39VOLUME NO 5 MAY 2023 Official publication of the SAIMC Oil, gas, chemicals, & mining | Process measurement | Wireless & telemetry IT in manufacturing | Control systems | Safety systems Motion control & drives | Sensors & transducers For endless possibilities
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www.instrumentation.co.za May 2023 1 Oil, gas, chemicals, & mining Wireless & telemetry Sensors & transducers Safety systems VOLUME 39 NO 5 MAY 2023 04 08 10 40 REGULARS FEATURES Process measurement Control systems Motion control & drives IT in manufacturing 14 22 19 26 31 38 35 39 News & events SAIMC news Automation professionals Product news Beckhoff Automation, Michael Brown Control Engineering CC, ifm - South Africa RJ Connect, Siemens South Africa, Fischer Connectors, Comtest, LOESCHE South Africa IDX Online, Zest WEG, SEW-EURODRIVE, Axiom Hydraulics, BMG Turck Banner, Emerson Automation Solutions, WIKA Instruments, Instrotech, Sensirion Zest WEG, Omniflex Remote Monitoring Specialists, Becker Mining South Africa VEGA Controls SA, Omniflex Remote Monitoring Specialists, Turck Banner ifm - South Africa, Chalmers University of Technology Schneider Electric South Africa, Comtest 39VOLUME NO 5 MAY 2023 Official publication of the SAIMC Oil, gas, chemicals, & mining | Process measurement | Wireless & telemetry IT in manufacturing | Control systems | Safety systems Motion control & drives | Sensors & transducers For endless possibilities OUR COVER 12 Endress+Hauser is at the forefront of the development of Ethernet-APL, which combines the benefits of simple and robust two-wire technology with the advantages of Ethernet, enabling top performance and seamless data access in the field for process plants. Read our cover story on page 12 to find out how Endress+Hauser is showing users in the process industry how they can createvalue by looking more closely at their data to gainnew insights into their processes and optimise theoperation of their plants.
2 May 2023 www.instrumentation.co.za welcome VOLUME 39 NO 5 MAY 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. No part of this publication may be reproduced, adapted, stored in a retrieval system or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of Technews Publishing (Pty) Ltd, Reg No. 2005/034598/07 LETTERS TO THE EDITOR Letters to the editor should be addressed to 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 I still remember my first computer. It was an Apple, and it had a 64K hard drive, and I was so proud of it. Around that time a famous quote attributed to Bill Gates was going around saying “640K ought to be enough for anybody” − which he later strongly denied. Another one came from Digital Equipment founder, Ken Olsen: “There is no reason for any individual to have a computer in his home.” Fast forwarding some years, last month the latest talk was about GPT-3.5. Now we have the new and improved version GPT-4, announced on 21 March, which is said to be ten times more advanced than its predecessor. According to OpenAI, GPT-4 is more reliable and creative, and can accept visual inputs including images, graphs and screenshots. Instead of focusing only on text, GPT-4 can analyse and comment on images and graphics. For example, it can describe the content of a photo, identify trends in a graph, or generate captions for images. It can also understand context and distinguish subtleties better, resulting in more accurate and coherent responses than its predecessor. Apparently GPT-4 is 82% less likely to respond to unethical questions, and it’s 60% less likely to fabricate facts – or have ‘hallucinations’ − and it can create a real human to circumvent Captcha. For $20 a month you can access GPT-4 through ChatGPT Plus. Anyone who loves photography, like me, will probably know that you can already create a realistic image, without needing a camera, by typing out a description of what you want. This has turned the photography world on its head. Should the really creative photographers worry? Maybe not. AI can’t replace the inborn creative potential of our species. It is by far one of the most important skills we have developed over a million years. Art generators still rely heavily on human ideas. When Gates says something, everyone listens. In his book The Road Ahead, he said: “We always overestimate the change that will occur in the next two years, and underestimate the change that will occur in the next ten.” I was looking at his most recent Gates Notes blog published on 21 March − “The Age of AI has begun” − where he says that even bigger changes are coming. He says he’s seen only two technological advances in his lifetime that struck him as revolutionary. The first was the graphical user interface. Remember when you had to type in a We’ve come a long way command at the C prompt C:> to do anything on your computer. In 1980, when he first saw the demo that allowed users to click on what they wanted, he knew it would change everything. Forty two years later he says he had the same feeling that the whole world was about to change when a bot from Open.ai met the challenge he’d created it for it to pass the Advanced Placement biology test. He reckons the development of AI is as fundamental as the creation of the microprocessor, the personal computer, the internet, and the mobile phone. It will change the way people work, learn, travel, get health care, and communicate with each other. Entire industries will reorient around it and businesses will distinguish themselves by how well they use it. These are some of the changes he foresees, and what we should do to prepare. Firstly, we should start asking how AI can benefit our businesses. Wondering whether you really need AI to run your business may be like wondering 20 years ago whether you really need a website. And the business leaders who figure that out sooner will have an advantage. We also need to start thinking differently about our jobs. AI can help us work more efficiently. This will eliminate the tedious parts of jobs and create opportunities for new jobs, some of which we haven’t thought of yet. I can think of one possibility. Maybe those useless ‘agents’ you find on websites like SARS, where you struggle to get through to a human being, will actually be able to help you. Among his words of wisdom is the advice to stop worrying about AI running amok. Today’s AI can learn to do things better, but cannot take on completely new tasks. Artificial general intelligence, or ‘strong AI’ would be capable of learning any task or subject, but it doesn’t exist yet. That future is distant and may never arrive at all. I don’t think we have any idea right now how AI will change our world over the next few years, but we can be sure that it will.
NEWS & EVENTS 4 May 2023 www.instrumentation.co.za ABB supports National Water Week General Motors has recognised Siemens Digital Industries Software as a 2022 Supplier of the Year. GM’s Supplier of the Year award recognises global suppliers that distinguish themselves by exceeding GM’s requirements, in turn providing customers with innovative technologies and among the highest quality in General Motors names Siemens Supplier of the Year Omron has long believed in the power of co-creation. Now the company is taking this vision further and partnering with OEMs to accelerate innovation. Its broad portfolio of industrial automation technologies is supported by a network of carefully chosen channel partners. Omron Solution Partners act as preferred integrators, following Omron standards in terms of quality of service, company ethics, and respect for society. It now has a new Solutions Partner, Lambda Automation, an automation and mobile robotics system integrator. Lambda traces its roots back to 2014, and by developing a talented and adept workforce, has discovered its place in the industry as a dynamic and flexible business that delivers high-quality solutions to an ever-growing list of loyal customers. The company prides itself on fast turnaround times and places tremendous importance on the ability to supply clients with custom-made solutions. Omron has a strategic partnership with Lambda the automotive industry. This is the sixth time Siemens has received the award. “We are delighted by this recognition of our contribution to GM’s leadership in the automotive field as they work toward their goals for sustainable innovation,” said Tony Hemmelgarn, president and CEO, Siemens Digital Industries Software. “This award demonstrates how the Siemens Xcelerator portfolio, and our comprehensive digital twin technology continues to enable true pioneers and innovators to bring together the physical and digital worlds. This is never truer than in the automotive industry as it faces the challenges of electrification, autonomy, and decarbonisation.” “We are thrilled to recognise these outstanding suppliers after yet another challenging year in the automotive industry,” said Jeff Morrison, GM vice president of Global Purchasing and Supply Chain. “They overcame countless obstacles and exemplified what it means to be resilient, resourceful and determined. Beyond that, these suppliers demonstrated their commitment to sustainable innovation and to driving advanced decarbonisation solutions, in collaboration with the GM team.” Each year, GM’s Supplier of the Year recipients are selected by a global, cross-functional GM team for their performance in criteria such as Product Purchasing, Global Purchasing and Manufacturing Services, Customer Care and Aftersales, and Logistics. For more information contact Siemens South Africa, [email protected], www.siemens.co.za The automation level in the water industry needs to improve to cope with the increasing demand for fresh and clean water. This is the message from technology leader ABB during Water Week, which was held from 20 to 26 March. The national campaign aimed to educate the public about its responsibility in water conservation initiatives, raising awareness of the need to protect and conserve the country’s water resources. ABB offers solutions for water and wastewater treatment to preserve and protect this precious resource. “The water industry needs to automate its processes to increase plant efficiency and productivity, and reduce plant maintenance costs. This will bring a more reliable service and preserve the water we have. With continuous investment in this area, we can ensure the responsible use of water,” says Joyce Moganedi, local division sales manager at ABB. She explains that the water industry can use affordable scada and PLC solutions. ABB offers automation at all levels of complexity, including DCS. “We believe these types of solutions are the catalyst needed for the successful implementation of IIoT,” she continues. Scada systems offer the flexibility to monitor, control and automatically manage specific plant processes. These range from visual awareness of operations to real-time information to act on any abnormalities in the plant, and increased plant availability; having accessibility to remote operations in the plant anywhere at any time; and increased efficiency and productivity. Such reliable systems are necessary for continuous future improvements. For more information contact ABB South Africa, +27 10 202 5105, [email protected], www.abb.com/za With a head office in Pretoria, it specialises in programming, robotics and panel wiring, and services the automotive, food and beverage, brewery, and dairy sectors. ”We are not a project house, we offer tailor-made solutions to our clients, as we know from experience that automation is not one size fits all, ” says founding partner, Francois Scheepers. “We are proud to welcome Lambda as a Solutions Partner,” says Omron’s Alexander Valla. “Given today’s industry trends, production challenges and labour shortage concerns, Lambda will be an excellent partner for end users in various industries to engage within order to improve system performance.” For more information contact Omron Electronics, +27 11 579 2600, [email protected], www.industrial.omron.co.za
NEWS & EVENTS 6 May 2023 www.instrumentation.co.za Mercedes-Benz Vans is consistently pursuing its goal of building the most desirable vans, and increased its sales by a total of 12% in the first three months of the year. Worldwide 98 900 vehicles were sold, more than ever before in a first quarter. The share of all-electric vans rose by 22% to 3600 vehicles. The eVans’ share of total sales increased to 3,6%. This once again underlines the company’s claim to be a leader in the field of electric vans. South Africa is poised to make an impact in the market of all-electric vans by 2024. Earlier in the year, Mercedes-Benz Vans South Africa announced that the much-anticipated eSprinter will be available in South Africa by 2024. This forms part of the goal to embark on a new era of sustainable mobility, particularly for businesses and individuals looking for a cost-effective, environmentally-friendly mode of transportation. By introducing its first electric van to the South African market, Mercedes-Benz Vans South Africa reaffirms its assertion that it is at the forefront of electric Mercedes-Benz Vans achieves best ever first quarter The importance of variable frequency drives (VFD) in reducing energy use in industries using electric motor control applications was the topic at Hannover Messe 2023, held from 17 to 21 April. Invertek Drives displayed its complete range of Optidrive VFDs at the exhibition and highlighted how VFD technology is not only helping industry make savings of up to 50% in some motor and pump control applications, Invertek Drives highlights VFD advantages van technology. Mercedes-Benz Vans South Africa remains committed to being the leader in the field of electric vans within the South African market. For more information contact Beate Mey, Mercedes Benz Vans, +27 69 146 3324, [email protected], www.mercedes-benz.com but also supporting a reduction in emissions, and the need for a reduction in climate change. “Energy efficiency is a core component in the future of drive technologies such as ours. Our variable frequency drives have been reducing energy costs, increasing efficiencies and helping support the reduction in associated emissions for 25 years in motor, pump and HVAC-R systems,” said Rhydian Welson, sales and marketing director at Invertek Drives. “Hannover is a key industry event for us. We have enjoyed meeting existing and future customers to discuss ways our drives technology can support them.” For more information contact Owain Betts, Invertek Drives, +44 1938 558 253, [email protected], www.invertekdrives.com
NEWS & EVENTS www.bmgworld.net BEARINGS • SEALS • POWER TRANSMISSION • DRIVES • MOTORS • MATERIALS HANDLING • FASTENERS & TOOLS HYDRAULICS • PNEUMATICS • FILTRATION • LUBRICATION • VALVES • TECHNICAL RESOURCES • FIELD SERVICES BMG-WEB-2022-Shop-Online SHOP BMG ONLINE FOR: • Electronic Motion Control • Maintenance Chemicals • Tools and Equipment • Power Transmission • Electric Motors • Adhesives • Fasteners • Bearings • Sealants • Gaskets • Seals SKF has received validation of its Scope 1, 2 and 3 emissions reduction targets from the Science Based Target initiative (SBTi). The SBTi has verified SKF’s net-zero target by 2050, validating its near and long-term science-based emissions reduction targets. SBTi is the global body enabling companies to set ambitious emissions reduction targets in line with the latest climate science. Validation means that SKF’s targets comply with the goals of the Paris Agreement. SKF has committed to reducing its absolute scope 1 and 2 GHG emissions by 95% by 2030 from a 2019 base year, and to reduce its scope 3 emissions by at least 31%. In addition, SKF has committed to reach net-zero GHG emissions across the value chain by 2050. Furthermore, SKF commits to a reduction in absolute scope 3 GHG emissions from purchased goods and services, fuel and energy related activities, upstream transportation, and distribution and use of sold products of 90% by 2050. Magnus Rosén, head of sustainability at SKF, says: “We have set a clear and bold path to reach net-zero emissions in 2050. Our SBTi approves SKF’s emissions reduction targets targets are based on an understanding of the complete life cycle, meaning we will prioritise actions that make the biggest positive impact, while avoiding negative trade-offs. By setting targets that align with the latest scientific research, we can help mitigate climate change, protect natural resources, and create a better future for all.” For more information contact Samantha Joubert, SKF South Africa, +27 11 821 3500, [email protected], www.skf.com
8 May 2023 www.instrumentation.co.za SAIMC NEWS 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) From the office of the CEO Johan Maartens. Remain in the loop The SAIMC has gained much attention in the last couple of years, and our members need to know where and when they can get involved, and how its actions can benefit them. On our website, you will notice a new button in the top right-hand corner labelled UPDATE ME!. The menu item will take you to a choice of Sign Up (for new subscribers to our Mailchimp platform) or Change Preferences. If you select Change Preferences, you will be requested to click on a button called Email Me A Link. You can make the necessary changes when you receive the link via email. If you select Sign Up, you can choose between SAIMC News and Branch News, with various branches listed. You can choose more than one. For our new MESA members and any other members interested in receiving MESA news, select the MESA button under Branch News. Calendars Branch general managers are tasked with entering their branch activities in the calendar on our website’s home page. If you do not see this information there, you can request them to update their calendars. On the home page you will also see a link to the various branches. Should you not see the Branch Committee’s details on this page, please get in touch with John Owen-Ellis at [email protected] or myself at [email protected]. Can South Africa survive the onslaught? South Africa faces many challenges. People in one group are afraid of losing their jobs because of automation, while others are trying to find a way to survive despite all the bribery, corruption, rapes, murders, etc. We are in general told what to think and what to believe. Most voters and journalists are told that apartheid and white people are the reason for the “greatest gap between the rich and the poor.” If this does not work, they are scared with the concept of artificial intelligence, and automation. For the ‘feeding trough’, artificial intelligence and automation are genuine threats. These technologies require technical expertise and not verbal diahorrea. No manner of long-winded arguments will be able to develop, install or maintain these technologies. They will be exposed for what they are – pure propaganda. Automated security systems would have made the SAPS obsolete if it was not for the ‘feeding trough’, and lawyers who implement systems requiring lawyers to be used. You cannot evict an unlawful occupier of your property unless you use lawyers, for example; and you can only use the SAPS in crime situations, while private security companies are faster, quicker, better equipped, and more efficient. Automation, in my eyes, is a minor threat compared to the ‘feeding trough’ that is pulling South Africa down to the world of greylisting, junk status, looting, potholes, load shedding, murders, rapes, etc. Many entrepreneurs, self-thinkers, and the ‘Economic IQ’ (a new word I just made up) have left the country. I wonder whether South Africa has enough resources to make significant changes next year. I wonder if we could get the passive masses off their rocking chairs and rock this South African boat. Yours in automation, Johan Maartens. National Members GAIL NORTON INSTRUMENTATION - South Africa
www.instrumentation.co.za May 2023 9 SAIMC NEWS The Durban branch of the SAIMC held its monthly technology meeting as usual at the Premier Splendid Hotel in Pinetown. Jurie Weidemann, external sales engineer at Pepperl+Fuchs, presented to an interested audience on the topic of Ethernet APL. In his introduction, Jurie very succinctly put it: “The world of technology is moving more and more toward digital communication across platforms. We all know there have been many digital communication technologies released in the past to enable better communication capabilities for the process industry. Few of them have been able to cut across protocols and different sectors of the process – now there is no longer a reason for the process industry to lag behind.” Jurie captivated his audience with his lively talk about progress from analogue signal transmission through various stages of digital communication, and how the speed and integrity of the transmitted information has improved over a relatively few years. A further important aspect is the ability of the latest systems to be function driven rather than device driven, with interoperability being an key aspect. This was an extremely polished presentation and with his 24 years of experience in the process automation industry, Jurie was well qualified to present to the Durban members. Jurie Weidemann (right) being thanked by John Owen-Ellis. SAIMC Durban Johannesburg golf day Where: Jacal Creek Golf Course When: September/October 2023 Cost: R4800 per 4 ball Watering hole: R1725 + R1500 corkage Save The Month For information and booking contact Cheryl Hird at [email protected]
10 May 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, system integrators & project houses EHL Consulting Engineers offers comprehensive C&I services across all industries including control system design, software development and system integration; legacy system upgrades and replacements; process automation and optimisation; and IS and SIL services. Tel: +27 11 370 7400 [email protected] [email protected] www.ehl.co.za EHL Consulting Engineers Autotronix is a recognised leader in industrial automation design and implementation having attained its ISO 9001 certification. Autotronix offers its clients turnkey control system integration services for energy management, PLC/HMI/scada/VSD, manufacture of control panels, applications for water distribution and manufacturing. The company operates from offices in Gauteng and KwaZulu-Natal. Tel: +27 31 705 0400 or +27 16 422 7644 [email protected] www.autotronix.co.za Autotronix Iritron is a new millennium technology company providing quality solutions in the fields of electrical instrumentation and control systems engineering, MES systems integration and simulations. It has a proven ability to manage projects efficiently and produce high quality results. It has an extensive track record of successfully implementing plant infrastructure reticulation, designs, and automation and information systems. Iritron, a TUV accredited ISO 9001:2015; ISO 14001:1015 and ISO 45001:2018 as well as a GAMP®5: A Risk-Based Approach to Compliant technology company, can offer its clients PLC, DCS, MES and scada software and hardware, as well as electrical and instrumentation design, engineering, project management and commissioning services. Tel: +27 12 349 2919 [email protected] www.iritron.co.za Iritron
www.instrumentation.co.za May 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 to maximise profits. This means reduced cost of ownership, increased uptime, consistent results and ultimately a solution that not only fits your budget but lets your business work whilst you’re at home with your family. To us that means providing a hassle free, customised engineering solution that exceeds your expectations. Are you ready to take your business to the next level? We are! Level 2 BBEEE , ISO 9001:2015, CIDB. Siemens, Schneider, Wonderware and Rockwell certified. Automation Innovation, it’s the new AI. Tel: +27 11 466 4172 [email protected] www.pcsglobal.com Proconics is a locally based multi-discipline engineering company that executes projects to improve and extend the life of factories. Proconics specialises in multi-discipline, short-term turnkey projects, featuring brownfield replacement projects as well as renewable grid connections. Tel: +27 16 982 7880 [email protected] www.proconics.co.za Proconics Philco Systems Philco Systems provides turnkey industrial automation solutions that are tailored to the client’s individual application, with 30 years’ experience in industrial automation design, drafting panel building, software engineering, field construction, commissioning and legacy migration. Philco Systems integrates a vast array of PLCs, VSDs, HMI, scada and instrumentation into custom solutions, which align with industry standards. At Philco we pride ourselves on building long-lasting customer relationships and have an excellent reputation for providing service and support to the clients’ automation systems. Tel: +27 35 751 1363 [email protected] www.philco.co.za What we are offering (an anually renewable subscription): South Africa’s only dedicated process control and factory automation publication. Whether you are a consulting engineer, a system integrator or a project house, we have the perfect marketing platform to put you in touch with nearly 4500 relevant control and automation practitioners in the automotive, food & beverage, mining, petrochemical, power, pulp & paper and water & wastewater industries. Name, contact details, logo and brief description of your business solution will appear in each issue of SA Instrumentation & Control magazine. Two A4 in depth editorials OR, two half page display advertisements – content of your choice. All articles will also be hosted on our website and appear in a prominent position in one of our electronic newsbriefs. PDF copies of the articles (to be used for your own purposes) will be provided after publication. Your listing will be published in a new “Choose Your Automation Professional” section of the annual SA Instrumentation & Control Buyers’ Guide and a link to your company web page in all directory listings. Contact: [email protected]
12 May 2023 www.instrumentation.co.za Process plants today compete to produce more products with less waste, as profit margins are under pressure and require increased yield and quality. Digital transformation has made it possible to obtain more plant data from process automation systems and instrumentation, and to use this valuable data from the field level for the optimisation of processes. However, field level connectivity and data access are crucial to support these trends. Ethernet is the broadly accepted standard for wired digital communications, and is standardised in IEEE 802.3, but it does not adequately meet the requirements of process automation. There are limitations such as low speed, limited bandwidth, and the complexity required by protocol conversions. Leading process automation suppliers recognised the need of their customers to add the universality and communication speed of standard Ethernet to existing field device installations. Ethernet had been deployed at the upper levels of the automation pyramid and in the field with four-wire Ethernet devices such as drives, flowmeters, analysers and motor control centres; but process plants needed more in order to support applications in the field, and access data from every part of the plant to extract more value from each production run. Ethernet to the field for process plants Endress+Hauser is at the forefront of the development of Ethernet-APL, which combines the benefits of simple and robust two-wire technology with the advantages of Ethernet, enabling top performance and seamless data access in the field for process plants. To meet this need, in 2018 a key group of standards development organisations worked together with major industry partners like Endress+Hauser to specify an advanced physical layer for Ethernet to meet the requirements of process industries. The players included FieldComm Group, ODVA, the OPC Foundation, PROFIBUS & PROFINET International, as well as major industry suppliers of process automation like Endress+Hauser, ABB, Emerson, Krohne, Pepperl+Fuchs, Phoenix Contact, R. Stahl, Rockwell Automation, Samson, Siemens, Vega, and Yokogawa. Their goal was to accelerate the development and adoption of a new open standard for an Ethernet physical layer for use in process automation and instrumentation, that could be deployed in hazardous areas, allow long-reach connectivity, and include an option for device power over the line. The new extension of Ethernet technology they came up with was Ethernet-APL, which was designed to be open, future-proof and ready for IIoT. Data from smart instruments in the field level could then be accessed easily for further processing in upper layer applications. Ethernet-APL is based on the IEEE 802.3cg standard, which was developed specifically for use in hazardous areas and enables it to operate over long distances and in harsh environments. This new Ethernet advanced physical layer, together with the automation protocols that define the structure and meaning of information being transmitted to and from field devices, is becoming one of the key enabling factors for IIoT in process automation. It is a single, ruggedised, and reliable physical layer with attributes that meet the requirements for the field of process plants. Ethernet-APL enables a logical extension of Ethernet-based communications from enterprise systems to the field. It enables long cable lengths and explosion protection via intrinsic safety, with communication and power over two wires. Based on IEEE and IEC standards, Ethernet-APL supports any Ethernet-based automation protocol and is rapidly developing into a single, long-term stable technology for the entire process automation community. Ethernet-APL is an important development for the process automation industry because it enables customers to use a single networking technology throughout their entire plant, from the field instruments to the control room. This reduces complexity and improves reliability, as customers no longer need to use different networking technologies for different parts of their plant. Ethernet APL also enables customers to use standard Ethernet protocols such as
www.instrumentation.co.za May 2023 13 COVER STORY TCP/IP and EtherNet/IP throughout their plant, providing them with a familiar and easy-to-use networking environment. Engineers from BASF recently evaluated the Ethernet-APL technology over several months in the BASF Ethernet-APL laboratory. They looked at different topologies and applications based on the requirements of BASF’s process plants, and identified many advantages of the new technology. These included simple and flexible installation; easy integration into the DCS; stable and fast Ethernet communication; high availability of the process; plug-and-play device exchange; and data export in the 2nd channel. BASF is convinced that Ethernet-APL is the best technology for future plants. “Using Ethernet-APL technology speeds up workflows and increases efficiency in operations and maintenance, and that‘s exactly what we want,” said BASF’s senior E&I engineering manager, Gerd Niedermayer. “Fieldbus technologies like PROFIBUS or FOUNDATION Fieldbus will be obsolete with the widespread introduction of Ethernet-APL – we won‘t need them any longer.” Among the many advantages that are being leveraged by Endress+Hauser are shortened commissioning times and increased maintenance efficiency. By providing seamless access to the data and algorithms of smart instruments through Endress+Hauser’s Heartbeat Technology, the full potential of the instrumentation is exploited, and plant downtimes can be minimised. Another benefit is high plant availability and increased production output with less plant shutdowns. Ethernet-APL is easy to adopt, topology design is flexible, installation is as simple as required and root cause of errors in the network and in devices are easy to troubleshoot. According to Endress+Hauser, a key benefit for engineers is the flexible and scalable network topology design, while there is no need for hazardous area calculations, and there is high availability due to a variety of redundancy mechanisms. For operators and maintenance personnel, advantages include the increased performance as a result of accurate digital process values, high-speed data transfer, and simple remote device access. Reliability is also optimised as a result of continuous diagnostics, monitoring, and remote verification, with seamless data access. In addition the flexible network design makes it possible to realise different topologies. Endress+Hauser is at the forefront of the development and implementation of Ethernet-APL, assisting its customers to integrate their field instruments into existing networks. The company’s commitment to the development of Ethernet-APL, and its growing portfolio of Ethernet APL-based solutions, have earned it recognition in the industry. The award-winning Liquiphant vibrating fork level switches were among the first products to incorporate Ethernet-APL. The company now offers a range of Ethernet APL-enabled solutions for plant processing, including sensors, controllers, and instruments for flow, level, pressure and temperature measurement. These solutions are designed to be easy to install and maintain, and can help companies to optimise their plant processing operations. Endress+Hauser is currently showing users in the process industry how they can create value by looking more closely at their data to gain new insights into their processes and optimise the operation of their plants. The goal is to show users what is possible with data, both today and in the future, and where the limits and dangers lie. Among the many possible applications are explosion hazardous areas, asset management at many measuring points, calibration of analogue communication loops, monitoring and optimisation using the 2nd channel, and easy access to device diagnostics. Plant extensions and migrations to Ethernet-APL are possible in both greenfield and brownfield sites; and Endress+Hauser is also accelerating the digitalisation of process engineering systems with its Netilion IIoT ecosystem, and advanced developments its its Heartbeat Technology, which creates opportunities for gaining insights into sensors and processes. One example is BP’s Clair Ridge Platform in the North Sea. This is one of the largest offshore oil platforms in the world. The platform uses Ethernet-APL technology from Endress+Hauser to enable real-time monitoring and control of its processes. This allows the platform’s control systems to communicate with sensors and other devices throughout the platform, providing operators with real-time data on the platform’s operations. Ethernet APL is a game-changer for the process automation industry, and Endress+Hauser is at the cutting edge. As this technology evolves and gains acceptance in the industry, the company will continue to be a leader in the development of innovative and reliable solutions that enable customers to improve their processes and achieve their goals. For more information contact Endress+Hauser South Africa, +27 11 262 8000, [email protected], www.za.endress.com “Using Ethernet-APL technology speeds up workflows and increases efficiency in operations and maintenance, and that‘s exactly what we want.” Gerd Niedermayer senior E&I engineering manager, BASF.
14 May 2023 www.instrumentation.co.za In the Spring of 2021, Beckhoff began to completely rethink the way it carried out final inspections of I/O components. Its aim was to increase testing capacity and throughput significantly, even though many different types of terminals are produced. The system, which was created entirely by the company’s own equipment manufacturing department, can program, adjust and test around 10 000 terminals per shift, fully automatically. The high speed and flexibility are the result of not only the sophisticated system concept, but also the intelligent XPlanar transport system, PC-based control, and the wide range of EtherCAT Terminals. Keeping pace with the growth that Beckhoff achieves year after year was, and remains, a challenge for Michael Golz, head of the demo systems department, and his approximately 40 employees, who are responsible for building the operating equipment, among other things. They have taken a completely new approach to the system for final inspection of I/O terminals – with the XPlanar as a transport system, Beckhoff’s XPlanar greatly increases testing capacity and throughput specially developed firmware programmers, and test stations with universal test cabinets. “On average, a fully tested I/O terminal that is programmed with the appropriate firmware leaves the system every 3 seconds, regardless of the type of terminal and the order in which they are delivered,” explains Golz. Currently, over 200 different types of terminal can be programmed and tested on the system. The number of different types present in the system also has no impact on the output rate of 10 000 terminals per shift. Easy, flexible, and transparent handling “The process is very simple,” says Golz. “The operator doesn’t have to set up anything; all they have to do is place a stack of trays with terminals at the infeed station and press a button.”The stack then enters the picking station, where a delta robot picks up the modules from the trays and places them individually on the waiting XPlanar movers. The system has two main paths, almost like highways, leading left and right to the programming and testing stations. The stations are located at exits or parking bays on the side of both lanes. Between the lanes, there is a third path where all movers return to the picker. This symmetrical setup has the advantage that even if an entire half of the system fails, the other side can continue to operate. The movers pass the terminals under a reading station through to the lateral programming stations. The reading station captures the individual Beckhoff Identification Code (BIC) of each terminal by means of multiple cameras and Beckhoff Vision. “After that, the system knows the terminal type and does everything completely autonomously – programming, adjusting the analogue channels if necessary, and function testing,” adds Brockhaus, who is responsible for system programming. At the same time, the BIC is ‘married’ to the mover via its ID. This means that the mover ID can be used to track the location of each individual mover or terminal, even after a power failure. When the mover has reached Image copyright: Beckhoff.
www.instrumentation.co.za May 2023 15 CONTROL SYSTEMS a free programming station, it positions the terminal precisely under its contact pins. Then, depending on the BIC, the corresponding firmware is loaded onto the terminal. It then moves on to one of the universal testing stations, which in turn calls up the device-specific test sequence based on the BIC. If the software has been loaded correctly and the function test reports no issues, the mover transports the terminal to the picking station’s second delta robot, which places the terminal on another tray via the middle track. The mover passes through the reading station a second time, only this time in the opposite direction. “The terminal is booked out via the renewed capture of the BIC on the return track, and the installation of the firmware and the function test of each individual terminal are documented in the central database, including all adjustment values in the case of analogue terminals,” says Stefan Engelke, who developed and programmed the test cabinets together with his team. All XPlanar degrees of freedom used The basis for this flexible yet fast process is an XPlanar system consisting of 100 tiles. “We built the two main paths with two outbound lanes and the return track in the middle from six XPlanar base sets, each containing 3 x 4 tiles,” says Golz. For the add-ons (programmer and tester), the remaining 28 tiles are screwed onto the side of the basic system. Each mounting position has a standardised interface with power supply (400 V AC), safety, Ethernet (LAN), as well as EtherCAT. “The interface and the system layout enable future expansions without major conversion work,” emphasises Golz, who is responsible for the mechanical design of the system, and the specific details for terminal contacting. XPlanar makes machinery modular, while also simplifying mechanics in many sectors. For example, the programming stations use XPlanar’s XY precision positioning. Therefore, immediately after reaching the exact position, programmers can lower their pins onto the terminal contacts and start loading the firmware. At the test stations, another XPlanar feature reduces the design work: the variable flight height. When it arrives at the test station, the mover lifts first so that the slide-in unit of the test station can move under the terminal. Then the mover lowers its hovering level again, and the terminal then rests on the slide-in unit and is drawn into the tester. The benefit of this is that all contacts are freely accessible and can be contacted. After the test, the terminal is then placed back on the mover in reverse order. The option to rotate the movers comes into play again during insertion and removal. It is used to rotate the movers by 180°, depending on the side of the system used. “This feature has also significantly reduced the mechanical complexity and has made space-saving configuration of the tester and programmer on both sides possible in the first place,” points out Golz. The strengths of PC-based control are also evident in the overall coordination and evaluation. If a tester detects a discrepancy on a terminal, this is registered via the BIC, while the tester sends the terminal back to the programming stations for reconfiguration. However, if error messages accumulate on a programmer or tester, this indicates a malfunction. “In this case, the tester is reported to the system as unavailable, and this position is no longer approached by the movers until the tester has been examined and, if necessary, replaced,” says Brockhaus. Although the system will then run with one less station for a short time, it is still up and running, and not significantly slower. “An I/O terminal that could cause any problems for a customer would not leave our system,” adds Golz. The system is a prime example of how PC-based control can be used to perform a wide variety of tasks and functions. In addition to a C6670 control cabinet industrial server, which coordinates the 33 movers on the 100 tiles, a total of ten C6032 ultra-compact Industrial PCs control the other system components. The delta robots are automated with the AX8000 multi-axis servo system and AM8000 servomotors. “We use the AMI8100 integrated servo drives to infeed and eject the trays because they are extremely compact and require only EtherCAT and 48 V voltage to operate,” says Brockhaus. AA1000 linear actuators are used by the programmers to contact the terminals; AA3000 electric cylinders are also used by the testers to feed in the terminal carriers. The entire safety technology is implemented with TwinSAFE. TwinCAT Vision captures the DataMatrix codes. Around 40 EtherCAT measurement terminals from the ELM series are installed in each of the four test cabinets. In addition, a wide range of EtherCAT Terminals from the EL series are also used. Golz says, “PC-based control has made a lot of things easier for us in this project and leaves us the option for further expansions.” For more information contact Beckhoff Automation, +27 11 795 2898, [email protected], www.beckhoff.com Image copyright: Beckhoff.
16 May 2023 www.instrumentation.co.za CONTROL SYSTEMS Michael Brown is a specialist in control loop optimisation, with many years of experience in process control instrumentation. His main activities are consulting and teaching practical control loop analysis and optimisation. He now presents courses and performs optimisation over the internet. His work has taken him to plants all over South Africa and also to other countries. He can be contacted at: Michael Brown Control Engineering CC, +27 82 440 7790, [email protected], www.controlloop.co.za Case History 187 Integrating or self-regulating or both? It is vital, when optimising a control loop, to establish at the outset if the process is self-regulating or integrating, as not only do these two process types behave completely differently ,but also they are tuned very differently. A typical self-regulating process is a flow where if you make a step-change to the input to the process, the output moves to a new value and then remains constant at that value. An integrating process on the other hand is one where if the input to, and the output from, the process are different, then the output is always either ramping up or down. It is only constant when the output is equal to the input. It is known as a balancing process. A very good example of an integrating process is the control of a level in a vessel. Unfortunately, it is sometimes very difficult to decide if a process is actually self-regulating or integrating. For example, certain processes, like certain temperature and pressure control of compressible fluids like gases and steam, sometimes seem to exhibit both characteristics. A good example of this is level control of a liquid in a tank that has not got a pump on the output of the tank. We call this a gravity feed tank. The output flow is dependent on the force of gravity acting on the height of the liquid in the tank. Now, if at a certain point in time the input and output flows are equal, the level remains constant. If one now makes a small step increase in the output flow, the level immediately starts ramping down, but as the level decreases, the head of liquid in the tank is getting smaller and hence the output flow starts decreasing as well. If you have not made too big a step, the level will actually eventually balance itself out. The resultant total curve recorded in the level now looks exactly like a self-regulating process. However, level is definitely integrating. So how do we define it? Basically what has effectively occurred is that the process started reacting as an integrator and then changed into a self-regulator. There are quite a few cases where this happens, and there are also some odd cases where a process starts as Figure 1. Figure 2.
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