data to help them make informed decisions about an effective re- sponse and corrective action. Conclusion Currently, the Secure-NOK SNOK Network Anomaly Detection solution is in its early deployment stages within the oil and gas industry, with interest coming from other parts of the energy sector such as the pow- er utility industry. Clearly the energy sec- tor is starting to realise that ICS networks need more hardening and early-warning safeguards in addition to conventional, de- fence-in-depth cybersecurity approaches. Davinder Harcharan, Siemens Industry Inc. Email davinder.harcharan-singh@siemens. com or jennifer.naidoo@siemens.com

For criminals, terrorists, and so-called hack- tivists, the vast and mostly invisible infra- structure within the oil and gas industry,

dustry as mandatory safeguards against such attacks.This attack frequency has only grown in recent years. That is because the

is rich with targets for cyber attacks. As the potential for cyber attacks against the en- ergy sector grows, a revolu- tionary early-warning system designed to protect the indus- trial control systems of the oil and gas industry has emerged to complement highly rec- ommended defence-in-depth

industry continues to deploy increasing numbers of Indus- trial Control Systems (ICSs) in networks along the entire value chain – upstream, mid- stream, and downstream – so operators can realise the quantum gains in operational efficiency, visibility, and safe- ty that other industries like

The energy sector’s

infrastructure is a prime cyber attack target.

strategies. Few people outside the oil and gas industry and its regulatory frameworks appreciate the vast nationwide infrastruc- ture that brings fuel to their corner gas stations and, for many, to their homes. But for criminals, terrorists, and so-called hack- tivists, this mostly invisible infrastructure is rich with targets for cyber attacks. After all, any big disruptions to the nation’s intricate network of oil and gas facilities used in ex- ploration, production, distribution, storage and refining, could be spectacular – and potentially devastating to the economy, environment, and quite possibly life safety. In fact, the U.S. Department of Homeland Security’s (DHS) Industrial Control Sys- tems Cyber Emergency Response Team (ICS-CERT) considers the energy sector’s infrastructure a prime cyber-attack target. In 2015, for the second consecutive year, it ranked second out of 16 categories behind critical manufacturing for the number of sig- nificant cyber attacks reported against it. For this reason, both the U.S. and the European Union are enacting new cyber- security regulations for the oil and gas in-

manufacturing have long enjoyed. They then connect their ICSs to their enterprise IT networks to gain much more operation- al visibility and business insights. That is when trouble’s door can open. The RUGGEDCOM RX1500 offers a rich set of modular WAN, serial, switching and routing options with enhanced security ap- pliance capability.This allows for hassle-free upgrades in the field, and the flexibility to adapt to changing network architectures and cybersecurity requirements. SNOK pro- vides an early-warning network monitoring system to identify and isolate cyber threats that may be undetectable by conventional IT security tools. In effect, it adds critical, extra hardening to the defence-in-depth cy- bersecurity umbrella already protecting ICS networks and any enterprise IT networks to which they are connected. Plug-and-play installation The Siemens Secure-NOK SNOK Network Anomaly Detection solution differentiates itself by running on the RX1500 Applica- tion Processing Engine (APE) module. The

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