FEATURES: · Control systems + automation · Drives, motors + switchgear · Measurement + instrumentation · Transformers, substations + cables
COMMENT
INDUSTRY 4.0 + IIOT
It’s time to pay attention to energy supply on site
O nce again we have a jam-packed edition for you to enjoy – whether you read it online or in hard copy – to keep up to date with what is going on in our industry. All the areas covered this month are important, but I’d like to focus here on transformers and substations. As we move towards a more sustainable energy future there is little doubt that shifting electrical energy about will become more – not less – important than it is now. Emphasis on the reliability and efficiency of each component in the system will become more critical. There are several reasons for this: first is the traditional one of trying to minimise losses between the source and the load; and second is ensuring that what precious energy we have (think alternative source over 350 km away) reaches our plant effectively. We are also moving to a time when the way we control our systems simply will not be the same as in the past; in the past we just burnt the coal, and somewhere we used the energy as and when we wanted it. Now there are many applications where energy really is needed on a ‘when and where’ basis – and our new control philosophies will need to allow for that, given our base may be significantly reduced from what it was in the past. But even on the plant site, where the substation was typically just ‘the building over there’ – and it had ‘stuff in and around’ it, we need to relook
For the design of radiometric measure- ments, a choice must be made to use a point source with a rod detector, or a rod source with a point detector. The rod source/point detector arrangement offers decisive advantages. (Read more on page 3.)
energy performance, efficiencies and costs. The cost of energy is now a crucial consideration in the life cycle costing and planning of any plant. Considering this, the route often taken of neglecting the stuff in the building over there ‘because it just worked’ is no longer an option. We need to be measuring and monitoring everything we can in the substation; we need to be reviewing the condition of our energy supply network – on our side; not just from the Eskom side (which we all have a feeling for). And this is the time to delve into the condition of the transformers and associated equipment. This is the time to see why (and this is not made up) we are spending quite a bit on transformer oil – even though we are not manufacturers of transformers; it is the time to check that the circuit breakers and protection networks have sailed through the various stages of load shedding unscathed. They may have, but it’s important to check. As with all things, out of sight and out of mind is simply not an option. Be proactive and review the condition of the plant. Let’s make a commitment to ensure that our energy supply network – much of it hidden, sometimes even buried – is cared for, and that we regularly consider its condition and performance. We’ll miss it the day it fails.
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MARCH 2022 Electricity + Control
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CONTENTS
INDUSTRY 4.0 + IIOT
Features
CONTROL SYSTEMS + AUTOMATION 4 Moving to digitalisation at Tiger Brands Siemens South Africa
5 Automated inventory management Francis Richt, Sandvik Coromant
7 Products + services
5
DRIVES, MOTORS + SWITCHGEAR 10 Making the case for an energy-neutral water sector Mads Warming, Danfoss Drives 12 Fault-finding and redesign to rectify motor vibration Rob Melaia, Marthinusen & Coutts
14 Keeping ladle cranes moving Nidec Control Techniques
15 Products + services
MEASUREMENT + INSTRUMENTATION 17 On the path to the process Dr Monika Heisterkamp and Dr Andreas Meyer, Endress+Hauser Liquid Analysis
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19 Products + services
TRANSFORMERS, SUBSTATIONS + CABLES 22 Failsafe networking for high-level grid stability Jan Aulenberg, Phoenix Contact Electronics
24 Resolving the ‘trouble’ with RTUs NovaTech Automation
26 Misleading claims on flameproof junction boxes for Zone 0 applications Dr Geof Mood, CCG Cable Terminations
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28 Products + services
Regulars 1 Comment It’s time to pay attention to energy supply on site 3 Cover article Rod sources – a game changer for radiometric measurements? 30 Cybersecurity Will 2022 see more sophisticated cyberattacks? 31 Reskilling The next ICT generation 32 Write @ the back SAICE can assist in ensuring sustainable solutions
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2 Electricity + Control MARCH 2022
COVER ARTICLE
Rod sources – a game changer for radiometric measurements?
R adiometric measurements have been used in industrial processes for several decades. They are an important component in the successful performance of critical level, density and flow measurements. Nuclear measurement gauges work where conventional measuring technology fails. They offer outstanding measurement results under extreme conditions. High temperatures, pressures and other difficult ambient and process conditions are no problem for radiometric measurements. When planning a radiometric measurement, the technical design is fundamental. It is created and developed based on process conditions, process geometry and customer input as well as local background radiation, site conditions, and mounting space limitations. For the design of radiometric level or bulk flow measurements, a choice must be made between two arrangements: a point source with a rod detector, or a rod source with a point detector. Due to the slightly lower purchase price, the arrangement with a point source and rod detector is frequently selected. However, the rod source (especially using Cobalt-60) and point detector arrangement offers decisive advantages in measurement quality during operation. With a rod source/point detector arrangement, less frequent production downtime, simpler and thus more economical spare parts inventory, increased long-term stability, temperature stability and consistent process quality, all contribute to mitigating the higher acquisition costs within a short period of time. Berthold, a global leader in measurement technologies, addresses these advantages comprehensively in a white paper and a webinar.
source which emits gamma radiation. The radioactive material is safely enclosed in a sealed and durable capsule, which guar- antees safe handling – even under extreme measurement conditions. With in-house source production in Bad Wildbad, Germany, Berthold produces the
safest and most secure sources on the market. Customers benefit from the expertise and support the company offers in source design, sizing, handling, and replacement. Rod sources deliver optimum measurement accuracy The custom-made rod sources have the radioactive material distributed across the entire source length as needed, depending on the application, vessel geometry, and detector. For continuous level measurements this improves the linearity of the count rate change at the detector to change in level, when compared to standard point sources, ensuring the highest accuracy with the simplest calibration. More detailed information on this topic is available on the Berthold website where visitors can watch the webinar and download the whitepaper. MECOSA (Pty) Ltd is the sole business partner for BERTHOLD in Southern Africa and has cooperated with Berthold for more than 35 years. □
High-quality radiation sources Radiometric measurement systems require a radioactive
Rod source with activated Cobalt-60 wire.
For more information contact MECOSA. Tel: +27 (0)11 257 6100 Email: measure@mecosa.co.za Visit: www.mecosa.co.za or www.berthold.com/rod-source
Rod source with point detector arrangement.
MARCH 2022 Electricity + Control
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CONTROL SYSTEMS + AUTOMATION
Moving to digitalisation at Tiger Brands
Touching the lives of millions of South Africans over the past century,Tiger Brands produces many of the country’s best known consumer brands including Oros, Energade, Hall’s, Fatti’s & Moni’s, Jungle Oats, All Gold, andTastic Rice. As the organisation embarks on a digitalisation drive, an overhaul of the technology management solutions at its manufacturing plants is required.
T aking a phased approach to the digitalisation rollout, Tiger Brands selected its beverages manufacturing facility in Roodekop, Germiston, some 25 km east of Johannesburg, as the first plant to be upgraded. The immediate challenges were linked to the stability of a legacy control system and the communication network in place. Additionally, the existing control and automation platform had limited capabilities in terms of batching, reporting and the tracking and tracing of materials. Plant upgrade The project involved upgrading the legacy plant control system with the implementation of a combined Siemens WinCC SCADA system and PM (process management) Add-ons, together with the associated network and con- trol equipment which included communication converters, PLCs, VSDs, and ASI modules for various process areas. As the chosen system integrator, Control Systems Integration (CSI) worked with Tiger Brands to execute the project. CSI has extensive engineering experience in the field, including expertise in the food and beverage (F&B) sector. Additionally, CSI’s management team applies industry best practice and professional governance models which are implemented jointly with its team of directors, to
consistent and specific batching to deliver more accurate throughput and quality. Tiger Brands can now adjust recipes in a more robust manner, according to the final specified product in the new environment. This was not possible with the previous control system. Furthermore, the Siemens solution presents Tiger Brands with a manageable OPEX pricing framework providing for a long-term approach in moving Tiger Brands onto the Siemens digitalisation framework. Managing time The project began in December 2019 with the hardware and software procurement phase. It was completed in August the following year with the final commissioning and handover process. Thus the project was commissioned during the Covid-19 pandemic. Commissioning took place in phases as parts of the plant became available using the new Siemens technology. Partnership approach According to Shailen Toolsi, Lead Process Engineer at Tiger Brands, “One of the reasons for the success of this project is the collaboration between CSI, Siemens and Tiger Brands, which brings about efficient technical and sales support. We see a long-term partnership with Siemens going forward.” “We are proud to be building on this partnership with Tiger Brands to demonstrate our expertise through the digital portfolio,” says Claudio Ranaudo, Senior Vice President, Digital Industries, Siemens Southern & Eastern Africa. “The future of the food and beverage industry requires production that is tailored to customer demands. Our F&B solutions provide flexibility and higher productivity and, with customisation at various sites, we can adapt our offering for the specific case as well as the entire industry. We look forward to working further with Tiger Brands to develop solutions that will enable a gateway for its digitalisation projects,” he adds. Recognising the value in the Siemens control system, Tiger Brands is currently implementing the same control system across another site. □
achieve project excellence. The close collaboration between Tiger Brands, CSI and Siemens provided a roadmap to a successful project outcome. Tiger Brands also uses Siemens Totally Integrated Automation (TIA) Portal. This offers the organisation a unified engineering platform and diagnostics for all the associated devices on site. The WinCC SCADA system and PM Add- ons provide enhanced visualisations and product traceability across the whole production line. The system also delivers
The beverages manufacturing facility in Roodekop, Germiston, was the first plant to be upgraded.
For more information visit: https://new.siemens.com/za/en.html
4 Electricity + Control MARCH 2022
CONTROL SYSTEMS + AUTOMATION
Automated inventory management For manufacturers, productivity is a primary goal and it has knock-on effects for resources, operational efficiency and the bottom line. Despite this, a major cause of wasted time continues to be overlooked: poor inventory management. Having the right tool available at the right time is critical for manufacturers. Francis Richt, Global Manager for Sandvik Coromant’s Digital Machining Business outlines how specialist tooling software can help manufacturers improve their inventories and profits.
I n a typical workshop operators can spend up to 20% of their time looking for tools, and about 15% of jobs are re- scheduled or delayed because the right tools could not be found. These findings, based on Sandvik Coromant’s re- search among its own customers, show the extent to which poor inventory management wastes time for manufactur- ers. Inadequate inventory management leads to accumu- lated high-value inventory levels, large volumes of stock becoming obsolete or stock-outs, which often means the inventory is depleted when a certain tool is needed most. Other effects include difficulties in measuring tool perfor- mance, and higher costs for stock management and pro- cessing orders. As a sector so concerned with time, manufacturing should not be wasting so much of it looking for tools and spare parts. One problem is that tool management and tool vending systems remain siloed within many organisations. In addition, most companies rely on people to inspect and replenish their tool cabinets. Many manufacturers are reluc- tant to embrace digitalisation because they are unsure how Industry 4.0 can fit into their established working process- es – like enterprise resource planning (ERP), supervisory control and data acquisition (SCADA) and manufacturing execution systems (MES) – and win the buy-in of workers on the shop floor. Sandvik Coromant has set itself a goal to change this within the next five years – by helping customers automate inventory management through software. In doing so, they can solve issues of poor inventory management in ways that overcome their reluctance to go digital, and benefit the bottom line. Faster production times In its Digital Factories 2020: Shaping the future of manu- facturing report [1] , Pricewaterhouse Coopers (PwC) ob- served that, “the full effect of digitalisation is only realised when companies are connected in real time to their key suppliers and critical customers.” In particular, they are achieving this by using Industry 4.0 devices like sensors on production and assembly lines to capture data in real time for improved analytical capabilities and empowered decision-making. As with supply chain management, this ethos of better data capture can also be applied to man- aging inventories. It’s a challenge because inventory management has many different facets. These include monitoring inventory levels and knowing when new tools need to be ordered, to
The software is designed to help manufacturers optimise tool inventories and profits. ensure production is never at a standstill. One example cited in PwC’s report is the Fujitsu plant in Augsburg, Germany, which uses automated shelf-life monitoring to optimise its inventory levels and prevent stock-outs. According to the report, the facility has “an interim storage facility – its ‘supermarket’ – and self-driving electric vehicles which are integrated into its manufacturing execution system in order to ensure a ‘just in sequence’ delivery of components.” In this case, digitalised inventory management does more than save the company’s time, it supports faster pro- duction times. Better inventory management is not exclu- sive to large multinationals like Fujitsu. With software, small- er or mid-sized manufacturers can also automate their own multifaceted inventory management processes. Adding value to processes Sandvik Coromant’s CoroPlus ® Tool Supply is designed to add value for customers by driving automation with higher efficiency and sustainability enabled by data and insights. CoroPlus ® Tool Supply brings together hardware – specifically, tool storage – and software. The customer is supplied with a purpose-made tool vending cabinet with drawer system which combines with a powerful software platform. This is accessible through a PC or tablet. The automation software offers manufacturers an alternative to doing everything manually, and can avoid incurring a time cost when there is little time to spare. CoroPlus ® Tool Supply
MARCH 2022 Electricity + Control
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CONTROL SYSTEMS + AUTOMATION
User Interfaces (RBUI). RBUIs also happen to be the lat- est trend in ERP software, allowing workers who repeated- ly perform the same tasks to access their frequently-used applications more easily. This can be crucial to winning workers’ buy-in. The Tool Supply platform includes con- nectivity cutting tool data through the CoroPlus offer. This connects with multiple suppliers’ product databases and allows the import of correct tool information, including ISO parameters, bills of materials and spare parts. Along with the CoroPlus ® Tool Supply software, Sandvik Coromant can also provide the cabinets that hold the tools. The company sees automation as being integral to im- proving efficiency and sustainability for its customers. A core aspect of sustainability, and particularly of energy ef- ficiency, is being able to analyse and predict the use of resources including the tool inventory. While Industry 4.0 is benefitting sustainability on the production line with sensors and insights, CoroPlus ® Tool Supply can do the same with inventories to ensure they are optimised in terms of time-, cost- and energy-efficiency. Over the coming years, the company envisages soft- ware like its Tool Supply becoming more widely integral to automation systems and decision-making across the man- ufacturing process. One example is: when planning to ma- chine a new component, the software helps the customer decide which tool to use. Another scenario would see the software more connected to the machine and the scope of work. If the user plans to machine 50 or 100 components, for example, are there enough tools in stock, will they wear out or can the work be completed with the existing inven- tory of tools? Sandvik Coromant sees this kind of automation happen- ing, but manufacturers can already use the software to up their productivity levels. □ Reference: [1] https://www.pwc.com/ca/en/industries/industrial-manufacturing/digital- factories-2020.html
Automated inventory management supports higher production efficiencies and can improve production times. is also designed to handle the many facets of inventory management, such as monitoring levels of inventory and automating tool purchasing. Automated tool purchasing is seen as a major value- add feature. The worker who standardly manually tracks the contents of a tool cabinet can rely on CoroPlus ® Tool Supply to order and replenish that tool stock automatically. The software allows workers to pick and return tools from the shop floor and supports them with the management of restocking and ongoing maintenance of the inventory – all in real time. So people and software work together. The challenge of overcoming manufacturers’ reluctance to go digital is best addressed by highlighting the benefits.
Making better decisions Another feature of CoroPlus ® Tool Supply is its Role-Based
Part of global industrial engineering group Sandvik, Sandvik Coromant is at the forefront of manufacturing tools, machining solutions and knowledge that drive industry standards and innovations demanded by the metalworking industry. Educational support, extensive R&D investment and strong customer partnerships ensure the development of machining technologies that lead and drive the future of manufacturing. Sandvik Coromant owns over 1 700 patents worldwide and is represented in 150 countries.
For more information visit: www.sandvik.coromant.com
CONTROL SYSTEMS + AUTOMATION : PRODUCTS + SERVICES
Emergency stops for automated production lines
Shrouded E-Stop buttons prevent unintentional actuation but still allow easy access for intentional use.
Banner offers a number of variations of its popular Emergency Stop controls with durable protective shroud. The shroud has a sturdy one-piece design which ensures safe and consistent operation for the long term. It prevents accidental user actuation of the E-Stop button, but it does not impede easy access for regular, intentional interaction. The 30 mm and flush-mount E-Stops are supplied with a pre-installed shroud, and panel-mount E-Stop kits are supplied with a shroud attachment. The shrouded designs are available for non- illuminated E-Stop models and those featuring Banner’s
industry-exclusive bright 360-degree illumination. Shrouded E-Stops are adaptable to various automat- ed systems, but they are particularly well suited for: - Material-handling conveyor lines - CPG packaging lines - Automotive assembly lines. For more information contact Brandon Topham at Turck Banner. Tel: +27 (0)11 453 2468 Email: brandon.topham@turckbanner.co.za Visit: www.turckbanner.co.za
6 Electricity + Control MARCH 2022
CONTROL SYSTEMS + AUTOMATION : PRODUCTS + SERVICES
Enabling project collaboration in the cloud
Following the free version of eManage which was made available last year, allowing users to upload, share and manage EPLAN Platform projects in the cloud environment, EPLAN introduced the full version of the software in September, with the release of the new EPLAN Platform 2022. The fee-based expansion stage of the cloud software offers more added value for automation engineering: master data can be accessed in the cloud as can supplementary documents, and performance is increased with additional capacity. Collaboration is at the core of the application, networking OEMs, system integrators, machine builders and operators. Full information access Generally, to date, if a project is shared in the cloud the schematics are visible, but not all the accompanying documentation. With the full version of EPLAN eManage, project stakeholders are provided access to all data and documentation relevant to the project, including bills of materials as well as neutral documents in Excel. These be- come interchangeable with a uniform foundation of data. EPLAN Head of Engineering Solutions, Claas Schreibmüller explains: “The complete overview of customer requirements and project requirements provides more transparency for all stakeholders involved in developing a machine or plant system.” Appropriate rights management ensures that data access can be precisely regulated. Master data available Many people are working from home these days and this is where users often bump up against system limits. While they may be able to access a project, often they cannot access the corresponding master data that is specified as a standard throughout a company for design projects. EPLAN eManage now offers the exchange of system- relevant master data, which can be easily retrieved and, as necessary, taken along according to the ‘pack and go’ principle. Project managers can easily make master data centrally available. Schreibmüller puts it simply:
Collaboration is at the core of the new full version of EPLAN eManage. “Wherever the user works, all relevant master data can be accessed and does not have to be laboriously copied.” Backwards compatibility Particular version requirements in supplier specifications or calls for proposals mean project partners are often faced with the challenge of using several different versions of EPLAN software. With the new version of eManage, projects from the EPLAN Platform 2022 can, as an example, be saved to be backwards compatible, for Version 2.9, for example. This eliminates the need to maintain multiple versions of the EPLAN software without violating contract terms and simplifies the entire workflow in the supplier environment. More storage With the full version of eManage, users gain additional storage capacity in the EPLAN Cloud. This is available to everyone in the company and is an active collaboration environment and not just storage capacity. It enables optimal conditions for global collaboration across national borders. For more information contact EPLAN Software & Service. Tel: +27 (0)11 609 8294
Email: Reyneke.J@eplan.co.za Visit: www.eplan.co.zaCaptions
A low-risk incremental approach to smart manufacturing
Smart manufacturing strategies have been evolving over the past decade among large corporations, and many small and medium manufacturers (SMMs) might not re- alise that these strategies are equally applicable to them and are within reach when implemented in practical steps. MESA, the international Manufacturing Enterprise Solutions Association, has produced a guidebook which looks at how SMMs have been implementing smart man- ufacturing initiatives and seeing the benefits of increased transparency and productivity, as well as the transform- ative benefits of higher levels of coordination and speed within the enterprise and supply chain.
The guidebook is intended for business owners and champions for digital transformation and continuous improvement among operations, engi- neering, quality, and IT staff.
The guidebook can be download- ed from the MESA website. For some MESA memberships it is available free of charge or at a discount. Companies looking to join MESA can do so via the website.
MESA has developed a guidebook to assist manufacturers looking to implement smart manufacturing.
For more information visit: https://mesa.org
MARCH 2022 Electricity + Control
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CONTROL SYSTEMS + AUTOMATION : PRODUCTS + SERVICES
Automation upgrade improves brick quality
A local clay brick manufacturer has upgraded one of its brickmaking plants with assistance from drive and con- trol technology specialist SEW-EURODRIVE. Using ad- vanced digital solutions based on Maxolution for factory automation, a new, optimised plant has been installed for the production of high quality rustic face bricks. “The new plant, which is expected to produce 100 million bricks per year, was built on the back of growth in the local construction industry, which, going forward, is seen as a key sector for South Africa’s economic rejuve- nation and much-needed job creation. “Our client is experiencing significant domestic de- mand and exporting its products into Africa,” says SEW-EURODRIVE Field Service Technician, Juandre La Cock. The rustication process used to make the textured face bricks is a masonry technique that involves cham- fering the edges of a brick to allow the mortar joints to be set back, and texturing face surfaces using a rough- ened roller with blades. The process follows the extrusion of the clay to form the cross-section required, with the bricks being rusticated on three sides, including the front face and both ends. The existing, basic rustication system was producing an unacceptable amount of waste and this led the brick maker, a longstanding client, to seek assistance from SEW-EURODRIVE. “With the introduction of an automat- ed solution we were able to reduce wastage significantly. This has resulted in the brick maker placing an order for another three rustication systems for installation at other operations in its portfolio,” says La Cock. Describing how the problem was solved, he explains that, to produce consistently patterned surface textures, the brick manufacturer needed to be able to vary the speed of the rustication process, to run more slowly or faster according to the viscosity of the clay. The drive units for the rollers also needed to enable the rustication process to match the line speed of the extruder. The solution comprised three servo motors with indus- trial gear units between each, to enable the drive speeds to be changed electronically using SEW MOVI-PLC con-
troller software. Automatic synchronisation of the speeds, varied to match the specific clay conditions and texturing requirements, resulted in a continuous operation produc- ing consistently textured high quality bricks. The automated rustication system was commissioned within a standard delivery time of four to six weeks. The equipment was built in Cape Town at SEW-EURODRIVE’s facility in Montague Gardens. Programming took place at SEW-EURODRIVE’s offices in Aeroton, Johannesburg, where most of the equipment was pre-commissioned to limit downtime and loss of production. As a result, the time required for on-site commissioning of the system was reduced to between two and three days. In addition, the client was supplied with a Drive Operating Panel which enables users to interface with the MOVI-PLC and change the settings as needed, to change over to a new face brick style, for example. As soon as the settings are saved, the line can again be started to produce the modified bricks continuously. Primed for service Most of the equipment installed at the brick manufac- turing operation, from gear units to conveyor belts, is supplied by SEW-EURODRIVE. “As well as our effec- tive solutions, it is our high standards of service that see this client returning time and again,” says Service HOD, Eben Pretorius. SEW-EURODRIVE knows that the need for an ac- celerated turnaround time on service or maintenance is critical for manufacturers, as every minute an opera- tion is left standing idle equates to loss of production. “We pride ourselves on our after-sales support, which includes a 24-hour service hotline, a spare parts service, a repair service and an on-site technician service,” says Pretorius. SEW-EURODRIVE technicians can also login remotely to assist clients with software problems and a field service team is on standby 24 hours a day, seven days a week to assist clients on site if the issue cannot be resolved telephonically. The Maxolution solution for factory automation and customised machine systems, offers clients a single source of innovative 4IR-aligned technologies to meet specific applications and needs. With Maxolution for factory automation, clients can balance the need to keep their future options open to react quickly to market requirements. SEW-EURODRIVE supports smart factory designs that comprise new, flexible, adaptable, modular structures. The company is developing its own R200-million smart component assembly factory in Aeroton. The new 26 000 m 2 building will also serve as the company’s South African headquarters, looking after 23 countries. It is scheduled for occupation this year.
The Maxolution solution for factory automation includes servo drives and PLC control software.
For more information contact SEW-EURODRIVE. Visit: www.sew-eurodrive.co.za
8 Electricity + Control MARCH 2022
CONTROL SYSTEMS + AUTOMATION : PRODUCTS + SERVICES
Integrated development software boosts productivity
OMRON’s updated Sysmac Studio 3D Simulation Inte- grated Development Environment (IDE) with 3D simula- tion integrates and verifies the movements of robots and peripheral equipment. It can digitally reproduce the en- tire facility to verify the operation to the same accuracy as the actual machine. This helps companies to introduce new efficiencies to processes and production capacity. The IDE facilitates design through advance verifi- cation. It uses simulations that meet the need for rapid changes in production sites, shorter delivery times for equipment development, high-precision assembly and simultaneous start-up of production lines at multiple sites. The new Sysmac Studio 3D Simulation can be pur- chased by simply adding optional licences for simulation functions to the Sysmac Studio programming software of OMRON’s flagship NJ/NX Series automation controllers. Josep Lario, OMRON EMEA Product Marketing Manager for Software, IPC and Visualisation, says: “Conventional simulators use dedicated software, which is expensive and requires specialist expertise. If the software is different from the controller, it’s difficult to match the simulation results with the actual machine operation.” Lario adds: “This is the first IDE in the industry to con- trol and verify robots and other peripheral equipment in a single operation. This enhances the efficiency of facility design and shortens the time needed to confirm the pro- duction capacity of the equipment, start-up and modifi- cations.” Main features: - A single software platform for logic, motion, se- quencing, sensing, safety, drives, vision and HMI - Fully compliant with open standard IEC 61131-3 - Supports ladder, structured text and in-line ST pro- gramming with a rich instruction set
switchboxes can be combined with single-acting or double-acting linear actuators or quarter turn actuators and are therefore suitable for diaphragm, globe and diaphragm globe valves as well as for ball valves and butterfly valves. Users can benefit from designs with simple proximity switches or micro-switches, and GEMÜ also offers programmable solutions with 24 V, AS-Interface, DeviceNet and IO-Link interfaces for process automation. Designs with ATEX, IECex or NEC approvals are avail- able for potentially explosive areas. The new automation components enable users to achieve reliable monitoring of the installed valves, espe- cially for plants with strict safety or quality requirements. GEMÜ also supports customers in the automation of their plants in external process environments. The updated software helps meet the need for fast changes in production sites and shorter equipment development times. - Includes CAM editor for easy programming of complex motion profiles - One simulation tool for sequence and motion in a 3D environment - Advanced security function, with 32-digit security password. For more information contact Omron Electronics. Tel: +27 (0)11 579 2600 Email: info_sa@omron.com Visit: www.industrial.omron.co.za
Valve automation for plant control systems
Valve manufacturer GEMÜ is expanding its product range for automation components in the processing in- dustry, introducing new electrical position indicators and combi switchboxes. The new electrical position indica- tors GEMÜ 1240, 1241 and 1242, and the combi switch- boxes GEMÜ 4240, 4241 and 4242 provide for reliable recording of valve end positions, supporting effective process automation – also in potentially explosive areas. An integrated sensor on the GEMÜ electrical position indicators and combi switchboxes records the end po- sition of the process valves and transmits it to the plant control system with a signal. With combi switchboxes, the process valve can also be actuated with the integrat- ed pilot valve. The process valve and automation com- ponents are optimally adapted to each other. The entire system is pre-set and tested, saving users time and effort in logistics, installation and documentation. The new electrical position indicators and combi
Electrical position indicator GEMÜ 1242 und combi switchbox GEMÜ 4242.
For more information visit: www.gemu-group.com
MARCH 2022 Electricity + Control
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DRIVES, MOTORS + SWITCHGEAR
Making the case for an energy-neutral water sector
Expanding water treatment globally is not only a key enabler for creating a better world for humankind, it can also contribute to combatting climate change and reducing carbon dioxide and greenhouse gas emissions. And digitalisation, intelligent automation and efficient drives can play a central role.This was the perspective presented by Mads Warming, Global Head:Water & Wastewater, Danfoss Drives, speaking at the 11th annual Sustainability Summit held as a live virtual event in South Africa last year.
Mads Warming, Danfoss Drives.
W arming said that currently, only about 20% of all wastewater globally is treated, which means around six billion people have access only to un- treated water. The United Nations (UN) Sustainable Development Goal (SDG) 6 defines improvement targets for clean water and sanitation. SDG 6.2 sets the objective of improving the pro- portion of wastewater treated globally from 20% to 60%, by 2030. Achieving this objective would bring with it a multitude of health improvements, and would play an important role in reducing the greenhouse gas (GHG) load. Typically, the key components in water treatment emis- sions are methane (CH 4 ), nitrous oxide (N 2 O) and carbon dioxide (CO 2 ). CO 2 results from the energy consumed, and the term ‘greenhouse gases’ encompasses all three com- ponents. Warming highlighted that: “Perhaps unexpectedly for many, the GHG effect of letting the wastewater escape un- treated into the surrounding environment is far more detri- mental than that of additional energy consumption resulting from new wastewater facilities.” According to the International Water Association (IWA), untreated wastewater running directly into the environment
generates a GHG footprint roughly three times higher than when the same wastewater is dealt with in a traditional wastewater facility. “The good news is we already have the right technology needed to move forward to achieve energy neutrality, and an additional one-third reduction in GHG emissions can be gained by using digitalisation and applying variable speed drive (VSD) control,” Warming said. “Furthermore, VSDs are playing a critical role in helping the water sector to reduce energy usage. And there is an excellent reason for this, as water and wastewater facilities are extremely energy intensive. The International Energy Agency (IEA) states that four percent of all electricity used globally goes towards water and wastewater handling fa- cilities alone. The IEA also says between 30 and 50 % of the electricity bill of a local government authority is typically related to these operations.” The world’s first energy-neutral catchment area With assistance from Danfoss, Aarhus Water, the second largest water service company in Denmark, has succeed- ed in bringing the entire water cycle (drinking water and wastewater) in a local catchment area into energy neutrality. Aarhus Water’s aim was to transform the water treatment facility of a catchment area in the centre of Aarhus – a small borough called Marselisborg, with a population of 200 000 people – into an energy producer, at the same time achiev- ing energy neutrality for the drinking water supply, waste- water pumping and wastewater treatment. Marselisborg is a traditional city area in a relatively flat geographic region, where water supply is based on ground- water, which is on average pumped from 35 m depths, and traditional household wastewater treatment. It has become the world’s first energy-neutral catchment area. The approach adopted by the utility and Danfoss was based on a two-step strategy: Reducing energy consumption throughout the water and wastewater facilities to the lowest possible sen- sible level, and Increasing energy production from the wastewater facility.
With assistance from Danfoss, Aarhus Water in Denmark transformed the water treatment facility of the Aarhus borough of Marselisborg to energy neutrality.
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DRIVES, MOTORS + SWITCHGEAR
condition-based monitoring of equipment such as pumps and fans, based on vibration and load-envelope detection. To illustrate how it works, using the example of a pump: the VSD creates a baseline for power consumption and vi- bration as a function of the pump speed, based on one day, for example, or one week’s operation. Having established the baseline, the VSD can detect anomalies and report them. As well as monitoring power consumption patterns, it monitors motor windings. This condition monitoring func- tionality helps water facilities run more cost-effectively and reduce energy consumption. The VSD also offers other digital functions which con- tribute towards operational efficiencies with a lower GHG footprint. For example, a standard integrated de-ragging function automatically prevents pump clogging. “Digitalisation and control using VSDs have been proven to be key enablers in achieving the goals of reducing wa- ter loss, cutting energy consumption and delivering better quality of water. Danfoss is ready to help by replicating the success of Marselisborg in other cities around the world,” Warming said. □
On the water supply side, energy savings have been obtained by splitting the city into pressure zones, where, based on pressure transmitters and VSDs, pressure is reg- ulated to optimal levels in each zone. This offers a reduc- tion in energy usage and has the added benefit of having brought leakage down to between only six and eight per- cent. The Marselisborg wastewater facility has been upgrad- ed with more energy-efficient equipment and, in particular, with advanced real-time process control based on online sensors. Other key elements include VSD drives on all rotat- ing equipment; carbon harvesting; highly efficient compo- nents (such as bottom aeration and high-speed blowers); and a CHP installation (generating electricity and heat). The experience from this and other facilities indicates that, of all improvements obtained over the years, more than 70% of the energy reduction/improvement is obtained from better process control, through digitalisation, where the VSDs can play a key role. Advanced VSDs support digitalisation With its newest water-dedicated VSD, Danfoss has placed greater support behind digitalisation. Edge computing technologies integrated into the VSD provide intelligent,
For more information visit: www.danfoss.com
DRIVES, MOTORS + SWITCHGEAR : PRODUCTS + SERVICES
Drives can cut energy costs significantly
harsh industrial environments. At the same time, clients are looking for products that are easy to operate and maintain,” says McCree. ABB recently relaunched its ACS580MV drive in the local market, offering higher efficiency, cost-effectiveness, and ease of implementation to the industrial sector, with applications specifically for pumps and fans. Built-in energy calculators, including used and saved
The growing need to reduce energy use and CO 2 emis- sions, and cut operational costs at the same time, is see- ing unprecedented levels of interest in energy-efficient technologies – including low and medium voltage drives – across sub-Saharan Africa, according to power and automation technology group ABB. Drives have significant potential for energy-saving across a range of industries, including power, water and wastewater, cement production, mining, metals and pulp and paper. By controlling the speed and torque of motors, drives can reduce energy usage by between 30% and 50%, significantly improving energy efficiency. Drives can be used to adapt the motor speed to the ac- tual need, which optimises energy consumption and re- duces the environmental impact associated with waste- ful energy use. ABB Product Marketing Manager Sean McCree says while financial decision makers are generally attracted by the potential of drives to save costs and reduce en- ergy consumption, electrical engineers are realising ma- jor benefits through greater network reliability, reduced maintenance demands and increased longevity of me- chanical equipment. “There’s a growing demand for energy-efficient products in the sub-Saharan market; products that take into account the region’s specific requirements, from the voltage level to protection design, to ensure the drives can work optimally in a variety of complex,
ABB’s ACS580MV drive offers higher efficiency, cost- effectiveness, and ease of implementation
kWh, CO 2 reduction and money saved, help users monitor and fine-tune processes to achieve optimal energy use. The ACS580MV is fully compatible with the ABB Ability condition monitoring services, which allow customers to obtain real-time data about the status and performance of monitored equipment from any location. The drive is supplied ‘ready to connect’ to the ABB Ability condition monitoring services, which simplifies on-demand remote support. “Since the launch of the 3.3 kV voltage range, we have seen significant growth in local order intake from existing and new customers. This is a clear indication that the market has realised the product is well positioned to offer value backed by a well-established local service team,” says McCree.
in industrial applications.
For more information contact ABB. Visit: www.abb.com
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DRIVES, MOTORS + SWITCHGEAR
Fault-finding and redesign to rectify motor vibration Rob Melaia, Engineering & Technical Executive, Marthinusen & Coutts In early 2020 a large South African petrochemical company asked Marthinusen & Coutts (M&C) to establish the cause of excessive vibration in a 17 MW 11 kV 4-pole synchronous motor which is used to drive a gas compressor.The investigation process proved intriguing.
T he motor, designed and manufactured by a reputa- ble Europe-based OEM, had been in operation for 13 years. No vibration problems had occurred in the ear- ly stages of its operation, but first became noticeable about five years ago and deteriorated in subsequent years, even- tually becoming so severe that the motor could no longer be used and was sent to M&C for investigation and repair. Resonance anomaly The investigation started with several non-destructive tests, but these failed to indicate the cause of the problem. Subse- quent investigations however showed a resonance anomaly, as the motor’s resonance frequency was found, through spe- cialised resonance test procedures, to be extremely close to the motor’s operating speed, even to the extent of impinging into that range at times – depending on ambient conditions. The originally intended speed range for the motor was 1 200 to 1 500 rpm, and the resonance frequency reading was between 1 200 and 1 300 rpm. This clearly could not have been the intention of the OEM at the time of manufacture, as the resonance frequency of a motor is required to be well clear of its operating speed. In addition, the resonance frequency is supposed to be higher than the motor’s rated speed, which would have meant it should be around 1 800 rpm or more.
While conducting the investigations and tests that revealed this irregularity in the motor’s resonance frequency against its operating speed, M&C also identified during testing a looseness of the stator core supports to the main stator enclosure, which should not be present in a healthy motor. The next step was to remove the inspection covers of the motor for a close examination of the stator and its support structure to the main enclosure. A key discovery was find- ing that the OEM had applied a highly unorthodox method of fixing the stator to the main frame. Instead of following the normal procedure of employing a heat-shrink interfer- ence fit to bond the complete outer diameter of the stator to the frame, the OEM had used about eight small, welded brackets for this purpose. We deduced that the OEM, having discovered that the required resonance frequency could not be achieved if the stator was firmly fixed to the frame in the normal way, installed the brackets instead, as a more flexible way of doing this for the express purpose of changing the resonance frequency to ensure it would not coincide with the motor’s rated speed. Fortunately, the motor had never been operated under its originally intended variable speed capability. The measure that was applied failed to fix the resonance frequency higher than the motor’s speed range, but it at least achieved the necessary objective of fixing the resonance frequency sufficiently below the rated speed so as not to cause operational problems. A machine design fault We deduced further that the OEM’s failure to achieve the desired resonance frequency by means of the proper fixing procedure was due to a design flaw in the motor. The meth- od the OEM had adopted to circumvent this problem had, however, revealed its shortcomings over time. An additional discovery we made during our investiga- tions into the problem was that there were cracks in the sup- port structure between the stator and the main frame. We deduced that the cracks in the support structure – which, as noted above, consisted of the small welded brackets used as an improvised solution to address the resonance problem the OEM had apparently encountered during manufacture – had been caused by the welds of the brackets having been subjected to excessive strain during years of operation. We then carried out the necessary repairs to return the
Main motor frame/ enclosure
Gap between stator core and main frame
Welded support of stator to main frame
Stator core frame
Stator winding overhang
In this close-up view of a portion of the stator core fitted into the main motor enclosure, one of the welded connections as modified by M&C can be seen on the left.
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DRIVES, MOTORS + SWITCHGEAR
motor to service. These had to be done with the customer’s express permission, since they were of necessity a com- promise – as was the case with the original manufacture of the motor. We welded new sections on the stator support structure, because we could not access many of the cracked sec- tions to weld them. After re-assembling the motor we ver- ified that the vibration had improved substantially but the resonance frequency was consequently located very close to the rated speed, due to the increase in stiffness we had added to the structure. On our test base we proved that with the resonance located lower than running speed no problems would occur on site, since the site base is more flexible than our test base. An offbeat add-on solution This being a compromise solution, we could not provide a 100% guarantee of reliability on the work done. The client asked if any further measures could be taken to assure a full guarantee of successful operation first time on site. In response we offered an offbeat add-on solution which, when tested and proven effective, enabled us to provide, with confidence, the assurance the client sought. The add-on solution entailed providing a made-to- measure removable 7.5 tonne mass of steel temporarily fitted onto the top of the motor. This mass further reduced vibration of the motor and lowered its resonance frequency by a small but sufficient margin to guarantee correct
Chargehand Alwyn de Bruin monitors the final tests on the 17 MW motor at M&C’s large motors test facility in Cleveland, after completion of repairs to the motor’s stator. operation on site. It was made removable because the customer wanted first to try running the motor without this additional measure. The success of our investigation and repairs was demonstrated when the motor was put into service after an unplanned breakdown. It operated with lower vibrations than it had operated at for over a decade – and this without the 7.5 tonne mass added! □
For more information visit: www.mandc.co.za
DRIVES, MOTORS + SWITCHGEAR : PRODUCTS + SERVICES
Innovation and growth in drive technology
Drive specialist NORD DRIVESYSTEMS continues on its course of growth. With innovative new products and com- prehensive investments – the largest to date in the com- pany’s history – it saw a close to 18% increase in sales for 2021, compared to the previous year. Additional advanced drive solutions are planned to be brought to market in 2022. Last year, the family-owned company based in North Germany launched four products that set new standards in the sector. The patented DuoDrive marks a new milestone. As an innovative geared motor which integrates the high-efficiency IE5+ synchronous motor into a single-stage helical gear unit housing, it sets new standards in terms of efficiency, installation space and version reduction. The new decentralised NORDAC ON frequency inverter and the additional sizes for the IE5+ synchronous motor and the NORDAC PRO SK 500P control cabinet inverter have been developed with the focus on customer benefit and energy efficiency, and ensure significant performance improvements in their areas of application. With the cancellation of most trade fairs in 2021, these new products have been presented only in digital form. In 2022, NORD DRIVESYSTEMS an- ticipates opportunities to stage live presentations. Last year, the company invested primarily in locations
The high-efficiency portfolio from NORD includes: the NORDAC ON frequency inverter, the integrated geared motor DuoDrive and the IE5+ synchronous motor. and logistics. Additional facilities were brought into opera- tion in Germany, Poland and the USA, and the starting sig- nal was given for a new production plant in China. Com- pletion of a new administration building at the company’s headquarters in Bargteheide is planned for this year. During 2021 NORD DRIVESYSTEMS also increased the number of employees in the NORD Group to around 4 700 and continued to focus on providing reliable support to customers, finding solutions, building its worldwide pres- ence and diversification across industries and regions. For 2022, the company is looking to grow further and to develop more new products in cooperation with its cus- tomers. For more information contact NORD DRIVESYSTEMS. Visit: www.nord.com
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