Electricity and Control July 2021

FEATURES: · Control systems + automation · Drives, motors + switchgear · Measurement + instrumentation · Safety of plant, equipment + people

Since 1921, the creative spirit has shaped KROHNE’s corporate culture – today we are a leading international supplier of process measuring technology. Get in touch with our spirit of creativity: 100-years-krohne.com

COMMENT

INDUSTRY 4.0 + IIOT

Safety matters A s always, the magazine is packed with a range of topics, but the one that stands out for me as we grapple with the realities of a patently deteriorating energy security scenario (notwithstanding the welcome announcement from President Ramaphosa on lifting the threshold allowing companies to develop embedded generation without a licence – to 100 MW) and the laborious rollout of the vaccination programme, is safety. Safety can apply to our equipment, our plant and our infrastructure; and, of course, it can apply to human safety – the safety of our people. I’d like to focus on the latter for this comment. Safety at our plants is critical, and yet one still sees mere lip service being paid to this in many situations. Often that is simply people being expedient – trying to get the task done as quickly and effectively as possible. The trouble only really starts when an accident occurs. Perhaps it is because I have supervised many, many young engineers, but I am exceptionally sensitive to the fact that, often, the concept of an ‘accident’ is not properly understood. Until after the fact, of course. Safety procedures are put in place to protect people. These are usually (hopefully) carefully thought through and institutionalised in a number of ways. If safety becomes a tick-box exercise, or if safety regulations are bypassed for convenience, then we have a problem. Safety is an attitude of everyone on the plant; and the safety rules that we put in place must support and encourage behaviour that keeps people out of harm’s way.

energy + information in industry

Accidents are unexpected events. No one sets out to have an accident. Although this sounds obvious, the point I want to go back to is the often-encountered view that the accident will not happen! “I will do it this way, not because it is safe, but because I know nothing will go wrong.” Inherently this view is the one suggesting accidents do not happen. (Having learned a lot from a fellow who was quite happy to scratch test (in those days) 380 V with the back of a finger, I know full well what can go wrong…) The tendency to take the risk is often driven by the sense that the task can be completed more quickly by cutting the safety corner. It may be driven by the sense that the safety rules are ‘silly’ or unnecessary. This is a dangerous attitude – and one we often neglect to consider. The simple message I want to get across here is this: do not cut corners; do not take chances. While you may well be safe 99% of the time, it’s that 1% when you are not that matters. I had a fascinating chat to someone just the other day about a particular safety regimen at a site. “Why”, he asked, “must we follow this rule? It wastes our time.” Probing a bit further it turned out that the person had spoken with many who had violated the rule – and lived to tell the tale. They had met no one who had not. Well, exactly! Be safe, stay safe, and take responsibility for your own safety, and that of others at your site.

Celebrating 100 years in the spirit of creativity, KROHNE is today an interna- tional company with a broad portfolio of instruments in process measurement technology. (Read more on page 3.)

Editor: Leigh Darroll Design & Layout: Darryl James Advertising Manager: Heidi Jandrell Circulation: Karen Smith Editorial Technical Director: Ian Jandrell Publisher: Karen Grant Deputy Publisher: Wilhelm du Plessis

Audited circulation: Quarter 1 (January-March) 2021 Total print and e-editions: 9559

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

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

Publisher of the year 2018 (Trade Publications)

Electricity+Control is supported by

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

Electricity + Control JULY 2021

1

The views expressed in this publication are not necessarily those of the publisher, the editor, SAAEs, SAEE, CESA or the Copper Development Association Africa

CONTENTS

INDUSTRY 4.0 + IIOT

Features

CONTROL SYSTEMS + AUTOMATION

4 Flexible I/O marshalling system in process automation Felix Schulte, Phoenix Contact Electronics

6 Products + services

DRIVES, MOTORS + SWITCHGEAR

4

9 ‘Climate-smart’ mining – a path to Industry 4.0 Eduardo Aparicio, ABB Southern Africa

11 Products + services

MEASUREMENT + INSTRUMENTATION

14 Optimising comminution processes Vega

16 Choosing the right tool for testing and troubleshooting A Fluke information note, supplied by Comtest

18 Products + services

9

SAFETY OF PLANT, EQUIPMENT + PEOPLE

21 Ensuring technical compliance for safety Johan Stols, WearCheck

22 Line fault transparency – enabling safe power-up Pepperl+Fuchs

24 Products + services

Regulars

1 Comment

Safety matters

14

3 Cover article 100 years KROHNE – 100 years in the spirit of creativity

28 Reskilling, upskilling + training Skills development – enriching young lives 29 Cybersecurity Understanding Zero Trust security models Combatting evolving cybersecurity threats

30 Engineering the future Sharing Africa’s voice in EU responsible sourcing initiative

21

32 Write @ the back Africa’s economic recovery – building a more resilient continent

2 Electricity + Control JULY 2021

COVER ARTICLE

100 years KROHNE – 100 years in the spirit of creativity Michael Rademacher-Dubbick, Chairman of the Advisory Board of the KROHNE Group

T oday, KROHNE is an international company with a broad portfolio of instruments, solutions and services, primarily in process measurement technology and for various industries. With over 4000 employees worldwide, the company offers local contacts for their customers in over 100 countries, and supports them in instrumentation projects of any size, from single devices to mega projects. But it wasn’t always like this: when Ludwig Krohne founded the company in 1921, the first customers were a small number of steel producers from the Ruhr area. At that time, KROHNE built variable area flowmeters for hardening furnaces. Unfortunately, the Second World War then brought great tragedy, as both Ludwig Krohne and his son Karl, who would have been his successor, lost their lives. This left KROHNE in the hands of Ludwig’s wife Anna Krohne. In 1949, she asked her grandson Kristian Rademacher-Dubbick to help her in the business. He lived as an artist, and Anna Krohne needed someone with creative ideas to help her market the products of the company. He accepted this task and soon took over full responsibility for KROHNE. Although he gave up his profession as an artist for this, he has always remained closely connected to art as an enthusiastic collector. At KROHNE, Kristian Rademacher-Dubbick found a new environment in which he could act creatively. As someone who had no knowledge about measurement technology or its marketing, he first wanted to find out what drove our customers, what they expected from KROHNE and its products, and what their wishes were. So he decided to ask them directly, and took his bicycle to visit the customers in the area. This way he found out about their expectations and wishes regarding process measurement technology. They also advised him to hire an engineer and to always put technology first. The engineer turned out to be the perfect sparring partner for the creative and unconventional ideas that my father presented to him in order to fulfil the customers’ wishes. He kept this approach throughout his career, initiating technical innovations and motivating his employees to think creatively. This is how KROHNE became a pioneer in many measuring technologies that are standards in the process industry today. The world’s first electromagnetic flowmeter was a KROHNE device, so was the first contactless radar device for level measurement. The realisation and industrialisation of these ideas were anything but easy and sometimes very lengthy. Parallel to pushing technologies forward, the company developed in the field of internationalisation: from the 1960s onwards, many German companies began to set up sites abroad. KROHNE followed their customers, and by the

1980s already had subsidiaries in countries such as China, USA, United Kingdom, Japan, India, Russia and South Africa. KROHNE developed from a pure measuring technology manufacturer towards a technology company already at an early stage, consistently investigating new technologies and integrating them into industrial measurement technology. Quantum leaps in innovation such as the development of a differential pressure measuring cell or the Entrained Gas Management technology for Coriolis devices could only be realised because people had the freedom to develop. This demonstrates to what extent KROHNE needs creative and innovative ideas: creativity is essential for the devel- opment of new measurement solutions for the future. That’s why KROHNE is placing their 100 th anniversary under the ‘THE SPIRIT OF CREATIVITY’. It stands for an open approach to unconventional ideas. By placing the anniversary under this core message, KROHNE has the op- portunity to show sides of the company that are more than pure technology: it is a multi-layered combination of core val- ues. Therefore, four more messages were added to THE SPIRIT OF CREATIVITY to reflect these core values.

Former KROHNE building on the Blumenthalstrasse in Duisburg.

Ludwig and Anna Krohne.

ƒ THE SPIRIT OF ADDING VALUE describes how we promote creative ideas and out-of-the-box thinking to realise added value for our clients.

ƒ THE SPIRIT OF PIONEERING shows how we use creativity for innovation and progress and to always break new ground. ƒ THE SPIRIT OF ARTISTRY reflects our close relationship with art and culture as a source of creativity. ƒ THE SPIRIT OF FAMILY CULTURE describes our corporate culture, which is characterised by family cohesion, stability, cosmopolitan attitude and appreciation. KROHNE’s 100 th anniversary will consist of many different activities that converge under these messages, and address and involve customers, partners and employees alike. All information can be found on 100-years-krohne.com. □ In 1949 Anna Krohne asked her grandson Kristian Rademacher- Dubbick to join the company when he was only 28 years old.

For more information visit: https://100-years-krohne.com/

Electricity + Control JULY 2021

3

CONTROL SYSTEMS + AUTOMATION

Universal I/O systems satisfy a wide range of requirements. However, the resulting advantages go to waste if the necessary interface and marshalling level cannot be designed just as flexibly.TheVIP I/O marshalling system ensures a high degree of flexibility. Flexible I/O marshalling system in process automation Felix Schulte, MSc, Global Program Manager, Phoenix Contact Electronics GmbH

Felix Schulte, Phoenix Contact Electronics.

T he basic structure of signal marshalling – the sorting and combining of field signals and their connection to the I/O system – necessary within the framework of process automation, has not changed for a number of years. The rigid system structures, resultant high planning outlay and considerable installation and commissioning costs regularly lead to project delays and increased overall costs. This is the case for new systems and the modernisation or extension of existing applications. System operators have therefore been placing specific demands on planners and suppliers for quite some time. For example, the systems must be able to respond flexibly to changes; design dependencies should be eliminated; and the systems should allow for greater focus on key design decisions. In this article we look at the existing problems, how planners and suppliers have already responded to these three framework conditions, and the advantages of Phoenix Contact’s flexible VIP I/O marshalling system in this context. Tailored signal conditioning In response to the operating ideals noted above, pioneering manufacturers of distributed control systems introduced universal I/O systems several years ago. Since then, this concept has become established on the market under various brand names. The difference between classic I/O systems and universal solutions is, as the name implies, the new I/O systems are versatile in application. This means the individual I/O channels can be adapted to the necessary

The classic configuration of a processing system comprises field distribution boxes and marshalling, interface, and control cabinets. 16, or 32 channels – for example, 16-channel input cards for analogue signals or 32-channel output cards for digital signals. In contrast to this, universal I/O cards open up the possibility of adapting each channel individually. For example, the first three channels of a 32-channel card can be configured as analogue inputs, the next five channels as digital outputs, the next channel as a digital input, and so on. At first glance, this appears to be a small measure, but it is of particular benefit when planning and realising the signal marshalling. Wherever conventional I/O systems are used, the sensor and actuator field signals available in any chosen sequence must be pre-sorted and grouped into blocks so they match the cards used. Moreover, the I/O card types required in such a classic structure can only be determined once it is clear which signals are present in the system and in what quantity. In contrast, universal I/O systems allow planning based just on the total number of I/Os. Initially, the individual functions are not important because the I/Os can be be adapted using software in later stages of the project. This seemingly simple measure also eliminates the need for complex signal marshalling, because each signal circuit is physically identical in structure. Considering the interface technology Thus universal I/O systems meet the system operators’ requirements listed above. Since channels can be reconfigured in any way, the universal solutions provide a flexibility that was not available before. They eliminate design dependencies during the course of the project. For

function via software. Until recently, solutions were made available with each forming signal blocks of 2, 4, 8,

VIP I/O marshalling is a flexible I/O marshalling system for the process industry.

4 Electricity + Control JULY 2021

CONTROL SYSTEMS + AUTOMATION

The VIP I/O marshalling system comprises a base element,

At a glance  The basic structure of signal marshalling in process automation has not changed in a number of years, although it can cause cost overruns and time delays.  System operators have been calling for planners and suppliers to allow more system flexibility, design independence and a greater focus on key design decisions.  Universal I/O systems meet most of these requirements, but the same flexibility is needed at the interface and marshalling levels.

IOA function modules, and the system cabling connection.

via connectors. The second block is the Input-Output Accessory (IOA) that performs the actual interface function. The third component is a system cable that connects the base element to the I/O system. With this configuration, the requirements of the end user can also be satisfied at the interface and marshalling level. The base element suitable for the I/O system can be installed in the project early on, without the precise signal types having to be defined. The function is then defined later simply by connecting the re- spective function module (IOA), with noth- ing needing to be changed in the wiring. This also means the wiring does not need to be checked again.

example, there is no need to have a detailed breakdown of the types of signals required in each part of the system in order to finalise the electrical design, including the necessary hardware. Universal I/O systems also solve the final requirement, because in this constellation, the detailed engineering can be finalised late in the process. Initially, only basic design decisions are necessary, such as which systems are to be used and what the concept for functional safety and electrical explosion protection should be. Despite all these advantages, universal I/O systems do not fully satisfy the operators’ requirements. Limitations come into play when considering the necessary interface technology. Until now, this was not taken into consideration, even though it is an elementary part of every system. As an example, relays for signal conditioning are necessary on the I/Os configured as digital outputs so that the actuators can be operated with a nominal voltage of 230 V. In addition, system parts used in applications where explosive atmospheres exist or can arise often necessitate interface blocks with intrinsic safety type protection. Other examples include signal isolators for separating ground loops and suppressing signal distortions and a range of other functions. Interface functions can be defined later It is important that the necessary interface technology is also considered. If operators use conventional solutions, such as interface blocks mounted on a DIN rail, the advantages gained from the universal approach are almost completely lost. The reason is clear: selecting the interface components means the precise type of signal must be known early on. Moreover, signals would need to be marshalled again in order to wire the field signals to the individual function blocks, such as digital output signals to relays. Therefore, solutions that provide the same flexibility at the interface and marshalling levels as universal I/O systems provide at the I/O level are required. The VIP I/O marshalling system from Phoenix Contact offers a solution. VIP I/O marshalling is a portfolio designed for use in uni- versal I/O systems. In essence, it comprises three blocks. The first of these is a base element that is attached to the DIN rail. The base element accommodates the field wiring and provides the connection to the I/O system

The intelligence is moving closer to the process in the field; universal remote cabinets are a compact and standardised solution for this.

Decentral control box solutions from a single source The universal I/O approach breaks open the mold of the rigid marshalling, interface, and I/O level structures. The intelligence is now moving closer to the process in the field. Universal remote cabinets have become established as a compact and standardised concept for this purpose. Following the principle of ‘We connect the field to your control system’, Phoenix Contact provides a comprehensive range of products and solutions for automation in process technology and process engineering applications. In addition to the flexible I/O marshalling system, various other products and services are available, in particular for decentral control boxes with universal I/O systems. These include power supply units that satisfy the specific environmental demands, surge protection products, terminal blocks, and Industrial Ethernet components. With its tailor-made solutions based on a future-oriented product range, Phoenix Contact has established itself globally as a reliable partner for the process industry. In summary, the VIP I/O marshalling portfolio includes both 8- and 16-channel base elements for various I/O systems. A broad range of function modules – for example, feed-through terminal blocks, fuse modules, analogue isolators also suitable for Ex areas, relay modules, and safety relays – provides the right interface for almost any demand. □

For more information visit: www.phoenixcontact.com

Electricity + Control JULY 2021

5

CONTROL SYSTEMS + AUTOMATION : PRODUCTS + SERVICES

Integrated technologies boost industrial performance

MAXOLUTION ® solutions from SEW-EURODRIVE are fully integrated and customised technologies developed to automate, integrate, upgrade and streamline existing production processes and allow for future technology to be incorporated. Dylan Enslin, MAXOLUTION ® Engineer with SEW‑­ EURODRIVE says, “Our strength is in our expertise and knowledgeof assessingand implementing the right solution for the customer’s system objectives. At SEW-EURODRIVE the advanced technologies behind our MAXOLUTION ® systems take into consideration that industry and its processes are constantly evolving, recognising the requirement for future upgrades and adjustments. ”Whether a customer is needing to source or enhance automated guided vehicles (AGVs) or electrified mono systems (EMS), or replace or upgrade motors and gear boxes, we can guide them from the project planning stage through to installation, ensuring that our custom- ised software meets requirements, that communications between machines are configured correctly and that the entire production process is seamlessly automated, in- tegrated and optimally calibrated for best performance, focusing on Industry 4.0 and the future,“ Enslin says. SEW-EURODRIVE believes that exchangeable mod- ules are the future of factories. MAXOLUTION ® systems enable the customer to respond swiftly to changes in market requirements, operating a ‘smart factory’ with a new, flexible and adaptable modular structure where components and machines can be added, duplicated or removed. This provides greater flexibility for produc- tion processes to be adjusted when needed and in the most efficient way possible. SEW-EURODRIVE was recently commissioned to de- velop a machine automation project with a customised MAXOLUTION ® software solution. The pre-project as- sessment included motor and motor size requirements, gear box configurations, the electronic capability need- ed to drive the specified motors and synchronised motor capability, all critical factors that needed to be taken into account in the design phase of the project.

SEW-EURODRIVE has the expertise to assess customers’ needs and implement the right solution to meet their process automation objectives. The company has also successfully implemented the MAXOLUTION ® concept for torque testing machinery in the mining sector, as well as in the automotive manufac- turing sector for an engine line where travel axis/hoist axis, gearbox sizing, variable speed drive requirements, motor positioning and electronic communications were specified for the implementation of an EMS system. According to Enslin, a number of global companies represented in South Africa, for example in the automo- tive sector, have used MAXOLUTION ® systems success- fully at their European headquarters, and have directed their local offices to implement the system due to its ef- fectiveness and superior technology. ”We assist the customer in selecting the best solution for their production requirements by ensuring that all components meet their needs and are compatible in or- der to deliver successful integration that supplies smart technology, machinery communications and a smooth, seamless and efficient system. MAXOLUTION ® offers maximum flexibility with maximum availability – in short we automate and integrate production systems reliably and efficiently,” says Enslin. ”Additionally, we work with external system integra- tors and OEMs (original equipment manufacturers) in a supporting role, assisting with project planning, costings, customised or standard software solutions, as well as de- sign recommendations and commissioning. “As SEW-EURODRIVE has a global presence, this enables us to tap into the expertise that has been developed across the full spectrum of the company’s technologies and applications if required. Another key benefit that SEW-EURODRIVE brings to the table is our comprehensive stock holding, which enables us to dispatch components at short notice. Nothing is out of reach when it comes to problem-solving and conceptualising a future-based integrated system solution – from planning through to design and commissioning,” says Enslin. For more information contact SEW-EURODRIVE. Tel: +27 (0)11 248 7000 Email: info@sew.co.za, visit: www.sew-eurodrive.co.za

In the automotive sector, a number of global companies represented in South Africa have directed their local offices to implement MAXOLUTION ® systems following their headquarters’ experience.

6 Electricity + Control JULY 2021

CONTROL SYSTEMS + AUTOMATION : PRODUCTS + SERVICES

Predictive control in minerals processing

process input variables and disturbances. MPC algorithms make use of machine learning, where the engine learns and updates the mathematical model using data, and the MPC then uses it for control.” It is a simple and powerful technology which integrates into the current control system to optimise mineral processes, addressing the objectives and complexities of the plant at the same time. “At its core, MPC uses supervised machine learning technology to assess current and predicted operational data. It compares the data to desired results, and then computes and updates the process online set-point targets,” said de Goes Arantes. MPC reduces variability, helps achieve plant stability, manages the process without constraints, and operates closer to specifications and performance limits while maintaining safety margins. The tool enables mining customers to achieve increased throughput, lower consumption of reagents, better recovery, optimum water and energy usage, and improved process stability.

Mineral processing plants are inherently complex, with wide-ranging resource-intensive operations. Mines generally are looking to achieve significant process objectives to lower energy and plant costs and make better use of water and energy resources. They are also required to meet statutory regulations and deal with workforce challenges. To address these complexities and offer solutions, Rockwell Automation recently hosted a webinar helping attendees understand how to meet these process objectives. Juliano de Goes Arantes, Pavilion Account Executive at Rockwell Automation, hosted the webinar in May, supported by Steffen Zendler, Rockwell Automation’s Heavy Industry Strategy and Marketing Manager for EMEA. They discussed the main control challenges faced in mineral processing operations. De Goes Arantes said that more than 75% of mineral processing plants are still using basic control strategies. An audience poll indicated a similar level in Africa, with 56% saying they use basic control, and 28% saying they use manual control. “While basic control provides adequate control in terms of plant safety, it rarely achieves optimal control in quality, nor does it operate most economically,” said de Goes Arantes. The webinar focused on Rockwell Automation’s Pavilion8 Model Predictive Control (MPC), a tool that reduces process variability and enhances stability over and above what is currently possible with more traditional control schemes. Making use of MPC, processing plants can leverage their control systems to optimise operations. De Goes Arantes explained: “MPC uses a model of the minerals processing operation to predict how the process output variables will respond to changes in the Mornsun has introduced the new 1 000 W ac/dc en- closed power supply LMF1000-20B series with the pow- er range now extending from 15 to 1 000 W – which can meet the different demands of various applications. LMR1000-20Bxx series is one of Mornsun’s enclosed ac/dc switching power supplies. It features universal ac input and at the same time accepts dc input voltage. It is cost effective and features low no-load power consump- tion, high efficiency, high reliability and double or rein- forced insulation. The converters offer excellent EMC per- formance and meet IEC/EN61000-4, CISPR32/EN55032, IEC/EN62368, EN60335, EN60601, GB4943 standards. They are widely used in industrial applications as well as in electrical security, telecommunications, street light control and smart home systems. The LMF1000-20B has the advantages of small size (190*127*40.5 mm), high power density, variable speed fan control, and units can be connected in parallel to boost power. It meets IEC/UL/EN62368, GB4943, High power density enclosed power supply

Juliano de Goes Arantes, Pavilion Account Executive at Rockwell Automation.

Steffen Zendler, Rockwell Automation’s Heavy Industry Strategy and Marketing Manager for EMEA.

The webinar is available on-demand via the Rockwell Automation website and includes an interactive Q&A session responding to a range of questions on how customers can implement this solution without needing to invest heavily in extra equipment and training – Rockwell Automation can offer the complete solution. For more information contact Rockwell Automation. Email: mjunius@ra.rockwell.com Visit www.rockwellautomation.com IEC/ES/EN60601 standards, which makes it a safe, reliable and cost-effective power converter. The LMF1000-20B features: - Input voltage range of 90 – 264 Vac/120 – 390 Vdc - Operating temperature range from -40°C to +70°C - Variable speed fan control - Remote ON/OFF, digital communication - Supports 3+1 parallel redundancy, current-sharing accuracy: <5% It iswidely used in industrial control systems, automation machinery, and measurement and control instruments. Mornsun power supplies are available locally from Vepac Electronics. For more information contact Vepac Electronics. Tel: +27 (0)11 454 8053 Email: sales@vepac.co.za

The LMF1000-20B is used in industrial control systems and other applications.

Electricity + Control JULY 2021

7

CONTROL SYSTEMS + AUTOMATION : PRODUCTS + SERVICES

MES selected for Sappi’s digital transformation globally

Sappi Limited has selected ABB by to support a major digital transformation project across its global manufacturing footprint in Europe, North America and South Africa. The rollout of ABB’s Ability™ Manufacturing Execution System (MES) for pulp and paper will be a key focus in the digital transformation of Sappi’s entire production fleet. The project has begun and will extend over several years. The implementation of ABB Ability™ MES, specifically designed for pulp and paper process optimisation, will enable the improvement of Sappi’s overall equipment effi- ciency (OEE) through optimised production planning and execution. Project goals also include making better use of materials and inventory, reducing costs of production and ownership, and reducing the group’s environmental impact by increasing its sustainability performance. Sappi’s own IT teams will deploy the solutions either collaboratively with ABB or independently in some cas- es. This approach is aimed at maximising user accept- ance and support. It will also enable Sappi to contribute to the continuing innovation of its MES platform. “For Sappi this is a key global IT initiative that will drive alignment with our Thrive25 Vision, putting in place state- of-the-art systems which will allow Sappi to thrive as the future unfolds,” said Jeff Wright, Project Director and North American CIO for Sappi. “We have partnered with ABB because of its demonstrated commitment to the pulp and paper industry, its proven technical solutions

[Source: Sappi Limited]

Sappi’s Ngodwana Mill in KwaZulu-Natal, South Africa. and worldwide team, as well as its clear strategies for future investment and improvement in its MES solutions. “ABB’s commitment to a collaborative partnership with Sappi, which supports our aim to innovate for op- erational performance not only through this multi-year implementation but thereafter as well, was also key in our decision to choose ABB.” Steve St Jarre, Global Business Development Manag- er at ABB said, “We are pleased to be supporting Sappi on its digital transformation journey which will help the group realise its operational goals. Our MES will provide transparency across the value chain, and includes op- timisation of material flow within the pulp mills. We are proud to be Sappi’s chosen partner and provide the traceability needed to enable the group to produce the right quantity and quality of any product at the lowest cost, for optimised operations.” The purely software-based 360-degree mover rotation extends the familiar, highly flexible XPlanar movement range by a full degree of freedom. The XPlanar movers can rotate endlessly around their own axes while levitating at selected positions on the system. The rotation can be executed dynamically with a frequency of up to 10 Hz and makes several ground-breaking applications possible. For instance, the mixing of liquids or the 360-degree inspection of objects can be achieved with this addi- tional degree of freedom. Furthermore, the movers can leave the rotation positions with an orientation changed in 90-degree steps, so that the transported workpieces are correctly aligned for the remaining processing steps. The 360-degree mover rotation is made possible by the integration of the XPlanar system into the PC-based control technology from Beckhoff. A simple software update is all that is needed to implement the new rotation function in ex- isting systems. Special hardware products are not required. For more information visit: https://new.abb.com

360° rotation for product transfer in production

The XPlanar planar motor system from Beckhoff enables contactless, parallel and individual transport of products. The XPlanar movers can fly freely in two dimensions over XPlanar tiles and execute lifting movements with a stroke of up to 5 mm. These system properties have been en- hanced with new software-based 360-degree mover ro- tation functionality.

For more information contact Beckhoff Automation. Tel: +27 (0)11 795 2898

The XPlanar movers can rotate through 360 degrees around their own axes and move onward after re-orientation in 90-degree steps.

Email: danep@beckhoff.co.za Visit: www.beckhoff.com/en-za

8 Electricity + Control JULY 2021

DRIVES, MOTORS + SWITCHGEAR

‘Climate-smart’ mining – a path to Industry 4.0

Reducing the carbon footprint of mining to mitigate the impact of climate change and accelerating the journey to the all-electric mine have become business priorities for many mining companies and their customers.This is an important focus in South Africa, where mining continues to be a mainstay of the economy and a major employer. Eduardo Aparicio, having recently taken up the reins as Local Business Area Manager, Motion, at ABB Southern Africa, highlights key trends transforming the mining industry and outlines his plans for the Motion business unit.

Eduardo Aparicio, ABB Southern Africa.

A mong the major trends fundamentally transforming the mining industry to become what ABB terms ‘climate-smart’, I would highlight three. Firstly, there is the shift from diesel to electrification as a main power source. Secondly, digitalisation not only increases productivity, but also facilitates maintenance. Thirdly, customers can reduce total cost of ownership by standardising on high-efficiency motors and drives. This means that assets are deployed optimally in a sustainable way that reduces the overall environmental impact. Of course, we cannot be certain how these trends will play out over the next five to 15 years. What we do know, however, is that the future is shaped by the innovations of today, which are transformed into the advances of tomorrow. Every company that operates in or serves the mining sector can participate in shaping this future – and can begin to have an immediate impact. Let us join forces to collaborate as we co-develop new ‘smart’ standards for mining. The switch to remote services accelerated in 2020 due to the Covid-19 pandemic. This also resulted in a faster uptake of Industry 4.0 solutions in the mining industry in terms of automating operations for optimised productivity, reducing equipment downtime and costs, carrying out predictive rather than preventive maintenance and enhancing safety for mine personnel to reinforce the ‘zero harm’ culture. Connected mines will generate a wealth of digitalised data from equipment, assets and applications. By the time this data reaches operators it must have been analysed, and should be easily accessible on any number of smart devices where it can be used. Such a connected process enables fast, smart and informed decision-making which can have a major positive impact on the bottom line. Mining is one of the key industries where ABB’s drives, motors, generators, mechanical power transmission products and integrated digital powertrain solutions can play a valuable role in this new connected era. As a global innovator ABB aims to transform society and industry to achieve a more productive and sustainable future for all. At ABB Motion Joining ABB Southern Africa to manage its Motion business unit, I am excited to be part of the South African mining industry’s ongoing transformation.

Pumping applications like this are widespread across industries and a prime area for energy-saving.

Assisting companies in major South African industries such as mining to adopt the latest technology on the path towards energy efficiency, reduced emissions and, in turn, carbon neutrality, is my main goal in my new position. This has been an important focus for me throughout my career in Spain and Mexico. As we all know, South Africa faces power constraints, coupled with lagging economic growth and development. Here I also see electrification and automation and power and water as critical business development areas for us as a business. In Mexico, for example, a career highlight for me was overseeing the establishment of a new Energy business unit that merged Power and Water to focus on the oil and gas industry. This is a sector where ABB has a global footprint, with clients across Europe and the US. It is also a significant sector in Africa, especially with recent oil and gas discoveries presenting opportunities in different regions of the continent. As a business, we succeed by adding value, which is a combination of our innovation, expertise and experience. Dealing with customers’ requirements means much more than offering technical solutions; it depends on understanding a customer’s business and how best to optimise it. I see our customers as our true assets, because if we help them to succeed, then we succeed in turn. And it goes further – we have a commitment and a drive to make the South African mining industry succeed, benchmarking itself against the best in the world. With South Africa contributing the bulk of our revenue on the

Electricity + Control JULY 2021

9

DRIVES, MOTORS + SWITCHGEAR

For more information visit: https://new.abb.com/africa always demanded the latest technology, and our solutions have been tried and tested in major markets such as North America and Europe. ABB has highlighted the role of high-efficiency motors and drives in reducing energy consumption. The technology to improve energy efficiency significantly is available right now. For example, high-efficiency motors and drives are well established and time-tested. I aim to increase the uptake of such technology, especially in mining, and to inform the market about the importance of our long-term sustainability goals as a future-orientated business. Of course, the benefits of greater energy efficiency go well beyond the fight against climate change. They contribute broadly to environmental conservation, cleaner air and water, better public health, energy independence and stronger economic growth and development. These considerations are critically important in the South African mining industry, which is taking significant strides towards a climate-smart future. □ drive shaft, the model provides a reliable representation of the drive system in the required level of detail. One possible application is the coupling of PLC and mechanical model via Sinamics DriveSim Basic. The calculated load profiles can then be loaded into the TIA (Totally Integrated Automation) Selection Tool or the Sizer and a drive selection can be made. The applicable drive parameters and the interfaces, known from reality, are available for thesimulation. Theuser configuresonly thepart of the drive that is needed for specific simulation purposes. A time-consuming complete virtual commissioning of the drive is not required, saving time and costs. The models in Sinamics DriveSim Basic link seamlessly to the existing drive documentation and have been validated against the real Sinamics drives using the same test vectors. For easy handling, Sinamics DriveSim Basic is available as a standardised FMU (Functional Mockup Unit) model. The software offers the same FMU file for every Sinamics drive. TheSinamics S120 andG120drives including the motor can already be represented. Further drives will follow. This FMU can be imported directly into the simulation program used. Sinamics DriveSim Basic is compatible with many commercially available simulation programs, such as Simit, Simcenter Amesim, NX Motion or Matlab Simulink. Together with other virtual Siemens solutions such as Simatic S7 PLCSIM Advanced or NX Mechatronics Concept Designer, a consistent model- based development process can be implemented.

At a glance  Major trends transforming the mining industry include: -

continent, my plan is to maintain this strong foothold, while continuing to expand into the rest of the continent, where mining especially is an important driver for growth and socioeconomic development. The mining industry has the shift from diesel to electrification as a main power source - digitalisation, increasing productivity and facilitating maintenance - reducing total cost of ownership by standardising on high-efficiency motors and drives.

Eduardo Aparicio has worked at ABB Power Systems and Industrial Automation in Spain and was Local Business Line Manager for Energy Industries in Mexico. He holds a Mechanical Engineering degree from Universidad UCLM in Spain and an MBA from IMF Business School and Universidad Nebrija, Madrid. He is an avid supporter of Real Madrid and the Springboks.

DRIVES, MOTORS + SWITCHGEAR : PRODUCTS + SERVICES

New software for easy drive simulation

With Sinamics DriveSim Basic, Siemens has introduced a new software solution with which, for the first time, drive constellations and their behaviour in machines and plants can be simulated, adapted and optimised. With the new solution, Siemens offers users a quick and easy entry into the simulation of drive technology and enables machine and plant manufacturers to accelerate the development phase in their own processes. Sinamics DriveSim Basic bridges the gap between logical and mechanical simulation. The application focus is on simulation support for the customer application – that is – the components that interact with the drive. The simulation provides answers to drive questions even before a concrete product selection has been made. For the virtual commissioning of the PLC control with known Profidrive telegrams or complex mechanics on the virtual

Sinamics DriveSim Basic allows for drive constellations and their behaviour in machines and plants to be simulated, adapted and optimised.

For more information visit: www.siemens.com

10 Electricity + Control JULY 2021

DRIVES, MOTORS + SWITCHGEAR : PRODUCTS + SERVICES

Arc fault protection in less than two milliseconds

Global power management company Eaton, has launched the ARCON ® 3G arc fault protection system in South Africa. This has been developed to reduce the risk of dangerous and costly arc flash incidents in low voltage (LV) switchgear assemblies which can result in injuries to personnel and damage to property. Arc fault events can most often be traced back to working under voltage with about two thirds of all acci- dents occurring in the course of service or maintenance work – for example, when a tool suddenly and uninten- tionally becomes a conductive instrument. The con- sequence is an almost explosive expansion of the arc fault, which can result in the ejection and deformation of equipment parts as well as fires. It has been proven that, depending on selectivity, up to 300 milliseconds may pass before the main switch identifies the fault and severs the connection. For a person standing in front of the device this can be life- threatening. Additionally, a fire caused by an arc fault might dam- age not only the installation itself, but also adjacent in- frastructure elements. For operators, this means revenue losses due to downtime as well as corresponding com- ponent repair or replacement costs. Kamogelo Makwana, LV Product Manager at Eaton South Africa says, “ARCON ® 3G protects man and ma- chine, even if the system is in a non-operational state when being worked on by a technician. This allows us to guarantee the highest degree of personnel and assem- bly protection.” ARCON ® 3G is a modular and compact system that detects an electrical arc caused by a short circuit through a combination of light and current detection, us- ing optical sensors and measuring current transformers. It has a total arc mitigation time of less than two millisec- onds. It continuously monitors itself and triggers an alert in case of a change in state. Such events are highlighted on a multilingual display, and a corresponding notifica- tion can also be submitted to a control centre via a hard- wired line.

This facilitates comprehensive personnel and assembly protection; the corresponding setup is entered via the display. In comparison to these configurations, the complex arc fault protection covers up to five zones. The connec- tion scheme corresponds to that of the enhanced arc fault protection system and is configured using a soft- ware solution. “Exposure to arc flash incidents continues to be a substantial cause of injury and death among workers, and a major cause of the negative effects that affect sys- tem availability and continuity for power critical opera- tions in the electrical industry,” says Makwana. “Our aim is to ensure personnel and assembly protection through ongoing research and development of the best arc fault mitigation and protection systems.” ARCON ® 3G’s high quality stainless steel housing en- ables best electromagnetic compatibility. With an oper- ating temperature range from -40 to +70°C, it is suitable for various applications, including process industries or data centres. The low mounting depth is also a valuable feature. Together with the separately executed display module, which complies with the IP55 protection rating, in ac- cordance with the xEnergy series, this provides for max- imum flexibility with regard to installation in the switch- gear assembly. The flexibility extends to the ignition module, also executed separately, which allows for placement of the master independently of the incoming section. An indi- vidual supply voltage for the light detection modules is not required. “With its continuous self-monitoring function and a total arc mitigation time of less than two milliseconds, ARCON ® 3G takes the lead for personnel and assembly protection,” says Makwana.

For more information contact Eaton. Visit: www.eaton.com

The modular design means that the ARCON ® 3G system can be used and expanded in numerous ways. In its basic arc protection version, it serves as an arc fault monitoring system and is connect- ed to the circuit breakers. This en- sures improved personnel protec- tion without the need for additional parameterisation. The next level provides en- hanced arc fault protection, which is achieved by connection to the circuit breakers, the ignition mod- ule as well as to an arc quenching device, also supplied by Eaton.

ARCON ® 3G has been developed to reduce the risk of dangerous and costly arc flash incidents in low voltage switchgear assemblies.

Electricity + Control JULY 2021

11

DRIVES, MOTORS + SWITCHGEAR : PRODUCTS + SERVICES

World-leading temperature control relays

Italy-based temperature control relay specialist TECSYSTEM has appointed Trafo Power Solutions – a leading local supplier of dry-type transformers – as its distributor in sub-Saharan Africa. Forover40yearsTECSYSTEM has been developing and manufacturing electronic and electromechanical devices for temperature control on equipment such as transformers, motors, generators and variable speed drives. David Claassen, Managing Director of Trafo Power Solutions says, “We have been using temperature control relays from TECSYSTEM on our dry-type transformers for many years. The quality of this product makes the company one of the global leaders in this specialised field.” Andrea Lorusso, Sales Area Manager at TECSYSTEM, says the company is pleased to have the expertise and network of Trafo Power Solutions to give the South African market easier

“This is part of our philosophy of providing a full solution to the customer, not just products,” Claassen says. “We are assisted in this by TECSYSTEM’s variety of highly reliable control relays, which ranges from hard- wired configurations to incorporating protocols such as SCADA and Ethernet.” The company will also be supplying TECSYSTEM’s air-forced (AF) fan cooling systems for cast-resin transformers, says Claassen, with control systems designed and installed by Trafo Power Solutions. The fans are installed on the transformer feet, in sets of three fans on each side of the transformer, directly under the windings. “They are typically used for additional protection rather than continuous operation,” he notes. “The fans provide efficient and prompt cooling if and when the transformer temperature exceeds a pre-determined value.” The company’s regular use of TECSYSTEM products means Trafo Power Solutions is well positioned to assist the market in making effective use of these technologies. There are also adequate stocks held in South Africa to allow for easy availability and quick access to the required products. “Our facilities are equipped to test the products before shipment to customers and to pre-programme the units according to the planned application,” Claassen adds. The programming is done on a dedicated simulation desk where the conditions in which the relay is required to operate can be replicated. This simplifies the job for the customer, who then has only to follow a wiring diagram when installing the relay. “We can also play a valuable role in remote troubleshooting for customers throughout Africa who, for instance, may need to update parameters in a relay,” Claassen says. “With our equipment and expertise, we can ‘mimic’ the unit on our side and assist them over the phone.” According to Giavenni, TECSYSTEM’s first micropro- cessor unit was developed in 1984 specifically to pro- tect cast-resin transformers from temperature overloads. Continuous research and development by TECSYSTEM has seen ongoing product improvements, ensuring reliability. “Quality is an important cornerstone of our production and all our products comply with the latest technical specifications and ratings. Our R&D department conducts preliminary and routine testing from the initial engineering phase through to production,” he says.

A control panel fitted with TECSYSTEM’s T154 temperature control relay and VRT200 fan control relay.

A TECSYSTEM NT935 temperature control relay.

access to its products. “Trafo Power Solutions understands their operating environment well, and appreciates the value that our technologies can add to the market,” says Fabrizio Giavenni, Sales & Marketing Manager. “As we continuously develop our product range, customers in South Africa can look forward to more exciting innovations.” The synergy between the two companies is based on the fact that Trafo Power Solutions equips all its cast-resin transformers with heat sensors that link to a temperature control system. Claassen emphasises that wherever there is an unusual temperature rise in a transformer, it is essential that the equipment can automatically generate an alert, so the problem can be investigated and solved. “Customers purchasing dry-type transformers are often supplied with a temperature control relay as a separate item – almost as an optional extra,” he says. “Our approach, however, is to consider the control and protection requirements as an integral part of the overall scope of designing a transformer.” Trafo Power Solutions designs a dedicated control and protection panel – which includes a TECSYSTEM relay – to suit each specific transformer. It is then a simple matter of cabling up the main supply, without having to deal with the complexity of linking up the control unit.

For more information contact Trafo Power Solutions. Visit: www.trafo.co.za

12 Electricity + Control JULY 2021