Electricity + Control September 2018

Fluke 1664 FC Multifunction Installation Tester helps expedite installations

FEATURES: · Control systems + automation + systems engineering · Drives + motors + switchgear · Energy management + environmental engineering · Plant maintenance, test + measurement · Sensors, switches + transducers

COMMENT

ON THE COVER

Old ways won't open new doors

C an you believe that we are rapidly moving into the latter part of the year? This business of time seeming to move faster needs deeper analysis, does it not? Let’s be frank: our economy seems to be floundering just as the rest of the continent grows and develops. This fact is quite apparent from many of the inter- actions I have had the privilege of being involved in over the past while. The manufacturing industry has been facing some terrible head wind with part of the trouble being trying to figure out how to remain genuinely competitive in the face of international competition and local uncertainty. Looking further into the industry, to what many may consider to be the gene- sis of South African industry, mining is far- ing no better. Again, the challenge seems to be one of uncertainty. African economies, we can see, are rising; and foreign direct investment onto the continent is growing substantially. The migration of people into African cities con- tinues unabated. Whereas monitoring cash flow through- out the continent shows Johannesburg to be prominent, the challenge seems to be finding ways to develop sufficient confi- dence for some of the cash to stick. Investors need to trust this economy. And contrary to what many have suggested to me, foreign investors really do not think they owe this economy anything at all. It is disturbing to see how little trust there seems to be in this economy. And rightly so. This part of the planet has in- credible natural and human resources. Re- alising the wealth beneath the soil poses challenges, for sure; but it is there. The human potential is unbelievable. Neither are being adequately devel- oped, and it is evident that we cannot avoid the obvious conclusion that we have

not really made it a priority to develop our human potential adequately. As the waves of the 4 th industrial rev- olution wash past us, to what extent will we be able to ride at least one of them? Fact is, if we can’t we may as well turn out the lights, which of course brings us on to another topic worthy of consideration. But let’s leave the energy sector to a later comment, shall we? Policy makers need to learn the bene- fits of long-term and stable strategies, as well as the power of developing the cour- age to be non-populist. Is it asking too much? Well, that depends on a little thing called leadership. Leadership is courageous; and coura- geous leaders can get people to believe in them and trust them. The current trust deficit extends well beyond just the foreign view of this econ- omy; it exists within all of the political structures I am aware of, as well as be- tween them. From where will courageous leadership emerge? Will it? And if it does, will it happen soon enough to begin to turn the econ- omy? Ask how you can fulfil both roles: em- brace the change and the enormous op- portunity it presents; and try as much as you can to reduce the number of people ‘hurt’ in the process. I believe we can achieve both objec- tives simultaneously. But it will take deci- sive leadership, won’t it?

Fluke 1664 FC Multifunction Installation Tester helps expedite installations

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

ECSEP 2018.indd 1 8/28/2018 10:35:34AM www.electricityandcontrolmagazine.co.za

Fluke offers 1660 Series Multifunction Installation Testers that protect appliances and share data via WiFi. (Read more on page 31).

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CONTENTS

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Features

CONTROL SYSTEMS + AUTOMATION + SYSTEMS ENGINEERING 4 The digital era in the art of brewing: Information provided by Siemens

6 The future of mining is automated: Chris Calam, ThermoFisher Scientific

9 Round Up

DRIVES + MOTORS + SWITCHGEAR 12 Next generation medium voltage switchgear: Joe Richard, Schneider Electric 16 Enduring market for dc drives: Andy Green, Nidec Control Technique s

18 Round Up

ENERGY MANAGEMENT + ENVIRONMENTAL ENGINEERING 22 New control strategy helps reap maximum power from wind farms: Aaron Dubrow, Texas Advanced Computing Center

24 Chemical cluster to transform energy storage: Bob Marcotte & Charlotte Hsu, University at Buffalo

26 Round Up

16

PLANT MAINTENANCE, TEST + MEASUREMENT 28 Using visual data to its full potential: Willem Beckmann, DataProphet 32 Prevention and protection in plant maintenance: Joy Sonn & Manoj Chandrasekharan, Schneider Electric

34 Round Up

SENSORS, SWITCHES + TRANSDUCERS 40 Bringing flexibility to damage inspection: Liezel Labios, University of California – San Diego

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40

42 Round Up

Regulars

1 Comment 31 Cover Article 44 Engineering the Future 46 Light + Current 48 Write @ the back 48 Events 48 Advertisers

2 Electricity + Control

SEPTEMBER 2018

Sivacon S4 Locally manufactured fully type tested power distribution panel for efficient power distribution

Siemens has partnered with a local sheet metal fabrication specialist iLED who have been appointed as the manufacturing partner for the Sivacon S4 .This local partnership will ensure fast availability, easy adaptation and customization of the highest level. The SIVACON S4 raises the bar in power distribution. Its area of application are current ratings up to 4000A in infrastructure and construction systems. This distribution system offers superior levels of safety for people and systems. The solution is a designed tested combination of power switchgear and control gear. It is globally renowned for superior safety, flexibility and system availability. The SIVACON S4 power distribution board makes project planning quick and easy with the free SIMARIS configuration software. The configuration software will assist in every step of your project, from initial planning to installation. The variable widths and flexible modularity make the SIVACON S4 the ideal choice for customer specific requirements. The main busbar can be arranged at the top or rear of the cubical as needed. Cubical busbars offer excellent front access to the terminals of all 4 conductors due to its staggered design. The sophisticated concept of internal separation offers additional value. Safety can be precisely targeted to the user’s specific requirements. The SIVACON S4 distribution board can always be assembled flexibly, economically and to exact customers requirements. Assembly kits are provided for AIR CIRCUIT BREAKERS, MOULDED CASE CIRCUIT BREAKERS, FUSE DISCONNECTORS, MINATURE CIRCUIT BREAKES, ISOLATORS and much more. Additionally, a number of different cubical door versions are available. The energy distribution board can be easily adapted for any available space. The SIVACON S4 and all auxiliary products comply with the standard IEC 61439, for design tested combinations of power switchgear and control gear.

Should you require more information on SIVACON S4 or the SIMARIS configuration Tool, please contact Yullen Govender Head of Low & Medium Solutions, Siemens Southern & Eastern Africa

yullen.govender@siemens.com +27 (11) 652 2693

siemens.co.za/EM

CONTROL SYSTEMS + AUTOMATION + SYSTEMS ENGINEERING

The digital era in the art of brewing

Information provided by Siemens

Whether as part of a cosy dinner, at a festival, or at a party – a glass of beer is integral to many occasions. On average, each German drinks around 106 litres a year (as of 2015, Source: STATISTA). Nationwide, that amounts to more than eight billion litres of the golden brew.

Take Note!

With digitalisation, all processes in the various areas of the brewery can be flawlessly controlled and visualised. The master brewer can now individually compose each recipe and adapt it flexibly. Quality control is even more accurate.

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Digitalisation in the brewery business Today, brewing companies are facing a multitude of challenges. The variety of types of beer on the market is increasing – as is cost pressure from the competition. To attain the goal of a more flex- ible and economical process, digitalisation of the brewing equipment along the entire value chain is vital, from the receipt of raw materials and delivery of products to production and corporate resource planning. If all processes are perfectly coordinated and all components of the equipment communi- cate reliably, the entire plant becomes more flexi- ble, ultimately reducing costs. The Stieglbrauerei zu Salzburg brewery, Aus- tria's largest private brewery, relies on a custom automation system to brew about 20 different types of beer efficiently, economically, and with consistently excellent taste. Choice of ingredients is not the only area in which the Stiegl private brewery insists on the very best quality. Technical implementation of the

brewing process has to meet the Salzburg-based company's high standards as well. Having started in 1492 with rather basic components like electric motors, the brewery continued with more com- plex control systems for automating the produc- tion processes during the 1970s. Today they have transformed to a new, customised automation solution, thereby digitising its processes from start to finish. Brewing beer remains a craft With digitalisation, all processes in the various areas of the brewery – including the brewhouse and the fermenting, storage, and specialty cellars – can be flawlessly controlled and visualised. Sim- ple but effective recipe control is at the core of the system. The master brewer can now individually compose each recipe and adapt it flexibly. Quali- ty control is even more accurate, and the unique flavours of the individual types of beer are more distinct than ever.

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4 Electricity + Control

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CONTROL SYSTEMS + AUTOMATION + SYSTEMS ENGINEERING

Nonetheless, in Austria's largest private brew- ery, brewing beer still is a craft: State-of-the-art technology only makes it easier. "The new system helps us compensate natural variations in the raw materials and maintain a consistently high quality," says Christian Pöpperl, master brewer in chief at Stiegl, who was responsible for the transition to the new automation system, explaining the advan- tages of the digitised brewhouse. After taking this step in technological evolution, the master brewers have noticed that they suddenly have time for their true passion again: coming up with new recipes. Traditionally, only hops, malt, yeast, and water go into the kettles of German breweries, but even a truly traditional beverage has to be marketed ― and that is where the beer label makes its grand en- trance. Simple paper is transformed into a unique branding tool, intending to influence in no small part the consumer’s purchasing decision. But looks are not everything – such a label should be able to withstand changing tempera- tures, condensation, storage periods, and bottle washing machines. Expectations are therefore high, as are the requirements for producers along the value chain. Refined, printed, and glued The beer label first sees the light of day in the pa- per mill. In order to refine the simple paper after the initial manufacturing steps, it is usually metal- lised and embossed. The resulting gloss heightens the sense of anticipation for a cool and refreshing beer. Such tasks rely heavily on state-of-the-art drive technology. The next stage of the process takes place at the printers: the paper must have proper fibre run- nability for optimal ink application. This can often be a real challenge, as labels are asymmetrical in structure and the surfaces of their different sides have varying characteristics. The paper has to lie perfectly flat so that nothing interferes with print- ing. During subsequent cutting and punching, the labels need to be prevented from sticking to each Visual appearance is crucial, and quality pays for itself

other in blocks. In addition, the paper should be ‘punchable,’ allowing the cutting blades to glide smoothly through many plies. Printed, refined, and cut, the labels go to the bottling company, usually one of many small brew- eries. This is where they pass through the labelling machine. At a speed of up to 60 000 bottles per hour, the labels have to be applied cleanly and in precisely the right position on the bottles. In the case of cold filling, the bottles also ‘sweat’ so the glue must adhere well to the back of the label. The bottles are then usually rinsed and packaged in crates or six-packs. Integrated control technology is needed to prevent damage, blistering, or wrin- kling during this process. Conclusion When the beer bottle is placed on the store shelf, the label can make its grand appearance – regard- less of how short-lived. But the label’s lifecycle is not over yet. Once the delicious brew has been consumed, the bottle goes back to the bottling company where the label faces its last challenge: the removal process. The glass bottles are cleaned in an alkaline solution at a temperature of 80°C. The label has to be removed from the bottle with- out losing printing ink or disintegrating. Some of the high-quality paper fibres are then processed as raw material for new paper products.

A more flexible and economical process requires the digitalisation of brewing equipment along the entire value chain.

Using the Siemens Simatic S7 technology and WinCC software, Stiegl's brewhouse in Salzburg has digitised its processes from start to finish.

Moscow, Russia, Ochakovo Brewery - June 13, 2013.

Electricity + Control

SEPTEMBER 2018

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CONTROL SYSTEMS + AUTOMATION + SYSTEMS ENGINEERING

Chris Calam, ThermoFisher Scientific The future of mining is automated

As global demand increases for resources locked deep within the earth, the mining industry must adopt processes and technologies that streamline every step of the process. Automation holds the key to a more efficient mining industry.

Take Note!

The principles of sen- sor-based ore sorting were first developed in the 1920s. The use of sensor-based technology greatly increas- es the efficiency of sepa- rating valuable minerals from waste rock. The first sensor-based sorting machine was in- troduced in 1972 at the Doornfontein mine.

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D uring the past decade, demand has in- creased for technologies such as industrial automation and control systems, simu- lator-training, equipment control and guidance, advanced mine-surveying technologies, under- ground mining and surface drilling technologies, and machine guidance and control systems. This article predicts that demand for cloud-based ser- vices, mining’s industrial “Internet of Things,” and new visualisation, simulation and optimisation software will influence the mining industry over the next five to 10 years, and that the increasing use of remotely-controlled automated equipment will be the most important development. Remote monitoring and control of equipment al- lows miners to automate industrial processes like blasting, drilling, and transportation. The new, au- tomated equipment used to perform these tasks is faster, more accurate, and can cover more area in less time. Efficiencies are gained through con- tinuous, consistent operations, improved commu- nications, and reduced infrastructure. Mine site safety can be improved by removing personnel from dangerous environments and placing them Remote monitoring and control of equipment

2

in remote control rooms where they can operate equipment from a safe distance.

Laboratory information management systems (LIMS) Laboratory information management systems (LIMS) are also key to automation. A LIMS is an essential part of mining and metals laboratories, and today serves as the foundation for a complete- ly automated lab by integrating with instruments and other laboratory tools, as well as enterprise systems like PIMS, MES and ERP solutions. And because a lot of the revenue of the mining com- pany can be generated at the downstream oper- ations level delivering processed materials to end users and other manufacturers, a LIMS is critical to determining a clear picture of the work-in-pro- gress status of the lab at any point in time, iden- tifying potential process bottlenecks and produc- ing real-time analysis of large amounts of data for quality control purposes. Driverless vehicles Around the world, automated vehicles are current- ly being developed and utilised for a wide variety of functions. Driverless mine trucks operate above ground at many operations, especially in Australia,

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Remote monitoring and control of equipment allows miners to automate industrial processes.

and are powered by GPS technology. The largest obstacles standing in the way of such technology are the extreme conditions of the mine combined with the task of navigating dark, winding tunnels. It is hoped that these problems, in the future, can be overcome with camera-based positioning sys- tems and additional multi-sensor systems for ac- curate positioning. Sensor-based sorting The principles of sensor-based ore sorting were developed in the 1920s, and the use of such tech- nology greatly increases the efficiency of separat- ing valuable minerals from waste rock. The first sensor-based sorting machine was introduced in 1972 at the Doornfontein mine. While such sorting technology was widely used at the time to sort glass, plastics, paper, and cardboard, the technol- ogy had not yet been widely adopted for raw min- erals and materials. Over the 80-year history of sensor-based ore sorting, there have been several types of sorting equipment developed: channel-type, bucket-wheel type, and cone-type. The most popular today, how- ever, are chute-type and belt-type. The most prevalent technologies being used in these systems are electromagnetics (EM) and X-ray Transmission (XRT). In both of these sys-

tems, particles are fed through a machine where they are scanned, and then valuable minerals are separated and sorted using pneumatic, mechan- ical, or hydraulic means. This automated technol- ogy is faster and more efficient than its manual counterpart, as sensor-based sorting systems boast the ability to sort through 200 tons of parti- cles per hour per machine. An adoption of these technologies in the miner- al mining industry at large would be nothing short of revolutionary.

Electricity + Control

SEPTEMBER 2018

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CONTROL SYSTEMS + AUTOMATION + SYSTEMS ENGINEERING

Data analysis Numerous global tech companies are looking to spearhead the foray into digital data analy- sis in mining. From exploration to delivery and everything in between, the digitisation of mining will streamline all processes while making the in- dustry safer than ever. Advanced sensing technology and real-time op- erational data will assist in a faster decision-making process and allow companies to be more transpar- ent with their local partners, while predictive algo- rithms will enhance the precision and accuracy of future projects. Incentives for automation The Mining Journal article quotes a Citi report on incentive for automated mining equipment such as driverless vehicles: “Labour is one of the biggest cost drivers for a big miner, contributing to more than 30% of miner’s cash costs. There is also the aspect of safety. Not only is this important per se, but the safest mines are often the most produc- tive.” The Citi report notes that while adoption of au- tomated equipment has been slow, the situation is poised to change because the obvious cost-re- ducing measures have already been taken, leaving automated equipment and technologies as the best option to improve efficiency and productivity, while reducing costs. In Deloitte’s ‘Outlook on Mining’, Rick Carr, Deloitte Mining sector leader, also recommends

embracing autonomous mining solutions: “Rather than layer incremental technologies over existing operating models, the industry could work with equipment makers to design autonomous solu- tions, collaborate with technology firms to develop sensor-driven production visibility tools, and em- brace mobile and modular solutions for bulk min- ing operations. For example, at Glencore’s Ulan West mine in Australia, an underground flexible conveyor system – the second of its kind in the country – is being installed to drive improved op- erations, increase safety, and lower total operating costs.” Given all the benefits of automation, what are min- ing companies waiting for? The CRC Mining web- site summarises a presentation given by Professor Ross McAree, an authority in robotics and auto- mation innovations for mining, at the International Mining and Resources Conference (IMARC) in Mel- bourne on September 23, 2014 in which he pre- sents six challenges to technology implementation: • The double burden of immaturity. • The need for a common interoperability plan. • Operational technology and information tech- nology must integrate. • Sourcing skilled people with appropriate exper- tise. • Altered responsibilities. • Equivalent levels of safety. Six challenges to technology implemen- tation

If South Africa’s mining compa- nies want to continue to meet the growing global demand for their products, they must embrace au- tomation sooner rather than later. The result will certainly be a more profitable, efficient, and safer in- dustry.

Chris Calam is the Sales Manager at ThermoFisher Scientific.

8 Electricity + Control

SEPTEMBER 2018

round up

CONTROL SYSTEMS + AUTOMATION + SYSTEMS ENGINEERING

Incremental encoders offer optimum flexibility

tether allowing for mechanical stresses caused by angular, axial or radial misalignment between the rotating shaft and the encoder. Again, the design of this encoder allows for unrestricted mount- ing depths as the shaft passes completely through the encoder body. Shaft diameters of 15 mm up to 42 mm are available with a protection class rating of IP40 and resolutions of 500, 1 000 and 1 024 PPR. Enquiries: Gerry Bryant.Tel. +27 (0) 11 615 7556 or email bryant@countapulse.co.za

The range of Hengstler incremental encoders offers users opti- mum flexibility with an encoder for every application. According to South African distributor, Countapulse Controls, the available options allow for customised solutions. With more than 20 standard models to choose from, customers are offered a choice between heavy- or light-duty options, as well as aluminium or stainless steel housing material. There are also multiple connection options, facilitating a fit-for-purpose encoder. The Hengstler RI32-O incremental rotary encoder is popular for light duty applications and, being one of the smallest encoders available, it is ideal for use in limited space. With an aluminium shaft and a 30 mm diameter housing constructed of plastic, the devices are lightweight and durable. The range includes 5 mm and 6 mm solid shaft diameters, with protection class ratings of IP40 and resolutions of up to 1 500 PPR (Pulses Per Revolution). Known as an economy encoder, the Hengstler RI38-O incre- mental rotary encoder is also favoured for light-duty applications. The shaft is made of stainless steel and the housing is constructed of glass fibre reinforced plastic material. This makes it an economi- cal, light and durable product. A 6 mm diameter solid shaft version is available with a protection class rating of IP40 and resolutions of up to 1 024 PPR. The Hengstler RI58-O incremental encoder is a universal indus- try standard encoder. The 58 mm diameter housing is aluminium while the shaft is stainless steel. This encoder offers a choice of product configuration options, for example, a clamping flange ver- sion with solid shaft diameters of 10 mm and 12 mm with a pro- tection class rating of IP64 and resolutions of up to 5 000 PPR. The encoder is available with a PPR up to 10 000 if required. Designed for direct mounting onto rotating shafts, the Hengstler RI58-D incremental rotary encoder is secured by a front clamping ring and the main body of the encoder by a stator coupling or set screw. The through shaft design allows for unrestricted mounting depths as the shaft passes completely through the encoder body. The front clamping ring version is available with shaft diameters of 10 mm and 12 mm and a protection class rating of IP64 with resolutions of up to 5 000 PPR Also, directly mounted onto rotating shafts, the Hengstler RI76TD incremental rotary encoder is secured by a front flexible

Electricity + Control

SEPTEMBER 2018

9

round up

CONTROL SYSTEMS + AUTOMATION + SYSTEMS ENGINEERING

Multi-channel power supplies for absolute accuracy

from the 2230G-30-6. All channels are simultaneously displayed on the front-panel display. To minimise the effects of noise on the device under test (DUT), the triple output power supplies use a linear design with <1mV rms ripple and noise. The linear design also ensures the supplies don’t add to ambient noise and affect other sensitive instrumentation being used for test. Using the supplies’ remote sensing capability, users can set and monitor output voltages with a 0.03% basic ac- curacy and a resolution of 1mV. Load current can be monitored to 0.1% basic accuracy, and 1mA resolution. The programmable multiple output power supplies include both front and rear access to the power outputs for orientation flexibility in test setups, while minimising required lead lengths to reduce noise pickup, minimise losses, and keep the test setup neat. The 2230G Series come with three standard interfaces options for PC-based control: USB, GPIB, and RS-232. Enquiries: Comtest.Tel. +27 (0) 10 595 1821 or email sales@comtest.co.za

Measuring air velocity in HVAC systems The Kobold compact KAH Series airflow velocity trans- mitters, offered by Instrotech, are ideal for accurate ven- tilation control in Building Automation Systems (BAS) and heating, ventilation and air-conditioning (HVAC) applica- tions. They incorporate innovative hot film anemometer technology which guarantees good accuracy at low air- flow velocity and makes the sensor highly reliable and heat resistant.This technology is superior to conventional anemometers with hot wire sensors or NTC bead ther- mistors. The sensor is much more insensitive to dust and dirt than all other anemometer principles, which trans- lates to high reliability and low maintenance costs. The configuration equipment allows air velocity adjustment of the sensor. Apart from measuring air flow velocity, the KAH air flow transducer transmits a normalised signal of 4-20 mA or 0-10 V. The measuring range and the re- sponse time can easily be selected with jumpers as per requirement. Specifications: • Selectable working range: 0 … 10/15 /20 m/s • Output signal: 0 …10VDC or 4 …20mA • Supply voltage 24VAC/DC • Low angular dependence Enquiries: Instrotech.Tel. +27 (0) 10 595 1831 or email sales@instrotech.co.za Comtest, local representative of Keithley, has announced the introduction of the Keithley Series programmable, low-noise, three-channel power supplies that deliver up to 375W in a compact 2U- high, half-rack-wide enclosure. Designed for maximum flexi- bility, accuracy, and low noise when testing LED drivers, automo- tive and power-IC circuits, the power supplies’ three-channels are isolated, independent and individually programmable with remote sensing for each channel. “Designers and test engineers are being challenged to test high-power circuits with a wide range of voltage levels and cur- rent draws in compact test environments, while also ensuring minimum noise and maximum accuracy,” said Lori Kieklak, vice president and general manager, Keithley Product Line at Tektronix. “This is particularly the case in R&D and in stacked, tightly-spaced automated setups with high production throughput. Keithley’s new series of multichannel power supplies provides the best perfor- mance and flexibility needed for testing a wide range of product configurations.” To provide this flexibility, the 2230G-30-3 provides 195W with two 30V, 3A channels and a 5V, 3A channel, while the 2230G-30-6 and 2230G-60-3 provide up to 375W, with two 30V, 6A channels and two 60V, 3A channels, respectively. Both 375W versions also have a 5V, 3A third channel. For higher voltages or currents, 30V channels can be combined in series to get up to 60V, and two or three channels can be connected in parallel to deliver up to 15A

Field controller for dc retrofit applications The new Allen-Bradley PowerFlex DC field controller from Rockwell Au- tomation enables customers to upgrade their dc motor applications to a modern system, without the need for complex external devices. An up-to- date digital networked control system helps customers to gather and lev- erage vital information throughout their enterprises. The dc field controller provides three-phase, four-quadrant (reversing) dc motor or generator field control. The field controller can be used on its own or with a PowerFlex DC digital drive. In stand-alone mode, it provides power to a dc motor field with a fixed reference by using fixed I/O. The field controller can also control electromagnets and other non-motor loads. For dc retrofit applications that require motor reversing, the PowerFlex DC field controller helps eliminate the need for an additional armature bridge or a complex system of external devices, saving customers time and mon- ey. The field controller offers output ratings from 17 A to 575 A and input of 200 V and 500 V. It enhances the capability of the PowerFlex DC drive family, designed for demanding stand-alone and coordinated drive system

applications. The PowerFlex DC drive family is well suited for dc motor applications and retrofits up to 6 000 Hp or 4 000 kW. The PowerFlex DC family has core capabilities aligned with the Pow- erFlex AC family of drives, including seamless integration into a Logix-based environment, flexi- ble feedback and communication options, as well as voltage settings designed to global standards. Enquiries: Michelle Junius. Email mjunius@ra.rockwell.com

10 Electricity + Control

SEPTEMBER 2018

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CONTROL SYSTEMS + AUTOMATION + SYSTEMS ENGINEERING

Selecting an industrial safety controller

easily in the HMI without complicated programming. Enquiries: BrandonTopham. Email brandon.topham@retautomation.com

An easy-to-use and flexible safety controller will make it that much easier to get your safety system up and running with min- imal downtime. It will also allow you to easily expand and adapt to future needs. Intuitive programming saves time and costs. An icon-based, drag-and-drop user interface reduces the learning curve and speeds up commissioning. This also makes it easy to quickly modify and update the configuration when changes are needed. Note that many safety controllers have password protection to ensure only authorised users can make changes, reducing the risk of operators bypassing the system. The XS26 expandable safety controller from Banner includes software with a seamless user interface for setting up and man- aging safety systems. The XS also has a built-in display and a micro USB connection to easily connect a PC or download a con- figuration from the XM memory card. A safety controller interface that automatically generates wir- ing diagrams speeds up installation. Once you have set up a safe- ty system configuration in the safety controller software, safety controllers like the XS and SC from Banner will automatically provide wire diagrams of your configuration, making it easy to commission your configuration. Live simulation allows users to

test configurations quickly. Look for a safety control- ler that offers a simulation mode so you can quickly test new configurations and changes prior to imple- mentation. An expandable controller provides flexibility for changes. Having a safety controller that can expand when you need it (especially with last minute chang- es) allows for the required agility to meet deadlines and implement changes quickly. In addition, an expandable safety controller lets you increase the number of inputs with expansion cards as safety devices are added. You can also increase the number of outputs with expansion cards as the need to safely control the machine changes. Once again, intuitive programming is important and helps make it quick and easy to implement changes. Finally, real-time fault monitoring allows quick iden- tification of problems. Look for a safety controller that can communicate with your PLC via Profinet, Mod- bus, TCP/IP, PCCC, etc. This allows you to remotely monitor your safety devices and will ensure that you are notified in real time when there is an issue with the safety system. In addition, with configurable IO, inputs can be changed to non-safe outputs to control indication lights for local notification of a fault. The XS26 and SC26 safety controllers can commu- nicate via Profinet, Ethernet/IP, Modbus, and PCCC up to 256 virtual status updates to a PLC and/or HMI that can be stored and tracked for future analysis. These controllers can also receive up to 80 virtual non-safety inputs to remotely turn safety devices or indicators on and off, enable mute functions, cancel off-delays, ini- tiate a reset, and accomplish other tasks quickly and

Electricity + Control

SEPTEMBER 2018

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DRIVES + MOTORS + SWITCHGEAR

Next generation medium voltage switchgear

Joe Richard, Schneider Electric

H owever, the electrical distribution industry is experi- encing workforce, financial and regulatory pressures that require new designs to meet modern applica- tions. The industry’s workforce is changing as experienced en- gineers and electricians retire and are not being replaced with individuals with the same experience level or an equiva- lent number of workers. Furthermore, the average man-hour costs are increasing across the industry and capital and op- erational expenditures are under more scrutiny. In order to deal with a tougher economy, budgets are being tightened, putting equipment space at a premium in facilities across many industries that require higher power density from their limited floor space. Added to this, both industrial and reg- ulatory standards for safety are increasing as the effects of electrical hazards are better understood and discussed. For these and other reasons, it is time to re-evaluate me- dium voltage switchgear applications. Traditionally, medium voltage switchgear has been Air Insulated Switchgear (AIS), meaning that the principal meth- od for achieving dielectric stability is sufficient air gaps be- tween phase conductors. In metal-enclosed fused switches, the cabinets are completely open and rely on an air gap to separate the phases and prevent cross-over to the grounded enclosure sheet metal. In metal-clad switchgear, the requirement for an insulating cover around each conductor was introduced. However, the widespread use of bus differential protection schemes shows the design community’s lack of trust in the current insulation system’s ability to prevent phase-to-phase faults. There has been some investigation of Gas Insulated Switchgear (GIS) types in the ANSI market over the past decade to address dielectric concerns and explore the bene- fits of reduced footprint and maintenance. But concerns sur- rounding regulatory oversight of SF6 gas have made many designers hesitant to use GIS in lower voltage ranges (5 kV and 15 kV), where there are several alternatives. Therefore, with fewer options at these lower medium voltage levels, it is challenging to address the need for increased equipment Medium voltage switchgear designs have seen only minor changes since the establishment of metal-clad switchgear in the 1970s.

Take Note!

The SIS system uses moulded epoxy insulation as the principal source of dielectric strength. SIS allows for a de- creased air gap between the phase conductors, which reduces equip- ment size. It can also eliminate exposed live parts when used throughout the switchgear’s interior.

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The electrical distribution industry is experiencing workforce, financial and regulatory pressures that require new designs to

ing a conductive layer to the outside of the insu- lating layer, which, when set to ground potential, creates a ground shield around each phase of the switchgear. This enhanced version is called a Shielded Solid Insulated System (2SIS). This in- novative additional step means that not only are there no exposed live parts, but every interior por- tion of the switchgear is at ground potential. The ground layer minimises phase-to-phase in- teraction, reduces the likelihood of arc flash and helps to protect the insulating material itself. The ground shield behaves like a Faraday cage, min-

protection, smaller footprint requirements and a higher level of safety. The latest design of medium voltage switchgear addresses these issues through an innovative insula- tion system called Solid Insulated Switchgear (SIS). This system uses moulded epoxy insulation as the principal source of dielectric strength. A key benefit of SIS is that it allows for a decreased air gap be- tween the phase conductors, which reduces equip- ment size. It can also eliminate exposed live parts when used throughout the switchgear’s interior. This insulation can be further improved by add-

meet modern applications.

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imising the propagation of electric field into the ambient areas of the switchgear. This helps pre- vent insulation break down phenomena such as partial discharge and tracking. 2SIS offers a num- ber of additional benefits. One benefit is that foot- print can be drastically reduced. Traditional met- al-clad switchgear has a standard section width of 36 inches, and depths and heights averaging 92 inches and 95 inches, respectively. Whereas 2SIS can obtain section widths less than 15 inches and depths as small as 36 inches. When comparing similar line-ups of metal-clad and 2SIS, the foot- print can be reduced by as much as 60%. Additionally, the decreased footprint helps to produce switchgear that can be front-accessible only in design. This allows the switchgear to be placed against walls and in corners of electrical rooms, which can preserve valuable and costly

creases the reliability of medium voltage switch- gear. The ground shield paired with the moulded epoxy insulation acts to increase the life expectan- cy of the insulation itself. By protecting not just the conductor, but the insulation, the switchgear life expectancy is increased. Standard industry hazards such as tools and sheet metal left on bussing during maintenance, or the intrusion of rodents and ver- min into live switchgear have traditionally resulted in damage to the switchgear, requiring equipment replacement. With 2SIS the switchgear is better protected from these common switchgear-killing scenarios. With a longer expected lifecycle comes a decreased requirement for maintenance. By pair- ing the shielded solid insulation system with a fixed vacuum circuit breaker, many of the failure points of metal-clad switchgear are removed, and yearly maintenance cycles can be pushed out to a 10-year interval. All of these features produce a switchgear design that is more reliable and longer lasting. 2SIS also addresses safety by reducing the like- lihood of arc flash incidents. By separating each phase by two insulating epoxy layers, two ground shields and an air gap, the probability of any kind of phase-to-phase interaction is minimised. Also, by ensuring that all parts on the interior of the switch- gear are at ground potential, there is little to no room for adverse current dissipation to occur. Ad- ditionally, with reduced maintenance requirements, personnel are in and around the switchgear less, thereby reducing exposure to medium voltage pow- er. Through safety interlocks and intuitive operation, inadvertent or ignorant misuse of the switchgear can be prevented, adding a level of safety by design. Looking to address issues of modern electrical design, Shielded Solid Insulated System switch- gear provides a variety of benefits. Benefits to adding connectivity to your MV switchgear Reduce downtime and gain greater efficiency Connectivity provides real-time information on the health of your system. This lets you identify areas for improvement, prevents network downtime by identifying problems, reduces maintenance costs, and improves efficiency. Increase safety Electrical switchgear failure can cause serious in- juries and damage. New, connected switchgear

facility space. Part of this benefit is de- rived from the ability of 2SIS to offer a wider variety of circuit breaker con- tinuous current ratings. Traditional met- al-clad switchgear only offers 1200 A and above ratings, but 2SIS switchgear offers circuit breakers with ratings of 200 A, 600 A and 1200 A. This allows designers to select breakers which more accurately reflect the loads they are feeding and reduce cost. Shielded Solid Insulation also in-

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includes features like integrated arc flash detec- tion, which reduces the risk of harm to people and equipment. Adding connectivity also allows local or remote monitoring and control of the switch/ fuse-switch functions for improved safety and ef- ficiency. Improve monitoring capabilities Connectivity gives greater visibility into operations and uses real-time data to support effective deci- sion making, thanks to innovative condition mon- itoring tools. Monitor power connections condition Thanks to 24/7 thermal monitoring of hot spots, abnormal conditions can be identified, either on cable and busbar connections, and users will be

alerted to potential problem areas and take preven- tive measures for avoiding unplanned shutdown.

Monitor environmental status Online device that monitor condensation within the switchgear helps prevents fast aging in harsh environments. Monitor circuit breaker performance Real-time monitoring of circuit breaker perfor- mance provides up-to-the-minute insight, and data on performance can be used for better predictive maintenance and the creation of long-term main- tenance plans.

Joe Richard is the Product Launch Manager at Schneider Electric.

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Enduring market demand for dc drives

Andy Green, Nidec Control Techniques

While it’s fair to say that almost all new-build machines and systems utilise the latest ac drive technologies, many legacy designs around the world mean that the demand for dc drives will continue for some years to come.

Take Note!

Modern dc drives provide many benefits, and are often based on current ac drive technology. Ac drives are are consid- erably more cumbersome and costly than dc if ener- gy is to be returned to the grid. To achieve full line re- generation a second grid facing inverter and filter components are required.

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O f course, for the manufacturers and users of these dc-based systems, getting the level of technology, innovation, product support and applications knowledge is easier said than done. Many of today’s suppliers of drives have simply not retained their dc expertise. Dc drives and motors remain common in indus- tries such as metals, plastics and rubber, cranes,

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Utilising the existing dc motor and upgrading the dc drive therefore becomes an attractive option. Dc motors are usually sturdily built and capable of of- fering many more years of service beyond that of a drive, while project costs are typically much lower, and disruption and risks are minimised. A lot of the major current projects in the drives market are for dc technology. This may come as something of a surprise as many industry commen- tators had already sounded the death knell for dc drive technology, predicting its demise within the coming two-to-three years. However, for the mar- ket’s more recognisable dc drive brands – those with extensive dc heritage – demand continues as the industrial world looks to support myriad legacy process machines, such as winders and extruders. The trick for manufacturers looking to continue supporting systems of this ilk and for end users who want to keep an obsolete machine running is to seek out a specialist drives supplier that of- fers high levels of knowledge, expertise and stock levels, all supported by a fair pricing policy. In ad- dition, those seeking a reliable dc drives partner should appoint one that can also supply dc motors, as this will help project and design continuity, and one who also manufactures ac drives so a bal- anced view can be drawn. Another point of note is that opting to continue with dc drives should not mean the technology is incompatible with the latest automation solutions. Well-supported dc drive technologies are able to take advantage of almost all modern automation systems that can be connected via a fieldbus. The latest digital dc drives support protocols such as EtherCAT, PROFINET and EtherNet/IP, making them a far cry from the archaic technology that

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mining, and paper and printing. The current trend is to replace dc systems with new ac drives and motors to reduce main- tenance overheads, however this can often be a significant task that requires machinery to be taken out of service for an extended period while me- chanical and electrical rework is undertaken. Another limitation here is that upgrading to ac drives obviously means upgrading to an ac motor. However, ac motors are typically larger than their dc counterparts, which would therefore require some design changes to the machine ―– hardly practical from a business or commer- cial perspective when dealing with legacy systems. Further- more, manufacturers of these machines will have know-how in maintaining dc technology and may be reluctant to start a new learning curve.

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Replacing dc systems with new ac drives can be a significant task that requires machinery to be taken out of service for an extended period of time.

some engineers imagine. One further key advan- tage of dc drive technology is the relatively low cost of providing true four-quadrant operation. That is, the ability to generate torque in any direction, typically for motoring or decelerating, and return kinetic energy from the mechanical load and motor back to the power grid. Such attributes are consid- ered essential in applications where braking and reversing is required, such as wire drawing, wind- ers, rolling mills and any application where gravi- ty is a factor or where energy has to be removed from a rotating system. Whilst ac drives are inherently four-quadrant and typically use a ‘brake’ resistor to burn excess energy, they are considerably more cumbersome and costly than dc if energy is to be returned to the grid.To achieve full line regeneration with an ac drive a second grid facing inverter and filter com- ponents are required. However, it must be noted that the characteristics of a regenerative ac drive in terms of harmonics, mains dip ride through ca- pability and their ability to control power factor all outweigh those of a dc drive. Put simply, modern dc drives provide many benefits, and are often based on current ac drive technology, ensuring they provide enhanced mo- tor performance and reliability. For retrofit projects specifically, dc drives offer easy integration with ex- isting motors, power supplies, applications equip- ment and communication networks. The only ca- veat is choosing the right supplier. Many suppliers of drives simply no longer have specialists in the business who really understand dc technology.

Aside from a multitude of applications in the process industries, the retrofitting of dc drives on cranes is another market segment where demand for this technology remains strong. This statement is corroborated by a recent landmark project in the US involving the upgrade of 10 oil rig cranes. Here, two dc regenerative drives were used on each crane for the swing and hoist. The hoist motor drive system now features a Mentor MP dc drive rated at 420 A continuous, while a Mentor MP dc drive rated at 210 A con- tinuous was retrofitted to the swing motor drive system. All of the drives were purposely sized for twice the normal power required, which means the system never runs at its maximum capacity. Aside from the performance attributes of the dc drives, it was the technical advice offered by the supplier that was appreciated most by the crane user, with technicians addressing any issues quick- ly and comprehensively. The oil rig crane upgrade programme was completed at the end of 2017. Although dc was popular in years gone by for technical performance reasons, now that ac can offer comparable, if not better performance, the latter has become the technology of choice for new-build projects. However, there remain plenty of dc motors in widespread use that need com- plementary drive technology, a fact that means dc drives are likely to be in demand for a number of years to come. For those looking to select a part- ner in dc drive technology, give it careful and con- sidered thought.

Andy Green is the Business Development Manager - Automation at Nidec Control Techniques.

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