40VOLUME NO 1 JANUARY 2024 Official publication of the SAIMC Control systems | Electrical power & energy efficiency | Mining & metals Condition monitoring & predictive maintenance | Oil & gas Automotive & e-mobility | Process measurement | IT in manufacturing
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www.instrumentation.co.za January 2024 1 Automotive & E-mobility Oil & gas Process measurement IT in manufacturing VOLUME 40 NO 1 JANUARY 2024 03 08 14 16 REGULARS FEATURES Electrical power & energy efficiency Control systems Mining & metals Condition monitoring & predictive maintenance 22 21 18 23 33 26 34 40 News & events SAIMC news Automation professionals System Integration Turck Banner RJ Connect, Neu Matics SA, ABB South Africa Beckhoff Automation Michael Brown Control Engineering CC Siemens South Africa VEGA Controls SA, Cortec Corporation, WEG Africa, Wearcheck ifm – South Africa, WIKA Instruments, Instrotech, Endress+Hauser South Africa, Turck Banner, ABB South Africa, Mecosa, R&C Instrumentation Stratus OUR COVER 12 40VOLUME NO 1 JANUARY 2024 Official publication of the SAIMC Control systems | Electrical power & energy efficiency | Mining & metals Condition monitoring & predictive maintenance | Oil & gas Automotive & e-mobility | Process measurement | IT in manufacturing Valve specialist, Valve & Automation supplies total valve and control solutions to a wide range of key process industries across southern Africa, including chemicals, and pulp and paper. Plant managers must cope with demanding process conditions, and reduce emissions, while meeting the demands for increased plant safety, at the same time reducing plant maintenance and production costs. Read our cover story on page 12 to find out about the company’s solutions, which range from knife gate valves from leading international valve company, Stafsjö, to fully-lined pumps and valves and triple offset rotary process valves, through to emergency shutdown valves and PST.
2 January 2024 www.instrumentation.co.za welcome VOLUME 40 NO 1 JANUARY 2024 Disclaimer While every effort has been made to ensure the accuracy of the information contained herein, the publisher and its agents cannot be held responsible for any errors contained, or any loss incurred as a result. Articles published do not necessarily reflect the views of the publishers. The editor reserves the right to alter or cut copy. Articles submitted are deemed to have been cleared for publication. Advertisements, inserts and company contact details are printed as provided by the advertiser. Technews Publishing (Pty) Ltd cannot be held responsible for the accuracy or veracity of supplied material. All rights reserved. No part of this publication may be reproduced, adapted, stored in a retrieval system or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of Technews Publishing (Pty) Ltd, Reg No. 2005/034598/07 LETTERS TO THE EDITOR Letters to the editor should be addressed to Kim Roberts at [email protected]. Sending material to this publication will be considered automatic permission to use in full or in part in our Letters column. Be sure to include your name, e-mail address, city and zip code. We reserve the right to edit all letters. EDITOR Kim Roberts MSc Chem [email protected] CIO & DIRECTOR Graeme Bell NHD Elec. Eng., MBA [email protected] CONTRIBUTING EDITORS Michael Brown BSc (Eng) (Rand), CEng MIEE MSAIEE Gavin Halse BSc Chem Eng Lance Turner BSc (Hons) Information Systems ADVERTISING Sales manager Jane van der Spuy [email protected] Tel: +27 83 234 5412 Heidi Hargreaves [email protected] Tel: +27 83 504 0436 DESIGN AND LAYOUT Technews Production Department SUBSCRIPTION SERVICES For address changes, subscriptions, renewal status or missing issues, email: [email protected] or write to: Technews Publishing (Pty) Ltd, Box 385, Pinegowrie 2123 SUBSCRIBE ONLINE www.technews.co.za PUBLISHERS Technews Publishing (Pty) Ltd Wild Fig Business Park, Block B, Unit 21, 1494 Cranberry Street, Honeydew It’s a fresh new year alive with possibility. Happy new year, and here’s wishing you one where you can rise to the challenges ahead and still enjoy all the good things we have in this country. This issue features a bumper automation professionals section, which, over the years has been the mouthpiece for the SI community in South Africa. We are kicking off with an overview of how to choose an SI, and a contribution from Iritron. There’s more to come, and we would welcome case studies and company profiles from our local SIs. A new year is for looking ahead, but if you’re like me, you’re still trying to figure out what’s going on with generative AI, and how to make it work for you. Tighten your seatbelt, there’s more. Scientists are pushing the envelope again, and this time it’s quantum computing. I wanted to know more, so here goes. Quantum computing is part of quantum mechanics, which explores how the physical world works at the molecular level. Basically it’s a new future generation of super-fast computers that process information as qubits, or quantum bits. This replaces the bits in normal computing that we are all used to, that can be either zero or one. The qubits in quantum computing are tiny subatomic particles that can exist in many different states. This means they can be a one or zero simultaneously, or any state between, like a coin spinning in midair. So, processing will have countless variables, not just two. Computing power will be increased exponentially, and quantum computers will be able to run calculations way faster than the ones we have now. Estimates say quantum computers will operate 158 million times faster than the fastest supercomputers available today. Complex problems, that would now take today’s most powerful supercomputer several years, will be solved in seconds. Even though large-scale quantum computers are not yet commercially available, quantum computing is already with us. In five to ten years it could become mainstream in the same way that classical computers did in the 70s and 80s. The world’s biggest tech companies are racing to get the edge with quantum. IBM has over 60 functioning quantum computers, and has as collaborators industry giants ranging from Exxon-Mobil to Sony. Its new 433-qubit Osprey chip is the world’s most powerful quantum processor, and its speed is greater than the total number of atoms in the known universe. IBM has recognised the importance of sharing in order to build an industry around quantum, and is making some of its technology The next quantum leap available for free. It has more than 20 quantum computers available on its open source quantum toolkit Qiskit, which has been downloaded more than 450 000 times. Quantum computers could open new frontiers in maths and science, and help solve challenges like understanding climate patterns. They could be used to solve problems that are unsolvable, with today’s computers, like in logistics and supply chain management. Quantum machine learning could also make huge improvements in data analysis and pattern recognition – whew, as if ML hasn’t already done that. This opens the way to developing new materials, and tracing financial transactions across global financial networks, for example, in money laundering. All the big banks have their own quantum teams exploring what can be done. The potential industrial uses are limitless, for example creating new car models from scratch, which now takes at least four years. Boeing has been working with IBM’s quantum team since 2020 on designing new materials for its next generation of aircraft. Other problems where quantum computers could be put to use include predicting traffic flow in complex urban environments; and by simulating complex chemical reactions that are impossible to model with normal computers, they could accelerate the discovery of new drugs. As with any new disruptive technology there are risks, and a major one is security. Today, cybersecurity is based on RSA, an asymmetric cryptography algorithm used to transfer data safely. While a regular computer needs billions of years to crack RSA algorithms, a fast quantum computer would take hours. Today’s encryption algorithms would become obsolete, putting communications, financial transactions and military defences at risk. Another race is on to develop new encryption methods that would be resistant to attacks like this. Even though it may not be widely accessible or practical for a few years, it looks like quantum computing is set to shake up the world yet again. I give it five years, and we will be talking about quantum computing and qubits like we first did about IIoT, or generative AI.
Empowering the next generation of engineers, innovators, and technologists is critical to helping them develop essential skills, gain valuable experience, and find inspiration to make a positive impact on the world. This is according to Wesley Hood, education and social impact specialist at RS South Africa. STEM skills are in high demand in many industries, from manufacturing to engineering, healthcare and information technology. However, South Africa faces a shortage of skilled STEM workers, posing a significant obstacle to the country’s development. RS South Africa is bolstering South Africa’s national effort in this regard, and is spearheading STEM at a tertiary level by providing sponsorships to leading universities. The most recent example is a significant donation of products to the Faculty of Engineering at the University of Cape Town (UCT). “We believe that by strengthening Empowering the next generation of engineers and innovators STEM education, we are not only investing in the future, but also inspiring young engineers to create a better world,” says Wesley Hood, education and social impact specialist at RS South Africa. “We have a good understanding of the needs of universities worldwide and the importance of industry support to sustain their innovation and growth; we support student development and provide opportunities for hands-on experience, preparing students for their careers.” RS South Africa is extending its collaboration with UCT by supporting its STEM High School Outreach Programme, which aims to encourage students to choose engineering as their preferred career path. For more information contact RS South Africa, +27 11 691 9300, [email protected], za.rs-online.com NEWS & EVENTS
NEWS & EVENTS 4 January 2024 www.instrumentation.co.za The energy landscape in Africa is undergoing a profound transformation. Against the backdrop of global efforts to address climate change and promote clean energy, African nations are embracing an energy transition that has huge potential for economic growth, environmental sustainability, and improved quality of life. The Africa Energy Indaba will feature this as a key topic of discussion in its 2024 event programme. The conference will be held from 5 to 7 March 2024 at the Cape Town International Convention Centre. “As advocates for positive change, we believe in the power of collaboration and innovation to create a resilient and inclusive energy future for the continent,” said managing director, Liz Hart. For more information contact Qondakuhle Dwangu, Africa Energy Indaba, +27 11 463 9184, [email protected], www.africaenergyindaba.com The energy transition in the context of Africa In an important digital initiative to make product selection and procurement easier for customers. SEW-EURODRIVE South Africa has launched an online purchasing feature on its website. According to training manager, Zander Claassens the portal allows customers to not only order products or parts, but also to find support in the form of documentation and CAD data. To maintain the personal touch, there is even a dedicated person to assist customers with their online requests from 7 a.m. to 9 p.m. daily. “The online purchasing portal offers users useful tools and functions, valuable information and practical assistance,” says Claassens. “It is clear that many customers are embracing online procurement platforms, especially since the COVID-19 lockdowns, and we are excited to enhance our sales and support channels further.” He explains that the wide and dynamic range of configurations in SEW-EURODRIVE’s offering needed the functions of the shopping cart to be specially developed to make it as user-friendly as possible for customers. There are four different functions that customers can choose from when adding a product to the shopping cart. The first is the product configurator, which guides customers in configuring their required equipment using dropdown options from the company’s vast range of products. The next channel is the spare parts or replacement product selection function, where one of two routes can be chosen. In the first, the customer can make use of the SEW-EURODRIVE serial number found on the product nameplate. Entering that serial number is a quick and simple way of requesting a replacement, and ensuring that the exact configuration is replicated. Another route enables customers to find a SEW-EURODRIVE replacement product for a third-party drive which is not an SEW-EURODRIVE item. The online tool will not understand the non-SEW-EURODRIVE serial number, but if the specific criteria are supplied, the system will identify what the customer needs so that the product can be delivered. Registered customers who have already been trading with SEW-EURODRIVE can also use a third option, a customer transaction overview, to help select what they are looking for. When they log onto the online purchasing portal, they will be able to view their history of quotations and orders. This makes it simple to re-order a component that has been purchased before, as they can select the item from a previous transaction or quotation. Lastly, customers can use the drive selection assistant – a smart online tool that guides the user through three simple steps to find the right SEW-EURODRIVE launches online purchasing drive. The first step is to select the application, and the second requires more application-related information; the third step then presents the customer with product configurations and suggestions from which the drive can be chosen. Claassens emphasises that customers wishing to transact on the portal can find support from a real person behind the portal who can provide hands-on advice and assistance. Customers can also rest easy in the knowledge that the security of the portal is world class. “Our cybersecurity is handled by a dedicated IT team in our group headquarters in Germany,” he explains. “Our customer and transaction data are double-encrypted when working online, while the online support is run on hyper-text transfer protocol secure (HTTPS) and is backed up on a geographical redundancy cloud-based system.” Another security precaution is that online purchasing is not permitted using credit cards. The company still follows its normal payment protocols with customers once they have placed items in the online shopping cart. For more information contact SEW-EURODRIVE, +27 11 248 7000, [email protected], www.sew-eurodrive.co.za
NEWS & EVENTS www.instrumentation.co.za January 2024 5 BMG has recently expanded its operation in KwaZulu-Natal, with the relocation of its Regional Service Centre (RSC) and the opening of two new facilities. “This expansion programme was necessary for the KZN operation to meet significant development in the region and greater market demand for engineering consumables and support services,” explains Keith van Wyk, BMG’s regional manager for KZN. “The consolidation of BMG’s KZN workshop facilities and field services into a centralised hub over seven years ago resulted in massive growth for BMG, and it became necessary to expand the operation from one facility into three to accommodate further expansion.” The BMG Springfield sales branch has moved from Imvubu Park to Riverhorse Road, while the engineering facility, which incorporates the Fluid Technology and Geared Drives divisions, is now situated at a new 1810 m2 facility in Mahogany Ridge. The materials handling, gaskets and chain sectors of the business are now located in a modern, well-equipped 1100 m2 workshop in Westmead. The Mahogany Ridge operation, in conjunction with the Westmead facility’s materials handling, gaskets and chain technical teams, provides assembly, repair, maintenance and support operations to ensure optimum performance of every component. The two new technical support facilities operate closely with 11 dedicated BMG KZN branches to meet every customer’s specific requirements. Benefits for customers include improved service, repair and delivery efficiencies, centralised technical support, and easy accessibility to BMG’s comprehensive range of quality branded components. In addition, the new KZN facilities are conveniently situated close to major highways, providing easy access for BMG’s broad customer and supplier base. As part of its commitment to offering dependable engineering solutions that optimise productivity at every plant, the BMG team in KZN also offers in-house staff and customer training at the regional training centre at the Riverhorse Valley branch. The Mahogany Ridge operation, which focuses on hydraulics and pneumatics, offers services that integrate quality branded components, advanced hydraulic engineering and contamination control. There is also a test and repair facility to ensure optimum performance and extended service life of every hydraulic system. BMG assists with the design, manufacture, assembly and repair of all hydraulic and pneumatic systems, whether for a workshop improvement or a hydraulic system for an entirely new plant. The highly experienced team follows stringent ISO-accredited procedures and works in consultation with customers to ensure the most efficient solution – from small, multi-purpose power packs to large power packs for mining and industrial applications. The Drives division, also based at the Mahogany Ridge operation, offers technical support and repairs for leading brands that include Hansen, Sumitomo, Nord, Varvel, Dynamic Oil, Fenner and Cyclo. Specialist services encompass designing systems for new applications and replacement drives for existing products. With BMG’s vast knowledge of gearboxes, the team is also able to repair gearboxes and drives that do not form part of its product line. BMG’s comprehensive range of equipment and components includes bearings, seals and gaskets; power transmission; hydraulics and pneumatics; fluid technology and filtration; drives, motors and controllers; materials handling; fasteners; and tools. The team works closely with customers in all sectors, including water and wastewater treatment facilities, mining, the food and beverage sector, and petrochemical plants. BMG also supplies and supports service providers to power generation and pharmaceutical plants, and also ports, rail and road facilities. The company offers around-the-clock repair service for all products. For more information contact Keith van Wyk, BMG, +27 31 534 4827, [email protected], www.bmgworld.net BMG expands its footprint in KwaZulu-Natal
NEWS & EVENTS 6 January 2024 www.instrumentation.co.za Schneider Electric connects to the future Schneider Electric had a major presence at the recent MESA Africa International Summit, which focused on ‘accelerating the journey to smart manufacturing’. SA Instrumentation & Control’s editor caught up with Dr. Suven M Ramsunder, Digital Transformation Expert, Anglophone Africa, to find out how the company is approaching the integration of artificial intelligence (AI) technologies into the manufacturing industry, both in its own factories and for its customers. Ramsunder says that AI in manufacturing is about using learning algorithms to create patterns based on relevant data. It breaks down silos of information and brings them together. You can then rely on these algorithms to give you critical parameters relating to key areas such as stock management, automated visual inspection, and industrial safety. This enables you to make decisions and convert them to actions that can be implemented on the plant. Data hub You can’t have AI without data, and Schneider Electric has made significant strides in the creation of one data hub which encompasses both hybrid cloud and on-premise, converging process and energy data to bring together all data sources and applications. Sustainability When it comes to sustainability, Schneider Electric is way ahead of the game. Among its many awards, it recently earned a place on Corporate Knights’ 2023 Global 100 list of Most Sustainable Corporations in the world − for the 12th consecutive time. Schneider Electric doesn’t just monitor electricity usage, but also looks at ways to use it more effectively. For example, by shifting production schedules to avoid high loads during peak consumption hours on the grid, it has realised savings at many of its plants, and also those of its customers. This also means having access to information on critical parameters relating to the use of electricity, looking at ways to monitor and better utilise it. This is where its concept of Electricity 4.0 – smart energy – comes in. The 21st century gave birth to a new world of electricity with the convergence of digital and electric at scale, and this is Electricity 4.0. Together with its partners across the world, Schneider Electric is building a New Electric World that provides smart energy to homes, buildings, data centres, industries, infrastructure and grids. Smart factories “It’s all about using electricity more efficiently through AI,” says Ramsunder. “A smart factory is more than just an autonomous unit, it is
NEWS & EVENTS www.instrumentation.co.za January 2024 7 Dr. Suven Ramsunder, Digital Transformation Expert, Anglophone Africa, Schneider Electric. a digitised facility that utilises connected devices and systems to share and collect data continuously.” Schneider Electric is one of the few companies that uses its own products in its manufacturing processes, so it can be tested before putting them out to market. A good example is its Lexington plant in the USA. One of its 80+ smart factories, this plant had been mass producing electrical equipment for more than 60 years. By implementing its EcoStruxure IoT platform, Schneider Electric transformed this brownfield site into a state-of-the-art digital manufacturing facility, which has empowered operators, reduced costs and improved productivity by enhancing its existing processes. Among the many improvements, the Lexington plant has achieved a 78% reduction in CO2 emissions, a 26% reduction in power usage, and a 20% reduction in water consumption. In addition the company’s Lexington and Le Vaudreuil, France plants have been recognised by the World Economic Forum (WEF) as Sustainability Lighthouses, two of only six worldwide. These plants, together with facilities in Batam, Indonesia, Hyderabad, India, and Wuxi in China, are also designated Advanced 4th Industrial Revolution (4IR) Lighthouses. Facilities in Wuhan, China and Monterrey, Mexico, are recognised as Developing 4IR Lighthouses. The challenges IIoT has huge benefits, but there are many considerations and potential risks. Some of these are installing new infrastructure, retrofitting existing infrastructure, managing costs, and most of all, people. People Any change brings fear, and in this case it’s the fear of using AI. Ramsunder says that what Schneider Electric is doing very well is educating its people on all new changes as technology evolves. This involves extensive knowledge sharing across the board, visiting customers, and educating and upskilling people. The company ensures that, with any new changes, it’s not just about the automation, but also about how that automation can augment the worker’s situation. It’s about technology and humans working together. This is the principle of Industry 5.0, and Schneider Electric has been using this principle for a while. Ramsunder adds that technology shouldn’t ever drive the way your business works; the business should drive the way technology is used – your business is driven by people and processes, and is enhanced by technology. Predictive maintenance Another critical role for AI is in predictive maintenance. You can have an abundance of information and maintain your systems every three to six months, but still get breakdowns in between. Meanwhile over-maintaining is expensive. Plant operators often don’t realise the people costs involved with maintenance. At the end of the day the aim is to do as little as possible, while still maintaining the integrity of the plant. Schneider Electric’s software draws models from the data, picking up tiny deviations, and uses these to decide when is the best time for maintenance. This results in huge cost savings, because then you don’t over- or under-maintain. It is also very important to validate the data − it must be valid and correct, otherwise the conclusions are based on false premises. Schneider Electric’s software validates the data sources in the background. This intelligence is built in by highly qualified domain experts at its Predictive Analytics department in the USA, and is backed by extensive research. It is a ‘locally global’ company, and can monitor a site anywhere in the world. Issues can be picked up quickly, with prompt feedback from the experts in the background. Connecting to the future Going forward, Ramsunder says that Schneider Electric is driving digitisation and electrification to realise sustainability and the next-generation automation industry, to accelerating decarbonisation using people and technology. It is not just about putting IoT-enabled devices on machines, but rather using AI to bring in the information to allow you to make the right decisions, with edge control up to the enterprise level. The company’s EcoStruxure IoT platform includes three distinct layers: apps, analytics and software; edge control; and connected products. The secret is to have the right people creating the right opportunities – giving them the freedom to create new environments and develop new skill sets. This will be accompanied by augmented reality (AR) and virtual reality training in the metaverse. Today is the time to start developing the skills needed for the future. For more information contact Schneider Electric South Africa, +27 11 254 6400, [email protected], www.se.com/za/en
8 January 2024 www.instrumentation.co.za SAIMC NEWS Johan Maartens. National Members From the office of the CEO I trust everybody had a wonderful break, renewed old friendships and created new memories. Making memories is like gathering firewood so that we can sit around the fire, looking back on our life, with the bad times forgotten and the good times like the sparks of a bushveld fire lighting up our thoughts. May this new year be a blessed one, a year in which we will experience the goodness of God in a country that desperately needs His assistance, blessing and favour. Now, back to the SAIMC. Our Vision for 2026 identified several projects for the near future. Here is one that has already kicked off. Making our members successful Members often request a letter of support or recommendation for a new job that lists their critical skills and supplies a referee. It makes no sense to provide any person with a letter just stating that they have been a member of the SAIMC. We have now created a template that will enable the SAIMC to provide you with a letter that will positively influence the reader. When you go to the saimc.co.za website, under Member Services you will find a template that will guide you in making it possible for us to give you a solid letter of recommendation. Some of the questions and the impact of your answer on the letter are listed below. If a member cannot supply information for a question, we will remove that part from the eventual letter of good standing. Question: Did you present, physically or online, a paper on a specialised field of expertise, and what was the title of the presentation? If a person answers this question, it will appear in the letter as follows: <Name> shared his/her extensive knowledge on … with others during the … SAIMC event. The event’s purpose was to share knowledge in the highly specialised field of … and to draw on the experiences of other practitioners. Question: Did you contribute to the knowledge sharing platform on the SAIMC website? If a person answers this question, it will appear in the letter as follows: <Name> participates in the knowledge-sharing platform of the SAIMC, where knowledge and experience are shared to benefit the industry < member to specify>. Question: The SAIMC is involved in government, the Engineering Council of South Africa, education institutions, industry and the public via various advisory councils and branch Time for action activities. What role did you play in any of the SAIMC’s activities? If a person answers this question, it will appear in the letter as follows: The mission of the Society for Automation, Mechatronics and Computer Engineering (SAIMC) is to inspire automation, while the vision of the SAIMC is to empower its members and ensure their success. The primary goal of the SAIMC is to impact South Africa positively at an international level, thereby enhancing its competitiveness in the global market. This goal is achieved through the SAIMC’s involvement in government, education and industry. To accomplish this objective, the SAIMC refers to various advisory councils, including the End User Advisory Council, the Supplier Advisory Council, the Education and Training Advisory Council, the Manufacturing Operations Management Council, and also the branches of the SAIMC. <Name> is a valued member of the SAIMC, contributing to the organisation’s goals in the following ways: <member to specify>. Question: Did you contribute to any of the following SAIMC goals, and if so, how? • SAIMC brand visibility and marketing. • SAIMC public relations and communication. • Developing best practices within the SAIMC. • Aligning industry, education, suppliers and government within the SAIMC. If a person answers this question, it will appear in the LOGS as follows: <Name> played a major role in assisting the SAIMC to achieve its strategic goals by < member to specify>. The bottom line Our members have been asking for value-added services from the SAIMC. Here is your opportunity to get a value-added service that could change your life. But if you do not do your part within the SAIMC to grow the industry and its members, the letter of recommendation you will receive will be very short. Yours in automation Johan Maartens
www.instrumentation.co.za January 2024 9 SAIMC NEWS The Durban branch of the SAIMC held their much loved and well supported annual year end dinner at the Mount Edgecombe Country Club in late November. The weather was the complete opposite to the previous year’s – with a beautiful warm and balmy (okay sweaty) evening, which meant that the welcome drinks were held on the gorgeous deck overlooking the greens. This proved to be a perfect start to a wonderful evening. As always, formalities were kept short, with Howard Lister standing in for Mark Calvert on the general manager front, and also multi-tasking as the very efficient MC. After welcoming and thanking everybody, Howard gave a brief run-down of the year that was, highlighting the success of the monthly technology evenings and the branch’s goals to become even more involved with our education system and universities. He presented Donald Hlubi of DCK Projects with his regional member certificate before introducing SAIMC CEO, Johan Maartens. Johan told everyone what the SAIMC had achieved during 2023, culminating in the new slogan, Inspiring Automation; but the highlight of his part of the proceedings was awarding John Owen-Ellis Honorary Member status in recognition of his 44 years as a member of the SAIMC. Durban Branch – Annual dinner From left: John Owen-Ellis, SAIMC Honorary Member, and Donald Hlubi, DCK Projects, receiving their awards. Records show that John first joined the SAIMC on 6 November 1979. Since joining the Durban branch management team in April 2001 he has worked tirelessly in a variety of roles, and in fact, he is still one of the most active members of the team today. Daleen Filbey from RX gave a short presentation about AATF 2023, and what’s in store for 2025, and this concluded the formalities. Dinner was a delicious buffet of Durban chicken curry and roast lamb with crispy roast potatoes and sautéed vegetables, which everybody tucked into while enjoying some background music provided by our musical entertainment for the evening – Angus. The committee decided that fixing something which isn’t broken wasn’t a good idea, so unanimously voted Angus back for another year – a decision which was not regretted once they got the party started a little later. Conrad Koch and Chester Missing were undoubtedly the firm favourites of the evening, with some additional guests (well puppets) making an appearance during the 40 minute act. Conrad’s clever brand of humour and skilful puppetry allows him to cover a variety of topics with impunity. Anthony Hittler from IFM provided the piéce de résistance and was awarded ‘best sport’ of the evening by being the managerrrrrrrrrrrrrr. The Durban management team would like to thank all table sponsors, and the following additional sponsors of the evening: Welcome drinks Music Photography Table décor Desserts Executing projects that improve and extend the life of factories To view all the photos from the evening please go to: https://saimcdbn.co.za/zen/SAIMC-Durban-Annual-Function-2023
10 January 2024 www.instrumentation.co.za SAIMC NEWS The SAIMC Secunda branch hosted an ECSA workshop on 1 November 2023 at the Proconics, Secunda office in Secunda. It was facilitated by Johan Maartens, CEO of SAIMC, who has been with the organisation since 1985. The main purpose of the workshop was to guide candidates on the latest ECSA registration requirements for technicians, technologists and engineers. Johan conducted the workshop from an assessor’s viewpoint, so that the candidates could better understand the requirements, and learn how to document their experience in a way that is easy to read and understand by following the 11 outcomes stipulated by ECSA. He started by explaining that candidates can register as professional engineers, professional technologists, or professional technicians, depending on the candidate’s qualifications and corresponding work experience. Secunda Branch To register as a professional engineer, candidates need to prove they can solve problems at a complex level, Technologists need to prove they can solve broadly defined problems, and technicians need to prove they have the right experience at the right level. Candidates are responsible for their own development, and also for ensuring they get the right experience, as required by ECSA for professional registration. Before the development of the Mechatronics discipline, control and instrumentation (and automation) engineers registered under the Electrical discipline, and thus were assessed by electrical professionals, which often made the review and interview process challenging. The Mechatronics discipline was developed to overcome this. It is extremely important for candidates to indicate the correct sub-division under Mechatronics when submitting their application documents to ECSA for professional registration. This will ensure that ECSA allocates suitable assessors for the candidate’s interview. The Mechatronics discipline has three subdivisions: Mechatronic Devices, Process Automation, and Factory Automation. Johan advised the candidates to be calm and patient in interviews. Contrary to popular belief, the assessor’s intention is not to trick the candidate with questions, but rather to assess whether a candidate is ready to take on the responsibilities of a professionally registered technician, technologist or engineer. The SAIMC Secunda branch committee would like to thank Johan for sharing his wealth of knowledge, and SAIMC administrator, Ina Maartens for her time and welcome presence; time spent with Johan and Ina is always enjoyable. We would also like to thank Proconics for hosting the monthly technology evenings. Michael Brown’s Practical Process Control Training Courses and Loop Optimisation Services Cell: +27 (0)82 440 7790 Email: [email protected] Website: www.controlloop.co.za MICHAEL BROWN CONTROL ENGINEERING CC Courses: These well known courses are unique and invaluable to newcomers as well as experienced practitioners and process engineers in the field of industrial regulatory control optimisation. The courses offer a new and very practical approach to this subject, which very few people really understand properly. Courses are available on demand for six or more delegates and are suitable for instrumentation and control technicians and engineers, and for plant process engineers. Many chemical and mechanical engineers have attended the courses as well as metallurgists. Even people with many years of experience in this field have found the courses a real eye opener. Optimisation Services and Consulting: Michael Brown has had 35 years of experience in control loop optimisation, and in that time has successfully optimised controls in many different types of plants, including pulp and paper, power stations, chemical and petrochemical, oil, steel, mining and metallurgical recovery, cement, brewing, glass, dairy, food, and sugar, both in South Africa and many overseas countries. His work has proved invaluable to plants and has resulted in greatly improved performance and ROI. THE PART 1 COURSE IS NOW AVAILABLE ONLINE VIA SELF STUDY AND ZOOM SESSIONS
• Single board construction. • Auto-balance. • Facility to accept the signal from a Belt Splice pick-up. • 220 volt/II0 volt supply voltage. • Ability to operate in either an instantaneous Trigger Mode or require a Reset Signal. • Fault/Trigger Relay & LED indicator. • 3 x Trip Relays & LED indicators. • High/Low (1-100%) range of sensitivity. • Lockable metal enclosure rated IP65. • Microprocessor based with the ability for inputs and outputs to be configured to suit special requirements. • Solid state user interface with LCD screen. • Totalising metal count facility. Industrial Metal Detection Equipment Metasearch 4 Controller Typical Conveyor Installations Belt passes through coil Advantages: Most sensitive arrangement and least costly. Disadvantages: Belt requires cutting and joining by vulcanising. Coil vulnerable to large rocks. Belt passes between 2 coils Advantages: Suitable for large burden depths. No cutting of belt. Easily replaced. Disadvantages: Coils need to be “phased” correctly. Coil vulnerable to large rocks. Coil positioned below the belt Advantages: No cutting of the belt. Coil relatively protected from damage. Easily replaced. Disadvantages: Not suitable for large burden depths. Not the most sensitive where small items need detecting. Saflec is capable of manufacturing specially designed coils to suit customer requirements such as the wood chipping industry. +27 I I 477 4760 | [email protected] | www.saflec.com Metasearch 4 FEATURES
CONTROL SYSTEMS Valve specialist, Valve & Automation (V&A) supplies total valve and control solutions to a wide range of key process industries across southern Africa. Chemicals, and pulp and paper are top of its list of industries with demanding process conditions, but the company also supports the mining and minerals, sugar, steel, power generation, and refining industries with manual valves, on/off valves, control valves and allied equipment. Key customers for V&A are Air Liquide, Anglo American, Sasol, Sappi, and Mondi. Chemicals V&A, together with its global partners, has a long history of working with chemical, petrochemical, and synthetic fuel companies. Conditions in these industries vary from aggressive chemical handling to extreme pressures and temperatures. In addition, production and engineering managers must reduce emissions, while meeting the demands for increased plant safety, and also reduce plant maintenance and production costs. This is a tall order, but V&A can help them rise to these challenges. V&A regularly supplies companies like Sasol Chemical Industries, Sasol Synfuels, Sappi Chemical Cellulose, and Mondi to help their production plants meet their core objectives. The company’s solutions range from fully-lined pumps and valves and triple offset rotary process valves through to emergency shutdown valves and PST. Both NAF rotary control valves and Stafsjö knife gate valves are designed for applications with abrasive slurries. Pulp and paper V&A also has extensive experience in the pulp and paper industry, together with global valve companies like Stafsjö. It regularly supplies equipment to major players such as Mondi Business Papers, Sappi Chemical Cellulose, Sappi Southern Africa, Sappi Fine Papers, mPact, and Nampak for processes that include digestion, recovery, bleaching, and causticising. Sappi has awarded V&A major contracts for manual and control valves for various projects, as has Mondi for other major projects. Significant contracts have also been awarded for pump protection systems by Sulzer and KSB for Eskom power stations. Valves for severe service Mining V&A also provides solutions to this tough industry, where most valves do not last more than a few weeks with abrasive slurries. Machinery and plant must be capable of dealing with media with a high volume of solids, abrasive material, corrosive chemicals, and high velocities. Engineers and plant operators must be able to have complete control over their operation, and select pipeline equipment that is reliable and able to withstand these harsh conditions. Linear and rotary valves must be able to operate for long periods without jamming or clogging. Replacement of parts and routine maintenance must be done quickly and easily to reduce downtime and the impact on production. To meet these demands, V&A can offer long-lasting Stafsjö MV standard, HG through going, and SLH-SLX high-pressure knife gate valves for slurries. Fully-lined Richter butterfly and ball valves are ideally suited for chemical applications within mineral separation. High-performance knife gate valves Knife gate valves work in the harshest environments, typically having a sharpened blade to cut through heavy liquids. They are perfect for isolation of liquids containing abrasive solids or fibres, slurries, or viscous, corrosive media. The valves have a minimised pressure drop in fully open position, they are easy to actuate, they have a relatively low weight, and they are cost-effective. One of V&A’s top suppliers is Stafsjö. Headquartered in Stavsjö, Sweden, the company manufactures high-performance knife gate valves for reliable and long-lasting operation in demanding industrial processes throughout the world. Stafsjö has a long history that is rich in tradition. The story began in 1666 with the manufacture of cannons, which lasted for almost 200 years. As testimony to the durability of Stafsjö products, one of these cannons can be found in Hout Bay. Weighing five tons, it was cast in 1780 in Sweden. According to the Cannon Association of SA, it was recently fired, to mark the coronation of King Charles III, using a kilogram of gunpowder. In 1928, Stafsjö introduced its first knife gate valves. Today the company focuses on process technology and has positioned itself in the paper and pulp industry. The company manufactures Courtesy of Sasol.
www.instrumentation.co.za January 2024 13 CONTROL SYSTEMS approximately 20 000 knife gate valves a year, with more than 80% destined for export. Here are two case studies highlighting the company’s excellence in this industry. World record tons of pulp The region west of Sao Paulo in Brazil has become the world’s largest producer of cellulose. With an annual capacity of 1,8 million tons of bleached eucalyptus hardwood pulp, Eldorado Brazil’s Três Lagoas mill is the largest single-line pulp mill in the world. The mill needed to develop a large scale, state-of-the art plant with high productivity and low conversion costs, meeting all sustainability requirements. “For technical excellence and quality, Stafsjö was a natural choice,” says chief engineer Vesa Romppanen from Andritz, the key supplier for the new pulp line. He specified and purchased the Stafsjö MV DN 1400/56 valve for high-density bleach stock and tower isolation. “We needed a tailor-made valve,” said Romppanen. “We knew from past experience that we could rely on the team at Stafsjö. Together we found the solution for this project, a customised 3,5 ton MV valve with purge ports close to the seat, capable of handling really high pulp concentrations. This was a huge project with many challenges, extreme pressures, and large amounts of pulp and water per second.” Everything has worked like clockwork since. A year after, Eldorado was producing a world-record 5000 tons in a single day. The facility is also contributing to the local population, providing jobs for about 25 000 people. Breaking new ground China is not only a huge and important market, it is also home to industries that require very large components. Stafsjö was confronted with a massive challenge. The end customer was a giant within the Chinese business world and one of the largest producers of pulp and paper in the industry. The company demanded high quality at a reasonable price, with near-zero emission rates and minimal consumption of resources, while still preserving growth and productivity. The blow tank tower was 32 metres high, with a correspondingly high pressure. The bottom valve had to hold this tightly and process highly concentrated pulp. The environment was aggressive and exposed. There was no knife gate valve available with such large dimensions. The result was one of the largest valves in Stafsjö’s history, tailored to meet the customer’s requirements. “This was a demanding project, and we were breaking new ground,” says key account manager for pulp and paper in China, Su Chuansheng. Think globally, act locally Operations director of V&A, Greg Woolfuth sums it up: “Our customers can trust us with world-class products and unmatched application knowledge, so that they can be relieved from the burden of worrying about manual and control valves, and can focus on their core business objectives more effectively. Our valve repair facilities in Secunda and Durban assist in extending the valve service life, thereby reducing the cost of ownership. We want to help them add value to their production process, so they are more competitive in a global market.” For more information contact Valve & Automation, +27 11 397 2833, [email protected], www.valve.co.za Courtesy of Sappi.
14 January 2024 www.instrumentation.co.za AUTOMATION PROFESSIONALS Abacus Automation supplies innovative, custom-developed technical solutions using standard PLCs, drives, scada and motion control equipment and is Siemens approved for crane automation. With 23 years in the industry, this award-winning and internationally acclaimed company has highly qualified, experienced and professional staff. It operates out of offices in KwaZulu-Natal. Tel: +27 31 702 5767 [email protected] www.abacus-automation.co.za Abacus Automation Control Software Solutions - CSS Customer-centricity allows CSS to attain a high percentage of repeat business from its growing customer base. With a solid 17 years’experience in designing customised C&A solutions, CSS partners with customers in relationships thriving on information sharing and open communication enabling them to enhance customer operations. Supplier Certification provides customers with the assurance that the CSS team is completely up to date on current trends and technology as indicated by a number of prestigious awards. Tel: +27 31 914 0040 [email protected] www.cs-solutions.co.za Moore Process Controls Moore Process Controls provides process automation and optimisation solutions to realise the maximum potential of your plant and assets. Its offerings include DCS, PLC, scada, compressor control solutions, MES, production management and predictive maintenance systems, control loop optimisation, alarm and energy management systems, plant security and access management systems, Matrikon OPC, OSi Soft, dashboards and historians, wireless and data solutions including digital twin, process simulators and training simulators and cloud-based IIoT solutions. Tel: +27 11 466 1673 [email protected] www.moore.co.za Consulting engineers, system integrators & project houses EHL Consulting Engineers offers comprehensive C&I services across all industries including control system design, software development and system integration; legacy system upgrades and replacements; process automation and optimisation; and IS and SIL services. Tel: +27 11 370 7400 [email protected] [email protected] www.ehl.co.za EHL Consulting Engineers Autotronix is a recognised leader in industrial automation design and implementation having attained its ISO 9001 certification. Autotronix offers its clients turnkey control system integration services for energy management, PLC/HMI/scada/VSD, manufacture of control panels, applications for water distribution and manufacturing. The company operates from offices in Gauteng and KwaZulu-Natal. Tel: +27 31 705 0400 or +27 16 422 7644 [email protected] www.autotronix.co.za Autotronix Iritron is a new millennium technology company providing quality solutions in the fields of electrical instrumentation and control systems engineering, MES systems integration and simulations. It has a proven ability to manage projects efficiently and produce high quality results. It has an extensive track record of successfully implementing plant infrastructure reticulation, designs, and automation and information systems. Iritron, a TUV accredited ISO 9001:2015; ISO 14001:1015 and ISO 45001:2018 as well as a GAMP®5: A Risk-Based Approach to Compliant technology company, can offer its clients PLC, DCS, MES and scada software and hardware, as well as electrical and instrumentation design, engineering, project management and commissioning services. Tel: +27 12 349 2919 [email protected] www.iritron.co.za Iritron
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