Electricity + Control September 2019

FEATURES: · Control systems + automation + systems engineering · Drives, motors + switchgear · Energy management + environmental engineering · Plant maintenance, test + measurement · Sensors, switches + transducers

COMMENT

ON THE COVER

A closer look at the unemployment figures

T he other day I found myself engaging a colleague about what seemed, on first reading, to be very, very bad news about jobs losses in South Africa. The unemployment rate had increased from 27.6% to 29% – devastating information by any account. However, what was emphasised to me was that the actual number of people in employment had, in fact, risen by 21 000 over the same period. Admittedly a drop in the ocean – but a drop, nevertheless. And, more people were identifying themselves as actually wanting work, including almost a quarter of a million people who had, previously, been ‘discouraged work seekers’. This resulted in that observed percentage change. Now this is significant – seeing those people putting themselves back into the equation and actively seeking employment. Do they see something that we do not? At the same time, the manufacturing sector is still under enormous pressure which is impacting upon large swathes of industry covered by readers of Electricity+Control . What was even more significant was the jobs that are emerging in the informal sector – rising by a massive 114 000. Again, this is significant. It speaks to people stepping up and finding that niche where they are able to make a living.To me that is a trend to be seriously encouraged. Similar arguments relate to the whole area of job losses associated with automation and new technologies. Make

no mistake, jobs are on the line just about as fast as efficiency improves. The challenge is to identify those areas where new skills are needed and where people can continue to make real impact. Let’s be clear: repetitive or dangerous jobs are going fast; routine jobs (which may well include those routine activities of many rather high-profile professions – such as diagnosing common ailments or dishing out legal advice…) are going to go fast; but non-routine and creative roles will begin to grow, as will the need for new technology related skills. We simply have to be preparing people for that, staying ahead of the wave as it approaches us – and then riding it. The cautionary note is that it is probable that we will not be able to reskill people as fast as their current roles become redundant – a crisis that will need thoughtful management. I am convinced that the rise in jobs in the informal sector is partly due to necessity, but equally due to the courage many are now finding to seek out the need in the market and serve that need.

FEATURES: · Control systems+ automation+ systems engineering · Drives,motors+ switchgear · Energymanagement+ environmental engineering · Plantmaintenance, test+measurement · Sensors, switches+ transducers

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CONTENTS

Features

DRIVES, MOTORS + SWITCHGEAR 4 Maximum positioning flexibility with six degrees of freedom Beckhoff Automation

7 Round UP

PLANT MAINTENANCE, TEST + MEASUREMENT 12 Smart condition monitoring supports increased productivity Mitsubishi Electric, Europe

12

14 Round UP

25

ENERGY MANAGEMENT + ENVIRONMENTAL ENGINEERING 20 Hybrid power solutions gain traction in mining Arthur Tassell, Editor: Modern Mining 23 What does the new Carbon Tax Act mean for industry? Zadok Olinga, SAEEC Nirvasha Singh and Gillian Niven, Webber Wentzel 25 Siemens Midrand microgrid demonstrates energy savings Siemens South Africa

27 Round UP

CONTROL SYSTEMS, AUTOMATION + SYSTEMS ENGINEERING 30 Artificial intelligence in industrial manufacturing Omron Industrial Automation

33 Round UP

SENSORS, SWITCHES + TRANSDUCERS 36 Ultrasonic sensors at work in challenging applications Instrotech

30

38 Round UP

Regulars 1 Comment 11 Cover article 39 Cyber security 40 Write @ the back

2 Electricity + Control

SEPTEMBER 2019

DRIVES, MOTORS + SWITCHGEAR

Maximum positioning flexibility with six degrees of freedom With planar movers that float freely to any position over floors of planar tiles that can be arranged in any kind of pattern, the ground-breaking XPlanar system from Beckhoff offers boundless potential for streamlining production machine and plant design.

Take Note!

1. The movers travel to processing stations, and into them, and they can turn, rotating the payload they’re carrying through all three axes so that it can be processed or inspected from any side. 2. The system’s highly flexible positioning capabilities make it particularly suitable for use in sectors with special requirements in hygiene and cleanability, zero emissions or lownoise – in the food processing and pharmaceuticals industries, for example. 1 2

S tefan Ziegler interviewed Uwe Prüßmeier, Senior Product Manager Drive Technology at Beckhoff Automation, discussing the unique value proposition of a system that can position movers precisely, dynamically and with exceptional flexibility. Based on the principle of flying motion Like the XTS linear transport system, XPlanar is much more than a drive system – it’s a comprehensive solution designed to make product transport extremely flexible. Compared to XTS, XPlanar adds movement in a second dimension and allows the movers floating over floor tiles to overtake one another and to be held in buffer zones or to bypass them. The free-floating planar movers also have a further important advantage: because of the contactless drive principle, they are silent and completely wear-free. Functionality Basically, a transport system simply moves products from one processing station to the next – from A to B, then from B to C, from C to D, and so on. With XPlanar, these stations need neither be in a linear arrangement nor visited in a fixed sequence. This means that a given product need only travel to those stations that are essential for processing it. By incorporating the second dimension, XPlanar opens up several other options too, including the ability to discharge individual movers from the production flow or to create special waiting zones in order to optimise processing sequences. Enabling faster movers to overtake slower movers is also important as it allows sub-processes to be executed swiftly, in parallel. Not only is each planar mover controlled individually, as a single servo

axis, it can also be synchronised precisely with other movers if necessary.

Six degrees of freedom The movers travel to processing stations and can also move into them. They can turn, too, rotating the payload they’re carrying through all three axes so that it can be processed or inspected easily from any side. The movers can also be raised or lowered slightly and even tilted. A little tilt, for example, can be useful to prevent spills when accelerating quickly while carrying a container full of liquid. Simple set-up Right at the start of the development process, the Beckhoff team decided it was important that the system should be highly integrated and that users would only have to plug in two cables – one for data communication over EtherCAT G and another for power supply. As a result, all other functionality has been fully incorporated into the modules. Design-wise, they are also extremely compact: the distance between the working surface of each planar tile and the carrier frame beneath it is just four centimetres (4 cm). Choosing individual planar components The system builds on one basic component, a planar tile measuring 24 by 24 cm. The tiles can be arranged in any floor or track layout. In addition to this standard tile, there will be another version in the future, identical in shape and size, over which planar movers can rotate through a full 360° – that is to say – infinitely. The movers available differ only in terms of their size and therefore their load- carrying capacity. They currently range from 95 by 95 mm, for payloads up to 0.4 kg, through to 275 by 275 mm, for a maximum payload of 6.0 kg.

Uwe Prüßmeier, Senior Product Manager Drive Technology, Beckhoff Automation.

4 Electricity + Control

SEPTEMBER 2019

With the XPlanar system, planar movers float freely over planar tiles that can be arranged in any layout.

TwinCAT software for ease of use The main objective is to make sure that users find the planar motor system easy to manage. In TwinCAT, the planar movers appear as simple servo axes, capable, in principle, of supporting all six degrees of freedom. However, given that the degree of flexibility available with six axes is not always needed from a practical perspective – or, at least, not throughout the XPlanar system – TwinCAT provides a way to reduce this complexity. It does this by representing each mover as a one- dimensional axis capable of optional additional movements in other dimensions – lifting, tilting and turning, for instance – that are available when it reaches a processing station. This means it’s enough, initially, to just set the desired route or track across the XPlanar floor; this simplifies operation significantly. TwinCATTrack Management A key factor in XPlanar’s exceptional flexibility is that its ability to transport products is not confined to the single tracks. Users can define additional tracks and movers can switch between them. To keep things simple, even when operating multiple tracks, TwinCAT offers Track Management, a user-friendly tool designed to support complex motion sequences, including the ability to overtake slower movers on the same track or to accumulate movers in waiting zones. To do this, it allows users to define parallel lanes, bypasses, or tracks to other plant areas on the XPlanar floor. Track Management lets movers switch smoothly from one track to another via a short parallel segment. All this takes is a ‘switch track’ command, without users having to deal with the specifics of merging in and out of the flow or avoiding collisions. Movers can also be positioned with complete freedom, without having to follow any pre-set tracks. Using Track Management, they are simply sent to specific coordinates within the defined XPlanar floor space – again, without any risk of colliding with other movers.

The planar tiles can be laid out in rectangular floor areas (right) or in free application-specific configurations (left).

Building the XPlanar floor Here, too, flexibility is front and centre.The tiles can be arranged in any shape – and even wall- or ceiling- mounted – so the XPlanar system can be configured to suit a given application’s requirements. For instance, users can leave gaps within the tiled floor to accommodate processing stations or lay tracks around plant components. This means users can set up a transport system in a cost-optimised way and, at the same, reduce machine size to a minimum. In addition, it’s easy to modify the planar motor system subsequently, just by adding more tiles when necessary – to accommodate new processing stations, for example, or gain extra space to optimise motion through curves. Putting innovation to work XPlanar opens up new avenues in machine and system design. Beckhoff found that users need to experience the system’s new possibilities hands-on in order to grasp them. At the launch, potential users were offered easy-to-use starter kits.These consist of six or twelve planar tiles installed on a carrier frame, along with four movers and a small control cabinet with an industrial PC, complete with pre-installed software, and the requisite electrical components. This offers machine builders an ideal basic kit with which to trial XPlanar in their own environments and

“XPlanar opens up entirely new avenues in machine building with its combination of capabilities – contactless product transport, two-dimensional positioning and additional movements in the third dimension.”

Electricity + Control

SEPTEMBER 2019

5

DRIVES, MOTORS + SWITCHGEAR

All images: Beckhoff Automation.

Movers can be positioned easily, with complete freedom and collision-free, in waiting zones (1 to 3) or in processing stations (1 to 8).

sort all the chocolates, which would be costly in terms of time, floor space and throughput rate. The problem can be solved much more efficiently using individually controlled planar movers operating on a single floor. Movers transporting individual chocolates could easily sort themselves at the end of the production line according to the chocolates’ particular shade of colour. Or, if movers were designed to carry an entire box at once, each mover could automatically travel to the system ejection point for the appropriate colour of chocolate, to pick up the products. Both of these approaches could be implemented much faster and with lower space requirements than, for example, the robot solution mentioned. Beckhoff has also received specific enquiries from the laboratory automation sector where there’s considerable interest in maximising the flexibility of analyses. For the most part, samples are tested for the same substance content, but less common analyses also need to be carried out for the purpose of individualised diagnostics. Even with mass analysis methods, XPlanar offers a great way to extract individual samples. It also creates additional quality assurance advantages by making it easy to discharge or exchange particular samples. There’s similar demand in the cosmetics industry too. For example, in one case, fragrances need to be filled into selectable, customer-specific bottles that are individually labelled and packaged. The main difference is that the XPlanar movers don’t need a mechanical guide rail so the system offers greater flexibility in terms of movement. At the same time, though, the mechanical guidance in XTS can be an advantage: compared to the magnetic counterforce of the planar movers, a guide rail allows significantly better dynamics and higher speeds in curves, especially in very tight curves, and even when carrying a payload. The specifics of a given application will determine which of the two systems is the better option. XPlanar and XTS complement each other. How do the XPlanar and XTS systems differ?

Planar movers can follow a variety of tracks across the XPlanar floor; they can also switch from track to track.

then use later in real-life applications. In addition, this kind of preconfigured system makes it easier to deal with questions and answers. Engineering applications There are almost no limits on using the XPlanar system with production plants and machines. The only requirement is that a product’s weight and volume are within the limits of what the planar movers can carry. Where this applies, users can benefit from all the system’s highly flexible positioning capabilities. These are particularly interesting in sectors with special requirements in terms of hygiene and cleanability, zero emissions or low noise. This is the case in the food and pharmaceuticals industries as well as in laboratory environments or processes that require a vacuum (in semiconductor production, for instance). The latter two sectors in particular can benefit from the fact that products are carried on floating movers, abrasion- and contamination-free. Depending on the needs of a given application, users can also apply plastic, stainless steel foil or glass plates to the XPlanar surfaces to make them easy to clean without leaving a residue. XPlanar was first exhibited at the SPS IPC Drives show in Nuremberg, Germany, in November 2018. The exhibit attracted considerable interest among visitors; it also spawned further ideas for possible applications because many users have been looking for a flexible solution to solve specific transport problems in their production facilities for years now. In the food processing industry, for example, in the production of high-quality confectionery there are always minor deviations in the colour of chocolate coatings. This is not a problem as such, provided there’s no variance within individual boxes of chocolates. However, at a production rate of 100 chocolates per minute, selecting ten individual chocolates with the same colour for each pack is difficult using conventional means. It would require using several pick-and-place robots to check and

XPlanar: Planar mover technical specifications ▪ max. speed: 4 m/s ▪ max. acceleration: 20 m/ s2 (without payload) ▪ four available sizes: 95 x 95 mm, 155 x 155 mm, 155 x 275 mm and 275 x 275 mm mover thickness: 12 mm max. payload (largest mover): 6 kg (at low speed) max. levitation height without payload: 5 mm max. levitation height with 1 kg payload: 1 mm max. angle of rotation (±): 360°, ±15° max. angle of inclination: 5° ▪ ▪ ▪ ▪ ▪ ▪

6 Electricity + Control

SEPTEMBER 2019

round up

DRIVES, MOTORS + SWITCHGEAR

Motor protection and detecting cable theft

information, including when the alarm was activated and how long it took for someone to respond. The system needs to be re- set at the location of the alarm in order to confirm response by security.When the re- set function is activated, the unit logs the date and time of the response.” The protection system works on 220 V or 110 V power and can also be used to monitor cable without power. A battery backup for SMS communication provides backup power for up to eight hours. Proloc and ProBeck electronic relays for motors (380 V, 400 V, 525 V, 950 V and 1 100 V – 3.3 kV and 6.6 kV) provide for thermal overloadprotection, earth insulation lockout, frozen or vacuum contact failure and earth leakage protection. Other use- selectable features include short circuit, frequency and power factor meas urement as well as minimum load, over voltage and under voltage protection. Becker protection relays are also used to control pumps and motors based on water levels, valve position, temperature sensors, time of day and moisture content of the soil. They can detect dry run in boreholes, tanks and dams and can be programmed to re-start pumps automatically after a specified time or at a set level.

A key safety feature is the door- mounted infra-red link that enables a laptop, with Proloc software, to be used to manage all settings and downloads so personnel do not have to open the panel door and expose themselves to dangerous live equipment. Enquiries: Becker Mining South Africa. Tel: +27 (0)11 617 6300, or email: info@za.becker-mining.com Proloc and ProBeck low voltage electronic protection and control relays provide for motor protection and can detect cable theft.

Becker Mining South Africa’s Proloc and ProBeck electronic protection and control relays are designed for motor protection and to detect cable theft.They can be used in diverse industries, including mining and quarrying, electrification, water and wastewater, chemical, petrochemical and general engineering, as well as municipalities. Nico de Lange, Vice President: Operations & Systems at Becker Mining South Africa says, “Becker’s low voltage relays, which incorporate advanced technologies to provide dependable protection of electric motors used on pumps, fans, conveyors and compressors, can also be used as highly effective stand-alone cable protection systems, to guard against cable theft. The relays are programmed to detect cable theft by identifying a change in impedance of cable, up to 1 100 V, connected to a motor or pump. “In the event of cable tampering, the unit sends an SMS or activates an emergency alarm or siren. The system can provide SCADA visualisation and communicate relevant information to a control room via an existing PLC. “It can log up to 1 400 events with real time and date and providing critical

Electrical switchgear for mining mill expansion

Gauteng based JB Switchgear Solutions was recently awarded a contract for the design, manufacture and supply of a range of electrical switchgear equipment to Gold 1 – New Kleinfontein Gold Mining Company’s Mill Expansion Project at its Modder East operations. The scope of the contract included a number of 525V-rated containerised motor control centres (MCCs), an 11 kV containerised switchboard and extension panel, as well as power and lighting transformers. In this instance, JB Switchgear’s popular Eagle series panel design was used for the 525 V MCCs. It is a robust, user-friendly system that carries IEC 61439-1/2, SANS 1973-1 and IEC/TR 61641 certification, and over 30 000 tiers have been installed on sites around the world. Starter sizes ranged between 0.55 kW and 75 kW and variable speed drives ranged from 45 kW to 200 kW. The project essentially includes a new ball mill, a new elution plant and an extension of the existing carbon-in-leach (CIL) plant. The 11 kV ball mill motor is rated at 3.3 MW.

Enquiries: Johan Basson at JB Switchgear Solutions. Tel: +27 (0)11 027 5804, or email: info@jbswitchgear.co.za

The contract included supply of a number of 525 V-rated containerised motor control centres.

Electricity + Control

SEPTEMBER 2019

7

round up

DRIVES, MOTORS + SWITCHGEAR

Multi-mount electric motors

The Bauer motor range from BI is available in various energy efficiency ratings, from IE1 as standard and IE2 high efficiency, through to IE3 and even IE4. “We are standardising on IE1 motors and are looking at IE2 as a standard option as well, although this is still in the pipeline,” Hiepner says. The multi-mount motor range, being cast iron, is particularly robust and therefore ideal for the tough operating conditions of

Traditionally, cast iron electric motors cater only for top-mounted terminal boxes. This is set to change with the industry’s first multi- mount cast iron motor available from leading supplier BI. The latest multi-mount cast-iron Bauer electric motor range from BI can accommodate the terminal box on the top, left-hand or right-hand side. A major benefit for customers is that it

reduces the need for multiple stockholding to accommodate different terminal box positions. Cast iron electric motors are available in a wide range, from 0.37 kW up to 400 kW, and BI has previously catered only for top-mounted terminal boxes. BI Bauer Electric Motors Product Manager, Lewis Hiepner, explains: “Some plants have top, left-hand or right-hand terminal boxes, and this makes it complex and costly to stock all three.” BI itself would order whichever variant was required ex-factory, with a normal lead time of about 14 weeks.

mining operations, among others. Hiepner says BI has received significant interest in the new Bauer motors – for their versatility, robustness and in view of their energy-saving potential.

A member of the Hudaco Group, BI is a leading distributor of bearings and power transmission products in Southern Africa. Enquiries: BI.Tel: +27 (0)11 899 0000,

email: info@bearings.co.za or visit: www.bearings.co.za

BI has introduced the first multi-mount cast iron electric motor in the industry.

Pump repower project for mine dewatering

control panel, exhaust muffler, and base frame. The power unit offers consistent power for pumping water, smooth operations, easy maintenance, efficient fuel consumption, and a reliable product that can work with the fuel quality in the region. The cooperation of the Ghana technical team and AME Pump segment team demonstrates how the combined expertise of the project team resulted in a product that met the customer’s expectations and requirements. “The plan was to give the customer not just an engine, but a complete pump power pack. Initially, the customer requested one engine for trial, but after seeing pictures of the complete power pack, it increased its order to seven engines, which we have supplied,” says Cobbah. Despite the technical challenges faced at the outset, the project has diversified Cummins’ product coverage on the mining site and in the West Africa territory. Customers now have more options for their pump-engine solutions.

collaboration with the on-site service support team, Account Manager and West Africa Territory Manager, combined their expertise to carry out the repowering of five dewatering pumps for BCM at a Goldfields site in Tarkwa, Ghana. The dewatering pumps are used for pumping water in a 24-hour dewatering mine pit. Before the repower, the customer had experienced product failures and support challenges. When Cummins was approached for product options, Joshua K Cobbah, Regional Leader for Cummins Ghana West, says the initial plan was to provide a ‘like-for-like’ engine option to replace the existing electronic engine, from another supplier, that powered a Sykes water pump. “At first we considered a QSX15 electronic engine for the repower,” Cobbah says, “but after thoroughly reviewing the customer’s requirements and expectations of product reliability and equipment uptime, the final strategy was to provide an NTA855 mechanical engine.” The NTA855 mechanical engine is a fully-packaged ’plug-and-play’ power unit, consisting of the engine, cooling pack,

Mining site operations are extremely demanding and dewatering pumps need to run continuously to remove groundwater to allow non-stop mining. Early this year, the Cummins Ghana technical team, in

Enquiries: Deepa Rungasamy, Cummins Africa Middle East. Tel: +27 (0)11 589 8512

The dewatering pumps are used for pumping water in a 24-hour dewatering mine pit at the Tarkwa site in Ghana.

8 Electricity + Control

SEPTEMBER 2019

round up

DRIVES, MOTORS + SWITCHGEAR

Reducing complexity in panel design A leading low-voltage electrical distribution system designed to reduce the complexities often associated with panel design is available from ElectroMechanica (EM), specialist supplier of high-end industrial electrical products, motor control switchgear and electronic automation products. Quadro+ from Hager combines modularity with familiar low-voltage (LV) components to simplify the design of professional distribution solutions. EM Product Manager, Christo van Rensburg, says, “The Quadro+ modules include assemblies, equipment and accessories required to build a complete enclosure, with IP30 or IP55 protection levels up to 4 000 A. This is a tried-and-tested international solution.” The Quadro+ system is designed around a rigid frame that offers adaptability, ease of assembly and quick build times, along with quality components. EM can offer customers complete solutions. When customers partner with EM, they can design and build a complete LV electrical distribution system suited to their requirements. The Quadro+ system includes support of essential third-party products like Socomec changeover switches, Lovato motor control and metering, Delta variable speed drives and automation products, with little additional effort. “This gives customers a single point of contact for all their needs and significantly simplifies the complexity associated with completing projects on-time,” says van Rensburg. EM offers a comprehensive range of enclosures, from a two-way surface enclosure to 168-way flush or surface distribution boards. IP65-rated enclosures are also available. While this range is suitable for residential and small commercial buildings, the Quadro+ system is tailored specifically for the larger commercial and industrial markets. “Selecting Quadro+, you opt for a fully-tested LV electrical distribution solution that has continually proven its worth in different industries. Quadro+ is manufactured in Italy, to exacting IEC and EN-62439-1&2 standards in respect of safety, performance and reliability,” van Rensburg highlights. The rigid structure (IK10 and IP55) of the enclosures provides for extra durability. Cabinets are shipped flat-packed to save on transport and storage costs. Only eight screws are needed to assemble the frame and all the screws are pre-mounted for a hassle-free and quick turnaround time. “The supporting HagerCad software makes planning and designing each system intuitive, simple and fast. Customers also benefit from local technical support and expertise. For designing, building or installing a distribution system, the Quadro+ solution offers convenience, adaptability, rigidity and overall quality. EM and Hager see this as a further opportunity to build on our reputation of being a trusted, reliable and on-time partner

Energy-efficient drives leapfrog ageing technology For ageing sawmills and sugar mills in KwaZulu- Natal the latest energy-efficient drives from SEW- EURODRIVE present an opportunity to cut costs and boost productivity. Clive O’Reilly, the company’s Branch Manager for KwaZulu-Natal, says the Durban branch is one of the key strategic locations for SEW-EURODRIVE. As well as a significant stockholding, the branch has a repair and service capability, an assembly line for new drive units and an in-house spray-painting facility. “Pulp and paper and sugar production are highly specialised industries with specific requirements and SEW-EURODRIVE is able to meet most of these needs with its standard geared units and industrial gearboxes, which are assembled locally. “They are energy-intensive industries so energy efficiency and optimisation are key. This is where, when it comes to standard IEC motors, our range plays an important role,” O’Reilly adds. He says many sawmills and sugar mills have old gearboxes – some of which have been running 20 years or more and are long past their service life. These need to be replaced and, he notes, “At the same time the sector is looking to leapfrog to the latest technology.” While the older drive trains comprise traditional components such as sprockets and chains, the latest trend is for direct drives onto the application itself. This reduces maintenance for end users, as it means less stockholding of critical spares such as V belts, pulleys, sprockets and chains, and increased efficiency simply due to it being a direct drive as opposed to a traditional mechanical system. The Durban branch also has a technical team that can attend to any issues on-site, such as emergency repairs or breakdowns. “Our fast turnaround time on delivery and aftermarket service is a key differentiator for us,” O’Reilly adds. This is especially important in industries such as pulp and paper and sugar where any downtime has a major impact on the bottom line. Enquiries: SEW-EURODRIVE. Email: info@sew.co.za or visit: www.sew-eurodrive.co.za

for more than 30 years,” van Rensburg concludes. Enquiries: Karen Zotter at ElectroMechanica. Tel: +27 (0)11 249 5000, email: karenz@em.co.za

Quadro+ is a leading low voltage electrical distribution system.

Today, direct drives are replacing older mechanical drive trains to reduce energy costs and improve production efficiencies.

Electricity + Control

SEPTEMBER 2019

9

round up

DRIVES, MOTORS + SWITCHGEAR

Long-lasting motors and gearboxes for vibrating screens

He also highlights the massive centripetal forces that are exerted on the screening machine by the unbalanced motor and gearbox. This make it essential to secure them well to the screen. “We specify our own fabricated bolts, nuts and washers for this,” he says. “If sub-standard fasteners are used, components can come loose and cause extensive damage.” Unbalanced motors usually have to be installed at an angle. Taking account of the weight of these components, there are rigging points all around the housing to manipulate the angle of installation.The feet are normally larger than those of other motors, to provide a better contact surface. Mayhew-Ridgers cautions that if there is the slightest imperfection in the flat surface of the join, this can cause costly damage to the drive and the screen. “This is why OEMs like Kwatani have such detailed installation procedures on issues like torqueing of bolts. Installers and maintenance teams need to stick closely to these specifications.” Enquiries visit: www.kwatani.co.za

Harsh operating conditions on vibrating screens demand high quality engineering and the strictest tolerances for unbalanced motors and gearboxes, or they simply do not last. Kenny Mayhew-Ridgers, Chief Operating Officer at Kwatani, says local design and manufacture to the highest standard is a non-negotiable. The company designs its own range of motors and locally manufactures the gearboxes for its vibrating screens. “We design our own motors with local conditions in mind, giving the customer a high-performance and long-lasting product,” says Mayhew-Ridgers. He highlights some key design considerations. These include optimal sealing arrangements to keep electrical components dry and clean. Power cables must always enter from the underside, to prevent water ingress. The design needs to consider various orientations of the motor, depending on the angle of installation. Dusty conditions on mines also present a challenge. “Dust ingress can compromise the sealing configuration of the lid,” he says. “Kwatani’s design is therefore like a top-hat, so the O-ring is not on a flat surface but rather on a cylindrical, vertical surface. There is a double-sealing arrangement for the lid, which includes a gasket.” Kwatani’s gearboxes are fully locally manufactured, with only the bearings imported direct from leading global producers. Gearboxes comprise two shafts, each with its own set of unbalanced weights linked to each other by a gear to achieve synchronised motion. The gears and shafts are locally fabricated by selected suppliers and the housing is cast by a local foundry and machined to exacting specifications. Mayew-Ridgers says Kwatani is probably the only OEM that services its own gearboxes. This ensures adherence to strict tolerances so that the units provide sustained performance and longevity.

Kwatani motors and exciter gearboxes are designed and manufactured locally.

Improved design and efficiency favours HV motor replacement

performance and direct savings in energy consumption. “When motor failures occur, Zest WEG Group has the ability to conduct a detailed on-site analysis,” Spohr says. “Based on a root-cause analysis, we can provide a failure assessment which will enable the customer to make an informed decision.” The assessment includes an energy consumption analysis conducted with specialised software. Taking account of the machine’s application, ZestWEG Group then recommends enhancements for greater control and efficiency. These include motor control options such as variable speed drives for applications such as fans and pumps. “New, more reliable motors also contribute significant productivity benefits,” says Spohr. Enquiries: ZestWEG Group. Visit: www.zestweg.com

“As a leading technology provider of a wide range of motor products, we have the capability to design a replacement motor to match the footprint of the original unit,” Spohr says. “This means there’s no need for the customer to modify mechanical infrastructure or electrical design to accommodate an upgraded motor.” He notes that, with the design lifespan of electric motors ranging from 20 to 30 years, there are still many old units in operation around South Africa. However, technological improvements in motor design and efficiency present a strong case for the replacement of old units rather than repeated repairs. The cost of a major motor overhaul can be up to 60% of the cost of replacement and the advanced technology of the new units offers greater reliability and efficiency, which means improved operational

The applications knowledge of Zest WEG Group, coupled with the design capability of parent company WEG, make it easier for old high voltage (HV) motors to be replaced with new, improved HV machines within the customer’s existing footprint and operational configuration. David Spohr, the group’s newly appointed Business Development Executive points out that, compared to HV machines designed 20 to 30 years ago, advances in technology often allow for new HV units to be manufactured at a smaller scale than the originals. Spohr works with customers to optimise their HV motor operations. WEG’s HV motors are typically purpose- built to meet the needs of the customer. While smaller in dimension compared to the original HV motors, new motors still deliver the required performance at even higher output and efficiencies.

10 Electricity + Control

SEPTEMBER 2019

COVER ARTICLE

New sonic industrial imager A fast, simple way to detect compressed air, steam, gas and vacuum leaks

L eaks in compressed air, gas and vacuum systems hit both production uptime and the operations bottom line. According to the US Department of Energy compressed air accounts for 10% of the electricity used in the USA. Allowing leaks to exist undetected produces hidden costs that negatively impact revenue. While this is a known issue, locating leaks has been a time- consuming and tedious process – until now. COMTEST says with Fluke’s new ii900 Sonic Industrial Imager, maintenance teams can quickly pinpoint the location of compressed air, gas and vacuum leaks. With SoundSight™ technology, the sound a ground leak produces can be seen, even in extremely noisy industrial environments or hard-to-reach locations. A SoundMap™ is overlaid on a visual image for quick location of the leak. No more waiting until second shift or a scheduled downtime to find leaks. Previously, the easiest way to identify leaks in compressed air, gas or vacuum systems was to walk the plant and listen for them, or conduct visual inspections with soap and water. However, only the most obvious, largest leaks make a noise detectable by the human ear while smaller leaks can go undetected. According to a study by the Compressed Air and Gas Institute (CAGI) an average compressed air system loses 30% of its air through leaks. If a leak can be heard, it is probably costing thousands of rand a year. The smaller leaks, the ones not easily heard, are a hidden source of wasted energy and productivity. With minimal training, maintenance technicians can begin checking for air leaks during their typical maintenance routine – even during peak operation hours. It’s a simple 3-step process: 1. Adjust the range 2. View the combined SoundMap™ and visual image 3. Identify the source of the leak. Now location and repair of leaks can be undertaken during normal operations and the repair can be immediately re-inspected to verify that the leak has truly been fixed.

The ii900 enables users to do more with existing air compressors, for example: - Delay the capital expense of purchasing an additional compressor - Ensure proper air pressure to pneumatic equipment - Lower utility costs (optimises compressed air budget) - Reduce leak detection time - Improve reliability in the production line - Make leak detection part of a typical maintenance routine - Train the maintenance team (in a matter of minutes!) - Instantly validate repairs. The handheld Fluke ii900 Sonic Industrial Imager is designed for production facilities that rely on compressed air. It is equipped with an array of miniaturised microphones and has the ability to easily isolate the sound frequency to identify leaks, background noise can be filtered and leaks are easily identified. The 7” LCD touchscreen overlays a SoundMap™ on a visual image for quick leak location identification. The ii900 means a better, quicker, simpler way to check compressed air leaks and, at the same time, conduct gas and vacuum leak identification.

FEATURES: · Control systems+ automation+ systems engineering · Drives,motors+ switchgear · Energymanagement+ environmental engineering · Plantmaintenance, test+measurement · Sensors, switches+ transducers

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For more information contact: COMTEST Tel: +27 (0)10 595 1821 or email: sales@comtest.co.za

Electricity + Control

SEPTEMBER 2019

11

PLANT MAINTENANCE, TEST + MEASUREMENT

Smart condition monitoring supports increasing productivity

One of the largest malted barley producers in the UK, Muntons, uses a smart condition monitoring system from Mitsubishi Electric to protect key parts of its production process plant against unscheduled downtime.

Take Note!

1. The principles of the barley malting process are quite traditional, but Muntons relies to a large extent on automation, electro- mechanical equipment and sensors to control air flow, heat and moisture. 2. The chosen SCM instal- lation provides condition monitoring on three critical fan sets. 1 2

M alted barley, which is used in the making of beer, spirits and a range of popular foodstuffs, is produced in large batches where environmental conditions are critical to a consistent product. Each batch is valuable, not just in monetary terms but also to the customer, so Muntons is pro-active in the servicing and maintenance of its equipment. As in many food industries, the principles of the barley malting process are quite traditional, but Muntons relies to a large extent on automation, electro-mechanical equipment and sensors to provide fine control over air flow, heat and moisture. Fans and motors are critical to the operation. Muntons processes many tonnes of product at a time, with key operations relying on a steady supply of blown air. The chosen smart condition monitoring (SCM) installation provides condition monitoring for two large 315 kW fan sets

and a single 90 kW fan set. Sensors monitor the electric motor, power transmission coupling and main fan shaft bearing on each fan set. Plant Engineer Michael Plawecki says, “We now have a clear picture of the health of the fan sets and advance warning of any required maintenance. Remote monitoring and fast diagnosis of any issues has also made us very responsive should the limits on operating parameters – that we have set – be approached. “As promised, the systemwas easy to install and relatively simple to commission,” Plawecki adds. The motivation for the SCM installation came from maintenance issues previously experienced with difficult-to-reach bearings inside a large fan housing. A bearing failure inside a fan assembly had caught theMuntons engineering teamunawares and caused a significant impact in terms of downtime. “We only realised we had problems when it was

Fans and motors are critical elements in Muntons large-scale production process, where stable environmental conditions are key to a consistent product. The SCM system was installed to protect these elements – and in turn the entire production process – against unscheduled downtime.

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SEPTEMBER 2019

PLANT MAINTENANCE, TEST + MEASUREMENT

too late – and we had to make an unscheduled stop on one of the lines to make repairs,” says Plawecki. Learning from that lesson, Muntons looked for a monitoring solution with predictive maintenance technology that could be linked into the company’s existing supervisory control and data acquisition (SCADA) system. The requirement was for a system that would provide maximum forewarning of any problems, yet would be quick and easy to install. “The SCM system from Mitsubishi Electric presented an ideal solution from an automation brand we trusted,” says Plawecki. The Mitsubishi Electric SCM solution comprises smart sensors that can be attached to bearing housings, gearboxes, pumps and motors to detect when equipment starts to operate outside its normal parameters due to wear. It provides a sophisticated early warning system for critical pieces of rotating plant equipment. Vibration frequencies and temperature readouts are monitored continuously and fed back to an L Series Mitsubishi Electric PLC (programmable logic controller) via an industrial Ethernet network cable. The PLC provides for simple integration to other network system hardware and software platforms, in this case integrating seamlessly with the SCADA system at Muntons. The sensors, developed by bearings expert FAG, monitor for changes in the complex vibration

patterns specific to the type of equipment to which respective sensors are attached. The software compares that data with highly developed data models from thousands of previous installations, providing an effective analysis-and-alert system for the user. Live information and alarms are displayed on a Mitsubishi Electric GOT Series HMI mounted to the control enclosure. The system can work autonomously, independent of any other automation systems, with multiple sensors located and recognised by unique IP addresses. At Muntons, the visual information and the alarms generated were easily connected into the existing automation software platform. With the SCM installed on the three critical fan sets, the Muntons engineering team is looking at the potential benefits of using smart conditioning monitoring elsewhere in the plant. “We are reviewing the entire facility to decide on which other parts of the plant we include, with the aim of speeding up maintenance and reducing scheduled maintenance periods,” says Plawecki. “We recognise that the investment in automation and predictive maintenance pays off quickly – by preventing unscheduled downtime – and it can also be used to increase operational effectiveness and productivity.”

“We now have a clear picture of the health of the fan sets and advance warning of any required maintenance.”

All images: Mitsubishi Electric Europe B.V.

As one of the UK’s largest producers of malted barley, Muntons is using predictive maintenance technology from Mitsubishi Electric to increase its productivity.

Electricity + Control

SEPTEMBER 2019

13

round up

PLANT MAINTENANCE, TEST + MEASUREMENT

Plug-and-play technology in new analytical transmitter

ABB has taken an innovative approach to transmitter design with its new AWT210 single-channel two-wire transmitter for measurement and control of pH, redox (ORP) and conductivity in hazardous and non-hazardous industrial applications. The modular design reduces process downtime and overall operations expenditure, improves safety and boosts performance by optimising plant control and availability. The low power high-performance transmitter is built around single sensor interchangeable modular plug-and-play technology.This means that a major benefit of the AWT210’s modular design is its ability to handle future sensor technologies such as ABB’s digital EZLink sensors. By simply upgrading the transmitter with the necessary module, operators can avoid the cost and time of purchasing and installing new transmitter units. Operational simplicity is key in the AWT210. With ABB’s common intuitive HMI, users can easily navigate the device. Easy setup menus provide step-by-step guidance and routine calibration tasks can be initiated at the touch of a button. The AWT210 pH and conductivity

both intrinsically safe and non-incendive versions for hazardous area installation certified by USFMc and ATEX/IECEx. To prevent unauthorised modifications to calibration and configuration settings, multi-level security access ensures that users can only perform tasks within their specific profiles, with a choice of read- only, calibrate and advanced security access levels. Enquiries: Visit www.abb.com

systems ensure optimal safe performance in the harshest of applications. Combined with greater user flexibility and environmental compliance, this makes them ideal for the oil and gas, pulp and paper, metals and mining and chemical and petrochemical industries. The flexible transmitter design enables the same unit to be used with pH, redox and ion-selective sensors as well as two- and four-electrode and toroidal conductivity sensors. Factory-calibrated modules for the different sensor types can be fitted quickly and exchanged when required via the transmitter’s hinged door, enabling fast and easy upgrading and maintenance in the field. The same approach applies when integrating the AWT210 into different control systems: it is equipped with a range of exchangeable modules available for 4-20 mA with HART®, FOUNDATION Fieldbus ® and Profibus PA ® communications protocols. With its range of wall, pipe and panel mounting options and IP66 rated enclosure, the AWT210 can be installed almost anywhere in an industrial process with

: The new AWT210 analytical transmitter offers a cost-effective and future-flexible solution for industrial pH and conductivity measurement.

SiSi safety gear for women working at heights

This limits the risk of secondary injuries for women, should they be involved in a fall-arrest incident, and it makes the harness more comfortable for women to wear confidently on the work site. “As more women are now working in industrial environments and as traditional gender-based barriers are steadily coming down in sectors once dominated by men, there is a need to provide gender-specific safety wear,” says Ronald. The Sisi range of fall arrest systems is manufactured in South Africa and available to order through leading PPE distributors. Sisi Safety Wear forms part of the BBF Safety Group (BBF) stable.The brand was initially developed to provide safety footwear to suit the contours of a woman’s foot. A decade later Sisi expanded

Sisi Safety Wear has taken another step in its drive to support women in industry – with the launch of a new range of fall arrest systems specifically designed for women who work at heights. Fall arrest systems are harnesses with permanently attached lanyards. Vanessa Ronald, Senior Brand Manager at the company says, “This is a very exciting move for Sisi and again underscores our commitment to women who work in traditionally male-dominated industry sectors. We believe that women should have access to personal protective equipment that has been designed to fit the female anatomy and not that of their male counterparts.” The leading local manufacturer of personal protective equipment (PPE) for women has introduced five different harnesses in its Core and Core+ Ranges, adding to the already trusted line of Sisi protective clothing and footwear. The Core range offers three standard harnesses with permanently attached, single- or double-leg shock absorbing lanyards, with snap or scaffolding hooks. The Core+ Range includes two belted harnesses with permanently attached, double- leg, shock absorbing lanyards, with snap or scaffolding hooks and adjustable shoulder straps. Sisi Fall Arrest Specialist, Ruaan Breedt, explains that the Sisi fall arrest range is especially considerate of the female form and includes a newly developed adjustable and elasticated chest strap.

into workwear, giving careful consideration to the functional and fit requirements for women working in industry. The fall arrest gear is the latest development in the Sisi range. Enquiries: Vanessa Ronald at Sisi. Tel: +27 (0)31 710 0605, or email: vanessa.ronald@bbsafety.com

The recently launched Core fall arrest harnesses are designed specifically for women.

14 Electricity + Control

SEPTEMBER 2019