SA Instrumentation & Control | Volume 40 | March 2024

40VOLUME NO 3 MARCH 2024 Official publication of the SAIMC System integration | Control systems | Safety systems Process measurement | IT in manufacturing | Fieldbus & industrial networking Power generation | Sensors & transducers | Motion control & drives INSPIRING AUTOMATION

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www.instrumentation.co.za March 2024 1 Fieldbus & industrial networking IT in manufacturing Power generation Motion control & drives Sensors & transducers VOLUME 40 NO 3 MARCH 2024 03 07 12 REGULARS FEATURES Control systems System integration Process measurement Safety systems 20 16 14 23 34 29 36 38 37 News & events SAIMC news Automation professionals Omniflex Remote Monitoring Specialists, Turck Banner Endress+Hauser South Africa, Samson Controls, Senseca South Africa, ifm - South Africa, VEGA Controls SA, Gail Norton Instrumentation Agencies Michael Brown Control Engineering CC, Opto Africa Automation Iritron, Control System Integrators Association Rugged Interconnect, Turck Banner, RS South Africa Iritron, Absolute Perspectives, LOESCHE South Africa, Siemens South Africa RJ Connect, Emerson Automation Solutions BMG, Horne Technologies ifm - South Africa OUR COVER 12 40VOLUME NO 3 MARCH 2024 Official publication of the SAIMC System integration | Control systems | Safety systems Process measurement | IT in manufacturing | Fieldbus & industrial networking Power generation | Sensors & transducers | Motion control & drives INSPIRING AUTOMATION Transparent energy monitoring reduces both machine downtime and the necessity to oversize components. Added to these advantages are simplified preventive maintenance and increased production efficiency. Read our cover story on page 10 to find out about the wide range of PC-based control technology from Beckhoff. This offers a solution that can be optimally adapted to individual applications with numerous SCT current transformers and EtherCAT power measurement terminals.

2 March 2024 www.instrumentation.co.za welcome VOLUME 40 NO 3 MARCH 2024 Disclaimer While every effort has been made to ensure the accuracy of the information contained herein, the publisher and its agents cannot be held responsible for any errors contained, or any loss incurred as a result. Articles published do not necessarily reflect the views of the publishers. The editor reserves the right to alter or cut copy. Articles submitted are deemed to have been cleared for publication. Advertisements, inserts and company contact details are printed as provided by the advertiser. Technews Publishing (Pty) Ltd cannot be held responsible for the accuracy or veracity of supplied material. All rights reserved. No part of this publication may be reproduced, adapted, stored in a retrieval system or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of Technews Publishing (Pty) Ltd, Reg No. 2005/034598/07 LETTERS TO THE EDITOR Letters to the editor should be addressed to Kim Roberts at [email protected]. Sending material to this publication will be considered automatic permission to use in full or in part in our Letters column. Be sure to include your name, e-mail address, city and zip code. We reserve the right to edit all letters. EDITOR Kim Roberts MSc Chem [email protected] CIO & DIRECTOR Graeme Bell NHD Elec. Eng., MBA [email protected] CONTRIBUTING EDITORS Michael Brown BSc (Eng) (Rand), CEng MIEE MSAIEE Gavin Halse BSc Chem Eng Lance Turner BSc (Hons) Information Systems ADVERTISING Sales manager Jane van der Spuy [email protected] Tel: +27 83 234 5412 Heidi Hargreaves [email protected] Tel: +27 83 504 0436 DESIGN AND LAYOUT Technews Production Department SUBSCRIPTION SERVICES For address changes, subscriptions, renewal status or missing issues, email: [email protected] or write to: Technews Publishing (Pty) Ltd, Box 385, Pinegowrie 2123 SUBSCRIBE ONLINE www.technews.co.za PUBLISHERS Technews Publishing (Pty) Ltd Wild Fig Business Park, Block B, Unit 21, 1494 Cranberry Street, Honeydew The thrill of space exploration captures our imagination. I‘ve been following NASA’s Perseverance rover and Ingenuity helicopter with fascination as these tiny vehicles pushed the boundaries of scientific achievement. So I was saddened to find out that after three years, 72 flights and 17 kilometres flown, we have to say goodbye to Ingenuity. The little helicopter’s mission is at an end after it lost a rotor blade during a hard landing. The Perseverance rover touched down on Mars in 2021 after travelling 480 million kilometres on its six-month journey. This was the most difficult Mars landing ever attempted. For the first time ever, NASA captured video of a rover landing on the surface of Mars after dropping down at 1500 km/h. It also captured audio of the wind whistling past on the ground. Perseverance topped this off by clicking a selfie using a camera on the end of its robotic arm. Ingenuity, a small, 1,8 kg solar-powered autonomous drone, made the journey to Mars strapped underneath Perseverance. The goal was to test powered flight in the thin Martian atmosphere that has a density only 1% of Earth. The blades on a rotorcraft have very little to bite into to gain lift, so Ingenuity was fitted with contra-rotating rotors made of carbon fibre rotors. They sat on top of one another and spun in opposite directions at about 2400 rpm, five times as fast as helicopter rotors on Earth. The goal was to gather data on new terrain too dangerous for the rover. In an achievement on a par with the Wright brothers’ first flight, Ingenuity tested the limits. It achieved the first powered, controlled flight by an aircraft on another planet. Even one flight with a crash landing would have been a success, by showing it could get through the launch, charge itself on the way, and survive the entry into the Mars atmosphere, descent and landing. But Ingenuity surpassed all expectations with a series of increasingly daring flights. It was designed to survive for 30 days and fly a total of five missions. Anything else would be a bonus. Instead, it kept going for three years and flew a total of 72 missions and 17 kilometres, giving NASA’s scientists undreamed of access to landscapes previously unseen. The Wright Brothers’ first successful flight lasted 12 seconds. Ingenuity showed that it could rise 5 metres, hover, tilt by generating thrust with its rotors, move sideways, turn, and return to its position while snapping photos of the Martian surface along the way. It was able to explore difficult The little helicopter that could terrain from above, study large regions faster than a rover, and carry out reconnaissance, massively expanding the horizons for future Mars missions. Meanwhile, Perseverance’s main purpose is to search for fossils of ancient microbes. It’s busy taking rock samples, and storing them for a future spacecraft to retrieve and bring back to Earth. The goal is to characterise the planet’s geology and past climate, and pave the way for human exploration. It‘s also looking for organic materials, and analysing any minerals that could show possible signs of life. It’s packed with cameras, sensors and testing equipment. It can handle tools to take microscopic images and analyse the composition of Martian rocks and soil. Its special drill can penetrate the Mars surface to collect samples using a robotic arm and hand. The Mars atmosphere is 96% CO2, and the list of firsts includes converting this into oxygen at a rate of six grams an hour. This is the first step in fuelling rockets that can lift astronauts off the surface and provide breathable air. Astronauts spending a year on the surface would use about a ton. The new technology will pay off down here too, with innovations like a sensor that can identify bacteria in a wound, an advanced geology drill bit, and Doppler Lidar for autonomous cars – not to mention unbreakable tyres with shape memory, and wear-repairing super-lubricants (there’s no way to give a rover an oil change on Mars). While Ingenuity’s mission is sadly over, Perseverance is only now getting to the most exciting part so far. It’s exploring an area on the edge of Jezero Crater with strong signatures of carbonate minerals. While it’s sad to be leaving Ingenuity behind, the future is bright for Perseverance. The essence of our nature is exploration and discovery. When we explore other planets we can be grateful for our place on Earth, and learn about our place in the universe and about pushing the limits. Who knows what more the expedition will find? I’m looking forward to lots more.

NEWS & EVENTS 4 March 2024 www.instrumentation.co.za ABB has earned this year’s Frost & Sullivan Company of the Year Award in the global emissions monitoring systems industry. Frost & Sullivan’s global team of growth pipeline experts chose ABB based on its visionary understanding of future world challenges, the deployment of best practices and strategic analytics, and also its innovation and technical expertise in emissions monitoring and methane gas leak detection. According to Frost & Sullivan, ABB is shaping industry trends and supporting customers across a complex landscape of stringent emissions regulations. “There has been a long-term commitment from ABB to the development of multiple innovative emissions monitoring and gas leak technologies that serve the broadest industry sectors worldwide,” said Jean-René Roy, global business line manager for ABB Measurement & Analytics. “It is fantastic that Frost & Sullivan has recognised our collective achievement and leading technology through this award, and I would like to thank my team for their continued dedication to the cause.” ABB’s extensive instrumentation and gas analyser portfolio includes continuous emissions monitoring systems (CEMS) used in power generation, chemicals and refineries, waste incineration, co-combustion, marine, and other applications. The portfolio also comprises the ABB Ability natural gas leak detection solutions, a comprehensive suite which detects and maps gas leaks with unrivalled accuracy. ABB wins award for excellence in emissions monitoring The South African Local Government Association has recently released a detailed guide on the integration of embedded generation and wheeling in municipal electricity billing systems. Notably featured in this guide is the fruitful collaboration between George Municipality and Open Access Energy, signifying a major progression in South Africa’s energy landscape. The guide, produced in collaboration with Sustainable Energy Africa, presents a comprehensive overview and valuable insights into this emerging sector. George Municipality faced substantial challenges with its existing metering data management system when it planned to introduce wheeling between municipal clients. Trailblazing wheeling solutions ABB’s emissions monitoring technology is also used to tackle the massive environmental problem of millions of leaking orphan oil and gas wells across the United States. The company’s high-sensitivity analysers can detect methane emissions from decommissioned wells down to one part per billion. For more information contact ABB South Africa, +27 10 202 5105, [email protected], www.abb.com/za The system struggled to process the detailed and frequent data required for sophisticated wheeling transactions, and limited the ability for municipal employees and wheelers to effectively allocate wheeled time-of-use (TOU) electricity. Open Access Energy’s Amptera software emerged as the solution to these challenges, helping George Municipality to overcome the complexities of wheeling transactions. The software provides comprehensive AMR functionality, allowing for the reading of smart meters, storage of meter data, and access for both the municipality and bulk meter customers to this data. Amptera enables TOU reconciliation, data aggregation and evaluation. These are crucial for real-time billing information calculation in order to streamline energy management and billing processes. Gerjo Hoffman, CEO of Open Access Energy, said: “Amptera has revolutionised the wheeling process by enabling access to billable smart meter data in real time. This is a game-changer in the energy sector, providing a reliable and efficient solution for contemporary energy distribution challenges.” Established in 2021, Open Access Energy is South Africa’s first multilateral wheeling software platform. Its software-as-a-service solution is aimed at independent power producers and energy traders, assisting wheelers in distributing energy to multiple customers. This initiative by George Municipality and Open Access Energy exemplifies a significant step forward in South Africa’s journey towards more adaptable and efficient energy distribution, demonstrating the potential of innovative technology in addressing complex challenges in the energy sector. For more information contact Dirk Slabbert, Paddington Station PR, +27 73 050 8530, [email protected], www.openaccess.energy

NEWS & EVENTS www.instrumentation.co.za March 2024 5 www.bmgworld.net BEARINGS • SEALS • POWER TRANSMISSION • DRIVES • MOTORS • MATERIALS HANDLING • FASTENERS & TOOLS HYDRAULICS • PNEUMATICS • FILTRATION • LUBRICATION • VALVES • TECHNICAL RESOURCES • FIELD SERVICES BMG-WEB-2022-Shop-Online SHOP BMG ONLINE FOR: • Electronic Motion Control • Maintenance Chemicals • Tools and Equipment • Power Transmission • Electric Motors • Adhesives • Fasteners • Bearings • Sealants • Gaskets • Seals South African engineer, Neo Hutiri has been selected as best of the best. The Royal Academy of Engineering is investing over £1 million this year in alumni of the Africa Prize for Engineering Innovation programme through grants, prizes and accelerator programme awards, to facilitate the long-term success of innovations addressing local challenges. The programme is Africa’s biggest prize dedicated to engineering innovation and supporting entrepreneurs to maximise their impact, and is marking its tenth anniversary this year. Hutiri won the Africa Prize in 2019, and has been awarded the Royal Academy of Engineering’s tenth anniversary medal, beating nine previous Africa Prize alumni from Nigeria, Kenya, Uganda, Ghana and Cameroon. The award was presented by HRH The Princess Royal at a ceremony that celebrated some of the most successful innovators and businesses from the past ten years. The medal comes with more than a million rand to boost his business, Technovera, which makes Pelebox Smart Lockers to improve access to medication for chronic diseases such as tuberculosis and HIV. South Africa has the world’s biggest ARV programme for patients living with HIV and AIDS, and there has been a steady increase in the number of patients with non-communicable diseases requiring chronic therapy. Pelebox is an internet-enabled smart locker dispensing system that enables clients to collect their repeat chronic medication in under 30 minutes instead of waiting hours in queues at healthcare facilities. They are now operational across South Africa, Botswana and Namibia. The best of the best For more information contact Benjamin Harris, Proof Communication Africa,+27 64 742 0880, [email protected], www.proofafrica.co.za Neo Hutiri, winner of the Royal Academy of Engineering’s tenth anniversary medal.

NEWS & EVENTS 6 March 2024 www.instrumentation.co.za Africa’s biggest machine tools exhibition is taking place from 21-24 May 2024 at the Johannesburg Expo Centre in Nasrec. It will be showcasing cuttingedge developments across the machine tool and related industries, and also the very latest global machine tool technology. It will also highlight the importance of local suppliers and their international manufacturing partners. The exhibition is seen as an important and relevant platform where buyers and sellers can meet face-to-face in a relaxed informal environment. At the previous show, 87% of visitors went there in search of new products and solutions, and to learn about the latest technologies and trends. At this year’s show, visitors can expect to see a wide range of products. They will range from machinery and tooling to control systems, robotics, design, accessories, and everything that twists, turns, rotates, cuts, forms, bends or shapes. Senior purchasing decision makers will have the opportunity to find what they need to take their manufacturing processes to the next level. Machine tool industry outlook Speaking at the recent Machine Tool Merchants Association AGM, chairperson Joanne Canossa described the past year as a high-speed rollercoaster for the industry. It is recognised that machine tools are a key driver in various sectors such as manufacturing, fabrication, engineering, and construction, and play a part in the country’s economic growth. Canossa explained that while the industry enjoyed a growth of 20,7% during 2023 up until Q3 compared to the previous year, there was a weakening demand for machinery and equipment during the latter part of the year, due in part to reduced manufacturing production in South Africa. The decline was largely a consequence of the country suffering the worst loadshedding on record during September. Machine Tools Africa exhibition RS South Africa recently exhibited at the MTE Moab Khotsong 2024 mining and technical exhibition in the Free State. Andrew Macnamara, director of MTE, said, “In light of the prevailing challenges confronting the mining sector, our exhibitions serve as invaluable platforms, offering essential solutions to enhance efficiency and showcasing cutting-edge technology and innovation.” MTE, a division of IMD Conferences Exhibitions and Workshops, celebrated its 30th anniversary last year. It has made a name for itself since 1993 through many exhibitions at mines and industrial operations across southern Africa. “Participating in MTE events provides us with a unique opportunity to introduce the latest industrial technologies and solutions tailored to the design, construction and maintenance of operations,” added Erick Wessels, RS sales director. A highlight for RS at MTE Moab Khotsong 2024 was its test and measurement solutions, which provide the latest measurement technology for tomorrow’s innovations. Its extensive range includes power supplies, signal generators, oscilloscopes, meters, spectrum analysers and electronic loads. Leading brands supplied are RS PRO, Aim-TTi, EA Elektro-Automatik, FLIR, Fluke, Keithley, Keysight, Pico Technology, Rohde & Schwarz, Tektronix and Teledyne Lecroy. “New technologies point the way and show how measurement and testing technology will develop in the coming years. Whatever your test and measurement requirements, RS has it covered,” concluded Wessels. For more information contact RS South Africa, +27 11 691 9300, [email protected], za.rs-online.com RS South Africa showcases test and measurement solutions “We are faced with local and global challenges, and as key players in the industry we need to understand the magnitude of this impact and how we can mitigate any risks for the future,” advises Canossa. Machine Tools Africa exhibition and its support to industry Canossa believes Machine Tools Africa will be a great step towards the recovery and upgrading of local manufacturing businesses in South Africa, with advanced technology, software and automation making more of an appearance at the show. “Industry players have an opportunity to highlight technological advancements, and also to show how technological infrustructure for human-machine collaboration can streamline processes and improve high-level decision making,” says Canossa. “It will be very exciting to see how our members and other companies utilise this platform to target and entice the manufacturing sector.” Education and skills development remain central to South Africa’s steel industry. Training and development of competent skilled staff has become a concern to the growth of the sector. World Skills South Africa will be participating at Machine Tools Africa to highlight its work in this area and to promote the much-lacking vocational training in our country. Visitors will also have the opportunity to listen to industry experts speaking at the free seminars, sharing their knowledge and experience across a wide range of important and current industry topics. For more information contact Dee Miloa, Specialised Exhibitions, +27 11 835 1565, [email protected], www.machinetoolsafrica.co.za

www.instrumentation.co.za March 2024 7 The latest developments in manufacturing include the adoption of advanced robotics and automation technologies, the use of 3D printing for rapid prototyping and production, the implementation of Internet of Things (IoT) devices for real-time monitoring and optimisation of processes, and the integration of artificial intelligence for predictive maintenance and quality control. Additionally, sustainable manufacturing practices such as recycling and waste reduction are becoming more prevalent in the industry. Manufacturing Execution Systems (MES) play a crucial role in manufacturing by providing real-time data on production processes, tracking inventory, managing quality control, and optimising overall efficiency. MES helps manufacturers make informed decisions and improve productivity. MES can also integrate with other systems, such as Enterprise Resource Planning (ERP) SAIMC NEWS Johan Maartens. National Members From the office of the CEO Date: Saturday, 24 August 2024 Time: 18h30 for 19h00 until late Venue: Monte Casino, Fourways, Johannesburg Theme: Masquerade Dress code: Mysterious, formal and masked Cost per table: R16 000 Sponsorships available INSPIRING AUTOMATION Annual Gala Dinner Have fun! Be intriguing… be mysterious…. For more information please contact [email protected] systems and plant control systems, to streamline operations and improve overall productivity in manufacturing environments. Data will play a significant role in manufacturing by enabling predictive maintenance, quality control, and process optimisation. Manufacturing companies are increasingly using data analytics to improve efficiency and reduce costs. Ensuring accurate data involves various steps, such as data validation, data cleaning, and data quality checks. It is essential to have proper data governance practices in place, and to use reliable data sources. Additionally, implementing data validation rules and regularly monitoring data quality can help ensure the accuracy of the data used for analysis. In an example, a data scientist analysed a manufacturer’s profit per employer, driven by the stringent labour practices placed on companies in South Africa. The manufacturer had various sites running different processes. It quickly became apparent that one of the facilities could remove a process line and replace it with one similar to a process line at one of the other plants. This resulted in more profit per employee, and the plant could now compete with the other plants within the company. Do not forget to obtain CPD points in our official publication this month – and if you are doing ‘engineering work’, you have until 31 December 2024 to register. Yours in automation Johan Maartens

8 March 2024 www.instrumentation.co.za SAIMC NEWS The annual general meeting of the SAIMC Johannesburg branch was held on 7 February 2024 at the Northcliff Country Club. The number of attending members was enough to reach a quorum. At the AGM a new branch management team was nominated and approved. The members are: Ann de Beer: Branch manager, Cheryl Hird: Treasurer, Dean Floyd, Diogo Fidalgo, Kevin Preston, Sagadevan Kanniappen. The new branch manager, Ann de Beer and her team would like to take this opportunity to thank Jenine Jansen Van Vuuren for her time as branch manager. Her effort and assistance over the past years are greatly appreciated. The calendar for 2024 is as follows: Technology events: These will be held on the following dates: 13 March at Phoenix Contact; 10 April; 8 May; 12 June; 10 July; 14 August; 11 September; 9 October. Johannesburg branch Durban branch Golf day: Date to be confirmed. Ladies event: Date to be confirmed. Training days and events: Dates to be confirmed. Year end function: 13 November. Johan Maartens of EXCO spoke briefly about the changes happening in ECSA from January 2025. A session with Johan will be incorporated into one of the technology evenings to get a clearer picture of the changes and implications for all registered engineers. The team is looking forward to an exciting new year and would welcome input from members on the topics they would like addressed in 2024. Please feel free to reach out to the team with suggestions. The technology event for 13 March 2024 will be hosted by Phoenix Contact. The topic under discussion is ‘Industrial Wireless’. The presentation has already been awarded CPD points. We look forward to seeing you all there. The Durban branch of the SAIMC held its annual general meeting at the Premier Splendid Inn in Pinetown on 24 January 2024, starting at 18:00. The small number of people attending the meeting was disappointing – ten − but there was an equal number of proxies and the meeting was declared properly constituted and was able to proceed. A decision had previously been made to hold the meeting in person rather than as a hybrid or totally virtual meeting, and we hope for a better turnout next year. Financially the year proved to be satisfactory, as shown by the report prepared by Kevin McElroy. A summary of the year’s events was presented by Howard Lister on behalf of Mark Calvert, the branch’s general manager, who was called away on business. Election of the branch management team was completed electronically beforehand, and the results were accepted by those present at the meeting. Office bearers were designated at the first meeting of the new team. The team for this year is: General manager: Mark Calvert Deputy general manager: Howard Lister Finance manager: Kevin McElroy Secretary: John Owen-Ellis Advertising: Jane van der Spuy Tertiary education liaison: Professor Akshay Saha and Anil Lonappan Regional development: Mfanasibili Nkonyane It was recommended that the successful practice over the past nine years of co-opting members be continued, as co-opted members have made valuable contributions during their tenure. After the business of the annual general meeting was concluded, the evening was rounded off with everyone enjoying networking over supper and some drinks.

www.instrumentation.co.za March 2024 9 Secunda Branch SAIMC NEWS The SAIMC Secunda branch held its annual general meeting on 17 January. The presiding general manager of the branch, Lezahn Meiring welcomed all members, most of whom had just come back from the festive season filled with great optimism for the new year. She gave her usual pleasantries and wished everyone a prosperous year ahead. She then proceeded to give a short report from the previous year, which was a successful one for the branch. The Technology Evening presentations in 2023 varied from compressors, condition monitoring, and functional safety to an ECSA workshop and digitalisation, to name a few. The Secunda branch will be 25 years old this year, which is a great milestone. Lezahn enthusiastically indicated that the branch looks forward to celebrating the achievement in many ways. She concluded her report by giving tentative dates for key events for the coming year, which include the annual Golf Day on 23 May at Graceland Hotel Casino and Country Club, a celebration for the branch’s 25-year milestone in November 2024, monthly technology evenings, and site visits. She thanked all members and the committee for being part of SAIMC and participating in all activities throughout the years. Lezahn was elected as the general manager for 2024, and the 2023 committee was elected to continue in 2024. After the AGM, there was a presentation from Nivaal Rampath, a sales specialist in level measurement and tank gauging from Emerson. His presentation was about ‘displacers vs guided radar’ and ‘ultrasonic vs non-contact radar’ level measurement. He gave technical differences in the measuring principles and how each should be applied. The February technology evening was held on 7 February, and RJ Ferreira from Valve and Automation, an old friend of the SAIMC, gave a presentation on butterfly triple offset valves (TOVs). It was extremely interesting to learn about the possibilities these offer, and the range of applications. Valve & Automation has recently moved its Vanderbijlpark workshop to the Secunda workshop, and a site visit there is being planned. RJ Ferreira from Valve & Automation (left), with Mkanyisi Zulu from the SAIMC Secunda Branch Committee. The presenters were thanked for always bringing interesting topics and discussions to our technology evenings.

10 March 2024 www.instrumentation.co.za Transparent energy monitoring reduces both machine downtime and the necessity to oversize components. Added to these advantages are simplified preventive maintenance and increased production efficiency. The wide range of PC-based control technology from Beckhoff offers a solution that can be optimally adapted to individual applications with numerous SCT current transformers and EtherCAT power measurement terminals. These include the integrated monitoring of the AC and DC supply, the 24/48 V DC power supplies of the three new PS device series, and the EL922x electronic overcurrent protection terminals. Universal system reduces work and costs No machine or plant works without reliable power supplies and the corresponding fusing. If this is combined with high-performance recording of energy data, advantages already result during the design of the machine. Additional power measurement technology at the power supply inputs provides an overview of the total power, including any losses. The new high-quality power supplies from Beckhoff’s PS series employ a systems approach to PC-based control because only when all components are optimally matched to one another can a system work optimally. In particular, the EL922x overcurrent protection terminals integrated directly into the EtherCAT I/O system not only reliably secure the power in the individual supply paths, but also continuously measure it. Machine manufacturers can avoid power peaks with this holistic approach. For example, they can reduce the connected load of the plant and also the installation costs for the Complete system for transparent energy monitoring end user, due to the smaller supply cable sizes. Furthermore, universal and system-integrated energy measuring technology satisfies the prerequisite for comparing the target and the actual state of the plant directly inside the machine controller. In this way, developing damage can be detected at an early stage, and process optimisation possibilities are easier to discover. Until now, continuous data monitoring has mostly been associated with significant investment, often requiring costly integration of external sensors, sometimes with the help of specialised components. However the power measurement terminals, current transformers, overcurrent protection terminals and power supplies from Beckhoff make this possible with standard components, correspondingly low costs, and reduced logistics requirements. Data transparency through complete measurement chain As an automation specialist, Beckhoff can combine power supply components to form a transparent and complete system. This provides a comprehensive overview of the energy and power supply of the machine on both the AC and DC sides. The complete measurement chain begins with the SCT current transformer at the main supply to the machine. The power supplies from the PS device series provide a safe 24 V DC for all connected automation components, while the overcurrent protection terminals not only secure the individual lines behind them, but also continuously monitor the current consumption. With the SCT series current transformers, Beckhoff has completed the power measuring chain from the recording of the physical measured values to the transmission of data to the cloud. The portfolio of current transformers covers all relevant applications for current intensities from 1 to 5000 A, and also ring-type and split-core transformer versions or three-phase transformer sets. There is a choice of two concepts which are highly scalable, and are thus suitable for a wide variety of applications. The SCT series is highly diversified, ranging from the low-cost three-phase transformer sets and standard industrial transformers for controls engineering through to solutions for test benches with particularly high accuracy requirements. There is a wide variety of requirements in energy management in the machine environment and in the energy economy, ranging from pure grid monitoring and process control through to high-end power monitoring. Extended by four new EtherCAT I/Os, a comprehensive range of EtherCAT Terminals is highly scalable in terms of both price and performance. Together with the proven EL37x3 grid monitoring oversampling terminals (and the associated TF3650 TwinCAT Power Monitoring software library), the new EL34x3 EtherCAT Terminals for energy management make up a comprehensive range of products that optimally adapt to the respective application in a wide range of uses. Distributed power measurement minimises costs The new concept of distributed power measurement offers a particularly efficient and inexpensive way to obtain exact power measurement data, even in high complex systems. The central element is the EL3446 6-channel Images copyright: Beckhoff Automation

www.instrumentation.co.za March 2024 11 current input terminal for measuring currents up to 1 A AC/DC. It can be used to determine precise power values, even with physically separated voltage and current measurement. All relevant electrical data from the supply grid, including real measured values for power, can be determined with the EL3446 as a current measurement terminal. The voltage values required for the calculation of the power data are transmitted via an EL3443 three-phase power measurement terminal, which needs to be installed only once for each system. The active power and energy consumption for each of the connectable phases is then calculated in the EL3446. Information is thus available on the effective values of voltage and current, the active, apparent and reactive power or frequency, the phase shift angle, and the harmonics. This enables comprehensive grid analysis extending up to energy management. This concept of distributed power measurement minimises hardware and installation costs. The wiring work for the voltage distribution is thus eliminated. In addition, the price per channel for power measurement is reduced by almost 50%, without having to reduce the sampling rate, as the number of measuring points increases. Power supplies with optimised convection cooling The new PS1000, PS2000, and PS3000 power supply series are the starting point for a powerful and safe power supply within the plant. They are suitable for virtually all areas of use, both in the 24 V and the 48 V DC range, and extending up to motion control applications with high requirements for back EMF. Excellent convection, minimised power loss, and high efficiency of up to 96,3% optimise the service life and reliability of the devices. The peak power capability of up to 150% makes it possible to provide up to 1,44 kW output power for short periods of time. In addition, the power supplies can switch off circuit breakers quickly and accurately through a precise tripping function, avoiding long machine downtimes. The devices are specifically designed with good convection cooling properties in mind. In addition, components that are particularly temperature-sensitive and prone to rapidly ageing are placed at the bottom of the unit, as close as possible to the incoming cool air. Due to this temperature-optimised design, all components used are subject to less thermal stress, and thus attain a long service life. In addition, components that are subject to less stress retain their technical characteristics for longer, and the influence of external heat is minimised. All this has a positive effect on reliability. Analogue monitoring terminal with fusing functionality In the EL922x EtherCAT Terminal series, Beckhoff combines functions for comprehensive energy monitoring in a highly compact way, with electronic overcurrent protection for fusing 24 V DC plant components. These analogue monitoring terminals record the current and voltage values for continuous power monitoring. Among other things, these enable a detailed analysis of power consumption and voltage, and also the monitoring of voltage limit values. Furthermore, status information (on, off, triggered), trigger events (overload, short circuit) and preliminary warnings can be displayed. The integration of electronic overcurrent protection directly into the EtherCAT I/O system reduces the costs and space required in control cabinets compared to other fusing products, without the need to use a conventional electronic solution as an inflexible standalone system. EL9227 EtherCAT Terminals also meet the most diverse requirements through numerous settings and process data options that enable transparent system monitoring. A total of 19 different one- and two-channel overcurrent protection terminals are available for current loads up to a maximum of 10 A. The system-integrated overcurrent protection offers numerous practical advantages. It reduces wiring work as the supply to the neighbouring I/O terminals connects automatically when the terminal is plugged in. In addition, the control cabinet design benefits from space and cost savings by eliminating an unnecessary additional coupling device and further digital I/O or supply products. Furthermore, EtherCAT offers access to numerous process data such as load, load current, input/output voltage, under/overvoltage and reverse supply. For more information contact Beckhoff Automation, +27 11 795 2898, [email protected], www.beckhoff.com

12 March 2024 www.instrumentation.co.za AUTOMATION PROFESSIONALS Abacus Automation supplies innovative, custom-developed technical solutions using standard PLCs, drives, scada and motion control equipment and is Siemens approved for crane automation. With 23 years in the industry, this award-winning and internationally acclaimed company has highly qualified, experienced and professional staff. It operates out of offices in KwaZulu-Natal. Tel: +27 31 702 5767 [email protected] www.abacus-automation.co.za Abacus Automation Control Software Solutions - CSS Customer-centricity allows CSS to attain a high percentage of repeat business from its growing customer base. With a solid 17 years’experience in designing customised C&A solutions, CSS partners with customers in relationships thriving on information sharing and open communication enabling them to enhance customer operations. Supplier Certification provides customers with the assurance that the CSS team is completely up to date on current trends and technology as indicated by a number of prestigious awards. Tel: +27 31 914 0040 [email protected] www.cs-solutions.co.za Moore Process Controls Moore Process Controls provides process automation and optimisation solutions to realise the maximum potential of your plant and assets. Its offerings include DCS, PLC, scada, compressor control solutions, MES, production management and predictive maintenance systems, control loop optimisation, alarm and energy management systems, plant security and access management systems, Matrikon OPC, OSi Soft, dashboards and historians, wireless and data solutions including digital twin, process simulators and training simulators and cloud-based IIoT solutions. Tel: +27 11 466 1673 [email protected] www.moore.co.za Consulting engineers, system integrators & project houses EHL Consulting Engineers offers comprehensive C&I services across all industries including control system design, software development and system integration; legacy system upgrades and replacements; process automation and optimisation; and IS and SIL services. Tel: +27 11 370 7400 [email protected] [email protected] www.ehl.co.za EHL Consulting Engineers Autotronix is a recognised leader in industrial automation design and implementation having attained its ISO 9001 certification. Autotronix offers its clients turnkey control system integration services for energy management, PLC/HMI/scada/VSD, manufacture of control panels, applications for water distribution and manufacturing. The company operates from offices in Gauteng and KwaZulu-Natal. Tel: +27 31 705 0400 or +27 16 422 7644 [email protected] www.autotronix.co.za Autotronix Iritron is a new millennium technology company providing quality solutions in the fields of electrical instrumentation and control systems engineering, MES systems integration and simulations. It has a proven ability to manage projects efficiently and produce high quality results. It has an extensive track record of successfully implementing plant infrastructure reticulation, designs, and automation and information systems. Iritron, a TUV accredited ISO 9001:2015; ISO 14001:1015 and ISO 45001:2018 as well as a GAMP®5: A Risk-Based Approach to Compliant technology company, can offer its clients PLC, DCS, MES and scada software and hardware, as well as electrical and instrumentation design, engineering, project management and commissioning services. Tel: +27 12 349 2919 [email protected] www.iritron.co.za Iritron

www.instrumentation.co.za March 2024 13 AUTOMATION PROFESSIONALS Systems Automation and Management is a supplier of data acquisition systems and innovative automation solutions and is one of the leading integrators of PLC, scada and fieldbus systems in South Africa. The company’s comprehensive range of capabilities includes industrial networks, automation and control, scada, custom solutions, information delivery, data warehousing, hardware and software, BMS, MIS and MES. Tel: +27 11 803 0570 [email protected] www.sam.co.za SAM – Systems Automation and Management Process Dynamics specialises in industrial automation and process control. The company is one of Africa’s leaders in turnkey automation projects and specialises in the integration of scada (WINCC, PCS7, Wonderware, Citect and Ignition) and PLC ( Siemens, Schneider, Rockwell and Festo) as well as MCC and control panel manufacturing and installation. Process Dynamics is ISO 9001:2015 accredited as well as a registered CIDB company. Tel: +27 11 394 5412 [email protected] www.process-dynamics.co.za Process Dynamics PCS Global At PCS Global we understand that you’re ultimately in business to maximise profits. This means reduced cost of ownership, increased uptime, consistent results and ultimately a solution that not only fits your budget but lets your business work whilst you’re at home with your family. To us that means providing a hassle free, customised engineering solution that exceeds your expectations. Are you ready to take your business to the next level? We are! Level 2 BBEEE , ISO 9001:2015, CIDB. Siemens, Schneider, Wonderware and Rockwell certified. Automation Innovation, it’s the new AI. Tel: +27 11 466 4172 [email protected] www.pcsglobal.com Proconics is a locally based multi-discipline engineering company that executes projects to improve and extend the life of factories. Proconics specialises in multi-discipline, short-term turnkey projects, featuring brownfield replacement projects as well as renewable grid connections. Tel: +27 16 982 7880 [email protected] www.proconics.co.za Proconics Philco Systems Philco Systems provides turnkey industrial automation solutions that are tailored to the client’s individual application, with 30 years’ experience in industrial automation design, drafting panel building, software engineering, field construction, commissioning and legacy migration. Philco Systems integrates a vast array of PLCs, VSDs, HMI, scada and instrumentation into custom solutions, which align with industry standards. At Philco we pride ourselves on building long-lasting customer relationships and have an excellent reputation for providing service and support to the clients’ automation systems. Tel: +27 35 751 1363 [email protected] www.philco.co.za What we are offering (an anually renewable subscription): South Africa’s only dedicated process control and factory automation publication. Whether you are a consulting engineer, a system integrator or a project house, we have the perfect marketing platform to put you in touch with nearly 4500 relevant control and automation practitioners in the automotive, food & beverage, mining, petrochemical, power, pulp & paper and water & wastewater industries. Name, contact details, logo and brief description of your business solution will appear in each issue of SA Instrumentation & Control magazine. Two A4 in depth editorials OR, two half page display advertisements – content of your choice. All articles will also be hosted on our website and appear in a prominent position in one of our electronic newsbriefs. PDF copies of the articles (to be used for your own purposes) will be provided after publication. Your listing will be published in a new “Choose Your Automation Professional” section of the annual SA Instrumentation & Control Buyers’ Guide and a link to your company web page in all directory listings. Contact: [email protected]

14 March 2024 www.instrumentation.co.za SYSTEM INTEGRATION Despite the multiple challenges faced by businesses in South Africa, the buoyancy of the technology sector worldwide has produced some green shoots for automation specialist, Iritron. This has been driven by advances in IIoT, smart sensors, on-line asset management, digital methodologies, and information sharing in the IT environment. The company has commissioned a number of projects in both the mining sector and in food processing production lines involving advanced technology solutions. According to Iritron CEO, Alwyn Rautenbach, the manufacturing and agricultural sectors in Gauteng and Western Cape are buoyant. The application of integrated digital control systems for solar energy installations is a growing aspect of its business. The same is true in the mining sector. “By combining our instrumentation and control expertise in the mining space with developments in solar, we have launched the concept of solar-powered Wi-Fi trailers, which bring Wi-Fi into the open pit environment. This allows remote control of autonomous drilling operations, and traffic control of vehicles operating in an open pit, resulting in safety improvements and cost and fuel savings to the mine,” he says. “Automation, digital control and the complex synchronisation of electric motor Iritron’s year of consolidation driven equipment has been an Iritron success story, and has established us as the go-to experts for industrial control management, plant optimisation and data recording,” he continues. In the mining space, the firm has been active in the delivery of automation and on-site instrumentation of crushers at an iron ore mine. It was involved with another customer in the upgrading of highly complex motor control and variable speed drives for plant controlling fans, pumps and conveyors. “The first four of a total of 67 motor control centres have been commissioned on this project, on time and within budget. This involved the replacement of obsolete equipment with advanced electronics, in an extremely confined space. We redesigned proprietary equipment in conjunction with the OEM, while ensuring that our design didn’t compromise the OEM certification and guarantees of the equipment. Furthermore, advance software programming skills allowed the synchronisation of conveyor motor drives. There were up to four VSDs per conveyor, all of which had to operate completely in unison,” he explains. Further mining projects on multiple fronts have involved management consulting to devise strategies and specifications for asset management systems, data sharing at ERP level, and the integration of existing communication systems with more advanced communications and telemetry. Designed and installed by Iritron, these systems provide management with a completely integrated dashboard for everyday operations and for disaster management incidents. The global nature of the mining industry has placed greater emphasis on ESG issues, and the accurate accounting, tracking and reporting of metal production. Global mining companies place as much emphasis on accurately accounting and reporting on production and work in progress as on financial accounting and reporting. Iriton’s integration and software expertise addresses all these challenges. Food production lines are another area of Iritron expertise, with recent projects aimed at optimising canning and packaging operations for major producers. “Currently, we are commissioning a data recording system for measuring line efficiency on a canning plant that produces condiments in Tzaneen. The customer had a target of increasing plant capacity by 50%, and required an integrated solution which measured line efficiency and performance of its fill and cap machine. Calling on two different technologies, our engineers were able to provide the customer with a system that records throughput against a target plan, identifies quality issues, and records downtime and line blockages. Such is the sophistication of the system that a plant manager can interrogate the system from any location via a smart phone. In a separate project, Iritron upgraded a TrakSYS system with a completely automated solution to allow the tracking and seamless capture of the mass and throughput of palletised products from production to warehouse. What of 2024? “Mines are demanding more technology to provide automation and real time, online condition monitoring for critical equipment such as drainage pumps, compressors, and bulk handling equipment like crushers and conveyors in order to improve efficiency and control costs. Collection of the operating data of these assets and presenting the information in a visual form allows mine engineers to optimise operations and to predict and prevent equipment failures while recording machine performance and power consumption. “Demand for copper and PGMs by battery manufacturers has led to an upswing in mining activities further north in Africa. Iritron has followed the trend, providing automated and system solutions for enterprises in Gabon, Senegal, Zambia and Tanzania. This situation is likely to grow as the switch to EVs gathers momentum,” concludes Rautenbach. Iritron’s commitment to efficiency solutions in mining, coupled with the company’s foray into the solar power industry with sophisticated control systems and specialised Wi-Fi enabled solar trailers, makes the future looks bright, despite local economic headwinds. For more information contact Gerhard Greeff, Iritron, +27 82 654 0290, [email protected], www. iritron.co.za Alwyn Rautenbach, CEO of Iritron.

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