Unlimited performance in limited spaces 39 VOLUME NO 2 FEBRUARY 2023 Official publication of the SAIMC Food, beverage & packaging | IT in manufacturing Sustainability & green manufacturing | Control systems Condition monitoring
Calibration Laboratory sanas 245 345 +27 (011) 021 8082 | [email protected] +27 (031) 579 2216 | www.sagauge.com MANUFACTURERS 2009 Made in South Africa Always in stock “Because quality matters” GAUGE
www.instrumentation.co.za February 2023 1 IT in manufacturing Enclosures & cables Electrical power & energy-efficient systems Control valves Sustainability, green manufacturing VOLUME 39 NO 2 FEBRUARY 2023 04 08 10 48 REGULARS Cover story 12 FEATURES Food, beverage & packaging Process measurement Control systems Condition monitoring & maintenance 14 30 24 34 36 42 45 39 44 News & events SAIMC news Automation professionals Product news A portfolio of guided radar level transmitters Endress+Hauser, Turck Banner, Omron Electronics, ifm South Africa, Gail Norton Instrumentation Agencies, Bearings International, Vega Controls SA, NSK South Africa Wika Instruments, GHMMesstechnik SA, ifm South Africa Instrotech, BMG Michael Brown Control Engineering CC, Beckhoff Automation BCW Global, RJ Connect Helukabel, igus South Africa Schneider Electric, Phoenix Contact, Comtest, Zest WEG Parker Hannifin SA, Emerson Automation Solutions, SMC Corporation South Africa, Axiom Hydraulics Festo South Africa OUR COVER 12 Unlimited performance in limited spaces 39 VOLUME NO 2 FEBRUARY 2023 Official publication of the SAIMC Food, beverage & packaging | IT in manufacturing Sustainability & green manufacturing | Control systems Condition monitoring KROHNE is a full-service provider for process measuring technology for the measurement of flow, mass flow, level, pressure and temperature and analytical tasks. Read the cover story on page 12 to find out more about the company’s new range of OPTIFLEX guided radar level transmitters. These are the first choice for liquid and interface level measurement in a wide range of industries, including food and beverage, chemicals, agri-food, metals, minerals and mining.
2 February 2023 www.instrumentation.co.za welcome VOLUME 39 NO 2 FEBRUARY 2023 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. Nopart of thispublicationmaybe reproduced, adapted, stored ina retrieval systemor transmitted inany formorbyanymeans, electronic,mechanical, photocopying, recordingor otherwise,without thepriorwrittenpermissionofTechnewsPublishing (Pty) Ltd, RegNo. 2005/034598/07 LETTERS TO THE EDITOR Letters to the editor should be addressed to Jane van der Spuy 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. CIO & DIRECTOR Graeme Bell NHD Elec. Eng., MBA [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 Wild Fig Business Park, Block B, Unit 21, 1494 Cranberry Street, Honeydew Welcome to this bumper issue of SA Instrumentation & Control. It has been a privilege to be able to put together this issue and I’ve really enjoyed being involved with such a respected magazine while we wait for our new editor. It’s still early in the year so my attention was attracted by a report from ABI Research entitled ‘74 technology trends that will − and will not − shape 2023’. It has a wealth of information, here are few of the highlights. ABI expects that there will be a revival in VR in manufacturing, with innovative new applications in the workplace. In the consumer area the wealth of new gadgets and gizmos we can enjoy is growing. Foldable devices, wearable technology for health and fitness, and smart homes are the order of the day. If you don’t already have a foldable phone you probably will soon. This is made possible by more sophisticated sensors to measure health data, with better algorithms that instantly interpret huge amounts of data. AI is with us. From healthcare to selfdriven cars and from manufacturing to entertainment and smartphones, it is being touted as the single most game-changing invention in the history of mankind. I am wary of hype but I couldn’t help noticing ChatGBT. In a mind-blowingly short time, like since December 2022, ChatGPT has taken the world by storm. I asked ChatGPT what it does and this was the answer: ChatGPT is a language generation model developed by OpenAI. It is based on the Generative Pretrained Transformer architecture and was trained on a large corpus of text data to generate human-like responses to natural language text inputs. ChatGPT is designed to be used in applications such as chatbots, customer service, and question-answering systems to generate text-based responses to user queries. I thought this was a bit bland, but it told me the basics. I also thought I would see how it handles an editor’s letter. The result is too long for this column, but it didn’t do a bad job, although it was a bit generic. But it left me wondering what it would produce next month. As an editor you can’t write the same thing every time. One area where it is causing huge disruption is in the academic world, where it can generate abstracts of scholarly articles or write a student’s term paper, while scoring 100% on a plagiarism detector. What’s in, what’s out Aerospace is always inspiring. Who hasn’t gazed in awe at the incredible images that emerged from the Webb-Ellis telescope last year; and low earth orbit satellites quietly make our internet world possible. Starlink has 3500 satellites in orbit, including those making a difference in the airspace over the Ukraine. `The number of LEO satellites approved for deployment will reach more than 30 000 by the end of the decade. There are other trends generating huge hype such as the industrial. This time last year the world was excited about NFTs, crypto and the metaverse. By last September, NFT markets were down 90% and crypto was in freefall. In 2023 the metaverse is still more dream than reality. Despite last year’s hype, companies won’t be investing vast sums in the metaverse in 2023. Your staff won’t be creating avatars and solving challenges in the virtual world. The current economic climate demands investments with a clear road to value. They will be investing in digital twins that mirror machines and facilities to optimise their operations. The metaverse is for another year. When it comes to lights out manufacturing, it looks like the lights will still be on for a while. Most manufacturers are at level 2 or 3 out of 5 in their digital transformation. Typically they have started to connect some wireless assets and integrate data sources. Most still need to retrofit sensors and manage the machines they have relied on for years. Apart from ‘factories of the future’ like the Mercedes Factory 56 and the Tesla Gigafactory in Germany, level 5 lights out manufacturing is still coming. In 2023 the challenge will be creating new possibilities when these technologies are used together − what Harvard Business Review calls combinatorial trends. Leaders will have to do more with less and strategically invest in technologies that are hitting a tipping point.
NEWS & EVENTS 4 February 2023 www.instrumentation.co.za Bosch Rexroth South Africa has announced that Mike Harrison, current Bosch Rexroth regional director East Africa and general manager of Hytec SA, has been appointed to the role of chief operating officer at Bosch Rexroth South Africa, reporting to Chris Riley, group CEO. In his new role, Harrison retains responsibility for Bosch Rexroth Africa Development, Mozambique and Namibia, while assuming responsibility for group strategy. He has been at the helm of Hytec for more than a decade, with the more recent extension of his role and responsibility to East Africa. Through his leadership, the company has experienced significant geographic expansion, both locally and at a regional level. He also played an instrumental role in the successful merger between Bosch Rexroth and the previously known Hytec Group. Harrison will be succeeded by Freddie Kühn as the new general manager of Hytec SA. Kühn is the current sales director at Hytec SA, having assumed responsibility for sales in the organisation three years ago as part of the group’s succession plan. He has contributed to the success of Hytec SA for more than 25 years and will now take responsibility for the rest of the functions within Hytec SA. Kühn has worked closely with Harrison and has made significant contributions to Hytec SA. For more information contact Gillian Allin, Bosch Rexroth South Africa, +27 11 979 4630, [email protected], www.boschrexroth.africa New leadership appointments at Bosch Rexroth South Africa Schneider Electric and Amtec Techniquip, a leading provider of locally manufactured educational equipment in South Africa, have seen their collaboration go from strength-tostrength to extend beyond the SADC region’s borders to include Nigeria. Funded by the Schneider Electric Foundation, the partnership has, since its inception three years ago, accelerated access to education through the provision of state-of-the-art training equipment to tertiary institutions that bridges the gap between theory and practice and forms a critical part of vocational training. “We are thrilled to now include Nigeria as part of our collaboration with Schneider Electric. The last three years have been rewarding and undoubtedly complemented our company’s passion for providing quality engineering education equipment,” comments Roger Forte, sales director at Amtec Techniquip. “There is a dire need for high quality electrical and engineering training education equipment in Nigeria. Through our partnership with Amtec Techniquip, we hope to emulate Schneider Electric and Amtec Techniquip extend partnership to Nigeria Mike Harrison, incoming chief operating officer, Bosch Rexroth South Africa. Freddie Kühn, incoming general manager, Hytec SA. the success of our counterparts in southern Africa and provide students with equipment that will support and accelerate their studies as electricians and engineers,” says Schneider Electric project manager, DL Steyl. Schneider Electric’s collaboration with Amtec Techniquip underscores the company’s ongoing commitment to providing world class equipment to institutions across Anglophone Africa. The equipment is for example used at F’SASEC (French Southern African Schneider Electric Education Centre) network partners, Schneider Electric partners, and customers in southern Africa. “Amtec Techniquip offers entrenched experience in the electrical educational training space and has been a valuable partner over the last three years. The equipment is professional and meets the highest standards set by Schneider Electric,” concludes Steyl. For more information contact Schneider Electric South Africa, +27 11 254 6400, [email protected], www.se.com/za/en Siemens Digital Industries Software has launched Hour of Engineering, an engaging online learning programme to empower educators to introduce students to engineering and technology with right-sized, kid-friendly learning content in as little as one hour. Through this new programme, Siemens intends to inspire, engage and educate students about the role and fundamentals of engineering before they begin high school, helping to create a robust pipeline of future engineers. Without that spark of interest, by the time students reach high school many will have already decided against engineering, based on common misconceptions about the field. “A career in engineering can take many different paths, all of which can be rewarding and help make the world a better place. It is vital that pre-high school students are exposed to engineering careers and concepts earlier. Our aim is to empower educators to do exactly that Siemens Hour of Engineering sparks interest in STEM with resources that can be deployed without additional training, and don’t place additional burdens on tight budgets,” said senior director of Siemens Digital Industries Software, Brian Grogan. Hour of Engineering is a direct response to the shortage of engineers. It aims to get students excited about engineering careers early and build confidence and problemsolving skills that they can apply in all fields of study, including engineering disciplines. Hour of Engineering learning content is aligned to science, technology, engineering and mathematics standards. Each learning activity is easy to implement and includes a teacher guide that provides suggested sequences for learning with options for one to 20 hours. For more information contact Siemens South Africa, [email protected], www.siemens.co.za
NEWS & EVENTS www.instrumentation.co.za February 2023 5 The importance of energy security in shaping South Africa’s economic future is a key focus of the Africa Automation and Technology Fair (AATF), the continent’s most comprehensive and focused automation platform. Taking place between 9 and 11 May 2023 at the Johannesburg Expo Centre (Nasrec), it will co-locate with Future Manufacturing Africa (FMA), a new trade show dedicated to the full manufacturing value chain for the African continent. Esteemed industry experts have been lined up to present at the dedicated conference, AATF Connect, which will be introduced by Gwede Mantashe from the Department of Energy. They include South African television presenter and moderator, Derek Watts; energy consultant, Chris Yelland; Dilley Naidoo, CEO of Madala & Associates; and Dhevan Pillay, South African Energy Conservation. Although President Ramaphosa has said Eskom is taking active steps to add new generation capacity to the grid on an urgent basis, a key focus of AATF Connect will be to seek real answers to the many difficult questions being asked about the measures the government has identified to address the energy crisis. The procurement of new generation capacity As an immediate measure, Eskom will buy surplus capacity from existing independent power producers (IPPs), mines and other private entities which generate excess power, while 2600 MW of capacity has been procured through BidWindow 5 of the Renewable Energy IPP Procurement Programme (REIPPPP), which should add capacity to the grid from early 2024. Energy shapes the future of Africa’s automation and manufacturing industries Eskom will also look to buy power from neighbouring countries with excess electricity capacity, such as Zambia and Botswana, through the Southern African Power Pool, and aims to construct its first solar and battery storage projects at Komati, Majuba, Lethabo and several other power stations. On paper, the measures for new generation capacity look positive, but there are still many gaps to be filled as to how these processes will roll out on a practical level. Easing of distributed generation regulations and new legislation After removing the licensing requirement for generation projects up to 100 MW in June 2021, President Ramaphosa has now announced the complete removal of the licensing requirement for embedded generation, to incentivise further private investment in electricity generation and reduce the lead times to commence construction of projects. The term‘embedded generation’ is ambiguous as it is understood differently in different contexts. There are also questions about transitional arrangements for those projects above the 100 MW threshold that are already in motion, and how these will be impacted. Incentivising investment in rooftop solar through feed-in tariffs The government has acknowledged the potential for households and businesses to install rooftop solar solutions and to connect this power to the grid. To incentivise greater uptake of rooftop solar, Eskom will develop rules and a pricing structure, known as a ‘feed-in tariff’, for all commercial and residential installations on its network. This means that those who have installed solar panels in their homes or businesses will be able to sell surplus power to Eskom. However, there are some complexities here, as most of these installations occur within municipal distribution systems rather than Eskom’s transmission systems. Improving the performance of Eskom’s existing power stations To address the red tape around buying spares and equipment to effect critical repairs at power stations, Eskom’s budget for critical maintenance will be increased over the next 12 months. But, if Eskom relies on emergency procurement procedures (which allows deviation from the mandatory tender requirements to buy spares and equipment on an urgent basis), this could open up the process to abuse and has the potential to be a vehicle for corruption and looting of this increased budget allocation. PhilipWoods, events director for Business and Technology at RX Africa, says: “We understand that delegates at the AATF and FMA are after real, honest discussions and debates about the burning issues that are impacting business today and the future economic growth of our country and continent. We look forward to bringing together the automation and manufacturing industry’s major players with energy leaders to tackle the major issues affecting progress and transformation, and we are confident that the event will be of great benefit to all involved.” Registration for both the AATF and FMA is currently open. To register or for more information, please visit https://www.africaautomationfair.com/en-gb.html
2023
www.africaautomationtechnologyfair.com REGISTER NOW! Contact Daleen Filbey on +27 (0)10 496 3502 | [email protected] SAEC EVENT SHOW INNOVATIONS
8 February 2023 www.instrumentation.co.za From the office of the CEO Johan Maartens. National Members Branches Johannesburg: Jenine Jansen van Vuuren at [email protected]; Mobile: +27 63 204 5248 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) A new study by the European Investment Bank, International Solar Alliance, and the African Union, has detailed the staggering potential of green hydrogen in Africa as well as the steps required to achieve this. According to the study, large-scale green hydrogen generation will enable Africa to supply 25 million tons of green hydrogen to global energy markets. Enter COP26 COP26 was the 2021 United Nations climate change conference. Before this conference, the UK worked with every nation to reach an agreement on how to tackle climate change. The package of decisions consists of a range of agreed items, including strengthened efforts to build resilience to climate change, curb greenhouse gas emissions, and provide the necessary finance for both. Enter South Africa The funding initiative of CPD26 spurs change through existing structures. In the case of South Africa, funding will take place using South Africa’s existing structures, such as Eskom. The COP26 funds are intended to retrain employees to move from a coal-based industry to a green hydrogen industry. If this does not occur, people in the coal industry will lose their jobs. Beneficiaries of these funds will no doubt inform anybody who wants to listen that the South Africa: spectator or participant? lack of transformation, COVID, and the fourth industrial revolution caused their demise. Have large-scale retraining programmes for employees in the coal industry or training new entrants into the fourth industrial revolution started with all assistance coming from abroad? How many people will lose their jobs due to the fourth industrial revolution? Maybe the right question is: “How many more people will lose their jobs due to funds misappropriated or mismanaged?” Will South Africa be a spectator or a participant? That is the question. Yours in automation, Johan Maartens Details to be confirmed Watch this space! Annual gala dinner September/October 2023 SAIMC NEWS
www.instrumentation.co.za February 2023 9 SAIMC NEWS The Durban branch of the SAIMC held their AGM on Wednesday 25 January at the Premier Splendid Inn in Pinetown. The turnout was good and the branch committee was impressed by how few ‘no-shows’ there were. Branch General Manager, Mark Calvert was unfortunately ill so Branch Secretary John Owen-Ellis ran the meeting and presented Mark’s annual report on his behalf. Finance guru Kevin McElroy presented the annual accounts, which reflected a healthy trading position despite much of the branch’s income having been affected by the years of COVID. After John and Kevin presented their respective reports, SAIMC CEO Johan Maartens took to the floor and gave a very comprehensive overview of the ECSA registration progress, and an update on further discussions with them about the creation of a recognised Automation qualification. Johan followed up by reminding the meeting that, with last year’s change in legislation mandating compliance with the Identification of Engineering Work, it is extremely important for us all to be aware of the new requirements and to register with ECSA if we are doing specified engineering work. He also offered to visit the branch if members need assistance with applying for ECSA registration. This discussion was well received and led to a lively debate about who would be liable in the case of engineering work going wrong. Johan pointed out that the onus now falls on the individual, who may suffer severe penalties, with the possibility that the employer might be largely absolved from accountability. The debate served to highlight many uncertainties, but it was clear that having work done by ECSA-registered people, whose actual capabilities had been approved after scrutiny by a group of experienced peers, is intended to reduce the risk of someone doing work exceeding their capability. The debate continued long after both the meeting had concluded and the meal was enjoyed, and will take place again in future. Durban Branch The Durban branch once again set the standard by using a fully digital nomination and election process for the 2023 management team. The very static constitution of the Durban branch management team over the last few years remains a concern but it was pleasing to see some new names being put forward this time around. On behalf of Mark, John thanked the 2022 management team for their dedication and enthusiasm in running the branch, especially as things recover from the setbacks of the past two years. The new committee was announced as follows: Donald Hlubi, Howard Lister, John Owen-Ellis, Jane van der Spuy, Kevin McElroy, Mark Calvert, and Siyabonga Mbamali. Office bearers will be elected at the next branch committee meeting, and as part of the succession planning of the branch, the Branch Secretary John Owen-Ellis thanking Johan Maartens for attending the AGM. tradition of using four additional mentees to be co-opted to the committee will continue. These mentees will be: Prof Askshay Saha, Marthel Mhlanga, Anil Lonappan, and Lee Naidoo. Johan highlighted the need for greater involvement of end users in SAIMC activities. He urged branches to seek more presentations from end users at technology evenings, where they could share their experience of automation projects and maintenance work at their plants. More talks at technology evenings need to be evaluated for CPD points. He also emphasised the need for branches to get category C representatives from end users in their region to serve on an SAIMC Advisory Council. For more information contact Jane van der Spuy, + 2783 234 5412, [email protected] www.saimc.co.za
10 February 2023 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 February 2023 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 PCS Global 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 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]
OPTIFLEX 3200 is the first choice for applications with hygienic requirements in the pharmaceutical and food and beverage industries. It features a CIP/SI-suitable hygienic design for liquid level and interface measurement in small vessels with process conditions up to 150°C and 40 barg. Insensitive to steam, foam and condensation, the device offers a measuring range of 0.6-4 metres with an accuracy of ±2 mm. OPTIFLEX 6200 is designed for solids, from granulates to powders, in the chemical, agri-food, metals, and minerals and mining industries. It can be used for level measurement in silos up to 40 metres, with a measuring accuracy of ±2 mm. Designed to withstand high traction loads and process conditions up to 200°C and 40 barg, it is insensitive to dusty atmosphere or deposits on the probe. OPTIFLEX 7200 aims at the chemical, and oil and gas industries for level and interface measurement of liquids in process and storage applications with ±2 mm. It offers an extensive choice of probes for measuring distances up 60 metres and dielectric constants down to 1,3, and can be used with aggressive media in process conditions up to 250°C and 100 barg. OPTIFLEX 8200 has similar features and offers a double ceramic process seal system for liquids up to 315°C and 320 barg. Both devices offer dynamic gas-phase compensation (DGC) with the coaxial probes, ensuring accurate measurement without increased New guided radar level transmitters COVER STORY
COVER STORY blocking distance in applications where the composition of the gas above the liquid can change suddenly, for example in steam boilers. All four new TDR transmitters feature two-wire 4-20 mA HART 7 communication with an optional second output (current or relay) and a real-time clock for event logging. They have been developed to be SIL 2/3-compliant according to IEC 61508 for safety-related systems and come with various Ex approvals. Common features also include a quick coupling system, and compact and remote converter versions up to 100 metres made of aluminium or stainless steel. All devices are rated IP66, IP68 and NEMA 4X/6P. Together with the cost-effective OPTIFLEX 1100 for basic liquid applications and the POWERFLEX 2200 for liquids in the nuclear industry, these guided radar level transmitters represent the KROHNE guided radar (TDR) level transmitter portfolio. KROHNE is a full-service provider for process measuring technology for the measurement of flow, mass flow, level, pressure and temperature and analytical tasks. Founded in 1921 and headquartered in Duisburg, Germany, the company employs over 3900 people worldwide and is present on all continents. KROHNE stands for innovation and maximum product quality, and is one of the market leaders in industrial process measuring technology. For more information contact KROHNE SA, +27 11 314 1391, [email protected], www.krohne.com
14 February 2023 www.instrumentation.co.za For many food manufacturers, rawmaterial accounting is a highly important and frequently discussed topic. The idea behind this is to measure the exact amount of delivered raw materials, such as milk, oil or alcohol, and then precisely allocate howmuch is used in each of the individual production steps. The goal is to provide as much transparency as possible when it comes to the rawmaterials used in the production of various products – such as cheese and butter at a dairy operation – and to be able to create full cost accounting. The Promass Q Coriolis-based flowmeter from Endress+Hauser offers food manufacturers the opportunity to optimise their rawmaterials accounting with innovative technology. The Promass Q is a multivariable measurement instrument that supplies users with not only common values such as mass flow, density or temperature, but also quality-relevant parameters such as overrun or brix measurement in real time to ensure optimal product quality. It is a genuine master of all trades designed to help food manufacturers with their daily challenges. Erroneous volume and mass flow measurements Volume and mass flow are two commonplace terms whose meanings can lead to very stark differences in materials accounting. In contrast to volume, mass flow exhibits a constant behaviour when subjected to changing influences such as pressure and temperature. Therefore, accounting systems rely on units of mass in most cases. Many companies nevertheless use volume measurements, which can lead to unwanted differences in the rawmaterials account settlement. But even mass flowmeasurements have potential sources of errors that users should consider. In the field, one of the primary causes of Master of all trades measurement discrepancies relates to undetected air or gas entrainment in fluids, which distorts the measurement value and leads to differences in the rawmaterials accounts settlement. To prevent this from occurring, customers rely on the Promass Q, a Coriolis-based flowmeter that detects gas entrainment and lowers the measurement error ratio to nearly zero. Gas entrainment distorts values at the delivery point Because dairy trucks are not full at the start of the run, their tanks contain a considerable amount of air. The milk constantly swishes around in the tank and mixes with the air. If volume flow is used as the measurement unit when the milk is retrieved from the farm, it leads to an exaggerated measurement, which in turn exaggerates the amount of rawmilk delivered to the dairy. This is because the air has significantly increased the volume. In practice, an increase of 10 to 20% is not uncommon. Assuming the air is purged during the production process, the dairy operator ends up posting a loss when settling the rawmaterial accounts. This also makes it difficult to create accurate full cost pricing. Many dairies have opted to replace volume flow with mass flow to measure the amount of milk that is delivered and processed. Unfortunately, unwanted accounting differences can still occur due to air entrainment, which also influences mass flowmeasurements. Although the effect is lower, it still exists and can lead to deviations. When processing large quantities of rawmilk, small percentage errors add up to significant sums in a year. Multifrequency technology for reducing measurement discrepancies To eliminate discrepancies in mass flow measurements, customers rely on the new Promass Q, which features the patented multifrequency technology. What makes it unique is that the Coriolis tube oscillates within two superimposed resonance frequencies instead of just one, a major advantage over the conventional Coriolis measurement principle. Measurement errors caused by entrained gas can be virtually eliminated. Compared to the processes available to date, the Promass Q allows food manufacturers to measure the quantity of incoming rawmilk more accurately, and as a result it significantly optimises the internal rawmaterials settlement. Determining overrun levels The Promass Q multifrequency technology not only makes it possible to eliminate mass flow measurement discrepancies with fluids. It can also precisely measure the overrun in other products where various gases are infused, such as cream cheese or ice cream. In this case manufacturers strive to create an especially light and fluffy consistency. In environments where experience served as the basis for entrained gas values and the amount of gas was adjusted after drawing samples – after all, rawmilk is subject to certain fluctuations – overrun can now be measured with a high degree of accuracy. This in turn helps reduce fluctuations in the quality of the product. The Promass Q has repeatedly demonstrated its suitability for measuring overrun. Users were able to monitor and regulate the entrained gas levels in the process by means of density measurements, thus preventing off-spec batches or fluctuations in product quality. For more information contact Endress+Hauser South Africa, +27 11 262 8000, [email protected], www.endress.com
www.instrumentation.co.za February 2023 15 FOOD, BEVERAGE & PACKAGING When a line needs to change over to a new product, automated labelling systems must be able to quickly switch from recognising opaque labels to clear labels. This may be a challenge for a contract beverage manufacturer that fills and packages products for multiple clients, Detecting transparent labels at high speed each with its own brand and using a different label. Some labels are transparent, others are opaque and they come in different thicknesses. To fulfil orders on time, the line needs to run at very high speeds, and any extra time spent changing equipment is time not being used to fulfil orders. A sensor that can quickly and accurately detect different thicknesses and colours of labels is needed to minimise changeover time. The solution fromTurck Banner is the SLU4 ultrasonic sensor, which allows the labels to run through the sensor at high speed before being placed on the bottles. The ultrasonic sensor detects each label or webbing, whether it is clear or coloured. The sensor instantly lets the bottling equipment know the labels are properly aligned so they can be affixed, and the line can continue operating smoothly. As one product ends its run on the bottling line, an operator can reconfigure the sensor for the next product using the SLU4’s OLED display, eliminating the need for a separate HMI or scada. The ability to switch sensor configuration at the source helps reduce the time needed to change the line from packaging one product to another. For more information contact Turck Banner, +27 11 453 2468, [email protected], www.turckbanner.co.za
16 February 2023 www.instrumentation.co.za Patient and healthcare worker safety in South African hospitals is set to reach a new level of excellence with the launch of the revolutionary HERO21 robotic sanitisation system – the first two units of which have been installed at Polokwane Provincial Hospital. The HERO21 is used in medical environments and other industries to disinfect rooms, protect employees and significantly reduce the risk of infections. The robotic systemwas developed by German company ICA Health, endorsed by Ruhr University Bochum and global electronics group Omron Corporation. Omron is responsible for the production of the robotics components, which are supported by its South African operation. Mamello Clinical Solutions (MCS) is the exclusive distributor and service partner for the HERO21 system for sub-Saharan Africa. MCS business development manager, Robert Makhubedu explains: “The HERO21 robot incorporates pioneering ultraviolet-C disinfection technology, which addresses the hygiene challenges of our time.” Conventional disinfection methods in hospitals, such as wiping and scrubbing, are often inadequate and can even promote germ resistance. The HERO21 provides the highest level of disinfection performance and thus offers optimal protection. When first disinfecting contaminated rooms with the HERO21, the cleaning staff who normally work in the front line are exposed to a far lower risk of infection. UVC First sanitisation robots in South Africa radiation destroys all pathogens in the targeted environment, including bacteria and viruses, Because UVC radiation is effective on its own, the HERO21 robot is a dry, chemical-free system. “We are pleased to have been able to deliver the first HERO21 disinfection robots to South Africa. In Mamello Clinical Solutions, we have found an ideal service and sales partner for a long and successful partnership. With the successful installation of the first two devices in Polokwane, a major milestone has been reached,” says Steffen Kriege, head of product management at ICA Health. Commenting on the relationship between Omron and ICA Health, Evert Jansen Van Vuuren, Omron Robotisation Solutions coordinator says: “Our mission, as Omron, is to improve the lives of the people we serve. The HERO21 robot disinfects multiple areas so that people from all walks of life can work in a safe, germ-free environment. The HERO21 works well with the Omron AMR navigation technology, which enables it to operate remotely without human intervention.” While sanitising systems have been in use for years, the COVID pandemic motivated ICA Health to ramp up the development of a robust system for hospitals. The HERO21 system is effective in high risk areas including operating theatres, emergency rooms and ICUs − and in other hospital settings. Because UVC radiation is dangerous, people are removed from the room to be sanitised and the robot moves through the space. Disinfection is achieved automatically, precisely, quickly and efficiently. The robot achieves a disinfection level of over 99,99% , with a coverage of 360° in the designated area. The cleaning cycle takes between two to three minutes to disinfect an average sized room such as an operating theatre. The robot’s navigation system in the target area is driven by world-renowned Omron LD90 robotics. The launch of the HERO21 robotic system adds a new dimension to MCS’s established product offering. “Our strategy is to become a distributor of choice for the world’s leading equipment and technology manufacturers, specifically geared to South African conditions. This partnership with Omron means that we are adding new brands, products and software systems to our range to serve a broader customer base. The HERO21 robot will make a massive difference in terms of patient and worker safety. It is an economically validated, reliable solution,”Makhubedu concludes. Apart from applications in the medical and healthcare sectors, the HERO21 is also suited for other industries such as hotels, restaurants and catering, pharmaceuticals, and corporate office buildings. For more information contact Omron Electronics, +27 11 579 2600, [email protected], www.industrial.omron.co.za
CONSISTENT + CONFIDENT You are poised to meet your safety and quality requirements while optimizing resources and securing process repeatability. We understand how you strive for constant product quality and optimized costs. Improve your processes with our comprehensive portfolio of measuring instruments: Promag H 100: The flow measurement specialist with an ultra-compact transmitter is designed for hygienic applications. Liquiphant FTL33: The compact point level switch saves your resources with a reliable overfill protection. Smartec and Indumax CLS54D: The toroidal conductivity systems optimize cleaning and reduce product loss. Contact us Email: [email protected] Tel: +27 11 262 8000 www.endress.com
18 February 2023 www.instrumentation.co.za FOOD, BEVERAGE & PACKAGING An essential requirement in the food industry is to ensure product traceability. Market demands in this segment are constantly increasing, and the industry is experiencing a steady rise in sales. As a result, manufacturers need to adapt their production methods, making themmore efficient in order to remain competitive. Barcode readers and flow sensors are part of the solution, and ifm electronic can assist with seamless product tracking in production and compressed air savings through energy monitoring, combined with simple and full integration into the digital network. Tracking the product One of ifm’s customers is an international company producing snack foods, and it is one of the leading manufacturers of potato crisps. The company needed to seamlessly track and trace the product from production to end user via codes printed on the packaging, and a scalable and easy to integrate solution was sought. To meet this requirement, ifm barcode readers were installed at the customer‘s site for the tracing of products. O2I5XX code readers from ifm are now used for product tracking on the production plants. Here, the simple connection via IO-Link also plays an essential role. Another benefit is that the price of the code readers is very attractive compared to the products previously used by the customer. Increased efficiency in crisps production Multicode reader verifies and analyses codes and text to give product traceability in the food industry. Energy monitoring Another application for sensors in food production is energy monitoring. The aim here is to increase overall equipment efficiency in order to reduce unit costs. Compressed air and nitrogen are important parts of the process. Compressed air is used in the pneumatic systems of the machines, and nitrogen is filled into the packaging before sealing to extend the shelf life of the products. However it is very important to contain costs. With the aim of including these two media into the energy monitoring system, the customer was looking for suitable flow sensors. For this purpose it opted for flow sensors from ifm’s SDX5/X6 series. These met the required specifications, were cost effective and could be easily integrated. With the integrated, IO-Link interface, their connection via the Al1920 IO-Link masters supplied by ifmwas also easy. Thanks to the digital connection, the measured values were directly available in the production plant’s network and could be processed both in the PLC and in the higher level energy management system. The simple digital integration via IO-Link was one of the main reasons to choose this solution. The result has been an enhanced energy management system and improved production traceability for the customer. Benefits include: • Implementation according to individual customer requirements. • Easy integration into the energy monitoring system. • An inexpensive and easy to install solution. • Monitoring of overall plant effectiveness. The customer was impressed with the technical support provided by ifm‘s application engineers, who in each case could present an ideal solution from a technical point of view. Given the positive experience, other locations will follow. A universal solution for production and logistics The O2I multicode reader verifies and analyses codes and text. It detects 1D and 2D codes, and text elements, and analyses their quality within a fewmilliseconds. The number of elements to be detected is irrelevant as the O2I can evaluate several codes or text elements, and their combination, with only one image capture. This makes the multicode reader a universal solution in production and logistics processes where the presence of codes and text information is to be checked for quality or used for product tracking. It can be quickly set up for simple applications directly on the device. More complex tasks can be implemented just as easily by means of the award-winning ifmVision Assistant. All in one system The O21 now also detects fonts and characters in addition to the familiar 1D and 2D codes (OCR). It ensures reliable identification even under difficult conditions such as changing extraneous light or shiny surfaces. Many benefits The advantages of the O21 series include: • Versatile use for quality and process control in production and logistics. • Detects and verifies text and codes alike. • High performance thanks to fast evaluation of several different codes and text passages in one image. • Reliable detection even in cases of extraneous light and challenging surfaces. • Easy parameter setting on the device or via the ifmVision Assistant. A video of the O21 multicode reader can be viewed at https://tinyurl.com/3ms3c9bm For more information contact ifm− South Africa, +27 12 450 0400, [email protected], www.ifm.com/za
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