38 VOLUME NO 6 JUNE 2022 Official publication of the SAIMC Mining, metals & quarrying | Building management Process measurement | Condition monitoring | Control systems
MANUFACTURERS Calibration Laboratory +27 (0)11 021 8082 +27 (0)31 579 2216 [email protected] www.sagauge.com 2008 MADE IN SOUTH AFRICA GAUGE SA Gauge is a specialist South African manufacturer of pressure and temperature measuring instruments. Pressure gauges, thermometers, diaphragm seal systems, pressure testing kits and related accessories are manufactured to standard and OEM specifications with short lead times. The SA Gauge pressure and temperature calibration laboratory has been accredited to SANAS ISO/IEC:17025 standards for calibration. Always in Stock “Because quality matters”
www.instrumentation.co.za June 2022 1 Control systems Building management Mining, metals & quarrying IT in manufacturing Electrical power & energy efficient systems VOLUME 38 NO 6 JUNE 2022 04 08 10 40 REGULARS Cover story 12 FEATURES Process measurement Condition monitoring Safety systems 14 24 26 28 30 36 34 38 News & events SAIMC news Automation professionals Product news New pressure sensors for hygienic applications push resolution limits. Omniflex Remote Monitoring Specialists, Endress+Hauser South Africa, VEGA Controls SA, SECO Process Instrumentation, GHM Messtechnik South Africa, WIKA Instruments, ifm – South Africa Turck Banner BAMR, R&C Instrumentation SEW-EURODRIVE, Schneider Electric South Africa Michael Brown Control Engineering CC Beckhoff Automation Becker Mining South Africa, Booyco Electronics Gavin Halse, EtherCAT Technology Group OUR COVER 12 38 VOLUME NO 6 JUNE 2022 Official publication of the SAIMC Mining, metals & quarrying | Building management Process measurement | Condition monitoring | Control systems For years, the ifm pressure sensors of the PI series have proven their worth in the food and beverage industry. But even what is successful can be improved upon. Pressure changes can now be visualised via IO-Link in high resolution with approximately 20 000 steps. This is an enormous benefit, especially for hydrostatic level measurement with head pressure.
2 June 2022 www.instrumentation.co.za welcome VOLUME 38 NO 6 JUNE 2022 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. 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COVID-19 South African Resource Portal www.sacoronavirus.co.za EDITOR Brett van den Bosch B Eng (Electrical & Electronic) [email protected] DEPUTY EDITOR Kim Roberts MSc Chem [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, Box 385, Pinegowrie 2123 Last year’s announcement by the Department of Mineral Resources and Energy that it was raising the registration threshold for self-generating electricity providers from 1 MW to 100 MWwas widely lauded as a crack in the damwall that would release a flood of pent-up renewable energy investment. The signs are positive that this relaxing of regulations is indeed bearing fruit: the National Energy Regulator of South Africa (NERSA) announced on 7 June that it had approved the issuance of registration certificates to 16 new power generation facilities, all of which were received during April and processed within 19 working days. All 16 use renewable energy (15 are solar-powered and one is windpowered). For the first quarter of the 2022 calendar year, a total of 54 generation facilities with a total capacity of 29 148 MWwere approved, representing a total investment of roughly R452 million. This investment is not coming solely from within our own borders, however. An adage passed down to us through the ages advises against looking a gift horse in the mouth, but as the ancient Greeks would attest, the wiser approach is to inspect it thoroughly from head to toe, lest it be of the Trojan variety. There are many countries around the world that have fully developed strategies to invest in the renewable energy sector in sub-Saharan Africa, and are already doing so. While we shouldn’t thumb our noses at foreign investment, European countries in particular have a long and bloody history of ‘investing’ in Africa by means of exploitation and colonisation. And now it seems the whole world wants a piece of our renewable energy action. It only takes a bit of googling to find detailed analyses of the sub-Saharan market, including governmental policy recommendations such as those put forward in the report ‘Scaling China’s Green Energy Investment in sub-Saharan Africa: Challenges and Prospects’. When I see our (mostly) beautiful weather described in said report as a “resource endowment factor” it chills me to the bone. This foreign investment drive comes through both public and private sector channels, each of which has its own strings attached. Per the aforementioned report, “African governments should also encourage Chinese partners to be more actively involved in various policy learning, sectoral planning and capacity-building effort.”. This could be interpreted as encouraging diplomatic meddling, which South Africa is particularly vulnerable to at the moment due to our many socio-economic challenges, and decades of mismanagement at Eskom, as well as pressure due to the fact that we’re lagging behind the targets put forth in the Paris Agreement on climate change. As for the public sector, let us not forget the lessons we should have learned from the downfall of our domestic textiles industry. Opening up the market to all and sundry only serves to undermine our economy, and our society due to resulting job losses, in the long term. It does not and should not sit comfortably to allow foreign powers so much leverage over us – leverage they can and will apply to serve their own interests. Yes, we need immediate solutions to make up for decades of mismanagement at Eskom. No, we don’t have the economic wherewithal to do it ourselves. But if we keep taking the easy way out, the threat looms large that the wealthy countries of the world will stand proudly bathing in our abundant sunlight while we thank them for letting us lounge in the shade they cast. Come for the sunshine, stay for the loot
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NEWS & EVENTS 4 June 2022 www.instrumentation.co.za Fluid Systems Africa was recently appointed as the official partner of Arpol flexible pipe couplings in Africa. Arpol designs and manufactures flexible joints for the connection and repair of all types of pipes and industries. Fluid Systems says Arpol’s flexible couplings connect pipes better, faster, safer and at a lower overall cost than conventional systems. Arpol was founded in 1976 in Barcelona, and specialises in the design and manufacturing of flexible couplings for all types of pipes and applications. The company’s size range is 48 to 3000 mm and it covers pressures from PN16 up to 1300 mm, and PN10 up to 2000 mm. Some of the sectors that put their trust in these flexible couplings are water purification and treatment plants, the chemical industry, power stations, domestic installations, civil construction and engineering, mining and bottling plants. Fluid Systems Africa becomes official Arpol partner Valmet is introducing a new wet electrostatic precipitator for the marine industry to enhance emission control. The solution goes even further than the global regulations set by the International Maritime Organization (IMO) in 2020, as it allows harmful particulate matter to be removed from the exhaust gas flow. “For years we have been developing solutions to help the marine industry reduce its emissions. The new wet electrostatic precipitator now enables our customers to efficiently reduce emissions from their fleet,” explains Timo Lamminen, product sales manager, Valmet. Valmet claims to be the first supplier to introduce a hybrid scrubber to the market years ago, and to have brought the most effective wash-water treatment system to the market in 2021. The introduction of its Wet Electrostatic Precipitator (WESP) is a Wet electrostatic precipitator keeps marine vessel emissions under control direct continuation on this development path of bringing marine solutions toward more sustainable ship transport. WESP is used to control particulate matter emissions, such as black carbon. The system also captures heavy metals, acid mist, oil mist and visible plume. Its operation is based on a very strong electrical field between discharge electrodes and collecting tubes. The electrical field charges the particles in the exhaust gas flow, resulting in their migration away from the flow to the collecting tubes. The process is controlled fully automatically by Valmet DNA or other distributed control systems, and can utilise new Valmet Industrial Internet (VII) features. The WESP system for marine use is based on technology by Valmet’s partner, AWS Corporation. Valmet recently tested a wet electrostatic precipitator and scrubber combination that In many cases, new pipelines involve pipe materials that are different from the previously installed pipes, and can create diameter differences that, even though minimal, can become an inconvenience when old and new lines are to be connected. Arpol couplings can be used to repair any point of the line, but also to connect dismantling pipes to different hydraulic pieces (valves, pumps, etc.) as well as different material pipes. Arpol couplings are up to the task of connecting different diameters, and they accommodate a large enough tolerance window to solve common old-line problems like angular deflections, pipe separations, settlement corrections and rough surfaces. For more information contact Fluid Systems Africa, +27 87 551 1677, [email protected], www.fluidsystemsafrica.co.za was able to slash exhaust gas particulate matter and black carbon emissions in a marine diesel engine by up to 99%. The solution enables shipping companies to lower their particle matter and black carbon emission levels and tackle global warming. It also makes it possible to comply with tightening regulations and even reach the EURO 6 norm, which is the tightest regulation for road transportation in the European Union. The pilot testing and configuration project was carried out together with VTT Technical Research Centre of Finland. Until now, IMO’s regulations on air pollution have addressed mainly SOx and NOx emissions, but the awareness of particulate matter and black carbon emissions is growing due to their negative impact on global warming and human health. Whereas SOx scrubbers can reduce particulate matter and black carbon emissions with limited efficiency, a combination of a wet scrubber and a wet electrostatic precipitator, or a standalone wet electrostatic precipitator, can capture these emissions almost completely from a ship’s exhaust gas. For more information contact Valmet Automation, +27 31 539 8640, [email protected], www.valmet.com
NEWS & EVENTS www.instrumentation.co.za June 2022 5 The reality of counterfeit bearings is definitely on the increase in South Africa. In fact, the Hawks police unit recently discovered a large quantity of fake bearings – valued at over R5 million – being stored at a warehouse in Johannesburg. “As global trade increases, the issue of counterfeit goods continues to affect all aspects of our economy. BMG, which is the authorised distributor of a wide range of engineering consumables, is concerned about the proliferation of counterfeit merchandise and the dangers associated with using inferior goods,” states Carlo Beukes, business unit manager for BMG’s Bearings division. “BMG has secured exclusive supply, service and distribution agreements with some of the world’s most respected manufacturers and our commitment to suppliers and customers is to respect the integrity of their brands. “In response to the recent discovery of fake NSK bearings, we wish to reassure our customers that all NSK products procured from BMG are genuine components. BMG is a preferred and authorised distributor for NSK and we have had a long-standing relationship with the company since 1976.” BMG is a member of the World Bearings Association (WBA) and in conjunction with bearings manufacturers, a useful application has been developed that enables identification of a counterfeit product by scanning QR codes on packaging. Beukes continues: “We encourage consumers to take special care when sourcing products from non-authorised suppliers.” Here are a few key aspects to consider regarding the legitimacy of product integrity: • If the price is much lower than from an official source, this should be a warning about where the product comes from. Is it an original Stark warning over counterfeit bearings product, has it been refurbished, or is it faulty or outdated stock? • Does the packaging have the correct identification markings in terms of the logo, branding, stickers and barcoding? If a seal over the box has been tampered with, this is a cause for concern. The authenticity of the product can be verified by the manufacturer or official distributor and by using the QR code application. • When the product is inspected, does it have the correct part number etched? Is the part number an official manufacturer’s part number? This can be verified by the manufacturer. • How professional is the machining of the product? The quality of the cage material, grinding marks and finishing are good indicators of whether this bearing is from a legitimate source or not. “The problems associated with counterfeit bearings include poor manufacturing design and quality standards, which means reduced service life of the component, increased downtime of machines, compromised productivity and greater component and maintenance costs. Although the cost of a sub-standard bearing is lower than the procurement cost of quality branded bearings, the costs incurred when this bearing fails are substantial. In the event of bearing failure, it is most often not simply a case of replacing the failed part.” Firstly, the operator has to consider lost production time while equipment is not functional, and secondly, the failed bearing tends to cause serious damage to machinery. For example, a counterfeit bearing installed in an electric motor will not only result in the loss of the part, but will also damage the motor itself as various components, like coils, seals and the shaft, are often damaged and need to be replaced. The BMG team encourages consumers to take special care when sourcing products from non-authorised suppliers. A special website dedicated to this issue has been set up at www. stopfakebearings.com For more information contact BMG, +27 11 620 7558, [email protected], www.bmgworld.net
NEWS & EVENTS 6 June 2022 www.instrumentation.co.za Technodyn International, strategic partner for global cloud enterprise software company IFS in sub-Saharan Africa, has announced that a global manufacturing study on sustainability and the circular economy conducted by IFS and research firm Omdia has found that a lack of centralised responsibility, legacy assets, infrastructure and upfront costs are the most significant barriers to investments in sustainability. The survey polled a range of high-level executives working for manufacturers across North America and Europe to better understand their views on sustainability and the circular economy (a model of production and consumption that focuses on the reuse and recyclability of products and materials). With only 12% of respondents having already rolled out circular economy programmes, the survey highlighted the significant work still to be done on addressing sustainability in the sector. The research encompassed three areas that impact the approach by manufacturers on sustainability. The first focuses on investment drivers. These include environmental responsibility and barriers like legacy infrastructure. The second area examines the Research underscores sustainability imperative for manufacturers sustainability implementation status, such as the key areas where companies are currently focusing on their sustainability initiatives and sustainability maturity level. Finally, the third area assesses the case for the circular economy and its benefits. “With the disruption caused by the pandemic being considered a catalyst for renewed sustainability, the IFS survey is timely,” said Heman Kassan, chief commercial officer at Technodyn. “There is a worldwide need to curb the impact of manufacturing on the environment through interventions such as reducing carbon emissions and industrial energy consumption. External pressures such as customer awareness and regulatory pressure are certainly helping to push it up the priority list for manufacturers. But there is still a disconnect to practically addressing the sustainability challenge.” There are positive signs, though. According to the survey, 80% of respondents are either in the process of piloting circular economy initiatives, have finalised objectives and are deploying them, or are in the process of developing objectives. The survey found that the top three drivers for sustainability initiatives at manufacturers are regulatory compliance (18%), business risk (15%), financial incentives and tax reductions (15%). This suggests that there remains a reactive mindset among manufacturers when it comes to sustainability and the circular economy, despite how important ESG (environmental, social and governance) reporting has become. The most significant benefits a circular economy model will deliver for an organisation are seen as being able to support a sustainable strategy, with 78% of respondents ranking it in their top five. This was followed by increased customer engagement (74%) and improved environmental protection (74%). “Of course, embracing sustainability and a circular economy mode of production are complex and expensive undertakings. However, the benefits of becoming more sustainable in today’s more environmentally conscious market certainly make it worth the effort,” said Kassan. The IFS research report can be downloaded from https://info.ifs.com/manufacturingsustainability.html Africa Automation Technology Fair (AATF), brought to you by RX Africa, is excited to announce that the 2023 edition will be the host of the collocated launch event ‘Future Manufacturing Africa (FMA) Trade Fair and Summit 2023’. FMA 2023 aims to exchange valuable industry expertise to increase investment prospects in the African continent’s manufacturing sector. The collocation is an effective way to introduce the inaugural FMA 2023 while expanding on insights into the competitiveness of markets across various sectors for fruitful investment and sustainability. The launch of FMA 2023 will be a distinguishing feature of the event, bringing a new audience sector to AATF. In attendance across the two events will be over 5000 visitors, several feature areas and over 200 exhibitors over the three days. AATF 2023 also introduces technology alongside industrial automation. The event will include: • African hosted buyer programme. • One-on-one meetings with hosted buyers. • African hosted buyer lounge. • VIP programme and VIP lounge. • Technology demo zone. • Automation technology experience. • Business connection zone. AATF 2023 to collocate with Future Manufacturing Africa • Visitor guided tours. • CPD accredited workshops. RX Africa, through AATF, connects business and various stakeholders with the latest industry innovations and global patterns in the automation and technology industry. For 2023, AATF has additional product categories and new show innovations centralised around the development of automation technology. AATF 2023 aims to take key stakeholders through the advance market-related innovations and mega-trends while transferring key insights on progressive and effective transformation in the technology and automation industry. The key extension is to mobilise opportunities within the industrial automation space and create a conducive environment for stakeholders to build sustainable solutions for African markets. RX Africa is providing a conduit that facilitates the connection between quality decision-makers, business leaders and government, amongst other patrons across various sectors. By attending AATF 2023, one can gain access to agile, advanced and innovative products and solutions within the African continent in an environment that offers comprehensive and focused industrial automation technology platforms in Africa. Stakeholders are introduced to systematic value chain solutions that raise awareness around the introduction of technology in their businesses. Being a participant and launching your new products and services at the fair will afford your business and solutions unprecedented brand awareness and exposure to prime networks in various sectors. To deliver a valuable and impactful experience, AATF 2023 works with industry associations and other partners to elevate the exhibitions and conferences. The trusted entities working with RX Africa for the fair are the Society for Automation, Instrumentation, Measurement and Control’s (SAIMC) Supplier Advisory Council, and Technews Publishing as the main media partner. Join us in the business of building businesses at the African manufacturing trade fair and summit. Be part of an experience that is increasing Africa’s value chain in the manufacturing sector. AATF 2023 will take place at the Johannesburg Expo Centre (Nasrec) on 9-11 May 2023. For further details on how to get involved and invested, visit www.africaautomationtechnologyfair.com
NEWS & EVENTS www.instrumentation.co.za June 2022 7 What if there was a robot that was easy to operate, did not require a safety fence, and was also attractively priced? According to Festo, that would bring about a whole new era in human-robot collaboration, which is now dawning with its world-first pneumatic robot. The human-robot collaboration (cobot) segment is growing rapidly in the industrial market. Cobots now relieve employees of particularly strenuous or monotonous tasks, thus giving them new levels of freedom and making their work easier and healthier. No technology has such a sensitive and flexible approach to human-robot collaboration as pneumatics. The benefits of pneumatics The Festo Cobot owes many of its advantages – such as sensitivity, weight and value for money – to pneumatics. The direct drives in the articulated joints are very cost-effective and particularly lightweight because, unlike electric solutions, no heavy gear units or expensive force-torque sensors are required. Cost-effective even for small- and medium-sized companies The Festo Cobot makes using cobots even more cost-effective for small- and mediumsized companies, as they often rely on manual work processes. This is achieved thanks to the flexible application options that mean small batch sizes or work steps can also be processed automatically. Thanks to its intuitive and simple commissioning and programming, it is quick as well as easy to get to grips with and does not require extensive training. The pneumatic Festo Cobot intends to be cheaper than electric cobots in the same class, and to provide excellent value for money in its main application area of small parts handling with payloads of up to 3 kg. “When it goes on sale in 2023, the Festo Cobot will set new standards in human-robot collaboration with its ease of use,” explains Dr Frank Melzer, member of the management board for product and technology management at Festo. Easy to operate and flexible to use The Festo Cobot consists of the hardware, a handheld module and Robotic Suite software for commissioning and programming in less Festo unveils world’s first pneumatic cobot than an hour. Prior knowledge of robotics is not required as the self-explanatory software contains clearly visualised and standardised function blocks. Pneumatic drives enable the robot arm to be easily guided by hand and without any resistance, so that waypoints or paths can be taught quickly and precisely. In small- and medium-sized companies, cobots are only attractive if they can quickly take on a new task and are not intended to be permanently used for the same purpose. The Festo Cobot meets these requirements as it doesn’t require an additional control cabinet that is cumbersome and difficult to connect. The compact controller that is integrated into its own base makes it particularly flexible, while simple connections also allow it to be used ad hoc without long changeover times. Common bus standards enable fast connection to higherorder controllers, and it also requires less space. Thanks to state-of-the-art and lightweight construction methods, the weight of the Festo Cobot has been reduced to well under 20 kg. Thus, it can be used quickly and flexibly at different locations. Working safer and faster With a length of 670 mm, the Festo Cobot is just like a human arm and has the right reach for it to be perceived as a helping third hand when working with a member of staff. It moves like a real colleague within a manageable radius. Thanks to the flexibility of the pneumatic drives, the cobot acts sensitively at a speed appropriate to the situation and with fluid, harmonious movements. It is as soft to the touch as human contact. The cobot’s pneumatic direct drives and its light weight reduce its contact energy. Christian Tarragona, head of robotics at Festo, says: “Thanks to precise pressure regulators in the articulated joints, the robot recognises when it is being touched and responds with appropriate safety functions.”This means employees can work together with their careful technical colleague in complete safety. For more information contact Festo South Africa, 08600 FESTO (33786), [email protected], www.festo.co.za
8 June 2022 www.instrumentation.co.za Branches Johannesburg: Dean Floyd at [email protected]; Mobile: +27 82 455 3929 Cape Town: Hein Ries at [email protected]; Mobile: +27 73 351 2875 Durban: Mark Calvert at [email protected]; Mobile: +27 83 452 3181 Gqeberha: Prof. Theo van Niekerk at [email protected], Mobile: +27 82 440 8957 Richards Bay: Mervyn Govender at [email protected]; Mobile: +27 83 299 2260 Secunda: Lezahn Meiring at [email protected]; Mobile: +27 84 440 7787 Tshwane : Mark Taylor at [email protected]; Mobile: +27 61 769 3344 Vaal: John Phala at [email protected]; Mobile: +27 71 679 5076 Zambia: Andrew Sikwese at [email protected], Tel: +26 96 963 1008 Council: Ina at [email protected], Mobile: +27 82 440 8957, Tel: 08610 72462 (08610 SAIMC) From the office of the CEO Johan Maartens. SAIMC NEWS National Members MALEs are ruling the world! No, it is not gender I’m referring to, but a class of drone known as ‘Medium Altitude, Long Endurance’, of which the Bayraktar TB2 is one, and about which I wrote in my previous column (www.instrumentation.co.za/16288r). Now that I have your attention, let us get onto other topics of the day. Myself (representing SAIMC), Prof. George van Schoor (North-West University), Henry Heymans (Siemens), Dr LW Beneke (Tshwane University of Technology), and Prof. Theo van Niekerk (Nelson Mandela University) recently put our heads together and drafted the Discipline Specific Training Guidelines (DSTG) for Mechatronics. These guidelines cover mechatronics devices, factory automation and process automation. The next task assigned to Prof. van Schoor, Prof. van Niekerk, Itumeleng Moerane (Bafokeng Platinum) and I by ECSA (Engineering Council of South Africa) is to draft the Code of Practice for Mechatronics. Our next assignment from ECSA is the registration of Enterprise Integration Professionals (for MOM/MES activities), following the recent vote by MESA Africa’s executive committee in favour of integration into the SAIMC. I will keep readers posted on our progress. “The alignment comes at a time where both business and operations seek the benefits of technology to improve operations and service, maximise customer engagement, and improve revenue. These are core components of operations technology and information technology convergence, and the smart factory that is the passion and expertise available within MESA Africa,” reads a statement fromMESA Africa. The SAIMC negotiated the collaboration deal with MESA International (Manufacturing Enterprise Solutions Association International), a global non-profit organisation providing education, networking and best-practice sharing around smart manufacturing and Industry 4.0. MESA’s community includes manufacturers, producers, industry leaders and solution providers focused on driving business results frommanufacturing technology. According to this collaboration model: The SAIMC will form a core committee to engage with MESA International. The name of this group is still under discussion. • Individual members of SAIMC may join MESA International at a reduced rate depending on their chosen category. There are four categories for individuals, ranging from $80 to $200 per annum. The benefits include white papers, event presentations, webinar recordings, eBooks and guidebooks. By the way, I see there are also many FEMALEs ruling the world. This is also not a gender, but ‘Freaking Expensive Medium Altitude, Long Endurance’ class drones like the Denel Dynamics Bateleur and the Yabhon United 40. Yours in Automation, JohanMaartens
www.instrumentation.co.za June 2022 9 SAIMC NEWS On 7 April, Mark Middelhoven from Flexim gave a presentation on the topic ‘Ultrasonic Flow Meters – More than flow rate’. He covered the basics of non-invasive flow measurement, the relationship between the speed of sound and concentration/density at a given temperature, different use-cases of non-invasive flow measurement (for example, corrosion-free mass flow measurement, absence of pressure drop, and automation of loading and unloading) and the prevention of mixing of incompatible fluids. Other topics covered were standard volume and mass flow rates for hydrocarbon gases, and ultrasonic meter diagnostics as a qualitative tool. On 5 May, students and staff from Vaal University of Technology (VUT) joined for a technology evening presented by LAPP, on cables and cable technology. Its presentation covered everything from cable pricing, different types of cable technology, manufacturing of cables and insulation in cables, to different types of protection for cables, cable standards and cable ratings. All instrumentation and control-related mechanicians, technicians and/or engineers are welcome to attend the branch’s monthly technology events in 2022, with the next two on the calendar scheduled for 7 July and 4 August. A vote of appreciation goes out to Proconics Secunda for sponsoring the venue, snacks and beverages for all technical events. Technical presentations at the SAIMC Secunda branch will earn CPD points for ECSA-registered individuals and all enquiries can be directed to the branch general manager, Lezahn Meiring, on +27 84 440 7787. Secunda branch www.saimc.co.za
10 June 2022 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, systemintegrators &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 newmillennium 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 tomanage 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, aTUV accredited ISO 9001:2015; ISO 14001:1015 and ISO 45001:2018 as well as a GAMP®5: ARisk-BasedApproach toCompliant 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 June 2022 11 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 Saryx Engineering Group PCS Global Philco Systems At PCS Global we understand that you’re ultimately in business tomaximise 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 Saryx is an-award winning company whose focus lies in offering its clients the best solutions and services, taking into account their business objectives, current infrastructure and product knowledge investments. Its solutions are delivered at a value that makes sense to the client, by bringing forth industry standard best practices, intellectual capability, knowledge and infrastructure. Saryx is a BBBEE, 7EP CIDB and ISO accredited company. Tel: 086 099 5105 [email protected] www.saryx.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 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 Proconics 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]
12 June 2022 www.instrumentation.co.za For years, the ifm pressure sensors of the PI series have proven their worth in the food and beverage industry. But even what is successful can be improved upon. Pressure changes can now be visualised via IO-Link in high resolution with approximately 20 000 steps. This is an Pressure sensors for hygienic applications Pushing the limits of resolution using a tried and tested formula. Factory setting measuring range [bar] Measuring range relative pressure [bar] G1 Asepto- flex Vario G1 sealing cone 0…100 -1…100 - PI1602 0…25 -1…25 PI1703 PI1803 0…16 -1…16 PI1714 PI1814 0…10 -1…10 PI1704 PI1804 0…6 -1…6 PI1715 PI1815 0…4 -1…4 PI1705 PI1805 0…2.5 -0.124…2.5 PI1706 PI1806 0…1.6 -0.1…1.6 PI1717 PI1817 0…1 -0.05…1 PI1707 PI1807 -1…1 -1…1 PI1709 PI1809 0…0.4 -0.05…0.4 PI1718 PI1818 0…0.25 -0.0124…0.25 PI1708 PI1808 0…0.1 -0.005…0.1 PI1789 PI1889 The PI1xxx series covers many measuring ranges. enormous benefit, especially for hydrostatic level measurement with head pressure. In such applications, the sensor must be designed for a larger measuring range in order to withstand the additional head pressure. With conventional sensors, a larger measuring range reduces the resolution of the pressure detection – this is no longer a problem thanks to the technological advancements of the new PI1xxx range. What is more, the sensor can detect the medium temperature and transmit it via IO-Link. This means that it is no longer necessary to set up an additional temperature measuring point. Advantages of the new PI pressure sensor Ceramic measuring cell The ceramic-capacitive measuring cell consists of a base body, two capacitor layers, a glass solder and a membrane. The capacitor layers on the base body and membrane are similar to a plate capacitor and form a measurement and reference capacitor. When pressure is applied, the distance between the membrane and the base body changes, and this changes the capacitance between the electrodes. This change in capacitance is evaluated and then processed to output an industry-standard IO-Link signal. Order no.
www.instrumentation.co.za June 2022 13 COVER STORY Precise level monitoring in tanks. Spray ball cleaning for harsh environments. The PI pressure sensor has a high-purity ceramic measuring cell. This offers high resistance and long-term stability, even with frequent pressure peaks or overload. In addition, the ceramic is resistant to abrasive media. Optimised ventilation The ventilation has been optimised compared to the previous sensors of the PI series. Moisture thus runs reliably off the Goretex membrane if the sensor is mounted with the display facing upwards or downwards. Flush measuring cell The measuring cell, which is flush with the process, gives deposits no chance. Only foodgrade and maintenance-free materials come into contact with the medium. High temperature resistance and measurement Being permanently resistant to medium temperatures of up to 150°C, the sensor can also measure these and output them cyclically via IO-Link. IP69K ingress protection Thanks to protection class IP69K, the sensor not only permanently withstands harsh environments, but also meets all the requirements of the food industry. Typical applications The pressure sensors of the new PI1xxx series are ideally suited for applications in the food industry – for example in dairies, breweries and many other applications where liquids are used. Pressure measurements in these applications are carried out in tanks as well as in pipes. The numerous improvements of the sensors offer important advantages to the user. In most cases, beverages are manufactured in individual, highly automated processes that require reliable sensors. They ensure maximum process reliability so that a high-quality product results. Sensors from ifm electronic comply with the required approvals such as EHEDG or 3-A. In addition, they are resistant to clean-inplace (CIP) and steam-in-place (SIP) cleaning processes. Added value thanks to IO-Link 32-bit IO-Link resolution The new PI1xxx models, with their 32-bit resolution and approximately 20 000 steps, offer a detailed display even across wide measuring ranges. Loss-free data transmission IO-Link enables loss-free data transmission as conversion losses are obviated thanks to digital communication, and external influences such as magnetic fields have no effect on data transmission. Diagnostic data is also provided via IO-Link. Transparent processes The current pressure is output precisely with the highest possible resolution via IO-Link. This makes it easy to keep an eye on your process at all times. In addition, the medium temperature is output cyclically via IO-Link. Easy setup The pressure sensor can be configured quickly and easily via IO-Link. This is supported by a simulation function, among other things. Improved technology Higher resolution, revised design The new pressure sensors, which are available in different measuring ranges from vacuum to 100 bar, communicate via IO-Link 1.1 and offer a resolution of about 20 000 steps. This is especially important for applications where differential pressures are measured and thus only a small part of the measuring range can be used. Temperature compensation has also been improved in the new series. Even seemingly small improvements to the design of a sensor can have a big impact in the application. For example, the vent hole on the new pressure sensor has been offset by 90° and is now located on the side when mounted conventionally. This prevents condensate, for example, from collecting on the membrane of the vent hole and causing soiling or impairing proper functioning. The PI has also been optimised in terms of user-friendliness: the new operating concept, with three pushbuttons, makes the act of setting parameters much more convenient and thus also faster. For more information contact ifm – South Africa, +27 12 450 0400, [email protected], www.ifm.com/za “The pressure sensors of the new PI1xxx series are ideally suited for applications in the food industry – for example in dairies, breweries and many other applications where liquids are used.”
14 June 2022 www.instrumentation.co.za PROCESS MEASUREMENT Temperature measurement has never been easy because of the physics involved. Temperature sensors are complex and there are many types to choose from, based on the particular physical properties behind the way they represent temperature. It is common knowledge that temperatures range from absolute zero (i.e., 0 Kelvin, which equates to -273,15°C) through to molten metal which can be thousands of degrees Celsius, so there is no such thing as a one-size-fits-all temperature sensor. Temperature sensors are chosen for their suitability to the temperature range they need to measure, with accuracy, linearity, stability and repeatability being key performance criteria. Technical specialists are required to set up, calibrate and validate the measurement. Omniflex has invested many years of research and development into temperature signal conditioning for the industrial environment, where control and measurement of temperature is key to many processes. Temperature monitoring for storage is a key performance metric in many commercial retail and pharmaceutical operations as well. It is important to remember that the temperature sensor is only measuring temperature at its own position in the room, fridge or freezer, so it stands to reason that the more temperature points you monitor, the better, in order to get a clear representation of the temperature in the space you are monitoring. The downside is the expense of temperature sensors, so there is inevitably a trade-off between that and the cost benefit of having many sensors for a given storage space. But with regulatory controls and financial liability now forcing auditable record-keeping that cannot be manipulated in the process, a temperature monitoring system needs to be cost effective, reliable and meet regulatory standards. A good example is the FDA (Food and Drug Administration of USA) 21 CFR Part 11 for pharmaceutical and research environments, which states that “Any studies in which data will be submitted to the FDA, regardless of drug or device status, must also comply with the 21 CFR Part 11 requirements. In addition, some funding agencies or the study grant may require that study records be kept in a 21 CFR Part 11-compliant system.” However, Temperature monitoring simplified even the food and beverage industry vendors are obliged to show compliance in cold chain management to the public, regulatory bodies and their insurers. Omniflex has developed a cost-effective solution for applications that need larger temperature coverage, easy onsite configuration and a simple connection system that does not require expensive expertise to apply and maintain. This solution provides a front-end device – the Teleterm mLC8 – which supports up to 80 digital temperature sensors using the Omniflex microLAN network. Up to 10 plug-in temperature sensors can share a two-wire cable on the mLC8, which has eight ports, enabling 80 temperature sensors to be monitored. Up to 32 mLC8s are supported by the touchscreen HMI, so a system with 2560 temperature points can conceivably be constructed. The system is reliable and dependable, safe and secure, simple to replace and maintain, and comes with a single central management terminal for surveillance of the entire system. Cloud-based historical logging and storage options are also available. The touchscreen HMIs range from 5 to 15-inch display sizes to suit various application types and space constraints, and they provide the management oversight required to manage the facility. The cloudbased history provides the compliance records needed for the facility. BYOGD – Bring Your Own Giant Display An additional option is to use the EasyView FHD module technology with Full HD (1080p) capability and HDMI interface. This opens up the potential for giant screens that can visually service an entire control room, using large wall-mounted computer display panels or TV screens – no PCs required. In this way, a full temperature monitoring overview can be displayed front and centre, keeping all plant personnel focused at all times, with immediate alerts for over-temperature alarm conditions. Applications for this solution include pharmaceuticals, laboratories, supermarket fridges and freezers, logistics warehousing, abattoirs, building management and air conditioning, cold rooms, computer server rooms and server farms. For more information contact Omniflex Remote Monitoring Specialists, +27 31 207 7466, [email protected], www.omniflex.com Temperature monitoring using MicroLAN mLC8 and digital sensors.
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