Electricity and Control June 2021

FEATURES: · Industry 4.0 + IIoT · Energy management + the industrial environment

· Measurement + instrumentation · Transformers, substations + cables

Beyond electricity and control to anomaly detection and machine learning

COMMENT

INDUSTRY 4.0 + IIOT

Energy efficiency can make the difference T here seems to have been nothing quite like the national energy utility to hammer home just how important energy efficiency is.

energy + information in industry

Of course it was predicted, but no one was really interested in hearing what was being said at the time. Energy efficiency, if tackled properly, will save users money and will also essentially ‘build’ additional power stations – in the sense that, if we could reduce the load, we’d be able to get away with our current kit far more effectively. So with the news just in that we are back at Stage 2 load shedding, let’s all look at our plants, our production lines, our offices and even our homes – and see if we actually can make a real difference in how much energy we use. Many organisations have made massive strides in this regard, but opportunities remain for much of our industry. I can recall the difficulty Electricity + Control had, as a magazine, trying to convince people that energy simply has to be – in all cases – a carefully monitored parameter that speaks to the efficiency of a plant. Perhaps fifteen years ago many still had the view that energy was simply a cost, and the efficiency of the process had little to do with the energy efficiency of the plant. (Perhaps many still do.) There was no real incentive to think otherwise. Perhaps we were too convinced that energy, in our context, would simply never be a problem. We had lots of coal, we had lots of power stations, and energy was cheap. Now there is a real call to ask what the correct and most appropriate approach should be. Now is the time to begin to think deeply about the real sustainability of everything we do. Let’s get ahead of the curve this time around.

Iritron advises that integrated automation and data acquisition systems are key to enabling real-time visibility and timeous decision making, improving operational efficiencies and long-term business sustainability. (Read more on page 3.)

While the new build fell way behind schedule and costs escalated, many of the existing plants began to grind and squeak as the utility gallantly tried to maintain output. Then industries, and homeowners too, began to see opportunities. Some of these were born of necessity (like onsite generation capacity), while in other cases owners saw a move to a far better and more sustainable future. Various industries considered gas, solar plants and even wind energy sources. The thinking caps were on. Just like the corona virus, however, the energy supply crisis is going nowhere fast. Load shedding and a severely restricted capacity to deliver baseload will be with us for some years to come. This is when it becomes almost a national imperative to look again, and very seriously, at energy efficiency. I recall vividly the days when, in as much as we used to publish articles aimed specifically at this topic, few truly saw the value. And that’s not surprising. Energy was cheap (too cheap, truth be told) and it was well-documented that we had built too many power stations, back in the day. Then, in the early part of this century, our economy began to grow, and grow… (although, to be fair, that process has been successfully reversed to reduce any unnecessary strain on our generation capacity). We found ourselves up the creek as it were – seemingly unable to stave off the predicament.

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 JUNE 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

INDUSTRY 4.0 + IIoT

4 A cooperative network for smart manufacturing Eplan

6 Products + services

ENERGY MANAGEMENT + THE INDUSTRIAL ENVIRONMENT

4

10 Meeting Africa’s rising electricity demand Ember

12 Smart energy management can minimise downtime Martin van Zyl, Schneider Electric

13 Products + services

16 Renewable energy projects in Africa

MEASUREMENT + INSTRUMENTATION

20 Collaboration sees industry first for fire pump test lab Instrotech

13

21 Products + services

TRANSFORMERS, SUBSTATIONS + CABLES

24 Streamlining renewables into the grid National Grid Electricity Transmission and Smart Wires

25 Products + services

Regulars

1 Comment Energy efficiency can make the difference

24

3 Cover article Beyond electricity and control to anomaly detection and machine learning

30 Engineering the future Being part of the climate change solution

31 Cybersecurity Increasing threats against industrial control systems 32 Write @ the back EPR Regulations: game-changing waste management rules

30

2 Electricity + Control JUNE 2021

COVER ARTICLE

Beyond electricity and control to anomaly detection and machine learning

F orty years ago companies started switching over from pneumatic and relay logic to electronic automation and control systems. At first these systems were all customised or built-to-purpose with little or no scalability and re-use. Over time they have become commercial off-the-shelf systems that are seen and used as commodities in the field of plant automation. Even though a lot of industries still operate manual systems and processes using a combination of manual labour and stand-alone equipment, there is a move to greater automation and systems integration. Manufacturers are looking to the automation industry to deliver additional benefit in the form of business-process automation (as opposed to physical process andmachine automation). This higher level automation is commonly called Manufacturing Operations Management (MOM) or a Manufacturing Execution System (MES), and most automation companies have added components of this to their product offerings. These systems are typically more complex than normal automation systems, as the data exchanged is normally contextualised information shared between different areas or departments of the business. This requires operators to change the way they operate the manufacturing facility. Due to the complexity and risk, these systems have taken longer to become widely accepted and it is only in the past few years that they have become more common. Over the same time, much has been said about the Fourth Industrial Revolution (4IR), the Internet of Things (IoT), Artificial Intelligence (AI) and Machine Learning (ML). These concepts, even though expressed in simple terms, sound utopian or futuristic to most manufacturing companies. Most believe they are not ready for any of this as they operate manual systems or have only islands of

automation but no integrated data acquisition system. What many companies fail to recognise is that without this real-time data visibility, their timeous decision-making ability is lagging and so is their market competitiveness. Making a decision to change hours after the event as opposed to seconds after the event wastes time and resources and makes companies less competitive. In the long run, this lag in decision-making can lead to ruin. Therefore, having actionable information in real time is critical to improving the efficiency and effectiveness of operations and ensuring long-term sustainability of manufacturing. Real-time information, once available can also be used for ML. By applying the appropriate algorithms to a historical dataset, companies can identify anomalies in equipment and process performance in real time. This enables them to predict upcoming quality issues, impending equipment failures, imminent process deviations and others, so they can be prevented. The difference between the automation systems of forty years ago and ML systems today, is that the time for them to evolve to become commodities has already passed and the time for them to be widely adopted has decreased considerably. There are companies today (small, medium and large) that have already invested in and are using ML solutions in their plants. Thinking that you have time before these systems prove themselves and that they present no threat to your business is a fallacy. Iritron can advise companies on MES, MOM and ML systems. □

For more information contact Iritron. Tel: +27 (0)12 349 2919 Email: gerhard.greeff@iritron.co.za Visit: www.iritron.co.za

Actionable information in real time is critical to improving operational efficiency and long-term sustainability of manufacturing.

Electricity + Control JUNE 2021

3

INDUSTRY 4.0 + IIOT

A cooperative network for smart manufacturing

The new partner network founded by EPlan towards the end of 2020 pools the worldwide expertise of its cooperation partners to increase benefits for customers.The EPlan Partner Network defines common binding goals to boost integration along the value chain. Users benefit from the greater continuity and integration, and the interchange among manufacturers makes it easier for customers to integrate different systems.

EPlan CEO, Sebastian Seitz.

E ngineering solutions provider EPlan started its Partner Network (EPN) at the turn of the year. It provides a framework for existing and new partnerships to work together in developing and marketing interfaces and is based on common binding goals to support this aim. The commitment increases customer benefits and enhances quality. Interaction and integration EPlan CEO Sebastian Seitz explains: “As well as using EPlan software, our customers use a variety of other software applications from various manufacturers in the ERP (Enterprise Resource Planning), PLM (Product Lifecycle Management), PLC (Programmable Logic Control), simulation and other environments. The effective interaction of these various applications is especially important to them. As part of the EPN, we will therefore be focusing on joint development of integrations as well as quality assurance and support.” Commenting on the motivation to found the EPlan Partner Network, the company’s Senior Vice President Strategy & Corporate Program, Marco Litto says: “The professionalisation of our network systematically increases

the benefits for end users.” The goals are ambitious. “The connectors between our systems should be planned, developed, tested, supported and marketed with at least the same rigour and soundness that we are accustomed to with our own

EPlan Senior Vice President Strategy & Corporate Program, Marco Litto.

solutions. Together with our EPN partners, this will allow us to achieve a completely new level of customer focus,” Litto says. “Open interfaces and modern integrations will create opportunities that will benefit users of the various software solutions and the partner companies themselves.” Key players on board Key players in automation globally – including Bosch Rexroth, B&R, Endress+Hauser, Festo, ifm electronic, Mitsubishi Electric, Phoenix Contact, Pilz, Rittal and Rockwell Automation – are already participating in the initiative. Software partners – such as configit, Contact Software, encoway, Gain, ISD, ISG, keytech, machineering, Procad, Quanos and SAE – are also participating in the new network. Other companies are being approached to participate too and EPlan is in talks with many. For instance, UDMTEK in Korea was the first Asian company to become an EPN member and others will follow. Rockwell Automation USA Vice President Global Business Development, Tom O’Reilly says: “A digital thread of data within and across organisations is one of the key requirements to bringing the Connected Enterprise to life. Together with EPlan, we support companies through their digital transformation by enabling data consistency, improving efficiency of engineering processes and shortening time-to-market.” Bosch Rexroth got involved at the start of the network. The company’s Vice President of Sales, SteffenWinkler says, “Configuration of automation solutions and the dynamic provision of exact device data are essential with regard to

The EPlan Partner Network brings together the expertise of cooperation partners with defined development goals.

4 Electricity + Control JUNE 2021

INDUSTRY 4.0 + IIOT

Cross-project collaboration The continuing digital transformation of engineering has seen EPlan also introduce a new service for cross-project collaboration – EPlan eManage – as part of its cloud services. This lets users upload EPlan Platform projects into the cloud environment and share and work on them there. As a first step, a free version of the new cloud-based software solution was launched in March. A fee-based version of the software will be released in August and will offer expanded functionality. EPlan eManage makes it easy to upload, manage and share projects in the secure ePulse cloud environment. As to- day’s ecosystem of industrial automation is characterised by many media discontinuities in the processing and transferring of documentation, the advantages of this system are clear: the EPlan Platform systems in connection with the new cloud service will network control cabinet manufacturers and pan- el builders, OEMs and system integrators, and machine and plant system operators. This means they can work together on a central project that can be synchronised on the EPlan Platform via eManage. Industry 4.0. The Bosch Rexroth ctrlX Configurator enables easy configuration of complete ctrlX Automation solutions. By directly integrating our configurator into the EPlan Platform, users will receive all device data of the configured system topology, including detailed product lists and CAD data, at the touch of a button. This integration ensures full data consistency and reuse of product data throughout the digital design phase.” UDMTEK CEO Gi Nam Wang also has good reasons for joining. “We decided to partner with EPlan through EPN to leverage our industry-leading offerings and combine them with EPlan’s best-in-class engineering platform. We are excited to partner with a world-class company as we embark on our next phase of growth and innovation.” EPlan makes it easy for users and companies to benefit from the EPN. A partner area on the website provides par- ticulars for companies involved in the network, information about integrations, contact people and current news. In this era of the digital transformation, when cloud

Clear access rights and role assignments ensure data security and provide flexibility for project access. Users of EPlan Electric P8 and EPlan Pro Panel are already benefitting from the integrated processes which enable them to upload their projects into the cloud and transfer them back to the EPlan Platform for further processing. With just one click users can publish their project data directly in EPlan eView. This allows defined stakeholders the opportunity to look at and comment on projects. It further enables cross-company review processes to be implemented digitally and, with its clear, central availability in the cloud, eManage supports project participants in searching for specific content quickly. Synchronised, current data EPlan eManage means that the EPlan Project is synchronised for all project participants and stakeholders. Changes in the project are visible to all participants and the project documentation is always current – across the entire project life cycle and even into operations and service scenarios. At a glance  Collaboration is changing the way engineering solutions are developed for smart manufacturing.  Easy interaction of various software applications from different manufacturers has become key to designing effective automation systems.  Open interfaces and modern integrations create opportunities that benefit users of the software solutions and the partner companies themselves. solutions are playing an increasingly critical role, it’s becoming more important for providers to coordinate integration across companies. Seitz says, “With the EPN, we’re maximising the overall benefits of our own solutions and those of our partners in the ecosystem of industrial automation for shared customers. Together we’re creating a win-win situation for customers and partners.” □ For more information visit: www.eplan-software.com

Eplan eManage allows Eplan Projects to be shared in the cloud with all project participants – enabling more collaboration in engineering.

Users of Eplan Electric P8 and Pro Panel can upload their projects into the cloud and transfer them back to the EPlan Platform.

Electricity + Control JUNE 2021

5

INDUSTRY 4.0 + IIOT : PRODUCTS + SERVICES

Leading new product introductions in electronics

As an authorised distributor Mouser Electronics Inc. is focused on the rapid introduction of new products and technologies, giving customers an edge and helping speed time to market. Over 1 100 semiconductor and electronic component manufacturer brands count on Mouser to help them introduce their products into the global marketplace. Mouser’s customers can expect 100% certified, genuine products that are fully traceable from each manufacturer. Through April 2021, Mouser launched more than 483 new products ready for same-day shipment. These are just a few of them. - Analog Devices LTC2672 16-Bit digital to analogue converter offers five-channel, current-source out- put DAC, with selectable output ranges, precision Turck is expanding its series of cabinet guards with the addition of the IM18-CCM. The integrated sensors of the narrow 18 mm device monitor temperature, air humidity and door distance, in order to send this information via Ethernet to higher-level IT systems. External devices such as vibration sensors for monitoring machine or equipment states can also be integrated via Modbus RTU and CAN. The IM18-CCM is particularly suitable for OEMs wanting to provide basic condition monitoring values in their IT systems. It detects critical states of the control cabinet directly in the field. Creeping changes or systemic problems can also be detected through long-term evaluations. The IM18-CCM thus bridges the gap between the OT and IT worlds and enables users Pepperl+Fuchs combines the advantages of IO‑Link and OPC UA in a single device, offering its customers data communication from the lowest field level to the cloud to facilitate Industry 4.0 solutions. Although sensor data is currently typically stored in central control systems that may be difficult to access, this solution now makes the information available to decision-makers and AI systems wherever it is needed, worldwide. When used as a sensor interface, IO-Link provides in-depth data to identify, configure parameters for, and diagnose a sensor. The data can be forwarded to computer- or Combining IO-Link and OPC UA

reference, and a multiplexer for surveying the channel output voltages and currents. - TDK InvenSense SmartIndustrial™ sensor plat- forms are compact, high-precision, low-cost, ac- celerometers and motion-sensing MEMS modules that give engineers a range of sensing choices for industrial applications. - Intel RealSense™ ID F450/F455 is an out‑of‑the‑box, credit-card-sized solution that combines an active depth sensor with a special- ised neural network to deliver secure and accu- rate facial authentication. - TE Connectivity’s MATE-AX miniaturised automo- tive coaxial connectors feature higher packaging density to enable a 75% space reduction and 34% weight savings compared to standard FAKRA connectors. to analyse the data from the factory level directly from their office desks. The Linux platform of the IM18-CCM also allows installation of any customised condition monitoring software. In this way, measured values can be pre-processed and prepared on the device for the specific requirements of the application. The IM18-CCM is the third model in Turck’s cabinet guard series. The two 12 mm devices IM12-CCM and IMX12‑CCM come with on-board condition monitoring software to monitor limit states and long-term data series. For more information contact Brandon Topham at Turck Banner. Tel: +27 (0)11 453 2468 Email: brandon.topham@turckbanner.co.za Visit: www.turckbanner.co.za cloud-based systems via OPC UA, the Ethernet-based protocol specifically designed for machine-to-machine or machine-to-cloud communication. The systems analyse the data for specific applications, such as predictive maintenance solutions in which an optical sensor, for example, can proactively flag lens contamination and thus prompt cleaning in good time before malfunctions occur. The flow of data helps customers to increase productivity and secure long-term business success as digitalisation becomes ever more important. For more information contact Pepperl+Fuchs. Email: info@za.pepperl-fuchs.com Visit: www.pepperl-fuchs.co.za For more information visit: https://eu.mouser.com or www.mouser.co.za

Mouser launched more than 483 new products through just one month, April 2021.

Sensor monitoring in OEM control cabinets

The 18 mm cabinet guard

with integrated sensors bridges OT to IT data communications.

IO-Link master with OPC UA interface.

6 Electricity + Control JUNE 2021

INDUSTRY 4.0 + IIOT : PRODUCTS + SERVICES

Secure data exchange for Industry 4.0 applications

Data exchange is an important issue to look at when integrating the production (operational technology, OT) and management (information technology, IT) levels in an organisation. This is due to the large number of variables and non-standardised interfaces, as well as the need to support access privileges and specific security requirements. Although OPC UA has established itself as a standard technology for achieving these goals, the devil is in the detail when it comes to implementing successful Industry 4.0 applications. Interface abstraction, data aggregation and security The dataFEED Secure Integration Server product from Softing Industrial works as an abstract interface between the worlds of OT and IT, offering users a set of key functionalities for efficient data exchange in a single component. In its role as an aggregating server, this middleware makes use of OPC UA’s address space modelling, especially for interface abstraction and data aggregation. In the process, the interface abstraction handles changes or extensions within one domain (OT/ IT) without any modifications then being needed in the other. Advantages here include the ease with which new IT applications can be integrated into the overall solution, to exploit short innovation cycles in IT or make targeted

client applications plus definable access types. Apart from full implementation of OPC UA security functions, whitelists and blacklists can also be defined to control data access from specific IP addresses, and detection of Denial of Service (DoS) attacks targeting OPC UA authentication is also included. Benefits for customers Whether customers are retaining existing setups or planning a new plant installation, deciding to deploy the dataFEED Secure Integration Server offers a significant set of advantages when running Industry 4.0 applications. In one recent example, integrating 1.5 million variables into an overall system was the challenge faced by a leading provider of power station process control systems. However, accessing such a large number of variables is a major stumbling block for many OPC UA clients. Because of this, the provider for the power station application chose to use the variable filtering option to achieve targeted variable access restrictions for individual OPC UA clients. In addition, only read access is granted to the individually configured variables. This prevents the unauthorised overwriting of assigned data values. In another example, a major supplier of automotive parts similarly chose dataFEED Secure Integration Serv- er specifically to handle variable aggregation and filtering from multiple, heterogeneous OPC UA servers, giving the OPC UA clients a standard, harmonised interface for ac- cessing all variables. In this case, the customer’s need to implement a state-of-the-art security standard was anoth- er key reason for choosing this solution. For more information contact Systems Automation & Management. Tel: + 27 (0) 11 803 0570, email: claude@sam.co.za mGuard Secure Remote Service Connector app is available in the PLCnext Store for this purpose. To keep customers’ data secure, the security-related parameters of the mGuard Secure Remote Service have been brought in line with the recommendations of the German Federal Office for Information Security (BSI) concerning encryption algorithms and lengths. With version 2.11, various subnets of a machine or system can now be easily added in the user interface. In version 2.12 onwards, they are made available selectively to users or user groups with fine granularity. Both version 2.11 and 2.12 of the remote maintenance ecosystem are available worldwide. For more information contact Phoenix Contact. Tel: +27 (0)11 801 8200 Email: info@phoenixcontact.co.za Visit: www.phoenixcontact.com/en-za/

The dataFEED secure integration server enables seamless, secure data exchange for production and management levels.

changes to the production environment. With data aggregation, data from multiple sources can be consolidated on a single OPC UA server, so the IT application only needs to access one server. This simplification to the communications infrastructure cuts configuration effort for users. Another key feature of the dataFEED Secure Integration Server is its built-in security model, with filters available to restrict the address space for individual OPC UA

New functions in secure remote service

10 years on from the original mGuard launch, Phoenix Contact is introducing version 2.11 of its mGuard Secure Remote Service ecosystem to the market with added features and new system functions. The system supports

Android-based mobile end devices for service technicians and iOS- based Apple devices. On the machine side, PLCnext Control devices from Phoenix Contact can also be easily and securely connected to the mGuard Secure Remote Service. The

The mGuard Secure Remote Service ecosystem supports service technicians in the field.

8 Electricity + Control JUNE 2021

INDUSTRY 4.0 + IIOT : PRODUCTS + SERVICES

The Open Integration Network

AATF Virtual Connect! 2021 Africa Automation Technology Fair 2021 will be staged virtually as AATF Virtual Connect! 7 to 9 September 2021. This was decided following feedback gathered from exhibitor and visitor surveys and consultation with industry stakeholders. The next in-person event has been rescheduled for 9 to 11 May 2023. In response to the automation industry’s request to connect and come together in 2021, Reed Exhibitions Africa created AATF Virtual Connect! which will take place in September 2021 and again in 2022. This will offer African and international industry decision makers and exhibitors a platform where they can gain industry insights and have focused meetings during the three-day event. Flow control specialist Rotork is a market-leading global provider of mission- critical flow control and instrumentation solutions for oil and gas, water and wastewater, power, and chemical, process and industrial (CPI) applications. It helps customers around the world to increase operational efficiency, reduce environmental impacts, improve product quality and provide safer working environments. “This programme is a great opportunity to collaborate How can field instruments and components be easily integrated into automation systems? The answer to this question is becoming increasingly important as digitalisation of industrial produc- tion progresses. The Endress+Hauser Open Integration partner program unites 13 manu- facturers that want to ensure the streamlined interaction of their complementary products. Recently flow control specialist Rotork joined the partner network. “Having Rotork join our partner programme provides us with additional expertise in actuators, instrumentation and the larger flow control market,” says Jörg Reinkensmeier, Marketing Manager at Endress+Hauser. “We will exploit this potential together with all our Open Integration partners, giving our customers freedom of choice.” The Open Integration cooperation partners test and document the integration of their offerings and how digitalisation may be fully used within typical process automation applications. Users benefit in two ways: by being able to combine the best-of-breed products for specific plant operations as well as fast and smooth commissioning. Automation technology suppliers value the advantages of the Open Integration programme as well, as they can ensure the fine tuning of the combined offering well in advance of installation and commissioning at customers’ sites.

Armin Nagel, Head of Sales CPI EMEA at Rotork. [Source: Rotork]

The partner programme aims to provide added value for customers by ensuring the seamless integration of intelligent assets. [Source: Rotork]

towards common customer benefits in a pre- sales stage and to extend our scope as a trusted partner in the market. The reliability and quality that we have come to expect from Endress+Hauser is also a key driver at Rotork. The company, and I personally, look forward to working together to help our partners provide premium flow control solutions,” said Armin Nagel, Head of Sales CPI EMEA at Rotork.

Jörg Reinkensmeier, Marketing Manager at Endress+Hauser.

The Open Integration Network To date 13 companies have joined Endress+Hauser’s partner programme. Members are well known suppliers of control technology, fieldbus infrastructure, measurement technology or actuator technology, such as Auma Riester, Bürkert, Festo, Flowserve, Hima Paul Hildebrandt, Honeywell Process Solutions, Pepperl+Fuchs, Phoenix Contact, Rockwell Automation, Schneider Electric, Softing Industrial Automation, Turck and from the beginning of 2021, Rotork. For more information contact Endress+Hauser. Tel: +27 (0)11 262 8000 Email: info.za.sc@endress.com Visit: www.endress.com

AATF Virtual Connect! is scheduled for September 2021.

For more information visit: www.africaautomationtechnologyfair.com

Electricity + Control JUNE 2021

9

ENERGY MANAGEMENT + THE INDUSTRIAL ENVIRONMENT

Meeting Africa’s rising electricity demand

An analysis of electricity supply globally has revealed that wind and solar showed resilient growth in 2020, despite the pandemic, forcing a record fall in global coal power. It indicates that almost a tenth of global electricity was generated by wind and solar in 2020. In Africa, Morocco and Kenya are the clear leaders and already ahead of the world average. However, data from 2014 to 2019 shows that only a third of the rise in Africa’s electricity demand was met with renewables, and two-thirds with fossil gas.

T he Global Electricity Review , published by independ- ent energy think tank Ember, analysed electricity data from every country in the world to provide an accu- rate view of the global electricity transition in 2020. 2020 global power trends The pandemic brought the world to a halt in 2020 and paused the world’s rising demand for electricity. The slight drop in demand (-0.1%) was the first fall since 2009, al- though it was smaller than the impact of the financial crisis. Wind and solar power showed resilient global growth in 2020, despite the pandemic, up by 15% (+314 TWh) versus 2019. The growth in wind and solar helped push coal power to a record fall of 4% (-346 TWh). Wind and solar Globally wind and solar doubled in the past five years to supply almost a tenth of global electricity in 2020. Among Africa’s leading economies, Morocco and Kenya had the highest levels of wind and solar, respectively generating 16% and 15% of their electricity from wind and solar in 2019. Morocco has achieved a rapid increase in solar power, increasing from near zero in 2015 to 4% of its electricity generation in 2019. It also increased its wind power from

9% of its electricity in 2015 to 12% in 2019. Kenya has seen a rapid acceleration in wind power, increasing from less than 1% in 2015 to 14% in 2019. Solar power remains at less than 1% of Kenya’s electricity. Many of Africa’s leading economies have yet to harness the potential of wind and solar power, which are now among the cheapest forms of new electricity. In 2019, Nigeria and Algeria generated less than 1% of their electricity from wind and solar, while Egypt increased to 3% in 2019 after re- cent growth in solar power. South Africa generated 6% of its electricity from wind and solar in 2020, tripling since 2015, but still below the world average of 9.4%. Across the G20, many countries mirrored the global average wind and solar share (9.4%) in 2020, including India (9%), China (9.5%), Japan (10%), Brazil (11%), the US (12%) and Turkey (12%). Europe is leading the way, with Germany at 33% and the United Kingdom at 29%, giving confidence in how wind and solar can be quickly built and integrated into the electricity system. Emerging economies such as India and Turkey have accelerated their deployment of wind and solar to reduce their dependence on fossil fuels. India’s wind and solar generation tripled in five years to provide 8.9% of total electricity production in 2020, now just below the global average. Lower electricity demand and wind and solar growth led to coal’s market share falling by 5% since 2015. In Turkey, wind and solar provided 12% of electricity generation in 2020, this share has tripled since 2015. This helped to reduce gas and oil’s market share by 11% over the same period, however coal’s market share continued to grow. Fossil fuels still dominate Fossil fuels generated 61% of the world’s electricity in 2020, down from 66% in 2015 when the Paris Agree- ment was signed. Coal was the single largest source, responsible for 34% of global electricity in 2020. The dataset of global electricity generation revealed that major African economies were significantly more reliant on fossil fuels for electricity than the world

Gas and renewables are meeting Africa’s growing electricity demand.

10 Electricity + Control JUNE 2021

ENERGY MANAGEMENT + THE INDUSTRIAL ENVIRONMENT

average of 61%. Above-average levels of fossil fuels were observed in Nigeria (81%) and South Africa (89%) in 2020, and in Egypt (90%), Algeria (99%) and Morocco (79%) in 2019. South Africa stands out with by far the largest share of coal (86%) in Africa, over double the world average. However, fossil fuels’ share of electricity generation is hugely varied across Africa, as many countries had far higher shares of clean electricity than the world average in 2020 (39%). Ethiopia, Kenya, Angola and Zambia all generated over 80% of their electricity from clean sources in 2019. Kenya recently pledged 100% renewable electricity by 2030, confirming its commitment to a clean energy future. Across the G20 there were also many countries with fossil fuel shares above the global average in 2020. Five G20 countries had over three-quarters of their electricity supplied from fossil fuels in 2020: Saudi Arabia (100%), South Africa (89%), Indonesia (83%), Mexico (75%) and Australia (75%). In comparison, France and Brazil generated only 9% and 14% of their electricity from fossil fuels, respectively. Africa’s rising electricity production In Africa, electricity production is still increasing every year. From 2014 to 2019, renewables met one third of Africa’s growth in production, with gas making up the remaining two thirds. Renewables growth in Africa has been accelerating since 2015, but it has not yet been fast enough to meet all the rising demand. The rise in gas was particularly marked in North Africa, where there were the biggest increases in electricity demand, and very little build-up of renewable electricity. As a continent, Africa – unlike Asia – has avoided a coal-reliant electricity grid. There has been no growth in to- tal coal generation since 2014, as South Africa’s falling coal generation was cancelled out by increases in Morocco and Zambia. In addition, there is very little coal capacity under construction or planned in Africa – only South Africa and Zimbabwe are building new coal. Commenting on the review, Peter Tunbridge, analyst at Ember, said: “The challenge remains to build renewables fast enough to keep up with rising electricity demand, not just for Africa but across the world. Emerging economies such as India and Turkey are accelerating their deployment of wind and solar beyond the increase in electricity demand, to reduce their dependence on fossil fuels. Wind and solar have the potential to power Africa’s electric future, and rapid deployment of these technologies will be essential for African countries to meet the rising demand for electricity and avoid a fossil gas trap.” Professor Anton Eberhard, Power Futures Lab at the University of Cape Town, said: “Solar and wind energy are now the cheapest sources of new power generation in Africa. Countries such as Morocco and Kenya have made impressive progress. Other countries, including South Africa, will add significant new investments in these technologies in 2021 and beyond. As the share of these

At a glance  While Morocco, Kenya and SA have shown significant growth in solar and wind power, many of Africa’s leading economies have yet to harness the potential of renewable energy sources.  The dataset of global electricity generation reveals that major African economies were significantly more reliant on fossil fuels for electricity than the world average of 61%.  The challenge remains to build renewables fast enough to keep up with rising electricity demand.

Fossil fuels’ share of electricity generation varies widely across African countries.

The Global Electricity Review This annual review analyses electricity data from every country in the world to provide an accurate view of the global electricity transition in 2020. It aggregates generation data by fuel by coun- try from 2000. 68 countries accounting for 90% of world electricity generation have full-year data to 2020 and have formed the basis of an estimate for changes in worldwide generation. All remain- ing countries have full data as far as 2019. G20 countries, which comprise 84% of world electricity generation, each have a sep- arate in-depth country analysis. All the data can be viewed and downloaded freely from Ember’s website. Duncan Gibb, Renewables Project Manager and Analyst, REN21, said: “It’s encouraging to see that Morocco and Kenya have made such progress with solar and wind power, and have reached high shares among African countries. Their success shows the impact of effective political leadership and well-designed regulatory frameworks that create market conditions where renewables thrive. At the same time, more than half of the population in sub-Saharan Africa still lacks access to electricity. Renewable energy, including solar and wind, can quickly and inexpensively help fill this gap. Ember’s Global Electricity Review shows the huge potential for African nations to build affordable renewables and provide electricity for their citizens.” □ For more information visit: www.ember-climate.org variable energy sources grows, there will be new challenges for power systems in Africa, especially for system operators who will have to procure and manage complementary flexible resources to ensure supply security and stability.”

Electricity + Control JUNE 2021

11

ENERGY MANAGEMENT + THE INDUSTRIAL ENVIRONMENT

Smart energy management can minimise downtime Martin van Zyl, Segment Leader, Consumer Packaged Goods at Schneider Electric highlights critical considerations in energy management and equipment maintenance to achieve stable production and consistent product quality.

B y design, critical industrial equipment provides exceptional longevity coupled with robust quality, features that allow manufacturing facilities to run optimally and, more importantly, continuously. Often, however, little thought is given to the realistic lifespan of such critical equipment and this can result in failures with sometimes catastrophic consequences. Complacency leads to the failure tomaintain andupgrade equipment. With critical equipment such as generators and uninterrupted power supplies (UPSs) included in this mix – and operating without efficient monitoring – a manufacturing plant is set for the risk of failure. The reliability of equipment and continuous power supply form a fundamental part of business sustainability, particularly when it comes to production continuity and avoiding downtime. This is especially true for industries such as food and beverages and pharmaceuticals where the quality of manufactured products is non-negotiable. Monitor, monitor, monitor The importance of monitoring cannot be overemphasised. At Schneider Electric we understand the value of holistically and deeply monitoring critical equipment, using industry software solutions supported by cloud analytics and expert engineers. Translating this into real-life applications and benefits, it’s important to address the following factors. ƒ Identify and mitigate power quality issues from both internal and external sources through continuous monitoring. ƒ Improve power quality to reduce equipment failure, prolong equipment lifespan and eliminate unknown tripping-and-stoppage events. ƒ Reduce energy costs by pinpointing savings oppor- tunities related to operational usage, power quality mitigation measures and utility optimisation initiatives. ƒ Leverage contextual information such as busbar tem- perature, ambient conditions, the number of opera- tions, the loading of the equipment and information from other condition sensors for insightful monitoring of smart, critical, electrical equipment. ƒ Safety First through connected MV (medium voltage) and LV (low voltage) switchgear that provides remote switching functionality to establish safe environments, keeping employees out of harm’s way while also em- powering quick response time through remote moni- toring and control.

Martin van Zyl, Schneider Electric.

Power quality Power quality issues can go unno-

ticed and have a major impact on operations and process- es, leading to equipment damage, degradation of equip- ment longevity and unplanned downtime. And these issues are more common than one would expect. It’s estimated that 70% of power quality disturbances originate within fa- cilities and cause between 30 and 40 % of resulting down- time incidents. Here, a power management system has the analytical tools to help manufacturers understand which power quality events could adversely affect operations. Manufacturers can monitor and analyse power quality disturbances to determine specific actions needed to correct issues. This might include the installation of power quality correction equipment, such as Power Factor Correction and Active Harmonic Filters. Accelerating the benefits Monitoring and management are great steps forward – and more insight can be gained through analysing the collected data in the cloud. The benefit of Schneider Electric’s cloud analytics is that the data is evaluated firstly through machine learning tools together with research and development information – and further by an experienced Schneider Electric engineer who will evaluate the results and provide specific recommendations to the onsite team on how to proactively prevent an issue from becoming a safety or downtime event. A typical basic example of cloud analytics services might be in the monitoring of a transformer’s busbar temperatures in context of the ambient operating conditions and load profile, to understand when these contextualised thresholds are exceeded – which would then require immediate intervention on site, such as tightening of cable or busbar connections. Cloud applications will therefore evaluate a holistic data set and its relation to critical assets, such as a transformers or UPSs, to identify potential issues long before a failure occurs. Now is the time to focus on equipment reliability, using intelligent monitoring and management tools coupled to cloud analytics that can predict unplanned downtime events and prevent possible failure. □

For more information visit: www.se.com

12 Electricity + Control JUNE 2021

ENERGY MANAGEMENT + THE INDUSTRIAL ENVIRONMENT : PRODUCTS + SERVICES

A new decade of renewables

More than 260 GW of renewable energy capacity was added to global energy supply in 2020, beating earlier estimates and all previous records, despite the economic slowdown that resulted from the Covid-19 pandemic. The International Renewable Energy Agency’s (IRENA’s) annual Renewable Capacity Statistics 2021 , released 5 April, shows that renewable energy’s share of all new generating capacity rose substantially for the second year in a row. More than 80% of all new electricity capacity added last year was renewable, with solar and wind accounting for 91% of new renewables. Renewables’ rising share of the total is partly attributable to net decommissioning of fossil-fuel power generation in Europe, North America and for the first time across Eurasia (Armenia, Azerbaijan, Georgia, Russian Federation and Turkey). Total fossil-fuel additions fell to 60 GW in 2020 from 64 GW the previous year, highlighting a continued downward trend of fossil-fuel expansion. IRENA Director-General Francesco La Camera said, “These numbers tell a remarkable story of resilience and hope. Despite the challenges and the uncertainty of 2020, renewable energy emerged as a source of undeniable optimism for a better, more equitable, resilient, clean and just future. The great reset offered a moment of reflection and a chance to align our trajectory with the path to inclusive prosperity, and there are signs we are grasping it. “Despite the difficult period, as we predicted, 2020 marks the start of the decade of renewables,” La Camera continued. “Costs are falling, clean tech markets are growing and never before have the benefits of the energy transition been so clear. This trend is unstoppable, but as the review of our World Energy Transition Outlook highlights, there is a huge amount to be done. Our 1.5 degrees outlook shows significant planned energy investments must be redirected to support the transition if we are to achieve 2050 goals. In this critical decade of action, the international community can look to this trend as a source of inspiration to go further,” he said. The 10.3% rise in installed capacity represents expan- sion that beats long-term trends of more modest growth year on year. At the end of 2020, global renewable gen- eration capacity amounted to 2 799 GW with hydropower still accounting for the largest share (1 211 GW), although solar and wind are catching up fast. The two variable sources of renewables dominated capacity expansion in 2020 with 127 GW and 111 GW of new installations for solar and wind respectively. China and the United States were the two outstanding growth markets from 2020. China, already the world’s largest market for renewables, added 136 GW last year, the bulk coming from 72 GW of wind and 49 GW of solar. The United States installed 29 GW of renewables last year, nearly 80% more than in 2019, including 15 GW of solar and around 14 GW of wind. Africa continued to expand steadily with an increase of 2.6 GW, slightly more

Solar and wind energy accounted for 91% of the record 260 GW of new renewables power generation installed in 2020. than in 2019, and Oceania remained the fastest growing region (+18.4%), although its share of global capacity is small and almost all expansion occurred in Australia. Highlights by technology ƒ Hydropower: Growth in hydro recovered in 2020, with the commissioning of several large projects delayed in 2019. China added 12 GW of capacity, followed by Turkey with 2.5 GW. ƒ Wind energy: Wind expansion almost doubled in 2020 compared to 2019 (111 GW compared to 58 GW). China added 72 GW of new capacity, followed by the United States (14 GW). Ten other countries increased wind capacity by more than 1 GW in 2020. Offshore wind increased to reach around 5% of total wind capacity in 2020. ƒ Solar energy: Total solar capacity has now reached about the same level as wind capacity, largely a result of expansion in Asia (78 GW) in 2020, with major capacity increases in China (49 GW) and Vietnam (11 GW). Japan added over 5 GW, India and Republic of Korea both expanded solar capacity by more than 4 GW. The United States added 15 GW. ƒ Bioenergy: Net capacity expansion fell by half in 2020 (2.5 GW compared to 6.4 GW in 2019). Bioenergy capacity in China expanded by over 2 GW, and in Europe, the only other region with significant expansion in 2020, by 1.2 GW, a similar to 2019. ƒ Geothermal energy: Very little capacity was added in 2020, mainly in Turkey, 99 MW, and smaller expansions in New Zealand, the United States and Italy. ƒ Off-grid electricity: Off-grid capacity grew by 365 MW in 2020 (2%) to reach 10.6 GW. Solar expanded by 250 MW to reach 4.3 GW and hydro by about 1.8 GW.

For more information visit: www.irena.org

Electricity + Control JUNE 2021

13