39VOLUME NO 11 NOVEMBER 2023 Official publication of the SAIMC Made in South Africa – Always in stock Control systems | IT in manufacturing | Smart factories | Sustainability Process measurement | Fieldbus & industrial networking Wireless & telemetry | Motion control & drives
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www.instrumentation.co.za November 2023 1 Fieldbus & industrial networking Process measurement Wireless & telemetry Motion control & drives VOLUME 39 NO 11 NOVEMBER 2023 03 06 08 40 REGULARS FEATURES IT in manufacturing Control systems Sustainability Smart factories 22 17 12 26 33 28 34 35 News & events SAIMC news Automation professionals Product news Omron Electronics, Turck Banner, Referro Systems ifm – South Africa Schneider Electric South Africa, LOESCHE South Africa, RJ Connect, Booyco Electronics, ABI Research, Beckhoff Automation Michael Brown Control Engineering CC, Beckhoff Automation, Epiroc South Africa, Iritron Emerson Automation Solutions VEGA Controls SA, WIKA Instruments, Endress+Hauser South Africa Pepperl+Fuchs, Gail Norton Instrumentation Agencies Smith Power Equipment, Neu Matics SA, BMG, SEW-EURODRIVE OUR COVER 10 39VOLUME NO 11 NOVEMBER 2023 Official publication of the SAIMC Control systems | IT in manufacturing | Smart factories | Sustainability Process measurement | Fieldbus & industrial networking Wireless & telemetry | Motion control & drives Made in South Africa – Always in stock Pressure and temperature gauges are very widely used on process plants. Gauges are relatively inexpensive, and because they are installed in large numbers, maintenance can be neglected, resulting in unreliable and compromised instruments. Poorly maintained, inaccurate gauges can compromise a plant’s ability to detect potential problems. Accidents, damage and injury to equipment and personnel is often the result. Read our cover story on page 10 to find out what guidelines SA Gauge recommends for the selection and calibration of gauges in order to prevent gauge failure.
2 November 2023 www.instrumentation.co.za welcome VOLUME 39 NO 11 NOVEMBER 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 Kim Roberts at [email protected]. Sending material to this publication will be considered automatic permission to use in full or in part in our Letters column. Be sure to include your name, e-mail address, city and zip code. We reserve the right to edit all letters. EDITOR Kim Roberts MSc Chem [email protected] CIO & DIRECTOR Graeme Bell NHD Elec. Eng., MBA [email protected] CONTRIBUTING EDITORS Michael Brown BSc (Eng) (Rand), CEng MIEE MSAIEE Gavin Halse BSc Chem Eng Lance Turner BSc (Hons) Information Systems ADVERTISING Sales manager Jane van der Spuy [email protected] Tel: +27 83 234 5412 Heidi Hargreaves [email protected] Tel: +27 83 504 0436 DESIGN AND LAYOUT Technews Production Department SUBSCRIPTION SERVICES For address changes, subscriptions, renewal status or missing issues, email: [email protected] or write to: Technews Publishing (Pty) Ltd, Box 385, Pinegowrie 2123 SUBSCRIBE ONLINE www.technews.co.za PUBLISHERS Technews Publishing (Pty) Ltd Wild Fig Business Park, Block B, Unit 21, 1494 Cranberry Street, Honeydew This year’s Nobel prizes were recently announced. I was fascinated by the Nobel Prize for Chemistry, which was awarded for research on quantum dots, and I wondered what they actually are. Well, they are a new class of materials different from molecules, and they consist of tiny semiconductor nanoparticles. Adjusting their size by a billionth of a metre can change their optical, electric and magnetic properties, and even their melting point. They have different colours, depending on their size. Their luminous properties are already found in the tiny dots that light up our QLED computer and TV screens. They can be used in everything from everlasting light bulbs to tiny low-energy sensors, to quantum computers. Since they can release electrons and create electrical currents, they can be used to produce highly effective solar cells that are far more efficient at converting the energy from photons than today’s ones. This is something worthy of a Nobel. It’s one of the most prestigious awards in the world, and honours people who have made outstanding contributions in their field. Many remarkable scientists have been recognised and celebrated. But not every brilliant scientist got this recognition. Here are some famous scientists who didn’t get the Nobel Prize. Thanks to Elon Musk, we are all familiar with the name Tesla. Nikola Tesla was a brilliant electrical engineer and inventor. His revolutionary work laid the foundation for the modern alternating current. You get electricity in your house because of him. By inventing the Tesla coil and the induction motor he transformed the world of electricity and power transmission. But in spite of his huge contribution to science and technology, Tesla never received the big prize. Apparently one reason was the ongoing feud between him and Thomas Edison. His eccentric personality and unorthodox ideas may also have contributed to his omission. Stephen Hawking captured our imagination with his pioneering work on black holes, cosmology and the nature of the universe. Despite being diagnosed with a motor neuron disease at an early age, he defied all odds and made an extraordinary contribution to physics. His work on black holes and the nature of time resulted in one of his most significant discoveries. Although Hawking’s achievements were widely recognised and admired, he never got the prize. Apparently the reasons for this are that the Nobel Prize for physics focuses on theoretical discoveries that can be proven experimentally. Hawking’s, while highly Joining the quantum dots influential, did not yield direct observational evidence. Albert Einstein’s name makes you think ‘genius’. His theory of relativity redefined how we think about gravity, space and time. His groundbreaking work earned him huge recognition in the scientific community, but the Nobel Prize eluded him for many years. He was eventually awarded it in 1921, but not for his theory of relativity that we all know about. The prize was given for his discovery of the photoelectric effect. Astronomer Edwin Hubble made groundbreaking discoveries that revolutionised our understanding of the universe. His observations and calculations gave compelling evidence for the expansion of the universe, and the existence of galaxies beyond our own. He has even had a space telescope named after him. Despite his role in advancing the field of astronomy, Hubble never received a Nobel Prize. Apparently his contributions were not directly aligned with the Nobel committee’s criteria, which focused on theoretical and experimental work in the field of physics. Thomas Edison held a record-breaking number of patents and was responsible for game-changing inventions like the phonograph and the electric light bulb. His work in electrical power generation and distribution transformed the world. Despite his huge impact on society and technology, Thomas Edison never received the Nobel Prize. It is speculated that the Nobel Committee’s emphasis on scientific discoveries and theoretical advancements played a role in the exclusion of inventors like Edison. He was too practical. I am wondering whether these incredible innovators were desperately disappointed at being left out. It occurred to me that as brilliant as they are, nobody really knows very much about Nobel Prize winners. Do you know the name of any winner in the last five years? The only ones I can remember are Mandela, De Klerk, Tutu, Luthuli and Gordimer, and that’s because they’re from home. But these famous scientists, who missed the prize, are household names and they have inspired generations of new scientists. Surely that’s more of a legacy than a once-off science award, however distinguished, that nobody later remembers.
NEWS & EVENTS www.instrumentation.co.za November 2023 3 The School of Electrical Engineering at the University of Johannesburg recently opened its doors for the 31st Southern African Universities Power Engineering Conference (SAUPEC). This prestigious conference focuses on power engineering, a crucial field that deals with the design, development and maintenance of power systems and equipment. It plays a vital role in ensuring the reliable and efficient generation, transmission and distribution of electricity. Festo Didactic, a global leader in technical education, sponsored this conference as part of its dedication to the advancements of teaching. The leading company is proud to contribute to a prominent platform that brings together experts in the field to share knowledge and advance the power engineering industry. During this conference, Festo exhibited its Cyber-Physical Factory, a cutting-edge system that utilises Industry 4.0 technologies. Attendees also had the opportunity to interact with Festo’s technical experts and learn more about this training system’s technology. Cyber-Physical Factory The Cyber-Physical Factory that was on display is a modular learning system for Festo sponsors Power Engineering conference training in Industry 4.0. It authentically replicates the stations of a real production system, integrating relevant mechatronic and automation technologies. With its training flexibility and expandability, the CP Factory represents numerous aspects of the Industry 4.0 value chain, including the integration of manufacturing divisions into digital production and automated and manual assembly, to mention a few. With the electricity shortage at its peak in South Africa, one of the key benefits that the CP Factory offers is its ability to measure the total energy system and the subsystems. The advanced system and subsystems allow the highest energy optimisation to be achieved. This, therefore, results in energy savings for the factory’s owner and reduces the factory’s energy input. Festo learning systems are equipped with innovative industrial technologies so that the knowledge required for digital production can be imparted, while simultaneously developing skills through hands-on trial and error. Due to its superior technology, Festo has become the performance leader in its industry. This success is attributed to its continuous innovations At this year’s Eskom Expo International Science Fair (ISF), young scientists reaped the benefits of their hard work and ingenuity, receiving full and partial bursaries, cash prizes, laptops, and opportunities for work-based exposure during their school holidays. The fair brought together the brightest young scientists from across South Africa and various other countries. Title sponsor, Eskom, awarded 23 full bursaries valued up to R450 000 each, and four special awards to the best female, best development, best energy, and best innovation projects in the energy category. Eskom Development Foundation acting CEO, Mologadi Motshele congratulated the remarkable young scientists, who have not only displayed exceptional talent, but also a steadfast commitment to scientific inquiry and innovation. “Your achievements are a testament to your hard work, dedication and boundless Eskom Expo honours young scientists David Setlhake, Area Manager South Africa. and problem-solving competence in various aspects of automation, as well as its unique and wide range of technical training and education programmes. For more information contact Festo South Africa, 08600 FESTO (33786), [email protected], www.festo.co.za curiosity. We are also excited to see a growing number of young women scientists emerging as true change agents in the fields of science, technology, engineering, mathematics, and innovation,” he said. Eskom Expo executive director, Parthy Chetty added: “I wish to thank the many partners and sponsors who share our vision of promoting STEM education by rewarding deserving young scientists for their hard work and dedication.” Through their generous sponsorships, Siemens, Innomotics and Siemens Energy supported previously disadvantaged schools with their prizes. FFS, Babcock International, Ekurhuleni Drums, Trisim Logistics, Berea Plumbers and the National Institute for Theoretical and Computational Sciences (NIThECS) supported learners with laptop computer sponsorships. The University of Witwatersrand, the University of Pretoria, and the Durban University of Technology provided academic support in the form of bursaries and mentorships. Engineering giant, Siemens Energy awarded two full bursaries worth close to R1 million for winners to study towards a Bachelor of Science in Engineering at any South African university of their choice. These included tuition fees, textbooks, accommodation, meal allowances and a laptop. The prestigious University of Pretoria/Dr Derek Gray Memorial Award consisted of the Derek Gray Gold Medal, attendance at the Stockholm International Youth Science Seminar during Nobel Week, and a three-year study bursary in science or engineering at the University of Pretoria. For more information contact JeVanne Gibbs, +27 76 674 1455, [email protected], www.exposcience.co.za
NEWS & EVENTS 4 November 2023 www.instrumentation.co.za The GHM GROUP, a leader in the field of flow, level, portable and environmental measurement technology, has taken a further step towards internationalisation. Its five brands will be merged into a single, agile company to respond quickly to customer needs and market trends. From 1 January 2024, the GHM GROUP, a leading sensor technology company, will become Senseca − one company, one brand, one purpose − to become a contributor to a sustainable future. More than a rebranding project, the five GHM GROUP brands (Honsberg, Greisinger, Martens, Val.Co and Delta OHM) will combine their expertise to continue on their global path of success within Senseca by maintaining the same entrepreneurial spirit they were founded on, along with their design and manufacturing excellence. “The transition from a group with five brands to a single company is a major change in how we approach the market and develop our products,” says GHM GROUP CEO, Christian Unterberger. “In an ever-evolving world, we want to create an agile company that can respond quickly to customer needs and market trends. Senseca’s philosophy is clear and simple − to place customers at the heart of every decision, and help them grow through an application-based approach. The new ‘One Face to the Customer’ focus is enabling our customers an improved experience with an easy access to the entire product range.” GHM GROUP becomes Senseca “Concentrating our efforts on a single brand, we can build stronger and longer lasting relationships with our customers, exploit synergies between sites, and differentiate ourselves in a sometimes complex market,” says Stefan Langer, vice president of the Industrial Business Unit. Jan Grobler, managing director of GHM Messtechnik South Africa (soon to be Senseca South Africa) says: “In today’s industrial world with its ever-increasing environmental standards, measurement, sensory and monitoring instrumentation will be key to the delivery of highly accurate data that meets the requirements of an integrated information supply. High-quality and reliable instrumentation play a crucial role in solving the complexities of industry as we now know it. In South Africa, Senseca will able to offer solutions to the challenges our customers face from one centralised source. We will be able to customise and tailor solutions more quickly. We at Senseca will be focusing on delivering technologies that respond quickly and efficiently to customer needs, enabling Senseca to maintain its prominence in this sector. We are excited to see the unique expertise of each former brand coming together to enhance our customers’ engagement with us. We will continue to build on the confidence in our design, technologies and manufacturing capabilities that is a hallmark of the South African market.” “The know-how of each brand is pooled in multidisciplinary teams working in three business units: Environmental, Industrial and Portable. People remain at the heart of the business, and their contribution of skills, knowledge and commitment will continue to be crucial to grasp the growth opportunities involved in this change. Each of us bears a unique and complementary value, and it is only by adding these elements together that we can truly generate a positive impact on ourselves, on the people around us, and in this case, on this new opportunity we are about to experience,” says Gianluca Maestroni, current CEO of Delta OHM and vice president of the Environmental Business Unit. The name Senseca is a neologism with several meanings. First and foremost, ‘sense’ stands for sensors, the core business of measuring, monitoring, testing and control equipment. But it also stands for the new shared purpose that sets Senseca’s future direction. This is to provide reliable data and facts that support businesses and society to improve the ecological and economic status quo with custom-made technology solutions. “At Senseca, we strive to safeguard our planet by balancing economic interests with environmental goals. There can be no economy without a healthy planet, and companies can make a vital contribution,” says Roland Baeuml, vice president of the Portable Business Unit. We want to rise to this challenge and become a role model in sustainable measurement technology.” For more information contact GHM Messtechnik SA, +27 11 902 0158, [email protected], www.ghm-sa.co.za
NEWS & EVENTS www.instrumentation.co.za November 2023 5 The primary objective of the Sasol-Kagiso Trust Interprovincial Technical Skills Competition is to emphasise the importance of technical and vocational skills development alongside academic streams in South Africa’s education. It aims to ignite a passion for technical skills at a young age, inspiring learners to pursue excellence in their chosen vocations. The latest competition saw 63 learners compete against each other in five specialisations, namely welding, construction, power systems, plumbing and woodwork. This aligns with South Africa’s National Development Plan by contributing to the target of producing 30 000 artisans annually. It also provides participants with opportunities to demonstrate their talents in specific vocational skills through tasks derived from real-life, industry-based scenarios. This approach ensures that the competition is relevant to the needs of the job market. Winners in each category were Rising stars shine bright Electromechanical manufacturing company, ACTOM recently celebrated its 120th anniversary with a ceremony held at the Royal Johannesburg Golf Club, which was attended by Dr Robert Nkuna, director general in the presidency, and several other dignitaries. Since its inception in 1903, ACTOM has become a major supplier of electrical equipment and services to a wide range of industries, including energy, mining and utilities. The company is a major contender in the renewable energy ACTOM turns 120 RS South Africa has introduced annual subscription options for DesignSpark, its fast-growing online community for engineers. This will deliver more choice for businesses to decide how they want to pay to gain access to DesignSpark’s advanced suite of design tools and resources. DesignSpark offers a suite of design tools, including DesignSpark Mechanical and DesignSpark PCB, plus comprehensive 2D/3D and electronics part libraries, and a host of design resources such as technology articles, projects and community forums. In April 2023, RS introduced three subscription levels for DesignSpark, payable via monthly subscription, which offered even more RS announces annual subscriptions for DesignSpark awarded certificates, along with state-of-the-art tools and gadgets to help them on their vocational journey. “Skills competitions raise professional standards and awareness, and they introduce the potential of a skilled career to a much wider audience,” said Noxolo Kahlana, head of the Sasol Foundation. The competition also aims to prepare a talented pipeline of learners who can represent South Africa at the World Skills Championships, showcasing the nation’s technical excellence on the global stage. “We believe that upskilling our youth with vocational training can assist with the high unemployment rate, given the many opportunities that there are for young people skilled in a trade,” says Mankodi Moitse, CEO of the Kagiso Trust. For more information contact Leigh Callipolitis, Creative Space Media, +27 11 467 3341, [email protected], www.creativespacemedia.co.za sector and has played a pivotal role in advancing the development of solar and wind power projects in South Africa. “ACTOM has maintained its leadership position in the electromechanical sector for 120 years due to its ability to adapt to the ever-changing market. For example, when REIPPs were introduced, we started supplying the balance of plants for those projects, together with equipment monitoring specifically for the renewable energy market,” says Mamiki Matlawa, business development executive at ACTOM. Matlawa highlights that ACTOM’s 120th anniversary coincides with a period of significant global shifts. South Africa’s recent hosting of the BRICS summit and the impending implementation of the Africa Free Trade Agreement underscore this transformative moment in history. She adds that ACTOM has plans to grow in the renewable energy space where there are opportunities to venture into partnerships with engineering, procurement and construction firms, or to become the preferred original equipment manufacturer for energy projects. For more information contact Mamiki Matlawa, ACTOM, +27 10 136 0200, [email protected], www.actom.co.za From left: Andries Mthethwa, chairman, ACTOM; Sivuyile Ngodwana, Mayor of Ekurhuleni; Mervyn Naidoo, CEO, ACTOM; Dr Robert Nkuna, director-general, Department of Monitoring and Evaluation within the presidency. benefits to users at very low cost. DesignSpark Explorer (which is free to users), DesignSpark Creator, and DesignSpark Engineer provide different levels of access to tools and design resources, enabling members to select the best option according to their requirements. “As always, we listen very carefully and react positively to customer feedback,” said Mike Bray, Vice-President of Innovation and DesignSpark at RS. “Since the introduction of Explorer, Creator, and Engineer earlier this year, it quickly became clear that many users wanted the option of an annual subscription. Right at the beginning, flexibility was built into our vision and approach for DesignSpark, so we have introduced this new option for businesses, organisations, and individuals to make life easier for them to gain access to the advanced, yet low-cost tooling offered by DesignSpark.” For more information contact Princess Tlou, RS South Africa, +27 11 691 9300, [email protected], za.rs-online.com
6 November 2023 www.instrumentation.co.za SAIMC NEWS National Members From the office of the CEO Changes at SAIMC First, I must say that this is the day after the Springboks played the semi-finals. Congratulations to all the people in the Springbok camp. What a show of unity, combined with humility and strength. What stood out for me was that the coaches did not tell them to play harder, they knew what they should do. The coaches brought them together as one team − the starting fifteen, the players on the bench and the non-players. This is what makes a team we can be very proud of. Rugby has once again brought South Africans together as one nation: no white apartheid, no black apartheid, just South Africans. But let me get back to SAIMC. Structure changes During the SAIMC 2026 strategy session held in October 2023, we discussed the exciting changes and challenges ahead. Our organisation has significantly transformed its structure since our last strategy session, SAIMC 2023, which was held five years ago. This changing structure reflects our commitment to adapt and thrive in an ever-evolving industry. Here are some highlights: • Two universities joined SAIMC as Didactic Members, Tshwane University of Technology and Nelson Mandela University. • ECSA requested SAIMC to assist with Mechatronics Engineering and Computer Engineering documentation. • MESA joined us as an Advisory Council. • Our membership nearly doubled during 2023, to over 1000 members. Taking advantage of new technologies The rapid advancements in automation, artificial intelligence and robotics have revolutionised our world. We must stay ahead of the curve and leverage these technologies to our advantage. Training and partnerships We must continue with our culture of continuous learning and adaptability, but in such a way that we do not lose our identity. We must invest in training programmes, workshops and partnerships that equip our members with the necessary skills to navigate this technology landscape. By embracing these new technologies, we can unlock unprecedented opportunities for growth and innovation. Collaboration Furthermore, we need to establish and maintain strong links with industry leaders, academia and government bodies to stay informed about the latest trends and regulations. This will enable us to shape policies and standards that promote the responsible and ethical use of automation technologies. Redefining our purpose The updated strategy meeting for SAIMC presented us with a unique opportunity to redefine our organisation’s purpose, embrace change, harness the power of new technologies, and review our motto. A new motto to shape our future identity One of the critical issues we needed to address was the need for a new motto. A motto serves as a guiding principle, encapsulating our values and aspirations. It should resonate with our members and stakeholders, inspiring them to embrace change and innovation, and it should shape our collective identity moving forward. The results Due to all these changes, combined with the new automation technologies we are facing, we have changed our motto from ‘Progress by Control’ to ‘Inspiring Automation’. Our vision is to empower our members, individuals and companies. Our mission is: • Promote automation. • Facilitate knowledge sharing. • Ensure sustainable growth of the SAIMC. • Provide accreditation. • Influence policy development. • Promote industry visibility. Our focus areas for the next three years will be: • Strengthening the organisational structure. • Education and training. • Stakeholder collaboration platforms. • Creating a value proposition for our members. • Public relations. As we work on this roadmap, we are depending on each of our members to support and advise us as we enter an exciting future of continuous innovation and change. Yours in automation Johan Maartens.
www.instrumentation.co.za November 2023 7 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) Durban branch The Durban branch October technology meeting was well attended, and the audience was keen to hear about navigating the digital value change and bridging the gap from sensors to the boardroom. The presentation was made jointly by James Adams (key account manager) and Hugo Pienaar (product manager) of Adroit Technologies, and they very competently showed the audience how to delve into the digital value chain and to enhance the journey by elevating production and real-time data to the cloud − from machines to the edge and beyond. Hugo showed how a gateway can seamlessly convert legacy devices and scada systems into edge cable devices, and how one can create a unified digital transformation strategy that seamlessly merges operational technology (OT) and information technology (IT) systems, harnessing the boundless potential of evolving cloud technologies. The SAIMC Secunda branch held its monthly technology evening on 4 October at the Proconics office in Secunda. Bruce Bonte from Yokogawa presented on differential pressure and blocked impulse lines. The presentation focused on increasing uptime through using technology that can identify blocked impulse lines, i.e., differential pressure transmitters. He explained that differential pressure transmitters have the capability to detect when impulse lines are blocking, which allows for predictive maintenance. Impulse lines can be blocked through material buildup, which can isolate the transmitter from the process, therefore affecting how the transmitter read process changes. A blockage in the impulse line may cause measurement failure, affecting process control and/or compromising plant safety. Before taking action in response to blockage alarms, it is important to consider plant operating conditions, and whether the problem is with the instrument or the process. It is also important to clean the impulse lines, purge air bubbles adequately, and use an appropriate manifold. Bonte is a PCI product specialist from Yokogawa. The Secunda SAIMC committee would like to thank Bonte and Sizwe Nkosi for their presentation, and Proconics for hosting the technology evening. Secunda Branch From left: James Adams; Hugo Pienaar; Mark Calvert, branch general manager. From left: Mkhanyisi Zulu, vice-chairman, SAIMC Secunda Branch; Bruce Bonte, PCI product specialist, Yokogawa. INSPIRING AUTOMATION
8 November 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 November 2023 9 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]
10 November 2023 www.instrumentation.co.za Pressure and temperature gauges are very widely used on process plants. Gauges are relatively inexpensive, and because they are installed in large numbers, maintenance can be neglected, resulting in unreliable and compromised instruments. Some plants choose not to replace failed gauges until they have to, and sometimes that is too late. A properly maintained and calibrated gauge will accurately indicate how a system is performing. Part of that function is to enable early detection of potential plant failures or accidents. Poorly maintained, inaccurate gauges can compromise a plant’s ability to detect potential problems. Accidents, damage and injury to equipment and personnel is often the result. Incorrect selection, installation, and neglecting to maintain pressure gauges can also result in unplanned production downtime, process issues and inferior product quality. In addition, allowing instruments that are critical to a process to drift out of specification can be a risk to employee safety. The cost of calibration is normally insignificant compared to the potential loss of production or injury costs. Ultimately, one needs to be able to trust the reading one gets from a pressure or temperature gauge. The use of pressure transmitters as the primary source of pressure measurement in sophisticated process applications is very common. However, as a backup to these electrical readings, and as a local display, mechanical dials indicating pressure gauges are still used on many systems. Today’s mechanical pressure gauges still employ old and proven technology in the form of a bourdon tube soldered or welded to a socket, with the tip of the bourdon tube connected to a geared movement. This indicates the pressure applied via a pointer and dial. Since the pressure gauge is a purely mechanical instrument, process conditions must be carefully considered before selection to ensure optimum accuracy and safety, and to maximise the instrument’s service life. In addition, best practice in measurement requires that special precautions be taken when dealing with process conditions such as extreme ambient temperatures, corrosive or solidifying media, vibration, pulsation, and overpressure. SA Gauge specialises in the design and manufacture of pressure and temperature measuring instruments. In addition to its absolute commitment to customer satisfaction, the company goes to great lengths to educate its customers so that they can make the best possible use of their pressure and temperature gauges. SA Gauge believes that all process and ambient factors should be considered when selecting and installing pressure measuring devices, and recommends that the following guidelines on selection and calibration be followed in order to prevent gauge failure. Working pressure Although pressure gauges will tolerate full-scale pressure for short periods, in general the working pressure should not exceed 70% of the full-scale value. For thermometers, media pressure should not exceed 2500 kPa without the use of a suitable thermowell. Wetted parts These must be compatible with the process media. Choose from Cu-alloy (brass) or stainless steel 316. With media that can corrode the wetted parts or obstruct the pressure port, a diaphragm-type chemical seal should be selected. Temperature The maximum permitted process temperature for pressure gauges with brass wetted parts is 70°C. For stainless steel wetted parts, the maximum process temperature should not exceed 100°C. Ambient temperatures are permitted from -20 to 60°C. Errors in accuracy need to be considered when using gauges above or below calibration conditions – usually 22°C. For applications where process temperatures exceed permissible levels, the media needs to be cooled down before entering the instrument. Accessories like cooling towers, siphon tubes, capillary assemblies, and diaphragm seals are typical devices used to separate and protect the instrument from the process heat source. How to look after your pressure gauge Neglected pressure gauges can lead to downtime and disaster.
www.instrumentation.co.za November 2023 11 Corrosive and solidifying media Some aggressive or corroding process media can attack copper-alloy or stainless steel 316, or solidify and obstruct the pressure port of the gauge. Diaphragm seals are designed to isolate the pressure gauge from the media to ensure accurate and reliable pressure readings. The wetted parts of the diaphragm seal are made from materials appropriate to the process such as stainless steel 316, hastelloy, tantalum or PTFE. Vibration Due to the purely mechanical nature of pressure gauges, vibration is one of the main reasons for premature gauge failure. Linkages, gears and bushings are all parts suffering from excessive wear when exposed to vibration. Pointer oscillation makes accurate reading difficult, but can be avoided by filling the gauge with glycerine or silicone oil. Liquid filling of gauges lubricates all the friction points, ensuring longer instrument life. Pulsation Dynamic load cycles of pumps and valves that cause a rapid change in pressure in a system cause metal fatigue in the elastic bourbon sensing element, resulting in gauge failure. While glycerine filling of the gauge will assist in countering pointer flutter, it cannot prevent the damage caused by pulsation to the bourdon tube. A flow restricting device is the best option here. Pulsation dampers such as inlet restriction or piston type snubbers restrict the pressure pulsation. Overpressure Overpressure typically occurs when a pressure gauge is subjected to a sudden rush surge of process pressure, such as when full bore valves are quickly and completely opened under load. This short period spike in the system subjects the gauge to more pressure than it is designed for, resulting in permanent damage. To prevent this, SA Gauge manufactures an overpressure protector that can be adjusted and locked to shut the process pressure off at a given set pressure. The spring-loaded overpressure protector automatically opens again once the overpressure condition has passed. On certain ranges there are diaphragm-operated gauges available that are capable of coping with five times overpressure without any permanent damage. Installation Always secure the instrument by means of a suitable wrench on the hexagon/square of the threaded connection. Twisting the instrument by hand on the case can cause damage to the internals of the instrument. For gauges with flanges, support the gauge fitting with a suitably sized wrench to counter the force of tightening the process fitting. This will prevent damaging the gauge internals. Calibration Even the highest quality instruments are subject to drift over time, resulting in inaccurate measurements and substandard performance. It is important that all instruments are calibrated by approved personnel. Calibration intervals and error limits should be defined, and records of the calibration results should be kept, maintaining instrument integrity. SA Gauge’s calibration laboratories are SANAS ISO/IEC 17025 accredited, and maintain the highest accuracies to ensure international traceability. SA Gauge is driven by a ‘customer satisfaction at all costs’ sales team, a ‘results driven’ engineering team, and a ‘first time right’ production team. Coupled with the company’s high internal standards for quality control, this philosophy ensures that its customers can be sure of receiving accurate and high-quality instruments that are made to their specifications at short notice. For more information contact SA Gauge, +27 31 579 2216, [email protected], www.sagauge.com
12 November 2023 www.instrumentation.co.za 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 190 Measurement problem ruins level control. . As mentioned many times in my articles, the widely held belief in many plants that tuning will solve all base layer control problems is completely fallacious. Bad tuning is generally not the main reason for loops to perform badly, or not at all. This is usually due to some sort of problem in the various elements of the loop, or in the design or the control strategy. The elements of the control loop consist of: • The process itself. • The transmitter. • The controller. • The final control element, which in most cases consists of a valve, an actuator, a positioner and a current to pneumatic (I/P) converter. In general, about 80% of all problems are due to faults in the final control element. However, the other elements in the loop can have problems, so it is important when performing optimisation that all these various elements, in addition to the control strategy, are investigated before even thinking of tuning. The example given in this article is of a very important level control in a distillation column in a large petrochemical refinery. The control requirement was that the level should remain as constant as possible at setpoint in the face of frequent load disturbances. A large number of downstream processes were adversely affected if the level varied. The operators reported that the control was not performing properly, and large variances in level were being experienced when the control was in automatic. The control seemed to work at differing speeds, sometimes responding very quickly with cycling, and sometimes extremely slowly. They had resorted to trying to control it in manual, with little success. The plant’s C&I personnel had been called on and had spent a long and fruitless period trying to retune the control, with no improvement at all. Level controls normally fall into the class of processes known as integrating or ramping, as opposed to the other class of processes known as self-regulating or self-balancing. This is typified by flow control, where a step change in the process demand output (PD) when in manual results in the process variable (PV) changing and then settling out again. The PV basically follows the movement of the PD. An integrating process is one where one has to balance the input and output of the process to keep the PV constant. This is best illustrated in Figure 1, where we can see a level control on a tank. If the controller is in manual, the level will only be constant if the input flow equals the output flow. This is known as a balanced process, and the PD value at this balance is called the balance point. If the operator makes a step increase on the PD, the output flow will now be bigger than the input flow, and the level will start moving down in a perfect ramp. If no further action is taken by the operator, the tank will eventually run empty. However, if the operator restores the PD to the balance point value, the in and out flows will again be equal and the level will remain constant, albeit at a lower level in the tank. If a step change were to be made on the PD in the opposite direction to close the valve slightly, the inflow would be greater than the outflow, and the level would start ramping upwards. This would continue until the PD was restored to the balance point. These movements are shown in Figure 2. In the example of the level control in the distillation column, a similar open loop test was performed and this is shown in Figure 3. It can be seen that when a 5% step change was made on the PD to open the valve slightly, the level started moving down in a constant ramp. It continued moving down until it reached 47%, and then the ramp rate suddenly and dramatically increased until the level reached 45,5%. At this point the ramp rate slowed down to the original rate. The PD was put back to the balance point shortly after this and the level then remained constant. A little later the PD was stepped down by 5%, and the level started ramping up at a rate Figure 1. CONTROL SYSTEMS
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