Valve Terminal VTUX Automation platform for the future 40VOLUME NO 4 APRIL 2024 Official publication of the SAIMC INSPIRING AUTOMATION System integration | Control systems | Water & wastewater | Paper & pulp Wireless & telemetry | Process measurement | Motion control & drives Electrical power & energy-efficient systems
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www.instrumentation.co.za April 2024 1 Process measurement Electrical power & energy-efficient systems Wireless & telemetry Motion control & drives VOLUME 40 NO 4 APRIL 2024 04 07 12 REGULARS FEATURES Control systems System integration Paper & pulp Water & wastewater 20 16 14 23 29 39 26 34 News & events SAIMC news Automation professionals VEGA Controls SA, Omniflex Remote Monitoring Specialists, Endress+Hauser South Africa Gail Norton Instrumentation Agencies, Comtest Michael Brown Control Engineering CC, Beckhoff Automation PCS Global ABI Research, Emerson Automation Solutions, ifm - South Africa, Senseca South Africa, AMETEK Land RJ Connect, Turck Banner, Parker Hannifin SA Turck Banner, SKF Neu Matics SA, Customised Motion Controls, Wearcheck, Yaskawa Southern Africa, WIKA Instruments OUR COVER 10 Valve Terminal VTUX Automation platform for the future 40VOLUME NO 4 APRIL 2024 Official publication of the SAIMC System integration | Control systems | Water & wastewater | Paper & pulp Wireless & telemetry | Process measurement | Motion control & drives Electrical power & energy-efficient systems INSPIRING AUTOMATION In the dynamic and challenging world of industrial automation, application success hinges on the ability to optimise efficiency, adaptability, and ease of use. Read our cover story on page 10 to find out about the latest innovation from Festo in the form of the Valve Terminal VTUX, and the numerous additional benefits offered by this advanced powerhouse, which truly sets it apart from the competition.
2 April 2024 www.instrumentation.co.za welcome VOLUME 40 NO 4 APRIL 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 Lately I’ve been getting an ever-increasing number of articles on cybersecurity in my inbox. It’s easy to put it on the backburner, but there is no doubt that this is a very serious problem that’s not going to go away if you ignore it. Unsurprisingly, the weakest link is people, although they usually don’t get treated as harshly as those in the game show, The Weakest Link − remember that? We generate around 2,5 quintillion bytes of data every day, leaving us all vulnerable to data misuse, cybersecurity attacks and identity theft, both in our own lives and in the commercial and industrial world. In a recent survey of 500 security executives from 13 countries around the world, including South Africa, cybersecurity company Trellix’s ‘Mind of the CISO 2023’ report has some sobering numbers. I thought the statistics were quite interesting. Cybersecurity incidents involving phishing were at 40%, ransomware at 36%, business email compromise at 32%, and credential stealing at 28%. The report also said that 28% of attacks were state-sponsored, meaning hacking syndicates backed by hostile states, while 24% were inside jobs. The leading cause of major cybersecurity incidents was password misuse at 56%, followed by insider threats at 44%, supply chain breaches at 40%, non-detection by existing technology at 40%, and missed vulnerabilities at 36%. These incidents led to a loss of customers, business downtime, reputational damage, regulatory penalties, and higher insurance premiums. Only 60% of the respondents were fully covered by their cybersecurity insurance. There are plenty of examples locally. In 2020, the credit bureau Experian had a data breach that exposed the personal information of 24 million South Africans and 790 000 business entities; and the hack of TransUnion in 2022 exposed millions of South Africans to potential risk. There are more. Liberty Holdings, ViewFines and Ster-Kinekor were all attacked. The Dis-Chem cyber attack resulted in the data of over 3,6 million South Africans being compromised. I’m sure we’ve all had random emails and WhatsApps where we wondered how they got our information. The most devastating ransomware attacks almost always begin with a simple Spear-Phishing attack to get a user with valuable credentials to click on an infected link. Of the South African companies surveyed by Trellix, 78% said they had paid a ransom of between five million and ten million dollars. There are many technical solutions that can be put into place, but the most important barrier is your people. The key lies in strong The weakest link passwords, regular training, checking your links with your end users and vendors, and not clicking on suspicious email links. A little prevention today could save you from huge problems tomorrow. As an example, I still remember my very first computer − a long time ago. It was a 64K Apple that I was ridiculously proud of, and my very first password was − password. At least that wouldn’t happen today. At the recent MESA conference, I heard of another typical example. This was the story of a company in Abu Dhabi that was subject to a cyber attack. On the first two tries the hackers were unable to breach the company’s security. Then they employed three pretty girls to stand outside the offices and offer the people going in a free USB stick. Within five minutes they were in, and had all the information. You also need to get your people’s cooperation, which is where training comes in. Nowadays, process plants operate on a whole new level. Everything is interconnected. While this brings huge benefits in productivity, it also makes them vulnerable. In response, companies are putting into place such strict policies that it’s very difficult to get access to a plant to work on it, and this is creating resistance from workers. In the future, cyber resilience is going to become even more important. Looking ahead, quantum computing has the potential to take this to a whole new level. Quantum computers can perform calculations exponentially faster than today’s computers. We can expect to see the arrival of post-quantum cryptography to make cryptographic systems secure against attack. On the other side, as quantum computers become more powerful, they could be a threat to current encryption standards like RSA. ‘Bad actors’ could decrypt encrypted data that is considered secure, potentially exposing sensitive information. While a regular computer needs millions 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. The race is on to develop new quantumresistant encryption methods that can withstand attacks like this. I’m optimistic that the good guys will win.
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NEWS & EVENTS 4 April 2024 www.instrumentation.co.za SEW-EURODRIVE builds support, trust into Africa Companies in various sectors across Africa are wanting to harness the power of modern advancements in drive technology, and SEW-EURODRIVE is there with the solutions and the support. “Many operations around the continent are still using conventional technology, but are looking for ways to improve efficiencies and productivity,” says Jonathan McKey, national sales and marketing manager at SEW-EURODRIVE. “They are also wanting to reduce their carbon footprint and energy costs, and we have the solutions for them.” The company is driving a concerted strategy to bring these solutions closer to customers through extending its local in-country presence. Having expanded and upgraded its facility in Aeroton near Johannesburg, SEW-EURODRIVE now boasts entities in Zambia, the Democratic Republic of Congo (DRC) and Kenya. The office in Tanzania has been thriving for ten years already. “This year, we are setting up additional resources in Botswana, Zimbabwe, Eswatini Image Filename: k24ICapr57a/d Caption k24Ic: Tebogo Moloi holds the Business Development Africa portfolio at SEW-EURODRIVE. Caption k24Id: Jonathan McKey, national sales and marketing manager, SEW-EURODRIVE. ifm - South Africa recently celebrated the launch of its new warehouse. The event commenced with a welcoming address by ifm - South Africa’s managing director, ifm - South Africa celebrates new warehouse and Mozambique,” says Tebogo Moloi, who is in charge of Business Development Africa. “Our philosophy is to build local businesses on the strength of their local expertise and market knowledge, bringing us closer to customers with enhanced offerings of technology and services.” With the local representatives being well qualified and experienced in their markets, SEW-EURODRIVE supports them with the necessary facilities and stockholding, and also specialised training. Moloi highlights that site visits to customers can become both more frequent and more valuable. “From our in-country bases, we are closer to customer sites and can deliver high value technical support when requested during our visits,” he says. “Regular engagement means that we build relationships of trust with customers by seeing their working environment and understanding their needs and challenges.” McKey explains that SEW-EURODRIVE is actively diversifying its offerings in Africa to meet each market’s specific requirements. Having established a firm base in South Africa over the decades as geared motor specialists, it has grown into aftersales service and industrial gear (IG) units. “Given the large installed base of geared motors and IG units in Africa, we can now also service and repair competitor products by leveraging our growing technical capability around the continent,” he says. McKey adds that as part of its standard and complimentary services around Africa, SEW-EURODRIVE conducts on-site surveys to assess customers’ operational infrastructure. The company can then recommend modernised solutions to enhance efficiency and reliability. “We also conduct energy audits, and advise on our energy-efficient solutions to reduce costs and carbon footprints,” he says. For more information contact SEW-EURODRIVE, +27 11 248 7000, [email protected], www.sew-eurodrive.co.za Alwyn Skelton, who expressed gratitude to the team for its hard work and dedication in bringing the project to fruition. He emphasised the significance of the new warehouse in enhancing ifm’s capacity to serve customers and clients more effectively and meet the growing demand for its products and services. Guests from ifm’s headquarters in Germany who attended the special afternoon included Kevin Duda, senior director of regional sales management, and Daniela Hamm, director of human resources. The festivities concluded with a tour through the new warehouse and a sit-down lunch with the decor in black, white and gold, with a pop of orange. ifm staff and guests came together to celebrate not only the launch of a new facility, but also the spirit of innovation, teamwork, and shared success that has defined ifm - South Africa’s journey. The celebration served as a reminder of ifm’s resilience and adaptability in the face of challenges, and its ability to navigate future endeavours with grace and success. In essence, ifm - South Africa’s celebration of the new warehouse launch was more than just an event; it was a testament to the company’s innovation, teamwork, and commitment to excellence that will propel it forward into a future filled with possibilities. For more information contact ifm - South Africa, +27 12 450 0400, [email protected], www.ifm.com/za
NEWS & EVENTS www.instrumentation.co.za April 2024 5 Schneider Electric and NVIDIA collaborate to optimise data centre infrastructure Schneider Electric has announced a collaboration with NVIDIA to optimise data centre infrastructure and pave the way for groundbreaking advancements in edge artificial intelligence (AI) and digital twin technologies. Schneider Electric will leverage its expertise in data centre infrastructure and NVIDIA’s advanced AI technologies to introduce the first publicly available AI data centre reference designs. These designs are set to redefine the benchmarks for AI deployment and operation within data centre ecosystems, marking a significant milestone in the industry’s evolution. With AI applications gaining traction across industries, while also demanding more resources than traditional computing, the need for processing power has surged exponentially. The rise of AI has spurred notable transformations and complexities in data centre design and operation, with data centre operators working to swiftly construct and operate energy-stable facilities that are both energy-efficient and scalable. “We’re unlocking the future of AI for organisations,” said executive vice president, Pankaj Sharma. “By combining our expertise in data centre solutions with NVIDIA’s leadership in AI technologies, we’re helping organisations to overcome data centre infrastructure limitations and unlock the full potential of AI. Our collaboration with NVIDIA paves the way for a more efficient, sustainable and transformative future, powered by AI.” Cutting-edge data centre reference designs In the first phase of this collaboration, Schneider Electric will introduce cutting-edge data centre reference designs tailored for NVIDIA accelerated computing clusters and built for data processing, engineering simulation, electronic design automation, computer-aided drug design and generative AI. Special focus will be on enabling high-power distribution, liquid-cooling systems and controls designed to ensure simple commissioning and reliable operations for the extreme-density cluster. Through the collaboration, Schneider Electric aims to provide data centre owners and operators with the tools and resources necessary to seamlessly integrate new and evolving AI solutions into their infrastructure, enhancing deployment efficiency and ensuring reliable life-cycle operation. Addressing the evolving demands of AI workloads, the reference designs will offer a robust framework for implementing NVIDIA’s accelerated computing platform within data centres, while optimising performance, scalability and overall sustainability. Partners, engineers and data centre leaders can utilise these reference designs for existing data centre rooms that must support new deployments of high-density AI servers and new data centre builds that are fully optimised for a liquid-cooled AI cluster. “Through our collaboration with Schneider Electric, we’re providing AI data centre reference designs using nextgeneration NVIDIA accelerated computing technologies,” said Ian Buck, vice president of Hyperscale and HPC at NVIDIA. “This provides organisations with the necessary infrastructure to tap into the potential of AI, driving innovation and digital transformation across industries.” Future roadmap In addition to the data centre reference designs, AVEVA, a subsidiary of Schneider Electric, will connect its digital twin platform to NVIDIA Omniverse, delivering a unified environment for virtual simulation and collaboration. This integration will enable seamless collaboration between designers, engineers and stakeholders, accelerating the design and deployment of complex systems, while helping reduce time to market and costs. “NVIDIA technologies enhance AVEVA’s capabilities in creating a realistic and immersive collaboration experience underpinned by the rich data and capabilities of the AVEVA intelligent digital twin,” said Caspar Herzberg, CEO of AVEVA. “Together, we are creating a fully simulated industrial virtual reality where you can simulate processes, model outcomes and effect change in reality. This merging of digital intelligence and real-world outcomes has the potential to transform how industries can operate more safely, efficiently and sustainably.” In collaboration with NVIDIA, Schneider Electric plans to explore new use cases and applications across industries and further its vision of driving positive change and shaping the future of technology. For more information contact Schneider Electric South Africa, +27 11 254 6400, [email protected], www.se.com/za/en
NEWS & EVENTS 6 April 2024 www.instrumentation.co.za Siemens Digital Industries Software announced that the RS Group has selected Siemens as its strategic electronic design automation (EDA) provider for its new, cloud native, DesignSpark Circuit Simulator tool, which empowers users to streamline the design process. After an extensive technical evaluation of available solutions, RS selected the Siemens PartQuest software – a cloud-based circuit simulation tool supporting analogue, digital, mixed-signal and multi-domain designs – as the enabling technology to power the latest generation of its DesignSpark Circuit Simulator tools. DesignSpark delivers a comprehensive environment to design, model, simulate and RS Group chooses Siemens simulation technology for DesignSpark BMG has established a dedicated VSD workshop at the company’s Cape Town Engineering facility. “Our new VSD facility is an approved warranty centre for BMG’s Danfoss/Vacon and Synergy VSD products,” says business unit manager, David Dyce. This electromechanical facility is manned by a team of globally-trained experts offering specialist services to customers throughout the Western Cape. Services include repairs, maintenance, option fitment, pre-commissioning, software loading/upgrades, testing applications, and small panel manufacturing. The team also provides onsite technical assistance for troubleshooting, commissioning, maintenance and repairs. The conveniently situated engineering facility also stocks the full range of BMG VSDs to clients from all industries, including the marine sector. In addition, BMG’s branch network in the Dedicated to drives Megatech SA has been importing high quality industrial plant equipment and spare parts since 2016. Based in KwaZulu-Natal, the company Megatech is expanding analyse electronic and mechatronic circuits and systems for the 1,3 million members of the DesignSpark engineering community. “The RS DesignSpark vision is to educate, influence, promote and enable engineers to design responsibly for a better world,” said Mike Bray, vice president of Innovation for DesignSpark, RS Group. “Our DesignSpark Circuit Simulator has the right set of tools to help our extensive community improve productivity and deliver innovation faster. Siemens demonstrated that it has the cutting-edge cloud technology we need to help us achieve our vison.” “Siemens is pleased to have been chosen by RS as a key technology partner for its DesignSpark platform,” said AJ Incorvaia, senior vice president of Electronic Board Systems at Siemens Digital Industries Software. “The DesignSpark Circuit Simulator offers robust circuit design and simulation resources to a DesignSpark community eager for advanced technology and solutions that help realise more end products in a collaborative environment that facilitates peer-to-peer knowledge sharing.” For more information contact Siemens South Africa, [email protected], www.siemens.co.za specialises in electrical and mechanical equipment and instrumentation. Its very wide product range includes motors, switches, breakers, transformers, variable speed drives, cables, pumps, gearboxes, expansion joints (bellows), seals, industrial brakes, industrial clutches, fans, filters, strainers, hydrocyclones and valves. A hallmark of its offering is excellent service with quick turnaround times. The company’s goal is to ensure customer satisfaction by supplying high quality parts and equipment from globally recognised brands, at low prices. Although based in KwaZulu-Natal, Megatech now also has customers in Gauteng and Mpumalanga, and with its fast-growing brands is poised to supply and deliver to all nine provinces in South Africa. On top of its broad product range, Megatech has also partnered with international companies such as Armaturen Goetze, Plutos Tech and Huachang to offer industrial and electronic engineering services. These include: • General plant maintenance and overhauling of equipment in accordance with OEM guidelines and applicable codes and standards. • System design, configuration, commissioning and testing of instrumentation and control systems incuding DCS and PLC/scada. • Upgrades, migrating from legacy to modern systems. • Integration of standalone systems with main process control systems. • Automation of manually operated systems, enabling optimum remote control. • Installation of safety instrumented systems (SIS). For more information contact Megatech, +27 31 942 9241, [email protected], www.megatechsa.co.za Western Cape area stocks a wide range of VSDs in various voltages and power sizes to suit the immediate needs of the market. BMG was appointed by Danfoss Drives in 2019 as the first authorised Danfoss DrivePro service partner in Africa, and this official certification has been renewed each year. This prestigious appointment gives customers the assurance that BMG meets stringent requirements to offer customised support and technical assistance for Danfoss VLT and VACON frequency converters. Danfoss DrivePro services, which cover the entire lifecycle of Danfoss and VACON AC drives, are designed to improve productivity and performance, minimising downtime, and giving peace of mind to every user. BMG has made a significant investment in distribution, engineering facilities and technical skills in strategic parts of Africa, including electronic workshops and a technical resources centre for the repair, maintenance and commissioning of Danfoss VLT and Vacon products and services. For more information contact Dave Dyce, BMG, +27 11 620 1546, [email protected], www.bmgworld.net
www.instrumentation.co.za April 2024 7 SAIMC NEWS Johan Maartens. From the office of the CEO National Members When South Africa clinched victory in the Rugby World Cup for the fourth time, the nation collectively rejoiced. The moment symbolised unity and optimism, as citizens rallied behind a diverse team representing the aspirations of the entire country. It evoked visions of a South Africa poised for a brighter future, reminiscent of the pride and integrity epitomised by Nelson Mandela. However, amidst this optimism lies a pertinent question: is South Africa truly a land of hope, or is it merely a fool’s paradise? The concept of a fool’s paradise, coined as early as 1462 by William Paston and popularised by William Shakespeare, describes a state of blissful ignorance in the face of impending danger. In recent years, South Africa has grappled with escalating challenges such as frequent power outages, water shortages, sewage issues, bribery and corruption. Industry and private individuals are increasingly reverting to generators and solar systems, masking the severity of loadshedding and contributing to a false sense of security. Some companies are installing rainwater tanks and sophisticated water purification systems. The failure to grasp the broader implications has led to a gradual deterioration of the country’s infrastructure. Politicians, buoyed by media support, often propagate messages of hope without addressing underlying issues. Johannesburg’s water crisis serves as an example where temporary fixes fail to address the systemic flaws in infrastructure management. Similarly, the recurring cycle of loadshedding underscores a lack of foresight and accountability. As critical systems falter, South Africa remains embroiled in divisive debates, deflecting attention from these shortcomings. Meanwhile, the nation’s infrastructure is crumbling due to incompetence and greed, laying bare the fragility of its societal fabric. In essence, South Africa stands at a crossroads, balanced between hope and reality. While moments of triumph ignite optimism, the nation must confront its challenges with pragmatism and resolve to build a sustainable future. Only then can South Africa transcend the trappings of a fool’s paradise and realise its true potential as a beacon of progress and unity. Characterised by its destructive policies, government has proved that it does not have what it takes to govern South Africa. The administration lacks the capacity to manage a nation as complex as ours, with its abundant resources and diverse demographic composition. The propagation of fear about potential job losses due to the Fourth Industrial Revolution pales in comparison to the ramifications of the greed and corruption that drive away job-creating entrepreneurs and hinder the employment of individuals with much-needed skills. This interference with entrepreneurial endeavours, coupled with the expulsion of dissenters without legal recourse under the guise of safeguarding employers, has perpetuated a thirty year long erosion of employment opportunities. Statistics reveal that South Africa’s GDP growth during this period lags behind that of nations such as Angola, Botswana and Zimbabwe. The concerns surrounding job losses due to automation are overshadowed by the systemic issues of incompetence and avarice. In light of these challenges, South Africa must redirect its focus. Embracing truth as a guiding principle is of paramount importance, as is an emphasis on education for today and for future generations. Encouraging the adoption of emerging technologies is essential. Blaming historical figures like Jan van Riebeek, the legacy of apartheid or the effects of COVID-19 is futile in addressing the employment crisis. In the evolving media landscape, transitioning towards AI-driven reporting is crucial as traditional news outlets vie to maintain relevance. By prioritising education, embracing advances in technology and fostering an environment conducive to investment and innovation, South Africa can chart a path towards economic resilience and prosperity. Yours in automation Johan Maartens
8 April 2024 www.instrumentation.co.za Secunda Branch INSPIRING AUTOMATION SAIMC NEWS Johannesburg branch The local Johannesburg Branch of the SAIMC hosted a technology evening at the Bryanston Sports Club on 13 March 2024. The evening was very well attended with more than 22 members present. It was sponsored by Phoenix Contact and the technical presentation covered the full gambit of industrial wireless technology in the automation field. It addressed various technologies and topologies, including trusted wireless, industrial bluetooth, wireless LAN/ Ethernet, 3G/ GSM based systems and Wireless HART. These technologies all co-exist in the same frequency band, are license free, and are not affected by electromagnetic Interference from plant and machinery. All these systems are capable of being integrated into existing systems, and are compatible with all scada, DCS and PLC brands. They are growing in popularity due to their security, cost effectiveness and ease of installation in many applications. Included in the presentation were case studies on various operational systems covering a vast array of applications. The case studies covered both local and overseas applications, and were relevant to all local industries. The applications included: • Replacement of cables on overhead cranes. • Mobile vehicle connections in warehouses and plants. • Vernacular control at Cape Point. • Aircraft gate support systems. • Leaky cables for track-guided systems in automotive manufacture. • Control of revolving machinery such as stranding machines. • Safe wireless transport systems for elevators. • Remote mill monitoring and bag filling. • Centrifuge control and monitoring at wastewater plants. • Safe wireless control and monitoring of fuel tank farms. There was very good interaction during and after the presentation, and the feedback received was very positive. Thank you to Kevin Preston from Phoenix Contact for an insightful presentation. Kevin Preston, group manager: IMA and IE, Phoenix Contact. Branches Johannesburg: Ann de Beer at [email protected]; Mobile: +27 82 365 7856 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: Enock Shikabeta at [email protected], Tel: +26 96 759 1936 Council: Ina at [email protected], Mobile: +27 82 440 8957, Tel: +27 11 312 2445 The SAIMC Secunda branch held its monthly Technology Evening on 6 March 2024 at the Proconics, Secunda office. Sagadevan Kanniappen from WIKA presented on Thermowell stress calculations as per ASME PTC 19.3. His focus was mainly on wake frequency calculations and the requirements for debottlenecking projects. He also discussed the data needed for thermowell design and presented a case study on the decommissioning of the Japanese Monju nuclear power plant. The plant was shut down after only three months of operation due to thermowell failure. In his presentation, he gave a short overview of the ASME PTC 19.3 standard. The standard was initially established in 1974 and was reaffirmed in 1986. In 1995, the Monju nuclear power plant experienced a thermowell failure. After conducting a root-cause analysis, it was discovered that the failure might have been caused by inline resonance, which was not considered in the standard at the time. Subsequently, the standard was revised to account for this potential cause of failure. It was revised again in 2010 and 2016. Sagadevan explained the concept of wake frequency calculations. To prevent any damage to the thermowell caused by mechanical loads during operation, it is recommended to perform a wake frequency calculation as per ASME PTC 19.3 TW-2016 for critical process conditions. These calculations require basic process conditions like the process medium, density of the medium, maximum working temperature and maximum working pressure. Wake frequency calculations can be done manually or through online tools offered by the original equipment manufacturers (OEMs). Sagadevan emphasised the importance of performing manual calculations to comprehend the software’s working, despite the convenience offered by online tools. Thermowells can be impacted by debottlenecking projects. When a wake frequency calculation is performed, it is based on specific process data, and the results determine whether it passes or fails. If there are changes to the process data, such as during debottlenecking projects, the wake frequency calculation must be redone. The failure to adhere to PTC 19.3 can have catastrophic consequences for both human life and the environment. The Secunda SAIMC committee would like to thank Sagadevan Kanniappen for his time and presentation, and Proconics for hosting the monthly technology evenings. Any companies interested in presenting at the Secunda Branch monthly technical talks can complete this form: https://forms.office.com/r/f5QXNLcDDt or contact the branch general manager, Lezahn Meiring at [email protected]
www.instrumentation.co.za April 2024 9 SAIMC NEWS Durban branch Date: Saturday, 24 August 2024 Time: 18h30 for 19h00 until late Venue: Monte Casino, Fourways, Johannesburg Theme: Masquerade Dress code: Mysterious, formal and masked Cost per table: R16 000 Sponsorships available INSPIRING AUTOMATION Annual Gala Dinner Have fun! Be intriguing… be mysterious…. For more information please contact [email protected] The SAIMC Durban technology meeting in March drew a record attendance, with an old friend of the SAIMC, Gary Friend, presenting on the very topical subject of ‘Risks, rewards, advantages and disadvantages of new technologies and the impact of legislation’. Gary is the MD of Extech Safety Systems. In the build-up to his presentation, Gary said, “We have all heard about the 4th Industrial Revolution (aka IIoT) and we all have it in our lives with phones, tablets, the internet and a whole lot more. It has already impacted industry, and more hazardous area products and applications are coming. The sky is the limit, or is it?“ Gary explained the differences between a standard and a code of practice, and gave examples. He demonstrated some of these differences and showed how they have evolved to cover developments in technology, sometimes causing difficulty in ensuring that a current standard or code of practice is legally enforceable. Legislation is not always in step with evolving codes or standards, and may refer to ones that are obsolete. This can result in confusion and possibly compromise investigations into liability should an accident occur. Gary is a well-known and respected member of our community. He has a BSc Electrical Engineering and is registered as a Professional Engineer in South Africa and a Chartered Engineer in the UK. He worked in several technical and design jobs before joining MTL in 1995 as a design engineer. Here he had several roles over 11 years, finishing as programme manager for the MTL4500/5500 range of isolators. In 2006, he returned to South Africa and joined Extech Safety Systems. He served on the SAIMC council from 2015 to 2018, and was instrumental in setting up SABS TC165 (IEC TC65 mirror). He sits on the Gary Friend (left) being thanked by Branch GM Mark Calvert. Ex steering committee and IS sub-committee of the SA Flameproof Association. He also sits on SABS TC31 (IEC065 mirror). He moved back to the UK in 2018, still working remotely, but full time for Extech, with regular six-weekly visits to South Africa. In 2018 he set up HazExpertise to do business in sub-Saharan Africa. The interesting topic, together with Gary’s solid reputation for delivering relatable and interesting presentations, drew a record crowd. Everyone thoroughly enjoyed the presentation, dinner and usual networking opportunities. Any companies interested in presenting and sponsoring a technology evening at the Durban branch can complete this form www.instrumentation.co.za/*presentations or contact [email protected]
10 April 2024 www.instrumentation.co.za Redefining Industrial Automation with the new Festo Valve Terminal Skye Prato. In the dynamic and challenging world of Industrial Automation, application success hinges on the ability to optimise efficiency, adaptability, and ease of use. Festo, a leading name in the realm of automation technology, with its roots in Germany, is perpetually striving to transcend the limits of innovation by catering to the developing needs of industries worldwide. The company recently introduced its latest innovation in the form of the Valve Terminal VTUX. This innovation marks the beginning of a new era in valve terminals, with its features making it an impressive solution for the future. “Since our groundbreaking introduction of the world’s first valve terminal back in 1987, we have developed numerous other terminals, each with its own specific focus. Thus, our adaptable Valve Terminal VTUX draws on years of experience and offers a highly expandable solution, enabling Festo customers to stay ahead of the ever-evolving technical changes in machine generations, from digitalisation, and cloud connectivity to machine design issues,” says Skye Prato, Business Unit Manager at Festo South Africa. The valve terminal seamlessly amalgamates the advantages of three classic valve terminal ranges that have set waves in industry: CPV, MPA-L/S and VTUG, into a single user-friendly system. This solution offers an impeccable combination of cost-effectiveness and advantages, leaving no room for doubts. It features an intuitive, modular configuration of essential functions, superior performance, and effortlessly integrable capabilities, all of which can be easily incorporated into the smallest of spaces. In this article, we will explore the numerous additional benefits offered by this advanced Festo powerhouse, which truly sets it apart from the competition. A closer look at the simplified disassembly and design of the VTUX from an expert During a recent conversation with Prato, the Valve Terminal VTUX took centre stage, as he delved into the valve terminal’s disassembly process, providing valuable insights into its features, upgrades, and versatility for various applications. Prato’s first point of emphasis was on the disassembling of the valve, highlighting its user-friendly design. With just a few screws and an allen key, users can easily access the valves, making maintenance and troubleshooting a breeze. The modular design allows for effortless removal and replacement of components, minimising downtime and maximising productivity. One of the most noteworthy upgrades to this technology is its redesigned valves, which have been expertly engineered to deliver higher flow rates and improved efficiency. As a seasoned expert, he further explained how the valve design has been optimised to accommodate larger flows without increasing the footprint. This innovation allows for greater
www.instrumentation.co.za April 2024 11 flexibility and scalability, ensuring seamless integration into a wide array of automation processes. The ultimate slim and lightweight solution Focusing on portability and convenience, Festo developers have put significant effort into reducing the size and weight of the VTUX valve terminals, a successor to the three previous classic valve terminals. This has resulted in a valve that offers excellent speed, payload and flow characteristics. These terminals are ideal for installation on handling systems or robots, where size and weight can significantly impact performance. Systematic interlinking With just one 10 mm valve and a working connection of up to 8 mm, high flow rates of up to 670 l/min can be achieved, thanks to this invention. In addition, VTUX offers a spectrum of interlinking plate widths tailored to varying flow demands while employing the same 10 mm valve. The two interlinking plate sizes for tubing diameters of 4 mm, 6 mm and 8 mm can be combined. Interlinking plates are available in four valves or a single valve configuration. The single connecting plates and modular tie rods enable a system that can be expanded as required to be set up within a short period of time. High-speed communication The streamlined, high-speed serial communication employed within valve terminals and base plates significantly minimises the need for extensive cabling and tubing, while facilitating seamless integration of functionalities and diagnostic capabilities. VTUX offers a wide array of interfaces supporting various bus systems and communication standards, including IO-Link, thus ensuring its adaptability, future readiness across diverse electrical networks and machinery setups. Whether deployed centrally in setups with numerous IOs and valve positions or used in decentralised valve terminals, the valve proves to be a versatile solution. Moreover, when paired with the company’s AP system, it enables a harmonised integration of both centralised and decentralised configurations, enhancing overall system efficiency and performance. Another benefit of this model is that its modules can be arranged as required. With the inclusion of AP communication technology, connecting is now easier, even over long distances. This technology plays a crucial role in creating safety designs, predictive maintenance, and data exchange with the cloud in the Industrial Internet of Things (IIOT). This terminal is the most connected terminal of its generation thus far. A customer-centric solution The Festo Official Partner, Supplyrite, transformed its customer’s operations with the VTUX, leaving them highly satisfied with the results. The customer’s application involved controlling an unwinder for material into a Nappy Line using a non-Festo Valve Bank that had eight 3/2 way valves. The valve met all the key requirements with high availability, a compact size for seamless integration into the existing panel, and significant cost-effectiveness over the previously installed valves. The VTUX Valve Terminal proved to be the ideal solution for the customer, thanks to its optimised valve design and innovative configuration. The 2x3/2 way configuration within a single valve not only streamlined installation but also enhanced efficiency, paving the way for improved automation processes. Its solution was further enhanced by the VTUX’s superior connectivity features. The Sub-D Multipin design enabled significant improvements in panel organisation, providing a neater, more efficient setup and eliminating the need for individual wiring into local PLCs. The transition to this valve terminal offered numerous benefits for the customer, including the longevity of the product, which aligns perfectly with their phased change-out strategy for older valve banks. By standardising the terminal’s units, the customer ensured continuity in their automation processes and streamlined their business’s stockholding, resulting in cost savings and operational efficiencies. Embracing the future of Industrial Automation with Festo The Festo Valve Terminal VTUX represents a major milestone in the world of Industrial Automation. With its advanced features, streamlined design, and seamless integration capabilities, this solution is poised to redefine automation processes across industries. This valve with an array of advanced technologies is the perfect solution for businesses that are looking to enhance their operations, flexibility, and efficiency and stay ahead of the competition. Its ability to simplify maintenance procedures, enhance communication, and enable scalability makes it a game-changer in the industry. The exceptionally modular VTUX can be adapted to application needs with simple modifications of the module to keep pace with changes in the machine. Partnering with Festo offers customers a unique opportunity to gain a competitive edge by leveraging the advancements of this valve, which is continuously setting new industry standards, explained Prato. Festo’s unwavering commitment to innovation and customer satisfaction through comprehensive solutions is unparalleled, making it an excellent choice for all industry-related needs worldwide. Their dedication towards innovation and customer satisfaction is evident through their unmatched comprehensive solutions in the industry. For more information contact Festo South Africa, 08600 FESTO (33786), [email protected], www.festo.co.za COVER STORY
12 April 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
www.instrumentation.co.za April 2024 13 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]
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