FEATURES: Industry 4.0 + IIoT Drives, motors + switchgear Sensors + switches Plant maintenance, test + measurement
Italian Craftmanship. Built to Pump. Priced to Flow.
WELCOME TO THE FUTURE OF SERVICE AND REPAIR OPENING SOON!
This 17 000m 2 state-of-the-art service and repair facility will allow for an expansion of our service and repair capabilities encompassing product repairs, fabrication, light engineering and motor rewinding and repairs. This R380-million investment into the economy will also house our expanded training centre, the DriveAcademy ® , providing crucial skills and training to the South African workforce.
INNOVATIVE CAPABILITIES
SEW-EURODRIVE's service and repair centre's capabilities includes sandblasting, spray painting, oil recycling, product stripping and load-testing.
We have introduced the in-house manufacturing of baseplates and guards, drop-in solutions, light engineering and 3D scanning.
Our motor repairs division will allow for motor assembly and rewinding, curing burnout ovens and rotor balancing
DRIVING SERVICE AND REPAIR. DRIVING AFRICA. DRIVING THE WORLD
COMMENT
The value of digitalisation in operational efficiency O ver the next couple of months, I need to travel from the far west of this planet, and then to the far east of this planet. and needs far less central processing for it to be useful in optimising, controlling and monitoring actual plant performance.
Naturally, I assume that the pilots are alive to the state of the planet and, in particular, that they are aware of what goes on in the ‘middle’ of the planet… This does get one thinking of auto pilots – and of brilliant old movie scenes. But enough of that. One of the topics in this month’s edition of Electricity + Control speaks to the evolution and digital transformation of industry. Of course, much of this has been ongoing over decades, and it reminds me again that it is helpful to distinguish between what some folk still insist on calling a revolution and what it seems most folk recognise as a transformative process. Industry 4.0, for instance, is not a revolution! It’s a process – slowly and steadily becoming more pervasive as we have witnessed over the past few decades. It can be thought of in much the same way as we used to think about energy eiciency. I recall when in this magazine we first highlighted the growing importance of energy eiciency, few in the industry then had the insight to appreciate the various pressures that were building – from the true cost of energy to why it was important to use less simply as a principle aligned to the survival of the species. One day you wake up and everything has changed! The plant’s processes no longer rely on analogue signals, and the processing power for the plant is distributed all over the place – it is no longer in one humming box with a heat haze surrounding it. Intelligence has become distributed to the point where even sensors have significant computing power, and the transmission of data has almost been replaced with the transmission of information. Information is processed data
I am aware that not all industry has been digitally transformed. But as you prepare for the journey, make sure you do not think of the process as any kind of a revolution! Revolutions are generally surprising, and generally people get hurt during them. I accept that some folk may well have been surprised by the transition from analogue to digital – and now to even more exciting intelligence-based systems – but the fear of getting hurt can be somewhat o-putting. As a heads up: many industries only realised the importance of focusing on energy eiciency when the cost of energy began to escalate. That is, frankly, too late. But it is true that increased costs of production are a very strong motivation to rethink the way you operate. Simply, the need for digital transformation in all operations is critical when you consider the costs of production – and the costs of having useful information on which you can base decisions to optimise your processes. Now is the time to consider what you might be missing by not looking at the next key steps to optimise your business and your plant. It is worth noting that progressive digital transformation can link every process in your business together – allowing for seamless sharing of information across the various activities. Later we will consider the impact of artificial intelligence…
Bearings International supplies premium pump solutions designed to enhance eiciency and performance in industrial operations.
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The views expressed in this publication are not necessarily those of the publisher, the editor, SAAEs, SAEE, CESA or the Copper Development Association Africa
MAY 2026 Electricity + Control
1
CONTENTS
FEATURES
INDUSTRY 4.0 + IIoT 3 Partnerships to scale next generation AI infrastructure Siemens Smart Infrastructure 4 Products + services News from Beckhoff, ABB, Schneider Electric, Seacom, Troye and Vertiv DRIVES, MOTORS + SWITCHGEAR 10 The Vyeboom pump station upgrade A case study from ElectroMechanica 11 Products + services News from Marthinusen & Coutts and Referro Systems SENSORS + SWITCHES 14 Products + services News from VEGA, Valmet, Vaisala, and Ametek LMS PLANT MAINTENANCE, TEST + MEASUREMENT 18 Maintenance training boosts uptime WearCheck 20 Protecting Africa’s power systems Mohamed Hosseiny, Hitachi Energy Africa 22 Smart ICCP monitoring for safer tank storage Ian Loudon, Omniflex 23 Products + services News from Becker Mining, Doble, G-Chem Aquacare, Instrotech, PPCL, and more
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REGULARS
1 Comment
The value of digitalisation in operational efficiency
28 Reskilling, upskilling + training Skills and sustainability – enabling a cleaner petrochemical industry Investing in young talent to develop artisans 30 Engineering the future Progressing South Africa’s green hydrogen potential 31 Write @ the back Eskom shares its 2026 Winter Outlook
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2 Electricity + Control MAY 2026
Industry 4.0 + IIoT
Partnerships to scale next generation AI infrastructure
A s AI drives unprecedented demand for data centre capacity, the industry faces a growing challenge in aligning rapidly expanding compute infrastructure with available power. To address this, Siemens Smart Infrastructure is expanding its data centre ecosystem through strategic investment in and partnership with Emerald AI, alongside the integration of Fluence battery energy storage solutions, and collaborative physics-based AI modelling with PhysicsX. Together, these capabilities create flexibility across compute, energy, and infrastructure systems, helping data centre operators connect to the grid faster, scale eiciently, and operate reliably in a power-constrained world. “Scaling AI infrastructure is as much a computing challenge as it is an energy and infrastructure challenge,” said Ruth Gratzke, President of Siemens Smart Infrastructure US. “As demand for AI processing accelerates, data centre growth is increasingly constrained by grid capacity and interconnection timelines. Addressing this requires complex coordination across the digital and energy domains. Siemens is investing in key technologies and partnerships to expand the ecosystem required to scale AI responsibly and support the next generation of data centre infrastructure.” Managing AI workloads dynamically Emerald AI enables AI workloads to shi¡ in time and location to align with grid conditions, allowing data centre demand to respond dynamically to available power. By coordinating when and where AI workloads run and dispatching on-site energy resources, this approach helps smooth peak demand, achieves faster and larger grid connections for data centres, and reduces pressure on constrained power infrastructure. Siemens’ strategic investment in Emerald AI strengthens its ability to introduce flexibility at the compute layer. Combined with Siemens’ expertise in power infrastructure and operational technology, this
can turn power-constrained locations into viable data centre sites and accelerate time to power, which can enable deployment of energy storage in months, rather than years of grid upgrades. Fluence’s en- ergy storage solutions can also provide dispatchable, on-site power which can enable data centres to operate during grid build-outs, ca- pacity shortfalls, or outages. By supporting consistent power quality and flexible scaling, Fluence can help data centre operators bring ca- pacity online faster while maintaining the reliability required for mis- sion-critical AI workloads. Strengthening this ecosystem further, Siemens is collaborating with PhysicsX to apply physics AI to the design and operation of data centre power distribution systems. Using AI models trained on Siemens’ multi-physics simulation data, engineers can predict thermal behaviour in complex busway systems in real time. With PhysicsX, simulations that once took days can run in under a second, enabling faster design iteration, optimised infrastructure for dynamic AI workloads, and providing a foundation for predictive monitoring across facilities. Physics AI enables faster design, optimised infrastructure The rapid growth of AI will continue to place new and o¡en highly dynamic demands on power systems, with large training and inference clusters creating rapidly shi¡ing loads that challenge traditional grid planning and data centre design. As a result, operators must find new ways to manage these demands while maintaining the performance and reliability required for AI infrastructure. Siemens’ expanded ecosystem is designed to help address this challenge by bringing together AI workload orchestration, grid-integrated energy systems, and AI-optimised physical infrastructure to support the next generation of AI infrastructure.
For more information visit: www.siemens.com
creates true IT/OT convergence between AI workloads and power systems. Energy storage solutions on-site A further key element of this ex- panded ecosystem is the addition of Fluence’s grid-scale energy storage solutions, designed to support the next generation of high-performance AI data centres. As compute clusters grow in size and density, Fluence energy stor- age solutions enable data centres to accelerate grid connection by shaping load and coordinating ramp rates, making large AI-scale demand more predictable and easier for utilities to approve. This
Building an ecosystem for next-generation AI infrastructure.
MAY 2026 Electricity + Control
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Industry 4.0 + IIoT: Products + services
Converged physical infrastructure for NVIDIA AI factories WRITE @ THE BACK
er, cooling, and controls - and optimise performance from grid connection through chip-level thermal management and heat-re- use pathways. Vertiv’s contribution is grounded in its ability to bring together one of the industry’s most comprehensive portfolios of critical power, thermal management, integrated controls, and lifecycle services into a cohesive, converged physical infrastructure. In contrast to conventional modular or prefabricated approaches that primarily compress schedule, converged physical infrastructure is intended to deliver fast deployment and compounding system-level gains. By standardising interfaces and creating repeatable building blocks, Vertiv aims to support more scalable AI factory execution, and enable improved performance, eiciency, and reliability. “As AI factories scale to unprecedented levels of power and density, enterprises require a converged approach to physical infrastructure that unifies power, cooling, and digital twin simulation to reduce deployment risk,” said Vladimir Troy, Vice President of AI Infrastructure at NVIDIA. “By integrating simulation-ready infrastructure models into the NVIDIA Vera Rubin DSX design, Vertiv is providing the repeatable building blocks and validated interfaces necessary to accelerate the path from design to operational readiness.” This collaborative output, Vertiv™ OneCore Rubin DSX, is a design outcome grounded in converged physical infrastructure that Vertiv will continue to iterate for multiple compute generations ahead. It is intended to support AI factory builders with parameterised infrastructure models and deployment-ready building blocks that span power, cooling, controls, and lifecycle services. Vertiv expects this work to inform future converged infrastructure oerings across hyperscale, colocation, enterprise, and emerging AI deployment environments. References [1] https://nvidianews.nvidia.com/news/nvidia-releases-vera-rubin-dsx-ai- factory-reference-design-and-omniverse-dsx-digital-twin-blueprint-with- broad-industry-support [2] https://www.vertiv.com/en-emea/products-catalog/facilities-enclosures- and-racks/integrated-solutions/vertiv-onecore-prefabricated-hybrid-built- data-center/
In March, Vertiv announced (alongside other leading industry players) that it is participating in advancing converged physical infrastructure designs for the NVIDIA Vera Rubin DSX AI factory reference design [1] and the NVIDIA Omniverse DSX Blueprint. As AI factories scale in density, complexity, and power demand, operators are under pressure to compress time to deployment, improve infrastructure use, and reduce integration risk. A new infrastructure design approach that reduces complexity, improves confidence before build-out, and accelerates time to capacity is now available to meet these evolving needs. Through its work with NVIDIA, Vertiv is contributing simulation-ready, or DSX SimReady digital power and cooling assets, validated interfaces, and repeatable infrastructure building blocks designed to help customers deploy AI factories faster and with greater operational assurance. This work reflects an expansion of Vertiv’s established approach to converged physical infrastructure – a system-level model that integrates power, cooling, controls, and services into interdependent designs optimised across the full power train and thermal chain. This approach is enabled through five foundational elements: repeatable building blocks, defined interfaces, system orchestration, digital continuity, and lifecycle support. Together, these elements support more scalable AI factory execution by helping reduce design complexity, strengthen coordination across infrastructure domains, and improve confidence from initial design through deployment and operation. At the core is a scalable building block architecture designed around the standardised 12.5 MW infrastructure blocks of Vertiv™ OneCore [2] integrated modular solutions that can be combined, configured, and extended to support deployments ranging from smaller AI clusters to gigawatt-scale AI factories. By establishing repeatable block-level designs with validated interfaces, Vertiv aims to simplify scaling and, in parallel, improve deployment consistency, system coordination, and operational performance. “AI factories are forcing a fundamental change in how digital infrastructure is designed, validated, and deployed,” said Scott Armul, Chief Product and Technology Oicer at Vertiv. “Vertiv’s role is to help turn complex AI infrastructure from a collection of separate products into converged, simulation-ready physical systems. Working with NVIDIA, we are helping customers move faster from design to deployment. By combining our power and cooling portfolio with validated interfaces and digital models, we can help customers accelerate development.” Vertiv’s collaboration supports
For more information visit: www.vertiv.com
the development of digitally validated AI factory infrastructure using real-time simulation and system-level modelling before physical deployment begins. This approach is designed to help customers: - reduce deployment com- plexity and field integra- tion risk - accelerate time to opera- tional readiness - improve infrastructure coordination across pow-
Through its work with NVIDIA, Vertiv is contributing simulation-ready digital power and cooling infrastructure models to help customers deploy AI factories faster and with more assurance.
4 Electricity + Control MAY 2026
Industry 4.0 + IIoT: Products + services
Processing data at the Edge
Edge computing offers speed, efficiency and resilience in today’s industrial automation solutions.
Hennie Smith, Solution Architect, Industry Automation at Schneider Electric, sees industrial automation as one of the most exciting solution frameworks in industry today. With data volumes growing exponentially, developers are working to deliver technology that can keep pace with industry requirements. A key element of today’s solutions is Edge I/O NTS (input/output Network Terminal Slice) which represents an evolution of computing from centralised servers to localised, device- level input/output processing, oering improved speed, eiciency and resilience. However, Smith says Edge I/O NTS is based on years of industry development, with its roots going back to the 1980s when personal computers and local area networks (LANs) allowed some distributed processing. Fast-forward to the 2010s and billions of devices started generating data. Sending all of it to the cloud became impractical, and this led to edge computing architectures where processing happens locally. Today, Edge I/O NTS manages sensors, machines and IoT; moving intelligence closer to where value is created: on the shopfloor and at the machine level. Rather than sending vast amounts of raw data to distant control rooms or cloud platforms, computation can happen at the source. This oers the key benefit of enabling immediate, context-aware decisions without the latency associated with centralised systems. From centralised control to decentralised resilience The rapid growth of connected devices has exposed the weaknesses of monolithic control systems. Centralised systems create single points of failure, while decentralised architectures distribute intelligence and risk. Edge-enabled systems can continue operating even when connectivity to higher-level platforms is disrupted, ensuring continuity and stability. Furthermore, Edge I/O NTS allows for improved cybersecurity, as distributed intelligence means threats can be isolated and managed locally rather than compromising entire operations. With Edge I/O NTS, intelligence is embedded directly into I/O systems allowing for faster decision making. In practice, local processing allows operators and systems to respond to anomalies
instantly. Autonomous fault detection and self-correcting mechanisms improve uptime, and dynamic optimisation of energy use, throughput and quality enhances overall performance. Importantly, these capabilities are not dependent on constant connectivity to the cloud or central control rooms. Even in remote or challenging environments, edge-enabled devices maintain core functionality, ensuring safe and eicient operations irrespective of external conditions. While products may dier, Schneider Electric’s Modicon Edge I/O NTS solutions share a common set of characteristics: - Interoperability allows for seamless integration with legacy op- erational technology and modern IT platforms, which ensures continuity and enables innovation - Scalable architecture allows systems to grow in line with opera- tional needs, avoiding future constraints - AI-ready frameworks support predictive analytics and machine learning - Remote management capabilities reduce the need for on-site interventions and support more agile maintenance strategies. The IT/OT convergence An important development in the evolution of Edge I/O NTS is the convergence of IT and OT. For example, today, unified data models enable operational insights to flow seamlessly into enterprise systems, improving visibility across the entire value chain. Standardised protocols also reduce complexity and support plug-and- play integration, and aligned cybersecurity strategies ensure consistent protection across both domains. Looking ahead, edge-enabled systems will continue to reshape industrial performance. Plants will become more agile, adapting dynamically to operational and market changes and autonomous operations will handle routine decisions. Embedded cybersecurity and transparent data governance will set new standards for digital trust, and real-time optimisation of energy and resources will support sustainability and decarbonisation goals. Edge I/O NTS with its built-in intelligence supports industry advances where human creativity and machine autonomy co-exist to deliver resilient, eicient, and sustainable operations.
For more information visit: www.se.com
MAY 2026 Electricity + Control
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Industry 4.0 + IIoT: Products + services
Extending IXP access to underserved areas WRITE @ THE BACK
and performance, regardless of geographic location. “This launch is about fundamentally rebalancing access to South Africa’s digital infrastructure,” said Prenesh Padayechee, Group Chief Technology & Operations Officer, Digital Infrastructure at Seacom. “Seacom PeeringReach gives networks in local municipalities a more cost-effective way to connect into the national peering ecosystem, helping them improve performance and, at the same time, keep connectivity costs under control.” Improving efficiency, simplifying network operations A key benefit of Seacom PeeringReach is its dedicated Layer 2 design, which eliminates the inefficiencies associated with indirect, multi-hop routing paths. By enabling more direct access to Internet Exchanges, the service improves traffic efficiency, predictability and overall network performance. It enables growth through simple provisioning rather than construction, significantly reducing cost and time to market. “ PeeringReach is about connectivity via an affordable enablement platform,” said Padayechee. “We are helping regional networks scale faster, operate more efficiently, and participate more affordably in the digital economy. By levelling the playing field for regional networks, Seacom PeeringReach improves national traffic efficiency, resilience and digital inclusion,” he said. The service supports bandwidth options from 1 Gbps to 10 Gbps without requiring major infrastructure investment. The introduction of Seacom PeeringReach reinforces the company’s role as a national interconnection enabler, extending exchange access to areas that historically have been underserved.
Seacom has launched PeeringReach , a cost-effective Layer 2 connectivity solution designed to extend South Africa’s Internet Exchange (IXP) fabric into local municipalities and regional hubs, addressing the high costs and complexity traditionally associated with accessing national exchange connectivity. Delivered over Seacom’s national long-distance fibre backbone, Seacom PeeringReach provides reliable, SLA-backed access to South Africa’s leading Internet Exchanges, including JINX, CINX, DINX and NAPAfrica. The service offers a simpler, more affordable alternative to indirect routing via upstream providers or large-scale infrastructure investments, helping customers
Prenesh Padayechee, Group Chief Technology & Operations Officer, Digital Infrastructure at Seacom.
connect directly to the IXP ecosystem.
Broader exchange access at a lower cost Historically, gaining access to South Africa’s peering ecosystem often required indirect connectivity paths or significant investment in national infrastructure, creating cost and operational barriers for networks operating in smaller towns and municipalities. Seacom PeeringReach removes these barriers by extending exchange access into local and regional areas through a single, integrated Layer 2 service. By making exchange connectivity more accessible and affordable, the solution enables ISPs, regional carriers, enterprises and content providers to improve network efficiency Cloud complexity is suffocating growth Helen Kruger, Managing Director of IT solutions and ser- vices provider Troye, says South African businesses are reaching a breaking point as AI adoption, cloud native development and distributed workloads are accelerating faster than traditional infrastructure can cope. Gartner last year [1] outlined key trends expected to shape the future of cloud computing indicating that it would consolidate its
For more information visit: seacom.com
businesses can achieve. Through Private Cloud, Hybrid Multi Cloud, and strategic consultation, Troye helps organisations move beyond simply hosting data towards platforms that actively ena- ble transformation. Private Cloud provides a secure and controlled foundation for critical workloads, delivering predictable performance and gov- ernance without sacrificing agility. Hybrid Multi Cloud extends that foundation, allowing workloads to move seamlessly across environments to meet performance, cost, and compliance needs. Some industry reports [2] show 87% of organisations now op- erate multi-cloud environments, and 72% embrace hybrid cloud strategies that blend private and public clouds. Through its stra- tegic consultation services, Troye ensures these environments are aligned with business outcomes, so technology decisions support long term growth rather than short term fixes. Kruger emphasises that modern applications demand flexibili- ty and consistency. Enterprises are expected to support traditional virtual machines as well as cloud native containerised workloads. Nutanix addresses this challenge with a unified platform that runs applications consistently across private and public clouds. Independent evaluations [3] highlight Nutanix as a leader in multi-cloud container platform capabilities, noting unified man- agement, hybrid deployment options, and governance – critical for modern distributed workloads.
role as the primary driver of AI enablement, drive multi cloud expansion and digital sover- eignty strategies. Yet, Kruger says, many or- ganisations remain weighed down by fragmented tools and operational silos that inflate costs and stall innovation. For businesses looking ahead, the issue is no longer whether to move to the cloud, but wheth- er their current environment is agile enough to compete. Troye’s cloud solutions are designed to unlock new pos- sibilities by simplifying infra- structure and expanding what
Continued on page 8
Troye Managing Director, Helen Kruger.
6 Electricity + Control MAY 2026
Industry 4.0 + IIoT: Products + services
40 years of PC-based control – today a global standard At Hannover Messe this year, Beckho highlighted the value that PC-based control has brought to the manufacturing industry, how it has evolved, and the advantages it continues to deliver. When Beckho elevated the industrial computer to the status of a central control system four decades ago, a paradigm shi¡ occurred. For 40 years, PC-based control has been putting the power of IT standards and Moore’s Law directly into the hands of machine and system engineers. With the bundling of PLC, motion control, and technologies such as measurement technology, robotics, and vision on a single integrated platform, users today benefit from outstanding performance combined with significant cost and space savings.
place via Lightbus. Introduced in 2003, EtherCAT has since become a global standard that is today deployed by users across all industries and markets. In parallel, the TwinCAT automation environment – which marks its 30th anniversary this year – provided the basis for the so¡ware. Since its market launch, TwinCAT has developed into a holistic solution: it combines all automation functions in a single integrated so¡ware platform. In addition to classic logic and motion control, the spectrum includes safety and measurement technology, HMI, and IoT connectivity, as well as image processing, robotics, and industrial AI tools. The optimum synchronisation of all processes via the PC-based controller gives users significant advantages, in terms of dynamics and precision, for example. More scalability, fewer interfaces In applications today, PC-based control provides exceptional scalability and a reduction in interfaces. Company founder and Managing Director, Hans Beckho sums it up: “A high-performance industrial PC, an equally powerful fieldbus interface with peripheral devices such as sensors and actuators connected to it, and control so¡ware with real-time capabilities for motion and logic control – that’s all it takes.” This approach provides the capability to consolidate all machine functions – from a simple PLC to highly complex robotics – into a single controller. As well as saving space, time, and money, this eliminates latency between distributed controllers. In line with the Beckho philosophy, the company has been developing and manufacturing all electronic assemblies and motherboards itself in Westphalia since the 1980s, to the highest quality ‘made in Germany’ standards. This oers users security and long-term availability and enables them to continue implementing the latest IT standards and processor generations in machine building. Basis for physical AI Four decades a¡er the launch of PC-based control, the industry is increasingly turning away from proprietary black box solutions and focusing on the future viability of open, standardised systems. PC- based control technology provides an ideal basis for the required IT/ OT convergence as well as for leading technologies such as machine learning and physical AI. As it reaches its 40th anniversary, PC-based control provides a future-ready and high-performance foundation for the manufacturing industry.
In the 1980s, industrial production was characterised by the classic, hardware-based PLC. The PLC was considered reliable, but on the downside, it was inflexible and expensive, with limited computing power. In 1986, Beckho responded to these limitations by delivering the first PC-based machine control system, which gave the target application – a double mitre saw – a significant boost in productivity. Separation of PLC and hardware The decisive technological step was the abstraction of the PLC function from proprietary hardware to a highly flexible solution based on industrial IT components. Beckho ensured deterministic behaviour by developing its own real-time extensions for standard operating systems – mainly Windows initially, but also others since then, including TwinCAT/BSD and Linux®. Machine builders were thus able to benefit directly from the rapid innovation cycles in IT and increasing processor performance. In the 1980s, for example, PC-based control brought floppy disk drives directly to the machine. Later, Ethernet communication opened up new possibilities in production and for integrating production into databases, ERP systems, and IoT solutions. Today, PC-based control forms the basis for physical AI in the factory. High-speed communication Appropriate I/O systems were required in order to use the ever-increasing computing power of industrial PCs up to field level. Beckho therefore flanked PC-based control with its own communication systems. Initially, data transmission took
For more information visit: www.beckhoff.com
For 40 years, PC-based control technology has laid the technological foundation for all Beckhoff automation components and solutions.
MAY 2026 Electricity + Control
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Industry 4.0 + IIoT: Products + services
ABB’s latest DCS release supports modernisation without disruption
improve lifecycle eiciency, and enable secure, future-ready opera- tional environments. Major updates are outlined below. - Version synchronisation and online upgrades for a more streamlined and predictable system-wide upgrade experi- ence, reducing engineering eort and minimising operation- al disruption. - Support for the latest Microso¡ operating systems and mul- tiple virtualisation platforms enables multi OS deployment, simplifying lifecycle management across modern IT/OT envi- ronments and enhancing long-term sustainability. - Enhanced OPC UA connectivity provides secure, standards based interoperability, ensuring seamless data exchange and readiness for evolving digital architectures. - Advanced device management with Field Information Man- ager (FIM) accelerates device onboarding, improves diag- nostics, and streamlines maintenance of instruments. - Expanded system-wide connectivity enables the use of addi- tional Virtual Plant Network Interfaces to optimise commu- nications and reduce system footprint. - Seamless evolution from Harmony Rack to SDe Series, sup- ported by automated conversion tools, allows customers to preserve prior intellectual investment. With these upgrades, SPR2025 delivers a more flexible, interopera- ble and secure control environment engineered to help industrial op- erators modernise their systems to meet the demands of tomorrow’s automation.
ABB has introduced SPR2025, the latest Symphony® Plus distributed control system (DCS) package to enable modern- isation and eicient performance in the process and power industries. This release supports upgrades for existing instal- lations and new deployments. SPR2025 helps modernise industrial operations quickly and eiciently, upgrading existing Harmony Rack-based sys- tems without disruption, or deploying the latest automation innovations for new projects. Online upgrades, enhanced OS and virtualisation support, powerful conversion tools, and a clear evolution path allow customers in industries such as power, water, oil & gas, pharmaceuticals and pulp & paper, to implement improvements at their own pace, ensuring con- tinual reliability and minimal risk. Symphony Plus delivers stronger communications perfor- mance and strengthens data integration across distributed operations. With system-wide OPC UA, ethernet backbone, and support for smart field devices using the latest FDI (Field Device Integration) technology, operators benefit from se- cure, standardised, and interoperable connectivity, enabling connection of dierent devices and platforms. The inclusion of ABB’s Automation Extended functionality enables Symphony Plus customers to adopt advanced auto- mation and digital technologies without disruption. By separating control and digital environments, customers can deploy system performance monitoring, advanced an- alytics, and AI-based decision support applications progres- sively, while maintaining the reliability and security of core control processes. “SPR2025 advances our com-
For more information visit: new.abb.com/process-automation
mitment to help customers mod- ernise without disruption, at their own pace and protecting their existing investments,” said Stefan Basenach, Senior Vice President, Process Automation Technology, ABB. “With online upgrades and enhanced digital connectivity, this secure, scalable and future-ready release empowers customers to operate more eiciently today and prepare for the next wave of indus- trial innovation.” Key enhancements intro- duced in the SPR2025 release strengthen system performance,
The latest release of ABB’s Symphony ® Plus Distributed Control System includes Automation Extended functionality, enabling innovation while maintaining core system reliability.
Continued from page 6
an increasingly demanding digital landscape. References [1] https://www.gartner.com/en/newsroom/press-releases/2025-05-13- gartner-identifies-top-trends-shaping-the-future-of-cloud [2] https://www.cdwg.com/content/cdwg/en/articles/cloud/ why-you-need-unified-approach-hybrid-multicloud-management.html [3] https://virtualizationreview.com/articles/2025/07/30/red-hat-suse-and- nutanix-lead-multicloud-container-platform-research-report.aspx
Cloud innovation has moved beyond chasing trends to building an adaptable foundation that absorbs change without disruption. Troye partners with organisations to design and implement cloud strategies that replace frag- mentation with clarity, and limitation with opportunity. Combining modern platforms like Nutanix with deep expertise in Private Cloud, Hybrid Multi Cloud, and strate- gic consultation, it enables businesses to run applications anywhere without chaos, and to grow with confidence in
For more information visit: www.troye.co.za
8 Electricity + Control MAY 2026
Industry 4.0 + IIoT: Products + services
Multi-touch panels for all applications
The Beckhoff multi-touch Panel portfolio offers the right device for every application and performance requirement. Different display diagonals and protection classes can be combined with different connection types, from the slim CP-Link 4 control panel to the panel PC with an Intel ® Core™ i7 CPU at the heart of the central control system. If the scalability of the standard portfolio is not sufficient, Beckhoff multi-touch Panels can have a custom logo or customized push button extension added to them from a minimum order quantity of 1. Beckhoff multi-touch Panels also provide the ideal basis for creating an entirely customer-specific design. 9 different diagonals from 7 to 24 inches classic and contemporary aspect ratios: 4:3, 5:4, and 16:9 push button extensions and various mechanical extensions can be combined available as a passive control panel or panel PC highest power density – for example, with an 11 th generation Intel ® Core™ i7 available as built-in devices or for integration directly on the mounting arm with a wide range of mounting options
Beckhoff Automation (Pty) Ltd Randburg 2169, South Africa Phone: + 27 (0)11 795 2898 info@beckhoff.co.za
Scan here to find out more about the multi- touch application spectrum
MAY 2026 Electricity + Control
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Drives, motors + switchgear
The Vyeboom pump station upgrade Vyeboom Irrigation Board operates one of the region’s largest pump stations, drawing from the Theewaterskloof Dam, near Villiersdorp in the Western Cape, a key source for regional, agricultural irrigation. A planned upgrade of the pump station raised a diicult question: how to modernise while safeguarding ongoing supply. In this case study, ElectroMechanica (EM) sets out the approach adopted and the success achieved.
approach that adds cost in most irrigation systems. The result was limited resilience during grid outages.
Ineicient pumping Operating a mix of pump sizes on a shared line made flow optimisation challenging. Instead of maximising flow, energy was lost in turbulence, meaning more power was used without delivering more water. The solution What turned a complex upgrade into a workable plan was not a single specification but a coalition that knew where its responsibilities overlapped. The irrigation board carried the pressure of keeping crops watered on time, supported by a consulting engineer who carefully evaluated technical and financial factors. On-site support was provided by system integrator WJ Cotter, who was responsible for installation and PLC/SCADA integration. Bridging disciplines To support them, partners stepped in with complementary expertise. EM’s engineers in Cape Town and Johannesburg tested electrical assumptions against the hydraulic redesign commissioned from a leading pump manufacturer. At the same time, WJ Cotter handled site integration and controls, ensuring the upgrade meshed with day-to-day board operations. That study confirmed that larger, more eicient pumps could be matched with medium voltage drives to work in step rather than at odds with each other. When scheduling challenges arose near the end of the shutdown window, EM helped keep the project on track by holding the equipment. Closing eiciency gaps Delta’s role was equally critical. Its MVF2000 drives, each rated for 800 kW and configured to take 11 kV input while delivering 6.6 kV output, replaced the station’s step-down transformers and closed a long-standing eiciency gap. With more than 96% eiciency, low harmonic distortion, and tolerance for the voltage disturbances common in South Africa, the upgrade delivered technical assurance and operational resilience. The integration ensured the drives were embedded into the control environment seamlessly, giving the board confidence in everyday operation. “The MVF2000 drives are proven worldwide, but at Vyeboom, it was EM’s local support and expertise that made sure they delivered real results for the board,” said Sergey Zubov, IABG Country Manager (CIS), Delta Electronics. Moving forward with confidence A site visit to a previous EM project allowed the board and the consulting engineer to see medium-voltage drives in operation – and that progressed the discussion from specifications to practical outcomes. They observed smooth starts and stops, spoke directly with operators, and confirmed how the technology
It was clear that the Vyeboom pump station needed an upgrade, but it needed to be completed within a narrow shutdown window to ensure farmers would have reliable water when the season opened.
T he decision was not simply about equipment. The upgrade was about ensuring farmers would have water when the season opened. The irrigation board faced a narrow shutdown window, a station operating under demanding conditions, and two very dierent options. So¡ starters were the familiar choice in medium-voltage systems, and drives carried the perception of added complexity. On paper, the drives promised smoother starts, lower energy use, and generator compatibility, but the board needed more than a specification sheet. They needed confidence that the upgrade would deliver reliably when it mattered most. The challenge The upgrade had to be completed within the short seasonal shutdown. Missing that window would have delayed the project by a year and extended the risks to infrastructure and supply. Equipment wear and downtime Traditional starting methods placed a significant load on the pumps, as is common in long-serving stations. Bearings and seals wore out faster, increasing the need for more frequent maintenance. Breakdowns raised the risk of interrupting water deliveries during critical periods. Water hammer also damaged valves, reducing their service life by half and driving up replacement costs. Limited backup options Pumps of this scale draw high current on start-up, even when fitted with so¡ starters. This made the use of generators impractical without significantly oversizing the sets, an
10 Electricity + Control MAY 2026
Drives, motors + switchgear
Looking ahead TheVyeboomprojectdemonstratedthatlastingprogressininfrastructure depends on collaboration as much as on hardware. It’s about building the confidence to change what already works, to make it work better, and that confidence comes from collaboration. Boards, consultants, suppliers, and engineers each brought their own perspective, and connecting those perspectives turned risk into momentum. For farmers, the outcome was reliable water when it was needed. For the irrigation board, it was confirmation that modernisation can be approached with confidence. And for the partners involved, it was evidence that independent expertise, when combined, can deliver outcomes greater than the sum of the parts. For the Vyeboom Irrigation Board, this modernisation has become a reference point. Acknowledgements to ElectroMechanica for permission to republish this article in Electricity + Control . For more information visit: www.em.co.za
performed under real conditions. The visit helped strengthen confidence in the decision to proceed with the upgrade. By the time the drives were commissioned for the Vyeboom pump station, the project was no longer seen as a risk but as a proven, long-term solution. As well as delivering new hardware, the project reinforced confidence in modernisation, built step by step through independent expertise, shared accountability, and operational proof. The outcome When the new drives finally started the pumps, the first dierence was obvious. Starts and stops were smooth, water hammer was gone, and farmers could count on water without interruption. But the bigger change unfolded in some unexpected ways. At Vyeboom, the board gained renewed confidence in modernisation. Seeing the system work in practice gave them the confidence to plan similar upgrades across their other stations – decisions that, only months earlier, had seemed out of reach.
Drives, motors + switchgear : Products + services
Refurbishing a 15 MW wound rotor induction motor
This challenging 15 MW stator and rotor rewind project for a platinum mine represents a significant achievement in motor refurbishment and demonstrates Marthinusen & Coutts’ capabilities in adhering to industry standards and ensuring meticulous attention to detail. The project was awarded to Marthinusen & Coutts (M&C), a division of ACTOM, in late November 2024. It involved a comprehensive overhaul of a motor that had been in service for over 18 years and the contract was awarded to M&C due to the company’s proven, successful repairs and its intricate knowledge of the design of these 15 MW motors. The primary objective of the rewind project was to restore the motor to its original high standards – as when it was initially manufactured. This goal required a thorough scope of work, including: - Rewinding the stator and rotor, incorporating steel binders into the rotor windings – a complex and diicult task to execute - Overhauling the brush gear compartment and installing new brushes - Re-insulating the slip rings with new insulation material - Installing new heat exchangers - Conducting sha¡ repairs and fully refurbishing the white metal bearing assemblies - Dynamically balancing the rotor - Skimming the stator feet and pedestal bearings - The complete assembly of the motor - Finally, a no-load test run was performed, and the motor was repainted to complete its restoration. Technical challenges and solutions The rewind process proved challenging, especially concerning the use of steel binders on the rotor. M&C engaged an expert cra¡sman with 35 years of experience in fitting these complex components. The project’s complexity required precautionary
measures during critical stages, including the burnout, coil manufacturing, VPI (Vacuum Pressure Impregnation), and curing cycles, as well as balancing to ensure the rotor met a tolerance of G 0.4. In selecting materials for the rewind, M&C, in consultation with its international insulation experts, chose a comprehensive insulation solution. Project management and compliance To keep the project on schedule, M&C adopted a proactive approach, although some delays occurred due to the complexities of the VPI processes. The project management methodology included clearly defined hold points, as requested by the customer. M&C’s Quality Control department communicated regularly with the customer, providing updates when hold points were ready for inspection. Safety was a top priority throughout the rewind process. Marthinusen & Coutts restored the 15 MW motor to its original high standards.
Continued on page 12
MAY 2026 Electricity + Control
11
Drives, motors + switchgear: Products + services
One drive, ten motors: rethinking medium-voltage motor control
and mechanical stress that typically plague traditional motor starting methods. In practical terms, the benefits are substantial, says van Wyk. So¡er acceleration reduces torsional stress on sha¡s, couplings and driven equipment, in turn extending asset life and reducing maintenance costs. Pressure surges are avoided in continuous processes such as pipeline compression and fans and pumps experience fewer process upsets and less unplanned downtime. Overall, this contributes to significant energy savings for equipment driven by the variable speed drive. Fewer assets, lower lifecycle costs By consolidating motor starts into a single drive system, industrial organisations can reduce capital and operating expenditure significantly. In some applications, customers have reported up to 80% fewer drives required compared to traditional systems. As well as lowering upfront costs, reducing the number of drives simplifies maintenance and spares management. It creates a cleaner, more manageable automation environment with intelligence built in. Additionally, the PowerFlex 6000T with Synchronous Transfer Bypass integrates into various modern digital architectures through networked connectivity, enabling direct communication with control systems. This connectivity supports predictive maintenance, enhanced diagnostics and improved visibility into motor and process performance. Operational resilience and flexibility The PowerFlex 6000T with Synchronous Transfer Bypass features dedicated variable-frequency drive input and output cabinets, individual per-motor bypass sections (which also serve as emergency direct online starters should they be required), line reactors and controls, all coordinated through a centralised control system. This design enables secure, seamless handover between variable-speed and fixed-frequency operation via dedicated buses. It supports a highly resilient motor control system that protects the process and the equipment. Well suited to mining, water, wastewater, oil and gas, concentrated solar plants and utility infrastructure industries, the PowerFlex 6000T with Synchronous Transfer Bypass is designed to perform in the most demanding industrial environments.
For South African industries facing rising energy costs, constrained capital budgets and increasing pressure to improve uptime – a review of how they start, control and protect large motors in their plants can make a dierence. Adrian van Wyk, CEO of Referro Systems, says a new approach to medium-voltage motor control allows several high-power motors to be managed using a single medium-voltage variable speed drive. This delivers significant reductions in capital expenditure, footprint and system complexity, without compromising reliability. Referro Systems, as a local distribution partner for Rockwell Automation, has introduced the PowerFlex® 6000 medium-voltage ac drive with Synchronous Transfer Bypass (STB) for use in mining, water, utilities and heavy-processing operations across South Africa. According to van Wyk, the solution represents a step change in medium-voltage motor control design, particularly for sites that have a number of large motors operating in unison. Conventional medium-voltage motor control systems typically rely on individual drives or starters for each motor. Although eective, this approach can be capital intensive, space consuming and complex to maintain – especially in applications such as pumps and fans, where motors are o¡en started one at a time rather than simultaneously. The PowerFlex 6000T with Synchronous Transfer Bypass addresses this challenge by enabling up to 10 motors to be started and synchronised across the supply line using a single medium-voltage drive. The system supports combined currents of up to 3 000 A, with a maximum of 680 A per motor, across voltage ranges from 2.3 kV to 11 kV. Once any motor in the system reaches operating speed it is synchronised to the fixed-frequency bus, and the drive is automatically freed to start the next motor in sequence, should the process require this. This architecture reduces the number of variable speed drives required across a site yet still delivers all the benefits of variable speed control during continuous speed requirements – smooth start-up, acceleration and deceleration control delivered by one variable speed drive. Smoother starts, longer equipment life The Synchronous Transfer Bypass technology is core to the solution. It ensures that voltage, frequency and phase are precisely matched during the transfer from variable-frequency operation to fixed-speed operation and vice-versa. The synchronous transfer enables a smooth, bumpless transfer. It eliminates the inrush current spikes, voltage dips Continued from page 11 Senior operators and technicians carefully supervised testing and li¡ing procedures, ensuring compliance with industry standards and regulations. Compliance with various testing standards – established by the International Electrotechnical Commission (IEC) and M&C’s internal standards – was maintained throughout the project. Eective coordination with the customer was maintained by compiling weekly progress reports and holding regular meetings that adhered to the outlined project timeline.
For more information visit: www.referro.co.za
Notably, the customer engaged an independent third-party specialist to verify and sign o on all hold points, further enhancing the project’s transparency and credibility. M&C’s dedication to quality workmanship and customer satisfaction is unwavering. It extends the lifespan of these 15 MW machines successfully and, as an expert in this field, it oers repair solutions for customers.
For more information visit: www.mandc.co.za/
12 Electricity + Control MAY 2026
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