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18.4

On the Cover... INSTROTECH’s Complete Weighing Solutions

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nstrotech – local designer and manufacturer of high quality process control instrumentation and industrial electronics – has FOUR new controllers on offer to the market, under the Calog brand. All feature an intuitive interface, with scrolling text prompts and up to 4 setpoints. The Calog Quad Process Controller – an advanced quad channel process controller with a virtually endless range of possible applications. Features include 4 process inputs (0/4-20mA) with optional channel averaging across 2, 3, or 4 input channels. The device supplies 24V excitation and is ideal for use in conjunction with a transmitter and it is easy to scale using low and high display values.

JULY/AUGUST 2015 Volume 18.4

Editor Debbie Scott debbiewnip@mweb.co.za

Advertising Sales Manager Roxanne Bredenkamp roxannewnip@mweb.co.za

Published by What’s New in Publishing cc ck 2000/037639/23 P O Box 2214 Primrose 1416 South Africa

Tel: 0861 PROCES (776 237) Fax: 086 723 5321 www.whatsnewinprocessing.co.za Printed by: Raptor Print Views expressed in this publication do not necessarily reflect the opinions of the publisher. Copyright reserved on all material

The Calog Quad RTD Controller – an advanced quad channel RTD controller, idea for numerous industrial temperature applications. Features include 4 RTD inputs (Pt100Ω, 385/392/Cn10); the ability to average the inputs across 2, 3, or 4 input channels, and use this averaged value for a display source or for setpoint activation; intuitive interface with scrolling text prompts; a choice of either C° or F° display. The Calog Quad Thermocouple Controller -– an advanced quad channel thermocouple controller, ideal for numerous industrial temperature applications. Features include 4 thermocouple inputs (J/K/N/R/T type) and the ability to average the inputs across 2, 3, or 4 input channels, then use this averaged value for a display source or for setpoint activation. Also and intuitive interface with scrolling text prompts; and a choice of either C° or F° display. The Calog Counter/Rate Batching Controller – an advanced controller with 3 independent counters, ideal for rate monitoring and batching applications. Features include: 3 independent hardware counters; Quadrature (x1, x2,

x4), NPN, PNP, TTL sensors and Intelligent count modes where users can choose from a variety of smart formulas to suit the application. Advanced features for this model are batching, batch count modification, programmable input functions, setpoint latching and startup inhibit. Optional features on all of the models are the 4-20mA or 0-10V analog output, the RS232/RS485 serial port and data logging function.

Instrotech also represents Vishay locally, and their Model 178 extensometer is a load sensor designed for force measurement on any load-bearing structure. This extensometer provides the total solution for weighing, level control, stress and fatigue monitoring. The design also allows multiple sensors to be permanently mounted for more complex stress profiling and analysis. The Model 178 extensometer provides the solution for non-intrusive level measurements for materials that are subject to uneven buildup, bridging, or sidewall collection. Also, liquids or wetted materials that are not suited for direct contact level measurement are an ideal application for the Model 178 extensometer. The design of the Model 178 makes it an excellent solution for retrofitting existing structures without compromise of the integrity of the vessel or structure. In operation since 1981, Instrotech distributes VISHAY, and manufactures as well as distributes CALOG process control instrumentation and specialised systems to a worldwide market. CALOG & Instrotech are COMTEST Group companies. Instrotech Tel. 010 595 1831 sales@instrotech.co.za www.instrotech.co.za


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18.4 High precision flow measurement critical to petrochemical industry

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ith the sole southern African sales and distribution rights for Brodie International under its belt, a local company addresses the accuracy of custody transfer through a portfolio of high precision fiscal measurement and control solutions. SA’s petro-chemical industry is now able to reap the benefits of custody transfer solutions that have been achieving the highest marks for customer responsiveness and satisfaction for decades in the international market. Through the integration of Brodie’s BiRotor Plus™ series of positive displacement meters, Soliflo is able to provide industry-leading accuracy and reliability critical to players both upstream and downstream in the petrochemical industry. Their piston control valve line-up provides a complete set of multiple control actions and types, based upon a consistent single design base and they support the installations of these positive displacement meters and piston control valves with a series

of strainers and air eliminators that provide the correct protection against intrusion of unwanted foreign material. BiRotor Plus™ The BiRotor Plus is a volumetric flow measuring device designed for the accurate measurement of petroleum liquids in a variety of applications. This double case meter combines the rugged durability and long service life of the tradition BiRotor meter with the improved accuracy and pulse output associated with today’s most sophisticated devices. Utilising single or dual outputs, with two non-wetted pick-offs mounted 90 degrees electrically out of phase, the BiRotor Plus complies with API Level B pulse output standards. Output signals are amplified and shaped by a pre-amplifier mounted directly on the meter for transmission to accessories such as totalizing counters, digital read-out devices, provers and other control equipment and instrumentation. Typical applications include loading/

unloading, batching, blending and inventory control of petroleum products where accuracy and repeatability are the deciding factors in meter selection. Soliflo is also able to supply packaged systems for blending and for the loading or offloading of tankers. The BiRotor Plus is recommended for loading and unloading tankers, railcars or trucks as well as for pipelines, aircraft refueling and general purpose flow measurement. The 3” (linearity +0.10% over 13.1 flow range) and 4” (linearity 0.075% or better over 30:1 flow range) BiRotor Plus models are industry leading in terms of accuracy and performance with repeatability reaching +/- 0.01%. “Applied in custody transfer, bio fuels and terminals, the BiRotor Plus provides amazing results in any of its variations (3” to 6”) saving operators in their total cost of ownership,” adds Dawson. The BiRotor Plus Meter utilises the exclusive BiRotor principle. There are no sliding, oscillating, or reciprocating parts. Cyclone meter The mechanical model 2200 Cyclone Meter is a 2 inch single case, positive displacement flow meter and has been designed for the high speed measurement of petroleum products. Of non-ferrous construction, its simple design utilizes the

rotating crescent principle of operation which allows for high accuracy performance that exceeds requirements found in aircraft re-fuelling, bulk plants, tank truck and general petroleum applications. As liquid enters the input chamber of the measuring element, an internal cylinder containing two crescent-shaped rotors is driven in a clockwise or counter clock-wise direction (flow direction dependent). As the cylinder turns within the measuring element the rotors divide and transfer a discrete volume of product to the outlet port.A mechanical coupling attached centrally to the measuring unit, provides rotational mechanical energy necessary to drive registration equipment. As the measuring unit rotates each revolution is transferred by mechanical output gearing and then to the adjustor. The adjusted output is then registered in exact engineering units. The Cyclone meter is equipped with the Model 4200 Adjustor for applications which require bi-directional or non-cyclic performance. Design features include an extremely wide flow range, low pressure drop, 90 offset or inline flanges affording superior accuracy and long service life. phil@soliflo.co.za

Safety limit switches provide superior interlocking and position monitoring

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he SI Series Safety Limit Switches are designed to effectively monitor the position of a wide variety of guards, gates, covers and other moveable machine fixtures and tooling. The SI Series is available in three models— SI-LM40, SI-LS31 and SI-LS83—offering various actuating systems, contact arrangements,

housing and mounting configurations to satisfy diverse industrial applications. Banner’s SI Series feature a limit-switch style, complying with Type 1 per ISO 14119 standards, with actuating elements integrated with the enclosure. Configured with a positive-opening design of the normally closed contacts, per IEC 60947-5-1 standards, these switches provide reliable monitoring regardless of environmental conditions and withstand any attempt to override the switch and defeat the system.With a unique limit-switch design, the SI Series Safety Limit Switches are ideal for safety or non-safety interlocking and position monitoring applications. The switches are ideal for monitoring sliding gates and guards on machines in safety fencing systems, in addition to solving simple position monitoring

such as end-of-travel and home-position. The SI Series offers multiple actuating systems, including plunger, roller, spindlemount lever and two lever styles. The switches’ actuator head is rotatable in 90-degree increments to ensure thorough monitoring. When properly interfaced, or used with an appropriate safety controller/module, two safety switches monitoring an individual guard can achieve a category 4 level of safety, per ISO 13849-1. Models are available with robust, die-cast aluminum or plastic housing with IP65 glass-reinforced thermoplastic switch housing. Models housed in plastic resist many aggressive chemicals and liquids found in industrial environments. brandon.topham@retautomation.com


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18.4

Simplifying wide-area plant network deployment with a single access point for Wi-Fi and WirelessHART

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he Smart Wireless Gateway 1552WU enables a full featured wireless solution based on a single platform for both WirelessHART sensors and Wi-Fi applications, helping to lower costs and reduce deployment time Jointly developed as an integral part of Cisco’s IoT Systems, the 1552WU Gateway is a fully- featured mesh access point that simplifies Wi-Fi and WirelessHART installations, lowers costs and reduces deployment time. Users no longer have to run fiber optic cables for ethernet communication to

every WirelessHART Gateway. The 1552WU seamlessly connects to neighboring access points allowing complete wireless coverage, with only local power wired to the 1552WU, resulting in a high-performing, secure, scalable gateway that safeguards data integrity. This product provides a solution that meets both the Operations Technology department and the Information Technology standards. By integrating the WirelessHART Gateway with Cisco’s outdoor, hazardous-locationqualified access points, the 1552WU provides customers with the efficiency, scalability, and security of a single wireless network solution that can be utilized for multiple use-cases, including plant control, worker mobility, and safety. This solution extends to meet the demands from both Operational Technology and Information Technology, in industrial environments to realize the Internet of Things vision. The 1552WU is another example of how simplifying the installation with wireless technology enables customers to apply Pervasive Sensing™ strategies to improve plant performance and reliability. As obtaining data from hard to access locations becomes easier and more cost effective, process manufacturers are better able to address concerns such as corrosion, energy consumption, health and safety, and the environment.

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HELUKABEL a leading international manufacturer and supplier of wires & cables, custom cables, cable accessories, data, network & bus technology and media technology, as well as pre-assembled cable protection systems for robotics and handling systems.

Helukabel SA offer a massive range of cables and wires to suit your purpose The range consists of - instrumentation, control, data & computer cables, drag chain,servo, motor and feedback cables Heat resistant, rubber, trailing, robotic, chemical resistant, welding, thermocouple / compensating Coaxial, panel, telephone, power, electronic, plus much, much more

A broad range of Cable Accessories, form part of the extensive range offered by Helukabel This includes Protective Tubing, Sleeving, Compression Glands, Reducers, Enlargers, Braids, Tube Holders, Drag Chains, Connectors and much more

Michael.Eksteen@Emerson.com

Severe service valves for demanding applications

evere service control valves are designed for demanding applications where there are high pressure drops, cavitation, high velocities, vibrations, noise, and high temperature or sub-zero temperatures. Severe Service Valves solve the most

Cables, Wires & Accessories

arduous applications in the power, oil, gas, petrochemical and power generation industries. The Series has been applied in the mining and other industries where erosive slurries are encountered. Control of steam and water in power generation is essential to ensure the efficient operation of the plant and to protect equipment. The Severe Service Valves can be used for steam and water pressure reduction and the control of boilers, turbines and pumping systems. The Severe service valves are available in two-port Globe, three-way Globe and Sweep angle types in sizes DN 15 to DN 400 1” to 16” and on request up to 24”. Flow characteristics are linear, bi-linear and tri-linear with a choice of ED, ZZ and MHP trims.With a local CFD design, the valves can be engineered to suit specific applications. The valves are offered in a wide range of materials and have a clamp in place, free float design. enquiries@mitech.co.za

If your exact requirements are not available from our massive standard range, contact us and we will design and manufacture your Cable, Wire, Spiral cable or Harness to your exact requirements.

Enquire about our exciting New Products

Now with offices in KZN & the Cape

Contact Details TEL: +27 (0)11 462 8752 FAX: +27 (0) 11 462 8638 sales@helukabel.co.za www.helukabel.co.za


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18.4 Stainless steel control valve for small volumes

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septic diaphragm valves are frequently used to control sterile applications. However, small volumes can only be controlled with an inadequate level of accuracy, or not at all. The 567 BioStar control valve has now been developed in order to solve this problem. The 567 BioStar control is a 2/2-way globe valve with a regulating needle or regulating cone for high control accuracy and precise dosing. The valve seat on both versions is sealed using a softseated seal. The actuator is separated from the mediawetted area by an FDA-compliant PTFE diaphragm. This ensures

a permanent, temperatureresistant seal and thus meets the high requirements of the pharmaceutical and food industries. Compared with bellows valves, cleaning the valve is significantly improved by the hygienic and minimal deadleg design. It is likewise possible to clean and sterilize the valve using a CIP or SIP procedure. The valve is also available with an integrated bypass so that the flow velocities required for the rest of the system can be achieved during the cleaning process. At the customer’s request, 567 BioStar control can be integrated into a multi-

port valve block. This is another special feature of the valve which not only requires considerably less space in the system, but also significantly reduces the installation and welding effort. All surfaces which come into contact with the product are precisionturned or polished. Furthermore, additional electropolishing can achieve a high surface quality of Ra 0.25 Âľm. EHEDG certification and testing in accordance with Procedure 3A are currently in preparation. The 567 BioStar control valve is available as an angled design in nominal sizes DN 8, DN 10 and DN 15. neels.kloppers@gemue.co.za

Coupling relays for safety-related activation

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n recent years, safety-related activation has become increasingly important in the field of process technology. The PSR-PC50 is a coupling relay that has been specially developed for this area and that can be used according to SIL 3. The coupling relay was specially designed for failsafe controllers in the field of process technology. As such, all requirements for use in applications up to SIL 3 are fulfilled, according to IEC 61508. Internally, the device has six contacts that are switched in parallel as well as in series. In this way, the safety required is taken into account, as well as the necessary availability. Continuous diagnosis poses a challenge for planners and planning engineers. Generally speaking, the controller diagnosis ends at the coupling module used. Often this is not sufficient for many users. To this end, the line/load monitoring function of the PSR-PC50 relay enables seamless diagnostics from the controller to the actuator. Open circuits as well as short circuits in the on-load voltage supply and diagnostic supply voltage are monitored. If an error occurs during normal operation, in all established safety systems it can be reported via the existing control line back to the corresponding digital output. In this way, the need for additional installation time and other digital inputs required for actuator readback is eliminated. kevinp@phoenixcontact.co.za

Microwave level switch for the food and pharmaceutical industries

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he microwave level switch - model LNM - made of stainless steel and food-approved materials has been developed for almost all applications in the food and pharmaceutical industry. The microwave field penetrates several millimeters into the medium and the level, even in the most difficult media, can be detected. The level switch is particularly suitable for use with foaming media because the foam, condensate or remains of the transported medium that sticks to vessels, is not detected. It is also possible to detect non-conductive media. The

output of the level switch only switches when the coupling section is completely covered by the medium. This means, it is possible to install LNM in tanks, independent of mounting position. In combination with the weldin sleeves model LZE or LZE-R, the probe provides a measuring point that has no dead space and meets European Hygienic Engineering and Design Group standards (EHEDG). This level switch is therefore very well suited for CIP/SIP cleaning standards (the process knowledge to clean high quality process equipment in a safe,

effective and repeatable way, meeting exacting industry and regulatory standards). A variety of adapter sleeves are also available for different process connections such as VariventÂŽ, dairy connection and Tri-Clamp adapters, so that the LNM may also be used in existing systems without problems. Electronics integrated in the stainless steel head, enables direct sensor signal processing without any other evaluation electronics. The output signal can therefore be transmitted directly to a PLC for further processing. sales@instrotech.co.za


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18.4 Control valve optimised for use as an anti-surge valve

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RCA rounds off the proven series of ECOTROL® control valves at the high end with the new development of the nominal size DN 700 (28”). This valve has been specially optimised for use as an anti-surge valve on turbocompressors, but can also be used for all control applications involving liquid and gaseous media. The requirement profile for the new development was: • High flow coefficient Kvs, which usually well exceeds the delivery capacity of the turbocompressor. The quantities of gas trapped inside the pipelines and heat exchangers can therefore also be relaxed in a very short space of time upon safety shutdown of the compressor. • Face to face dimension according to the specifications of EN 558. • Mechanical resistance to the energy converted at the antisurge valve and to mechanical forces due to pressure fluctuations or unfavourable pipeline layouts. • Favourable acoustic characteristic values. • Short actuating times – usually considerably less than 2 seconds for the complete 0 100% valve opening. The overall length in accordance with EN 558 represents a particular constructive challenge in the case of globe style control valves, especially with large nominal sizes, since the ratio of seat diameter (ideally the same as the nominal size of the valve) to the overall length becomes

increasingly unfavourable the larger the nominal size becomes. For this reason the parametric modelling technique using an upfront CAE tool was applied for the first time for the fluidic optimisation of the housing shape. In this development process the component to be developed is defined (apart from fixed boundary conditions such as the process connections, the wall thicknesses and the trim) by a variable, parameter-controlled geometry. Beyond that, with reference to the target market as an anti-surge valve, the relaxation of an ideal gas with a pressure ratio x = (p1p2)/p1 = 0.7 and the flow direction ‘flow to open’ were specified. In constant alternation between variation of the geometry and evaluation of the results (in the case of the valve housing the flow coefficient determined by means of CFD), the system converged after more than 60 variants to an optimum solution with a 25% higher coefficient of flow (in comparison with a conventional design). In combination with the associated spring-return pneumatic piston actuator, which can be operated in both singleaction mode and (for significant improvement of the control dynamics while maintaining a defined safety position in case of a failure of signals or power) double-action mode, this valve offers a technically and economically ideal solution for many applications. sales@valve.co.za

A bull’s eye in quality. Paperless recorder – Every measurement counts! Ecograph T RSG35 Versatile and economical • Up to 12 inputs • Internal memory 128 MB • Ethernet, RS232/RS485, USB, Modbus RTU/TCP Slave • Safe and complete recording and visualization of all process sequences Ecograph T RSG35

R14117* 11–35 pcs.

Price/piece in R

Version for panel mounting

1–3

4–10

11–35

4 × univ. input, Ethernet + USB

R15180 R14573

R14117

4 × univ. input, Modbus + RS232/485 + Ethernet + USB

R18800 R18048

R17484

Mathematics package, 4 × universal input, Ethernet + USB

R19280 R18509

R17930

Math. package, 4×univ. input, Modbus + RS232/485 + Ethernet + USB

R22900 R21984

R21297

*Refer to website for sales and supply conditions.

For technical details and applications visit: www.za.endress.com/e-direct Tel: 0861 363 737 (0861 endres) 24 hr Helpline: 082 443 4214 Service Hotline: 0861 347 378 (0861 ehserv) info@za.endress.com www.za.endress.com


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18.4 Signal conditioning—What is it?

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fficiency and availability of production facilities depend on the reliable transmission of signals between field devices and the process controller. Interference in the signal circuit may cause related processes to run incorrectly. It is the task of the galvanic isolation function on signal conditioners to prevent this problem. These conditioners may offer additional functions such as signal splitting or signal conversion. However, users are not interested in having a multitude of functions, but having a product design that meets their requirements. Ensuring safe and efficient process control is a must when it comes to initiating a seamless workflow with a high degree of production stability. This process control is closely linked with error-free transmission of measurement and control data between the sensors in the field and the control level, or between the controller and the actuators. Interference in the signal path between the field and control level can cause processes to be controlled incorrectly due to distorted signals. One potential cause for interference of this kind is the equalizing currents created as a result of ground loops. These currents are caused by differences in potential between the grounded field and controller sides. They lead to deviating measuring and controller signals and can affect communication to such an extent that safe process control is no longer an option. Similar problems occur when high-performance components are grounded near signal lines or cause interfering signals from frequency converters in motor load changes. Interference can be fed directly into the signal path as well. Sensors are often installed in pumps, motors, and fans to monitor temperatures, frequencies, or oscillations. If an isolation problem occurs on these devices, high voltages can find their way into the measuring circuit and cause a surge on the signal line. If the total of the signal current and

fault current is between 4 mA and 20 mA, the fault will not be detected and displayed as a malfunction, but can still have serious consequences. Signal conditioners are used exclusively in safe areas. They do not have a barrier function designed to prevent unacceptably high energy in hazardous areas. The use of signal conditioners is particularly helpful if • plants are large and have long signal paths. • Powerful components are grounded in the vicinity of the signal lines. • The signal line environment is placed under significant electromagnetic charge by other signals or by motors with frequency converters. • No single-channel input isolators are present in the respective controllers. Signal conditioning is more than galvanic isolation Galvanic isolation as offered by signal conditioners can prevent interference of this kind, or at the very least protect the process control system. The signal conditioner separates the loop into two circuits, which are connected to each other via a transformer. Other tasks performed by these interface modules include converting signals. Conversion is needed if field devices cannot deliver the standard signals that the controller needs to process the signal. This situation exists with many small PLCs. Even though they are cost-effective, they often have only voltage inputs as standard. This is why a signal transformer is needed if only current signals are provided from the field. In addition, the analog inputs are usually purely passive—a transmitter power supply with current output or voltage output via a signal conditioner is therefore very beneficial. Also, small PLCs often allow only a few signal types on the input side. You will generally not find temperature inputs for all commercially available temperature sensors. Signal conditioners offer short-circuit protection for each individual current circuit,

since the conditions switch corresponding outputs on the control side into the safe mode. Measuring instruments on other channels are not affected by a failure. Often, field signals need to be shared by various systems, such as control systems, emergency shutdown (ESD) systems, or data acquisition systems. If this is the case, several systems must not be connected in series to the output side. If the connection to one of the systems were to be interrupted, none of the other systems would receive any more signals either. The galvanically isolated outputs on a signal splitter guarantee reliable distribution of the process signals to the various systems. This avoids the problem of high resistive loads in a series connection. Eliminating counter currents plays a role when viewed against safety and availability. If field devices such as 4-wire transmitters with active current output and a control system attempt to supply current to the signal circuit, the result is a nonfunctioning current circuit. With signal conditioners, it is usually possible to handle all combinations of current sinks and current/voltage sources. Safety first—isolation quality The basic functions of signal conditioners have varying technical differences, depending on the supplier. It is plain to see that with over 15 years of experience, Pepperl+Fuchs reflects users’ priorities. The main customer need is good isolation, to ensure the device reliably fulfils its core tasks. The isolation quality of a circuit is influenced by many parameters. Influencing factors range from circuit design, such as the spacing between the isolation plugs, to the quality of components used. The need for electric strength increases proportionally, since users increasingly face high, steep pulses. The test voltages and maximum permissible working voltages are relevant in this regard; today they are typically

anything up to 3 KV (test voltage) or 300 V (working voltage) and thereby ensure protection against contact on the controller side. A crucial factor for users when choosing devices is often whether the manufacturer has much experience in developing and manufacturing isolated barriers for hazardous areas. After all, it is precisely in the hazardous area that good isolation quality is essential; the products used here must meet stringent standards as well as passing various external tests. For logistical reasons, the higher-value circuit concepts and components for the isolated barriers for signal conditioners are then applied, ensuring that users receive extremely reliable products. Every degree counts When selecting signal conditioners, it is important to look for low self-heating and a relatively high permissible operating temperature—for switch cabinet builders, literally every degree counts. Today’s standard operates at an ambient temperature of up to 70 °C. However, the requirements for the lower temperature limit are by no means unlimited. Ambient temperatures lower than - 20 °C are not practical in switch cabinets. The measure of all things According to users, suppliers often underestimate the importance of the dimensions and mechanical properties of isolators. A module width of as little as 6 mm is possible today and is offered by various companies— even for dual-channel types with a packing density of 3 mm/ channel. However, the overall height is also a big factor to consider. Experience has shown that in virtually pure signal conditioner applications—i.e., without or with a small number of isolated barriers—you can find products from multiple suppliers. When replacing or expanding, new signal conditioners must fit into the existing switch cabinet grid. From the users’ perspective, noncritical functions such as the display or removable terminals are actually counterproductive when viewed against this


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18.4 background—both functions require extra space. The mechanical stability of the housing is important in the context of mounting and handling—something that manufacturers often underestimate but is repeatedly requested by customers. With this in mind, the manufacturer carries out Elmech tests in a separate, independent testing laboratory. The purpose of these tests is to examine the mechanical properties of the devices according to the specified standards. The tests include subjecting prematurely aged devices to mechanical and climatic loads and then monitoring compliance with the relevant specification. Summary The use of signal conditioners in safe areas effectively prevents interference in the signal path between the field and control level, thereby increasing machine and plant availability. Interference of this kind

may be undetected equalizing currents, but could equally be dangerous contact voltages in specific fault situations on the field side. Signal lines in large plants or near grounded, powerful devices are particularly sensitive to interference. The increasing electromagnetic load of plants and the related risk of unwanted couplings can be effectively counteracted with galvanic isolation provided by signal conditioners. Furthermore, signal conditioners offer key additional functions such as signal splitting or signal conversion. The latter is increasingly gaining importance in areas where there are larger numbers of small PLCS that can process only a limited range of input signals. In addition to the basic functions, users want signal conditioners that are practical and technical in design: firstclass isolation quality, maximum permissible ambient temperature, minimum height and width of the module, and robust mechanisms can all be found at the top of users’ wish lists.

If galvanic isolation is not present, an equalizing current can flow via the grounding shared by field devices and the controller; it is this current that distorts the signal current

Galvanic isolation prevents equalizing currents in ground loops and also protects controllers against other interference

DIN rail mounting, isolation quality up to 3 KV/300 V (test/working voltage): signal conditioners for the SC-System are ideally suited for applications in safe areas

mbracco@za.pepperl-fuchs.com

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18.4 Legrand SA celebrates 30 years in South Africa

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egrand, world leading manufacturers of products and systems for electrical and digital building infrastructures, opened a South African subsidiary in Johannesburg 30 years ago.

Johan Bosch, general manager, Legrand SA (left) hands Jeffrey Sihlangu, warehouse manager, an award to mark his 30 years with the company. Mr Sihlangu has been with the company since its inception in 1985.

To celebrate this milestone, the company hosted a function for customers, architects, contractors, consultants and interior designers, as well as friends from the media. A highlight of the event was the announcement of Legrand’s new general manager, Johan Bosch.“Legrand’s environmentally approach to constantly changing global markets, encompasses ongoing technological developments of the company’s extensive product portfolio. Energy efficiency, quality

power supply, optimum safety and enhanced aesthetics are critical in the advancement of all Legrand systems,” states Johan Bosch, general manager, Legrand SA. “The company has made a substantial investment in research, development and design, to adapt products specifically to the South African market. “Many products in Legrand’s range have been awarded SABS certification. This mark enhances quality systems like IEC and ISO 9001, to give users the pledge that products have been manufactured in accordance with stringent specifications, in terms of design, development, production, installation and servicing. “Legrand’s extensive range features innovative systems to meet exact user demands, also allowing for simple and efficient installation and modification.” The latest trend in the development of new systems - including lighting and motion management systems - is to make industrial, commercial and domestic buildings more energy efficient. There is also an important focus in South Africa on enhanced safety. New Legrand CCTV solutions, emergency lighting devices, home automation solutions and video door entry systems have recently been launched to the local market. Legrand systems include power distribution, switches and sockets, residential and lighting management components, cable management and structured cabling, as well

as connection products. These flexible systems provide solutions in installations in residential, hospitality, office, retail and educational environments. Products and systems are also designed for data centres and industrial applications.

Pierre Nothard, chairman, SAFEhouse Association, Johan Bosch, general manager, Legrand and Gian Campetti

The company benefits from the Group’s ongoing research and development programme and close international ties give the local operation the edge on product design, selection, cost efficiency, safety and reliability of equipment. Today, Legrand SA has a comprehensive distribution network across Southern Africa. The Group, with a 4,5-billion EUR turnover, employs a team of about 35 000 people in more than 70 countries. legrand.south-africa@legrand.co.za

High-performance, safe coupling relays just 6 mm wide

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he new PSRmini safety modules are the world’s slimmest safety relays with the power of a large safety relay. With their compact 6-mm width, they ensure high safety

thanks to positively driven contacts. For users, these slim modules require up to 70 percent less space. A comprehensive package of tests and approvals ensures that the modules can also be flexibly used in applications and environments that exceed the norm. For example, the relays are G3-compliant according to ISA S71.04-1985 for use in especially corrosive atmospheres and are IECEx-certified, thereby facilitating the decentralized design of an application down to Ex Zone 2. Repeat tests in a process plant, which are prescribed by standards, can easily be performed visually and directly on the device. Complex manual measurements that are currently required when using standard relays that are not forcibly guided according to EN 50205 are therefore often unnecessary. In addition, in some common control systems, monitoring of the controls of the coupling module may be influenced in the event of an error, so that the repeat test, the so-called proof test, can be designed to be almost fully automated. This increases efficiency since downtime can be reduced without necessitating additional effort for required hardware or installation. The compact design of the safety modules is made possible through Phoenix Contact’s

newly developed relay technology. The design is based on a slim, powerful, and force-guided basic relay characterized by minimal space requirements, low energy consumption, and high system availability. Despite its compact width of just 6 mm, the component features the same performance as traditional EN 50205-compliant elementary relays with forced guidance. The elementary relay from consists of an NO and an NC contact and is suitable for a modular application configuration. To achieve the manufacturing precision required to meet Phoenix Contact’s high quality requirements, the elementary relay and all of its individual parts are manufactured entirely at Phoenix Contact. Since only the 6-mm modules require a single enabling contact, applications can be built with new and improved costeffectiveness. The termination carrier also provides the option of using system cabling solutions for quick, error-free commissioning and connection in the field. The complete PSRmini range of safety relays consists of 28 products for mechanical engineering and the process industry. kevinp@phoenixcontact.co.za


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18.4 New knife gate valve

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he HL valve represents the first step in the new “Slim line” consisting of compact versions of Stafsjö’s existing product range. Driving forces have been ongoing continuous cost reduction program combined with market driven factors, especially when we are expanding into new business segments. The HL will broaden the product range in high and low pressure applications ensuring reliability, low cost of ownership and customer satisfaction. Product features Stafsjö’s knife gate valve HL is bi-directional and tight in both pressure directions. It is a full bore valve with excellent flow characteristic. HL is equipped with a through-going gate for secure shut-off of static and high concentrated media, often a problematic duty for traditional valves. HL is developed for severe operating conditions with pulp, caustic liquor, reject and waste, but it is also suitable for other applications with powder, slurry and ash. HL has a two piece valve body in stainless steel with purge ports and integrated guiding pads. PTFE body gaskets gives a secure sealing between the body halves. The valve is equipped with a gate in stainless steel and removable retainer rings which simplifies the change of seats. The valve is modular designed meaning that it can easily be customised with gate, seats and box packings according to media and requirements, as well for actuators and accessories. Sealing principle When the valve is fully open the bore is practically entirely free from cavities and as a consequence flow characteristic is excellent. In this position the two seats are protected by the retainer rings and the gate, preventing media from entering the valve body. When the valve is operated from opened to closed position, the valve body, gland boxes and the seats gives the gate continuous support for reliable and secure shut-off. Internal guiding pads make this operation smooth and easy. When the valve closes some media can enter the valve body, but it is returned to pipe line when the valve is operated to open position. Stafsjö’s unique gland box packing, TwinPack™, gives a secure sealing where the gate exit the valve body and assures that no media reaches surrounding environment. sales@valve.co.za

The first of its kind a level switch that can handle any environment ... ... temperatures from - 196 to +450 ºC, pressure from -1 to +160 bar, all liquids. The new, patented drive of VEGASWING 66 as well as extremely temperature resistance materials make it possible. • Point level switch and overfill protection device • Liquid gas vessels, boilers and distillation columns • Quick function test via keypress • More reliable than capacitive probes and float switches • Double security (through second line of defence) • All approvals and up to SIL 3

www.vega.com/VEGASWING Phone +27 11 795 3249


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18.4 Advanced fire-rated cables period of time with rating up to 3 hours. These are ideal for use in areas where function integrity is of the utmost importance such as hospitals, fire brigade, power stations, offshore plants, multi-storey buildings and public places.

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dvanced cables with the ability to maintain their integrity for up to two hours in fire condition have been introduced locally for fire alarm and emergency evacuation systems or wherever long term electrical circuits are required under fire conditions. The new generation cables are designed to self extinguish when exposed to flames and are halogen-free so will not emit corrosive or toxic gasses under fire conditions. This makes them ideal for use in public areas to ensure essential electrical services are maintained in the event of an emergency. The new Helufire PH30/120 cables expand the company’s range of function integrity products that include a large variety of security cables, as well as heat and fire resistant cables, enclosures, protection boxes, glands and accessories. High standards Building regulations, as well as regulations relating to public places, transport and key points require high levels of function integrity on critical equipment especially fire control panels evacuation systems etc. The range of Helufire cables are specially designed to withstand direct flames and heat of 850° for 30 minutes for the PH30 cables and two hours on the PH120 cables. They are also shock resistant and able to

VEGA Instruments

withstand the kind of forces that one might expect in a severe fire related incident with falling objects or even shock from blasts caused by flammable substances exploding. All Helufire cables are also manufactured in accordance with BS EN 50200:2006 which requires tests to be conducted to verify circuit integrity of cables exposed to fire at 850°C for the required duration as well as mechanical shock. Extraordinary applications Helufire cables are typically used in industrial complexes, power stations, communal establishments mines and public places or wherever the highest levels of function integrity are required to ensure the safety of people, animals or property. The cables are suitable for fixed installations on or beneath plaster in dry and moist room applications. They are also suitable to be run outdoors or underground in conduits that exclude excessive water build-ups. The cables are available in 2 or 4 core varieties from 1mm to 2.5mm cross sections to compliment Helukabels extensive range of function integrity cabling products and accessories. The line up of new products is further bolstered by security cables up to 1kV with the ability to withstand bare flames for extended

HONEYWELL

Enclosures In addition to cables, the company also offers the full range of Spelsberg function integrity junction boxes and enclosures. These are able to match the cable products with different flame resistance ratings with the additional benefit of having IP67 protection ratings for dust, water and mechanical stress resistance. Spelsberg junction boxes are suitable for high-voltage cables and wires, busbars etc and are manufactured to the highest To complete the range, cable protection systems, glands, terminals and marking systems accompanied by the correct processing tool are added to give a one stop shop solution. doug.gunnewegh@helukabel.co.za

A.T. TECHNICAL SERVICES & SUPPLIES

SOLIFLO (PTY) LTD

Level switch for Solids/powders

➢ 011 795 3249 w w w.vega.com

➢ 011 805 1201 Boni.Magudulela@honeywell.com

➢ 0012 345 1005 admin@atts.co.za

➢ 011 792 2196 sales@soliflo.co.za


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18.4 Motion detectors provide automated light switching

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ntroducing the WLS28-2MQ motion detector switch for automated lighting. Banner’s motion detector switches provide an efficient solution to automatically turn on or off the light in applications where a physical switch cannot be used or the placement of the switch is not useful. Banner’s motion detector switches are available in two options, an in-line module or built-in motion detector for the company’s industry-recognised WLS28-2 LED Strip Light. The in-line module allows operators to place the motion detection switch away from the light, and can be used with any Banner dc voltage lights. The WLS28-2 with built-in motion detector models provide easy and fast installation in one place.

The motion detection switch offers a simple, convenient lighting solution for applications that don’t easily allow manual on/off switching. For example, if the motion detection switch is inside of an electrical enclosure, it will automatically turn the light on when the door is open and off when it is closed.The motion detector switches feature M12 connectors and rugged metal housing for secure, durable performance. Detector switches are rated for 12 to 30 V dc. Banner’s WLS28-2 LED Strip Light delivers a versatile lighting solution, featuring a space-saving, low-profile design and various lengths from 145 mm to 1130 mm. For increased flexibility, the WLS282 Dual Color is available in cascadable models for connecting multiple lights end-to-end. All models offer enhanced light quality with bright, densely spaced LEDs to ensure even, bright and highly efficient illumination. brandon.topham@retautomation.com

Belt drift switch for field applications

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Relay

he new belt drift switch is designed for heavy duty application and used for drift monitoring of conveyor belt installations. The belt drift switches are used to protect the installations from damage or destruction in the event of belt drift and are positioned in pairs on both sides of the conveyor belt. The ball bearing stainless steel actuating roller is resistant to wear and is used for belt speeds up to approximately 5 m/s. The device features a robust aluminium housing and is equipped with two forceactuated changeover contacts with a snap-action function with 1two2015/08/05 adjustable02:15:23 switching points. Inadmissible belt technology.pdf PM

Nobody manufactures 6 mm safety relays. Until now... C

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Relay Technology Designed by PHOENIX CONTACT

drift occurs when the belt edge approaches the end of the supporting rollers through lateral movement and surpasses it. Then the actuator (roller lever) is operated and displaced. In case of displacement of the actuator, the cam operating switches are activated. The switching angle can be set via an adjustable camshaft. In this way, a pre-warning can be implemented in addition to the safety shutdown. As soon as the belt moves correctly, the roller lever will automatically return to its home position. info.za@ifm.com

Maximum performance – minimum size With the PSRmini product range, Phoenix Contact is bringing to the market the most narrow safety relays in the world. At widths of just 6 mm and 12 mm, they provide maximum functional safety through force-guided contacts according to the standard EN 50205. The highly-compact design means space savings of up to 70 %. This is possible thanks to the newly developed relay technology from Phoenix Contact with switching loads up to 6 A.

For More Information Please Contact Us On: JHB: 011 801 8200 CT: 021 930 9666 DBN: 031 701 2701 PE: 041 364 0451 www.phoenixcontact.co.za


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18.4 Integrated data acquisition for power consumption provides ideal basis for efficient energy management

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or efficient energy management in building and plant operation, it is necessary to log the consumption of water, electricity, and heat at the shortest possible intervals. PC-based control offers the ideal basis for the acquisition and processing of this consumption data, including secure communication with Cloud-connected database systems. Consumption data concerning the use of electricity, water, heat or gas in networked buildings, properties, towns or plants can be made available via the Cloud. These large quantities

of data – often referred to as ‘Big Data’ – can be used by building occupants, building operators or municipalities in order to optimise energy consumption. Malfunctions and excessive consumption can be easily identified. This identification of malfunctions, as well as gathering detailed, highly accurate consumption statistics – often remotely – is streamlined through this process. Beckhoff supplies the ideal platform for Smart Metering in PC-based control. Consumption data is cost-effectively acquired via modular I/O terminals. These

flexible devices are ideal for the most diverse types of signals, either by the direct connection of a sensor, by distributed I/ Os on a fieldbus (e.g. EtherCAT, PROFINET or BACnet/IP) or via lower-level buses such as M-Bus. Control, regulation, and data pre-processing are performed by anEmbedded PC, which is easily scalable with different performance classes. The programming of PLC functions, the integration of program codes as required (such as for C++), and the configuration of I/O points, database interfaces, and the OPC UA (Unified Architecture)

communication protocol, all take place in the universal TwinCAT engineering environment. A modern, Cloud-connected system interface can be realised via the TwinCAT database server. Optionally, the data can also be buffered and analysed locally in an Embedded PC. With OPC UA, the Embedded PC serves as the client and the higher-level energy management software as the OPC UA server. OPC UA offers the option of secure data communication, standardised according to IEC 62541. kennethm@beckhoff.co.za

Addition to AS-i power supply family

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ue to innovative technologies, these new AS-i power supplies require considerably less space in the control cabinet, as compared to common cabinet power supplies. Another advantage of the efficient design is the above average degree of efficiency of up to 94 per cent. This saves energy costs and reduces waste heat in the control cabinet. The switched-mode power supplies provide the specific nominal power across the entire temperature range. Derating only has to be taken into account above an operating temperature of 60 °C.All AS-i switched-mode power supplies are equipped with double terminals. This simplifies wiring and provides more clarity in the control cabinet. Instead of an inrush current limitation with a simple NTC, charging the capacitors of the switched-mode power supplies is microprocessor-controlled. This ensures an ideal start-up of the voltage supply. In the development of the power supplies, particular importance was attached to the dimensioning of the components, so that operation is permanently ensured. This results in an excellent MTBF value of about 1.4 million hours. Moreover, all the power supplies feature sufficient power reserves to reliably handle even short current spikes. info.za@ifm.com

New energy saving centrifugal pump

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ntroducing the reliable and highly efficient XST Series of standard centrifugal pumps with axial suction and radial discharge. Compared with conventional

end suction centrifugal pumps, the XST requires 33.3% less space than conventional types and is easy to install. The pump and motor’s monoblock design

improves performance with 70% less maintenance cost.Designed in accordance with ISO 2858 and EN 733 standards, the pumps are ideal for circulation and transfer of clean, chemically non-aggressive water and other liquids that are similar. Thanks to the new wetted part design of impeller and pump body, the pump efficiency is 3 8% higher than conventional end suction centrifugal pumps.The XST has a flow of up to 220 m3/h, a head of up to 95 m and a 0.75 -55 kW power range. The pumps are suited for use in a medium temperature from -10°C - 85°C as standard (optional-20°C - 120°C). The pump body, impeller and bracket are treated by a

special e-coating which gives better corrosion resistance. The integrated pump cover and front motor cover reduce the possibility of pump damage. Both the pump shaft and motor shaft have no coupling connection (pump with power of 7.5 kW and below), which increases pump efficiency and reduces wearing parts.Typical applications include boosting water pressure, irrigation, water circulation in air conditioning systems, commercial use and small HVAC systems. XST pumps are also suited for fire-fighting systems and for cooling in industrial applications. enquiries@raptech.co.za


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18.4 Easily distribute numerous complex functions in a control system with up to 256 processor cores

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any-core controllers will play a central role in the future of machine control and in the realisation of Industry 4.0 concepts. To meet the rising requirements of Smart Factories, with their increasingly intelligent machines and production systems, high-performance controllers such as the C6670 industrial server are becoming indispensable. To make effective use of this immense computing performance, however, powerful software support, such as

that provided by the TwinCAT 3.1 automation platform, is a necessity. Many-core computers differ from conventional Industrial PCs in their architecture. They feature several processors, also referred to as “packages”, and each is equipped with multiple cores. Their memory architectures also provide a notable difference. One technique, known as NUMA or non-uniform memory access, provides each processor with its own dedicated memory.

Beckhoff has implemented this design with its C6670 industrial server featuring two Intel® Xeon® packages, each offering 6, 12, or 18 cores and from 64 to 2,048 GB of RAM. This immense computing power can only be utilised effectively, however, if the performance of each core is fully leveraged by TwinCAT 3.1 software. The flagship control software is capable of mapping the various machine and process workflows – highly suitable for parallelisation and distribution of different tasks as function modules. Easy modularisation and user-friendly diagnostics With TwinCAT, users can implement individual automation tasks in the form of modules. Written in PLC or C++ code, these machine modules are assigned to individual tasks within the TwinCAT system and executed in user-defined cycles. The tasks can then be simply distributed over the real-time cores. To intelligently define the execution sequence, the individual tasks can be prioritised.

Critical for reaching the highest level of system performance, the diagnostic functionality of TwinCAT 3.1 analyses the load of each core individually. Cores can also be assigned exclusively to the TwinCAT runtime process, in which case they are referred to as “isolated” because they do not execute any Microsoft operating system functions along with the TwinCAT real-time system. This makes it easy to separate Windows processes from real-time processes. Support for up to 256 processor cores Since TwinCAT 3.1 was designed for up to 256 processor cores, it provides a future-proof solution, offering the ability to run automation applications on the complete spectrum of currently available processors. Depending on the amount of computing performance needed, the system designer can configure the appropriate number of cores for the respective real-time applications. kennethm@beckhoff.co.za

AS-i and IO-Link combined in one module

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O-Link is the intelligent connection between the device (sensor or actuator) on one side and PLC or field module on the other side. The AC5225 AS-i IO-Link module combines the advantages of the AS-i wiring system with the standardised IO-Link communication. The simple AS-i system connects the data and power supply for IO-Link sensors and actuators. AS-Interface has become a well-

established means of simplifying and speeding up machine wiring, while adding diagnostics. IO-Link, as a supplementary system on the lowest field level, is rapidly increasing in the number of devices available on the market as this standard is now supported by so many major manufacturers. IO-Link not only simplifies the design and construction of machines by virtue of its standardisation, it also significantly extends the functionality of machines. Short set-up times, higher productivity, and new modern maintenance concepts send a clear message for IO-Link. To assure its international use, IO-Link has been incorporated into the globally recognised PLC standard IEC 61131. Mandatory test specifications, test tools for masters and devices, and the resulting manufacturer’s declaration ensure the interoperability and quality of IO-Link. As defined by the IO-Link standard, the AC5225 can connect to binary or analogue sensors, standard devices or IO-Link-enabled. A feature of IO-Link is exact data transmission with IO-Link: IO-Link and AS-i transfer analogue values in a digitised manner, i.e.

without conversion losses. Distorted signals by electromagnetic interference or contact resistances are excluded. Using an IO-Link sensor extends the powerful AS-i diagnostics to the sensor level. A further characteristic feature of IO-Link is the elimination of manual parameter setting for sensors in the event of a damaged sensor replacement, since the parameter sets can be downloaded from the controller to the IO-Link sensors or actuators. In this case, the sensor settings are saved in the AC5225 AS-i module and would automatically be transferred to a new sensor. Standard cables are used at the IO-Link sensor/actuator level. This means that timeconsuming cable assembly work for field devices is eliminated The AC5225 IO-Link AS-i module is built with quick installation in mind, and with IP67rated housing. A wide selection of IO-Link enabled sensors is available for variables such as pressure, temperature and flow, with more to be announced. info.za@ifm.com


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18.4 Complete pressure portfolio

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ith the release of the OPTIBAR series, a well known manufacturer is extending its range of process instrumentation to include pressure measurement. The new OPTIBAR series includes a variety of pressure transmitters with ceramic or metallic measuring cells, application specific diaphragm seals, primary elements and accessories to equip flow, level or process pressure applications – from single transmitter to complete measuring points. Starting with transmitters, the portfolio holds pressure transmitters with ceramic or metallic measuring cells for standard applications: OPTIBAR PC 5060 with capacitive ceramic measuring cell is aimed at all applications up to +100 bar / +1450 psi gauge. OPTIBAR PM 5060 with metallic measuring cell and fully welded process connection is used for high pressures up to +1000 bar / +14504 psi gauge, aseptic processes, and, in combination with diaphragm seals, for high temperature or corrosive applications. Compact and ultra-compact transmitters, e.g. for OEM applications, are also available. The differential pressure (DP) transmitter OPTIBAR DP 7060 marks the center of the transmitter range. It can be used for either

flow, level or process pressure applications up to 420 bar / 6091 psi. The integrated absolute pressure measurement eliminates the need for an additional sensor in flow and level applications, e.g. to measure head pressure in closed/pressurized vessels. Smallest measuring span of 10 mbar / 0.145 psi gauge is ideal for applications with small turndown ratios, and quick step response times allow for use e.g. with pulsating flows. All OPTIBAR PC, PM and DP transmitters are based on a modular concept and share interchangeable housings, electronics, display and adjustment modules. Hereby, different requirements such as intrinsically safe / explosion proof concepts or 4...20 mA HART 7 / HART SIL 2/3, FOUNDATION fieldbus, PROFIBUS PA communication options can be met with just one platform. For DP volume or mass flow measurement of liquids, gases or steam, KROHNE offers a wide portfolio from primary elements to complete measuring points from one source with matched, pre-configured components. Medium temperatures -200…+1000°C / -328…1832°F, process pressure up to 420 bar / 6091 psi, and line sizes from DN25…12000 / 1…470” can be covered. As primary elements,

averaging pitot tubes are available as a simple, cost-efficient and long-term stable alternative next to orifice plates. Pitot tubes are especially suitable for applications that require a low pressure loss, retrofit of existing pipes with a flow measurement, line sizes > DN 300 / 12”, or low pressure gases. The portfolio also includes wet-calibrated meter runs for small line sizes and low measurement uncertainty, a flow computer, optional pressure and temperature compensation as well as accessories for safe and easy installation of pressure transmitters in the process such as valves and manifolds, condensate pots, or general accessories. All DP flow instruments can be wet calibrated up to DN 3000 / 120”. Hydrostatic pressure is used to measure liquid level, density or liquid-liquid-interface in open and pressurized vessels of any size. The OPTIBAR modular product line offers a complete portfolio of pressure and DP transmitters, diaphragm seals and accessories for measurement of corrosive and noncorrosive liquids and slurries up to 450°C / +842°F and 420 bar / 6091 psi. As a simple level measurement solution for wells or tanks, submersible probes are available. A large portfolio of process connections, including different hygienic process connections for a hygienic, dead zone-free installation, covers the requirements of various industries. The OPTIBAR modular product also covers process pressure applications to measure pressure in pipes or vessels from -1…+1000 bar / -14…+14504 psi gauge and 0…+600 bar / 0…+8702 psi gauge absolute. Over 250 thread, flange and aseptic process connections are available for different industry standards, including special materials. As standard, the transmitters cover process temperatures up to +150°C / +302°F without diaphragm seal. For temperatures up to +450 °C / +842 °F or corrosive mediums, OPTIBAR DS diaphragm seals are available, also pre-configured with direct, capillary or combined direct/capillary mounting. salesza@krohne.com

2015 ROADSHOWS coming up....

Secunda

1 October 2015

Register to visit The Control Roadshow at: http://www.whatsnewinprocessing.co.za/roadshows.html

Vanderbijlpark

3 November 2015

To book your stand, please contact Roxanne 0861 776 237 / roxannewnip@mweb.co.za


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18.4 Inverter for single phase electric pump control

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taltecnica’s Sirio 2.0 is a new electronic device for single phase electric pump control based on inverter technology. It is ideally suited for use with variable speed drives to provide constant pressure control. Sirio 2.0 controls

the starting and stopping of the electric pump and modulates the motor rotations according to the water request from the system. Sirio 2.0 provides an accurate pressure reading due to the modified pressure sensor amplification circuit, while its I/O expansion card allows connection to other devices. All functioning variables are indicated on the front panel including actual pressure frequency, incoming voltage, output current, internal temperature and IGBT temperature. The LV DCDC converter features higher resistance to input voltage and fluctuations and lower EMI. Board-to-board connections are internally connected through

ribbon flat cable instead of pin strips increasing reliability as well as allowing for easier replacement during service. The user has a choice of automatic or manual functioning mode and voltage can be adjusted from the menu for operation in rural areas where power supply is not stabilised. Sirio 2.0 automatically reduces power to the pump when the temperature increases and avoids over-temperature on the IGBT and DC bus capacitors, as well as extending operational life. Constant pressure is assured due to regulating the speed of the pump motor and energy is saved due to less pump absorption. The inverter allows

a gradual pump start and stop, reducing hammering and avoids a breakaway starting current. Protection is provided against dry running in the event of water shortage on the suction. The device offers an automatic reset and efficient leakage monitoring to protect the pump in the event of repeated restarts. Maintenance is easy and access to the calibration menu is possible without removing the plastic enclosure. Operating on 230 V ac ±10% 50/60 Hz, the inverters have a maximum 800 kPa (8 bar) pressure limit and are suitable for fluid temperatures up to 50°C. enquiries@raptech.co.za

Multi-touch HMI range expanded with 11.6-inch widescreen panel

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ith its comprehensive range of Control Panels and Panel PCs, Beckhoff provides the optimum product portfolio to address all multi-touch HMI needs. These devices offer a solution for complete machines or systems, in an integrated and customisable manner, and provide a top quality look and feel. The new 11.6-inch widescreen display format offers increased scalability in the range of compact HMI

SOLIFLO (PTY) LTD

A.T. TECHNICAL SERVICES & SUPPLIES

devices. The popular CP2xxx and CP3xxx multi-touch panel series from Beckhoff are complemented by new 11.6-inch devices in 16:9 widescreen format. The display range now comprises a total of nine models: 7-inch, 11.6-inch, 15.6-inch, 18.5-inch, 21.5-inch and 24-inch in widescreen format; 12-inch, 15-inch and 19-inch in the conventional 4:3 format. With this wide range of options, the multi-touch panel series from Beckhoff now offers the modern widescreen format in the fine scalability offered by traditional 4:3 HMIs. Another bonus is the high resolution of the new 11.6-inch display, at 1366 x 768 pixels. This matches the impressive resolution of the 15.6-inch and 18.5inch devices, enabling the use of an existing visualisation on HMIs in three different sizes without additional engineering effort. This is particularly beneficial for machine builders that use a uniform user interface for their machine range and want to scale the operating panel according to the machine size in a simple and costeffective manner. The new widescreen devices are available as built-in Panel PCs (CP26xx and CP27xx) as well as built-in (CP29xx) or mounting arm (CP39xx) Control Panels. All Beckhoff multi-touch panels in the mounting arm configuration feature a high-quality housing machined from aluminium with metal perimeter protection for the display front. kennethm@beckhoff.co.za

HONEYWELL

VEGA Instruments

Float Level switch for Pump Control

➢ 011 792 2196 sales@soliflo.co.za

➢ 012 345 1005 admin@atts.co.za

➢ 011 805 1201 Boni.Magudulela@honeywell.com

➢ 011 795 3249 w w w.vega.com


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Industrial LED light bar provides bright, even light for increased productivity

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eaturing bright, high-quality and uniform light, the WLB92 industrial LED light bar is designed to increase worker productivity and ergonomics. With a rugged metal housing and shatterproof light cover, the WLB92 is optimal for a variety of industrial lighting applications including robotic work cell lighting and quality inspection, while having aesthetics suitable for an office environment. The WLB92 LED light bar delivers a versatile lighting solution with models available in ac or dc voltage supply and

brandon.topham@ retautomation.com

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multiple connection options, including ac quick disconnect and ac conduit. The WLB92 also features several mounting options, such as surface, swivel, snap and hanging brackets to accommodate diverse installation needs. To ensure continuous run and permanent installation, the WLB92 is equipped with industrystandard conduit knockouts. An optional dimming function is also available to allow users to customise light levels. The WLB92 is available in 550 or 1100 mm lengths. All WLB92 models offer enhanced light quality with bright, densely spaced LEDs to ensure even, bright and highly efficient illumination. AC models are also DLC qualified and have a fiveyear warranty.

Even foam is no problem for the new level sensor for hygienic applications

xact level measurement in heavily foaming media is no problem for the new LR2750 level sensor for hygienic applications.. The device was specially developed for demanding applications in the food industry. It features a hygienic design and resists aggressive cleaning processes. In addition, the sensor is equipped with an Aseptoflex Vario thread for a multitude of process adapters.

Always a good solution

ue to the use of high quality and insensitive sealing materials such as PEEK and EPDM, as well as a high grade stainless steel housing, the new level sensor is best suited for internal and external cleaning. LR2750 meets IP 69K requirements, has an enhanced pressure resistance of up to 40 bar and is also rated for high medium temperatures of up to 150 °C. This makes the sensor extremely resistant to the most adverse operating conditions such as steam cleaning. An optional tank adjustment feature ensures extreme flexibility for the LR2750. Even if an installation proves to be difficult, the device operates precisely and reliably. Whether smaller storage tanks, expansion tanks, separators, or for filling, the LR sensor can be used almost everywhere. info.za@ifm.com

Are you looking for a truly universal flowmeter? OPTISONIC 3400 is the answer. The unique 3-beam device measures conductive and non-conductive, low and high viscous liquids from –200 to +250 °C / –328 to +482 °F medium temperature. The full bore unobstructed sensor features an all-welded construction without moving parts and can measure bidirectionally, starting at nearly zero flow. And the advanced signal converter covers all I/Os, HART® 7, FOUNDATIONTM fieldbus, PROFIBUS® PA and Modbus communication protocols and features enhanced diagnostics and status indications according to NAMUR NE 107. OPTISONIC 3400 is a tough and durable device for just about any environment or application – the accurate and ultra-reliable flowmeter of choice. KROHNE – Process instrumentation is our world. KROHNE South Africa 8 Bushbuck Close Corporate Park South Randtjiespark, Midrand Tel.: +27 113141391 Fax: +27 113141681 Cell: +27 825563934 John Alexander j.alexander@krohne.com www.za.krohne.com


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18.4 Guided radar level transmitters improve reliability at UK power station

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archwood Power operates a £380million natural gasfired combined cycle (CCGT) power station on Marchwood Industrial Park, adjacent to the River Test near Southampton in the UK. The station generates 842MW of electricity for the national grid, enough to supply nearly one million homes. The facility uses the latest technology to ensure maximum energy efficiency and minimal impact on the environment. It is currently one of the most efficient power stations in the UK. The under-slung condenser vessel sits directly under the steam turbine in Marchwood

Power station, condensing the exhausted steam and returning it to an aqueous state, which is then circulated for reuse in the generation cycle. A reliable, accurate level control is critical in this part of the process; if the vessel gets too high, it could impinge on the turbine itself causing untold damage and loss of generation. The correct condensate level needs to be maintained to ensure the condenser back pressure is at the optimum value, lowering the flash point of water and preventing wet steam from contacting the low pressure turbine blades, assisting steam flow through the turbine and increasing efficiency. When originally designed and commissioned, the plant installation consisted of three differential pressure transmitters, using a 2 out of 3 voting method and a single magnetic float gauge on a bypass chamber. However, there were ongoing issues with differential pressure measurement, mainly due to the condensate filled impulse lines and vacuum within the condenser, which meant they often had an unreliable level measurement on at least one, increasing the risk of nuisance trips. A differential pressure-based level system for this type of

measurement is complex and requires a lot of interconnecting pipe work, valves and condensate pots. There was much ongoing work undertaken, balancing the condensate in pots and the wet legs, as well as regular recalibration of the differential pressure transmitters themselves. Marchwood Power’s requirement was three devices that would remain accurate in relation to each other and the process, enabling higher plant availability. Marchwood opted for additional interconnecting pipe work where the magnetic level gauge is installed, so that they could fit three VEGAFLEX GWR transmitters into bypass tubes, using the same 2 out of 3 voting method, which would give them reliable accurate level measurement and control. VEGAFLEX use guided wave microwave pulses which are virtually unaffected by temperature, pressure, vacuum to detect the level. There were no issues with the bypass tubes sharing the same vessel connection ‘manifold’, as it is a ‘clean’ process. The units were mounted to the side of the boiler, alongside the existing MLG, where there was plenty of head room for

installation. The measuring range required was over 1.7 m and the temperatures were much lower than the process at 40 degrees C, (even though VEGAFLEX can go to 450ºC and 400 Bar if needed). Marchwood installed each GWR in a 50mm diameter bypass tube configuration, with isolation valves at the top and bottom. Once in place, it just needed the GWR units to be cabled and they were ready to commission. Marchwood Power engineers carried out the setup themselves using PACTware software, so they could have a full configuration back up and calibration record. As well as reducing maintenance costs, the installation of the new sensors was a more reliable, simpler system and the cost was much lower than the original arrangement. Since installation, no outages due to unreliable levels have been recorded; there is very good correlation and repeatability between devices, which makes the 2 out of 3 system work as it should. With no moving parts, and unaffected by density, pressure or vacuum changes, the VEGAFLEX GWR sensors have delivered the reliability that Marchwood Power were looking for. chantal.groom@vega.com

Wireless vibration and temperature sensor provides superior machine monitoring

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esigned to effectively monitor machines for increases in vibration and temperature, this wireless vibration and temperature sensor measures RMS velocity in millimeters per second or inches per second, and temperature. This enables the sensor to identify machine problems before they become too severe and cause additional damage or result in unplanned down time. The sensor is optimised to work with 1-wire serial radio devices, such as the wireless Q45VT Node, the P6 Performance Node and the MultiHop M-H6 radio. Operators can easily set vibration thresholds based on the ISO 10816 standard. When a threshold has been exceeded, the wireless node can provide local indication, send the signal to a central location, and send the vibration and temperature data to the gateway for collection and trending. The wireless sensor provides continuous vibration and temperature measurements to quickly detect any machine failure or potential problems. This allows facility managers to reduce labor costs by eliminating manual checks and the risk of human error. The wireless vibration and temperature sensor is ideal for a variety of machine monitoring applications, including motors, pumps, blowers and many other types of machines throughout a facility.Manufactured with a robust zinc alloy housing, Banner’s wireless vibration and temperature sensor provides reliable performance in harsh environmental conditions. The sensor also offers multiples mounting options, including hex screw, epoxy, thermal transfer tape or magnetic bracket mount, to accommodate diverse applications. brandon.topham@retautomation.com


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18.4 Wireless DC Clamps improve measuring productivity in-field

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nnouncing the addition of two new dc current clamps to the Fluke Connect® system of wireless

test tools: the Fluke a3003FC wireless DC current clamp and the a3004 FC Wireless DC 4-20 mA Current Clamp. Both fullyfunctional current clamps can wirelessly send measurements to Fluke Connect® enabled master units as well as the Fluke Connect® mobile app so users can view measurements from multiple devices simultaneously, review equipment history, and share measurements with other team members for faster troubleshooting. The a3003FC wireless DC current clamp measures up to 2000 A dc making it ideal for very high dc current measurements typically found in utility and dc machine controller applications. It features a large jaw size (64 mm) for clamping around and measuring on large, high current conductors. The a3004 FC Wireless DC 4-20mA Current Clamp measures 4 to 20 mA signals without

breaking the loop so process control technicians can make accurate measurements without

interrupting the workflow. It features a detachable clamp with extension cable for measurements in tight locations. Both current clamps can record and store up to 65,000 measurements with the logging feature to isolate intermittent events or record fluctuations without even being there. Fluke Connect® System The Fluke a3003 and a3004, along with more than 20 other Fluke tools, are part of the Fluke Connect® system — the world’s largest portfolio of connected tools. It allows technicians to make better and faster decisions by having access to maintenance records wherever they are working. The Fluke Connect® app can be downloaded for free from the Apple App Store and the Google Play Store. sales@comtest.co.za


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18.4 Thermal imaging camera can avert disaster

Land Arc thermal imaging cameras installed at a lime manufacturing plant in the Northern Cape

the detection of a hotspot will trigger an alarm and set in motion a sequence of measures to prevent fire and avoid damage to the belt. In the event of the SCADA or control system being unavailable for whatever reason the onboard intelligence of the camera acts as a failsafe system and still triggers an alarm that will allow appropriate action to be taken. Management of warm materials on conveyors is a hot topic following a recent fire which destroyed an entire incline conveyor system at a lime manufacturing plant in the Northern Cape which caused several of millions Rands damage to the plant and led to considerable loss of production.

methods to try detecting hot materials, but in many instances these are unable to detect small hotspots on the moving conveyor. The addition of Land thermal cameras allows users to monitor the entire conveyor width simultaneously at ranges from -20 to 1000째C continuously. The real live imaging and software automatically detects temperature variations and can trigger a number of responses via onboard I/O s that can trigger sprinklers, alarms, strobes or stop the belt or feeders, whichever is appropriate. Images may also be transmitted to a controller for further action, while simultaneously recording alarm conditions for review at a later stage.

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dvanced thermal imaging cameras are being used as a frontline defence against fires on conveyor belts transporting warm materials or in instances where a risk of fires poses a danger to people or process equipment. Although infrared thermal imaging cameras are not new in military and law enforcement circles, the adaptation of the cameras to meet industrial applications is quite unique. Ruggedized versions from specialist manufacturer, Land, have been designed to work in grueling industrial applications using non-military type technology that circumvents the need for expensive export licenses. These are required on traditional thermal imaging camera to prevent the technology from ending up in radical military hands. The new range of cameras can operate in dirty, dusty and hot applications found in mining and industrial sites and aredesigned to operatereliably with little need for maintenance over extended periods of time in harsh conditions. Automated solution The cameras are used to detect hotspots that are above the desired temperature of materials being transported. With parameters stored onboard the camera as well as on the Arc Land Imaging Processing Software (LIPS),

Thermal image showing hotspots among material on a moving conveyor belt

Preventative measures Following the catastrophe the local distributors were called in to design and install a system to prevent a recurrence of this type of event and have subsequently installed Land Arc Thermal cameras as well as scanners to identify hotspots, as well as identify trends which show when the temperature of clinker from the rotary kilns is rising above the normal range. With the equipment and procedures in place the plant is now able to significantly reduce costly belt repairs, reduce downtime and prevent dangerous situations from occurring in future. Many materials that are transported on rubber conveyors contain hot inclusions that can damage the belt or cause material fires. As a result processing plants usually make use of traditional temperature measurement

The thermal imaging cameras can work reliably in hot, dusty and dirty environments

About the camera The Land Arc range of cameras are general purpose radiometric thermal imaging cameras which are designed to be rugged enough for industrial applications while being small enough to fit into confined areas. The cameras are able to provide detailed high resolution thermal images with high temperature accuracies. The cameras are supplied with viewer software as standard and have direct connection to a range of I/O modules through standard industrial Ethernet. A choice of enclosures allows the cameras to be used in a wide variety of applications gavinw@protea.co.za

Intelligent surge protection for process technology

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lugtrab PT-IQ surge protection devices for MCR and process technology warn plant operators before protection of the plant is lost. To achieve this, each voltagelimiting component in the protective plugs is continuously monitored. If the performance limit has been reached as a result of frequent surge voltages, this is indicated by a yellow signal on the protective device and via remote signaling. At this time, the arresters are still functional and the plant is protected. However, replacing the component is recommended to prevent unnecessary servicing. Plugtrab PT-IQ Ex protective devices are available for intrinsically safe areas. These

devices can be installed in Ex Zone 2. The intrinsically safe protective circuits can be routed up to Ex Zone 0. Thanks to multi-level monitoring and signaling, the plant operator always knows the status of protective devices and therefore has an overview of surge voltage protection in the plant. This intelligent surge voltage protection is available with traditional screw connection technology as well as innovative push-in connection technology. A controller supplies up to 28 protection modules with voltage and allows for connection of a central remote monitoring system. tonyr@phoenixcontact.co.za


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18.4 Controlling valve noise

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ontrol valve noise is generated by high pressure drops across the valve and by the subsequent turbulence downstream. As a direct result, noise is radiated to the surrounding area by the down-stream piping system. In situations where equipment damage or personal injury could be caused by a noise source, noise reduction is not only desired, it is mandatory. A diffuser plate is a pressure reducing device that is installed downstream from a control valve. The total pressure drop needed for flow control of a flow control loop is divided between the valve and diffuser. This enables the valve to operate at a lower pressure ratio and greatly reduces the control valve noise level generated by steam, gas or vapor flow. A properly selected diffuser valve combination can result in up to a 40 dBA noise reduction. The

diffuser plate must be designed for each unique installation so that the noise levels generated by the valve and diffuser are equal. Locally manufactured Diffuser Plates are designed for use with its Globe control valve on high pressure drop applications for gases and vapours. It significantly reduces the control valve noise level generated by the gas or vapour flow. The Diffuser Plates are installed downstream from the valve to create a back pressure. On high pressure drop gas applications the valve size is selected to maintain the velocity at the outlet within the limit of Mach 0.33 (1/3rd of sonic). By creating a back pressure, the gas or vapour is more compressed, and therefore a smaller valve can be selected and still keep the velocity within acceptable limits. Special trims are still often required inside the valve as the downstream plate is not effective at creating back pressure at low flow rates. In these conditions, the valve sees the full pressure drop. However, the velocity in the smaller valve is still acceptable due to the lower flow rate. enquiries@mitech.co.za

Solar connectors with crimp connection

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he proven Sunclix solar connector program has been expanded by adding a DC plug-in connector with crimp connection for machine installation. Two different sizes of contact inserts allow the connection of cables with cross sections of 2.5 mm² to 6 mm² (AWG 14-10). Prices in line with the market and a connector construction that meets the needs of the market make the plug-in connector with crimp connection suitable for use with PV modules. Voltages of up to 1500 V and currents of up to 40 A allow future-oriented use in temperature ranges of -40 to +90 °C. The plug-in connectors fulfill the requirements of Protection Class IP68 (24 h/2 m) and have been submitted for certification according to UL 6703 and German Institute for Standardization (DIN) EN 50521. seanh@phoenixcontact.co.za


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18.4 Security routers for process technology

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ecurity is becoming increasingly important in the process engineering industry - the new MGuard security router is addressing this trend. The security router meets the demanding hardware requirements of the process industry as well as the strict IT requirements for security products. Hardware features include an extended temperature range of -40 to +70 째C, IECEx and ATEX approvals for Ex Zones and corrosive gas testing in accordance with ISA-S71.04-1985 G3 Harsh Group A. From a software point of view, existing MGuard security functions were enhanced with additional security components for OPC Classic, a protocol widely used in the industry. These include DPI (deep package inspection) and NAT (network address translation) functions. DPI allows for a high-quality OPC Classic firewall in the production facility, whereas NAT provides the option of integrating plants with identical IP addresses into a higher-level production network quickly, easily, and without address conflicts. patrickr@phoenixcontact.co.za


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18.4

Promoting ideas. Building on experience. Remaining curious. We are your reliable partner in the search for tomorrow’s solutions. We provide a wealth of experience, but we’re always open to new ideas. For us, thinking one step ahead is just what we do. Innovation is our passion – and your competitive advantage. www.pepperl-fuchs.com


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18.4 The risk of fire and explosion in the workplace

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n this opinion piece Kevin Murphy and Alan Wild, founders of Spill Doctor SA, discuss the risks associated with the improper handling and storage of chemical and toxic substances. Spill Doctor SA is an international company specialising in environmental, health and safety products for the storage and distribution of flammable liquids The risk of fire and explosion from substances such as chemicals, solvents, fuels and fuel gases is ever present in many working environments and these can cause devastating fires and explosions if handled or stored incorrectly. Being highly flammable, many of these substances, when exposed to air, evaporate causing dangerous vapours to accumulate. This in turn poses a serious risk of ignition or explosion. However this can be avoided by properly assessing the risks associated with improper handling and adopting precautions such as safe storage. Improper handling and storage can lead to major loss of life and serious injury, as well as significant damage to property. Employers working with and handling dangerous substances such as chemicals, fuels and gases have a legal obligation to manage the associated fire and explosion risks. This means preventing the release of dangerous substances; preventing or controlling sources of ignition; ensuring products are stored correctly; and establishing appropriate procedures for the delivery, handling and use of these substances. First and foremost, employers should always attempt to completely eliminate the fire and explosion risks from dangerous substances first by using a nonhazardous substance. However if this proves impractical, measures must be taken to control the risks and mitigate the effects of any fire or explosion. Control measures must be applied in a priority order, starting with reducing the quantity of the dangerous substance to a minimum. Mitigation measures will include reducing the number of employees exposed to the hazard and providing staff with suitable personal protective equipment. Safe storage The safe storage of flammable liquids in process areas, workrooms, laboratories and similar working areas is paramount.

Regulations (and best practice) state with the indoor storage of all flammable substances, employers must eliminate or control the risk; reduce the quantity of substances stored on site and mitigate the effect of any foreseeable fire or explosion. Flammable liquids Flammable liquids must be stored in a separate area of the workplace in purpose made bins or cabinets that comply with South African regulations. During dispensing, there must be good ventilation and sources of ignition, such as a spark from a tool or electrical component, must be removed. Containers should also be kept closed when not in use and whenever possible safety containers with self-closing lids and flame arresters should be used. It is also advisable to have a suitable spill kit on hand to capture any leaks that could pose a safety or pollution risk. Flammable dusts If flammable or explosive dusts are present, steps must be taken to remove any sources of ignition. Work areas should also be regularly cleaned to keep them dust-free. Flammable solids Many types of packaging material such as plastic foam, polyester wadding and textiles give off dense black smoke when they burn, so they should not be stored close to heaters or electrical equipment which could act as an ignition source. Flammable gases Gases are often stored at very high pressure and any uncontrolled release can fill a large area quickly. This is particularly the case with liquefied gases such as liquid petroleum gas (LPG). As a result, gas cylinders should be stored in a designated area in purpose built stores. The cylinders should also be restrained and you should try to protect the valves from potential damage caused by impacts. Oxygen Materials that ordinarily burn slowly, will burn vigorously in an oxygen rich atmosphere, therefore oxygen cylinders must also be stored in a secure and controlled manner. In addition, oxygen must never be used as a substitute for compressed air, or to sweeten the air in a working area or confined space. Furthermore, grease or oil must not be used on equipment

containing oxygen as they can selfignite. Reactive chemicals Some chemical products incorporating organic peroxides can explode if not stored and handled correctly and certain chemical substances can react with incompatible materials or contaminants, causing an explosion. Oxidising chemicals can cause flammable materials to ignite and some substances such as sodium react violently when they come into contact with water. In addition, chemical products should be stored and used at the recommended temperatures to prevent dangerous decomposition or unwanted reactions. Information on storage and handling temperatures can be found in the substance’s material safety data sheet (MSDS) or by contacting the manufacturer. Using flammable liquids If flammable liquids are used in a work process, it is likely that a limited quantity will have to be stored and readily available inside the workplace. In assessing the risks from flammable substances, employers will need to justify the requirement to store any particular quantity of flammable liquid within the work room or working area. However, the guiding principle is that only the minimum quantity needed for frequently occurring activities or an amount required for use during half a day or one shift should be present in the work room. The actual quantities allowed inside the work area or building will depend on the work activity and also the arrangements in place for controlling the fire risks. When not in use, containers used for storing flammable liquids needed for ongoing work should be kept closed and placed in suitable fire-resistant cabinets or bins which are also designed to retain spills. The cabinets should be located in designated areas that do not interfere with any escape route from the working area. Ideally, this will be away from the processing area. Flammable liquids should also be stored separately from other dangerous substances that pose a risk of fire or which could compromise the integrity of the container. Substances with oxidising and corrosive properties should not be stored together.

Maximum storage quantities Local fire department by-laws dictate the maximum quantities of flammable substances that should be stored within your premises without a flammable substance certificate. It is recommended you liaise with your local fire department for the maximum allowable quantities applicable to your area.   Typically, these limits are no more than 40 litres of class I (flash point of < 37 deg C) and 200 litres of class II and III liquids (flash point > 37 deg C) .  Outdoor storage If dangerous substances such as oils and chemicals are stored externally, employers also need to ensure they do not pose a risk of polluting nearby drains or watercourses. Companies can be prosecuted for such incidents even if the problem is caused by vandals. Employers need to ascertain the amount of product that need to be stored; the types of containers they are stored in and the need for spill pallets or standalone stores with built-in sumps to capture spills and leaks. The bund of any storage unit or a spill pallet must be able to contain at least 110% of the volume of the largest container or 25% of the total volume stored, whichever is greater. They must also be made of a material compatible with the chemical being stored. Storage areas should also be located in suitable areas, for example, away from drains and staff should also be trained on how to deal with spills. Spill kits and absorbent materials should be present on site and a pollution incident response procedure should be drawn up and followed at all times. It is always better to try to keep any spill of hazardous substances on the surface, so spill kits should be located next to chemical and oil storage areas and sealing products should be positioned next to the site drains. An inventory of all the chemicals on site should be drawn up and should be kept in a location where it can be easily accessed by spill responders or outside agencies, such as the fire service. The location of spill containment equipment should also be marked on a site plan, and this too should be readily available to staff or emergency responders. kevin@jesbragroup.com


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18.4 Some like it (not too) hot

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n production areas that have complex processes, temperature is a frequently used physical variable. It has a crucial influence on parameters such as efficiency and energy consumption. The same applies for the drying level, for example, in fluidized bed systems. To use the measured temperatures for control and regulation purposes, the signals must be transmitted accurately and without distortion. This is ensured using specific isolator modules between the field device and controller. Precise temperature measurement alone is no guarantee of adherence to a correct process temperature. Among other things, an optimal configuration requires the measured values to be transmitted from the temperature sensors correctly and unchanged. This task is performed by isolator modules. Through the galvanic isolation of the measurement circuits, they offer effective protection against potential shifts and compensating currents that result from ground loops. If a fault occurs, they also provide protection against high voltage on the signal lines. Undistorted transmission with isolator modules Isolator modules are available either as signal conditioners for the secure area, or as isolated barriers that protect an explosive area from excess energy input. Depending on the type of signal to be transmitted, isolators are available, for example, as current drivers (analog control signals), signal converters (analog measurement signals), isolating amplifiers (digital measurement signals), or solenoid drivers (digital control signals). Since the temperature values are analog measurement signals, signal converters are used for transmission. Their tasks include the recording, amplification, and conversion of analog temperature signals. If the field device delivers no standard signal or the standard signals are not compatible with the control unit, the input signals are converted to typical norm signals such as 0/2 V … 10 V or 0/4 mA … 20 mA to enable different measurement variables to be processed in control units.

The most common sensors used for industrial temperature measurement are resistance thermometers and thermocouples. One important shared property is that their initial values are available in the form of electrical signals that are relatively easy to transfer to measurement and control instruments for processing and display. Furthermore, resistance thermometers and thermocouples can be manufactured with very low tolerances. Requirements of temperature thermometers To achieve a high level of flexibility, temperature converters must be suitable for all standard sensor signals. Ideally, only one type of isolator should be required to safely transmit temperature signals from different sensors. It is also possible to continue using existing isolators when exchanging field devices at a later time. Another prerequisite for flexible use is that switching points for limit value outputs can be set within broad limits and line-break and short-circuit monitoring is available. Modern interface modules must also be able to achieve very accurate results with minimal measurement currents even without measuring bridges. For use with thermocouples, universal isolators should allow external or internal cold junction compensation. During internal cold junction compensation, the temperature at the terminal is measured with a separate temperature sensor and is used as the correction value. In the other case, the cold junction is contained in a tempered device; the cold junction thermostat. How the different output conditions can be most efficiently taken into account with the maximum possible flexibility is shown by the two temperature converters KFU8-GUT and KFD2UT2. They convert the signals from the sensors into proportional output currents of 4 to 20 mA um. The range of applications spans from thermocouples of various types to all common resistance thermometers available on the market (Pt100, Pt500, and Pt1000, Ni100 and Ni1000). The fact that the user can also connect

potentiometers and voltage sources makes the two modules particularly flexible to use. The KFU8-GUT-1.D also offers two independent contact outputs and adjustable limit values. All devices reach functional safety level SIL 2. Redundancy with thermocouples An additional input for a second thermocouple is provided for redundancy. This is an important addition, particularly in terms of possible measurement errors by thermocouples. Disturbances occur, for example, when the thermoelectric voltage changes as a result of oxidation or galvanic currents due to poor insulation of the two conductors. If there is a discrepancy between the two measured temperature values, an error message is displayed. If one thermocouple fails completely, the measured values of the second thermocouple are analyzed. This significantly increases the availability of the temperature measurement and therefore the availability of the entire plant. The integrated monitoring of the measurement circuit is also relevant in terms of sensor breakage and short circuits. Along with the functions above, the temperature converter KFD2-GUT with limit values also offers other advantages. If the device is designed with limit value outputs that can be parameterized, switch signals are already available at the relay output without having to rely on a central controller. For internal cold junction compensation, a removable terminal block with integrated and cast Pt100 temperature sensor is available. The temperature converter is programmed using PACTware™ configuration software. Signal splitting for more flexibility Additional redundancy is provided by the KFD2-UT2-Ex2 universal temperature converter in intrinsically safe applications. This offers the option of signal splitting. This means that the signal is made available to different systems for further processing via two analog outputs with 0 to 20 or 4 to 20 mA. All named modules have a galvanic isolation between

the input, output, and supply. Possible errors are displayed and output via a red LED according to NAMUR NE44. The relevant outputs can be configured by users themselves. The described measurement converters are part of the K-System. The comprehensive portfolio of isolator modules includes a large number of different models—from a simple isolator through to high-functioning modules as isolated barriers for the explosive environment or as signal conditioners for the safe area. In the K-System, the power supply to the modules is provided via the Power Rail, a DIN rail with integrated conductors. This reduces the wiring outlay and also offers the option of collective error reporting.

Using 3- and 4-wire arrangements helps avoid distortions from line resistance in the measurement results. The voltage UT is the same as the difference U1 - U2 (3-wire measurement) or UT = U1 Temperature converters of the type KFD2-UT2 as signal conditioners in the slimline 12.5 mm version for use in the safe area High-functioning modules provide additional adjustable limit values, used here as isolated barriers for the explosive environment

mbracco@za.pepperl-fuchs.com


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18.4 New tool to precision-align rotating shafts

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he Fluke 830 Laser Shaft Alignment Tool has been specifically engineered for precision-align rotating shafts. Rotating machinery is susceptible to misalignment, and usually rulers and dial indicators are used to

ensure rotating machinery is properly aligned. This could be costing the facility thousands of rands per year in replacement bearing costs, hours of unnecessary repair time, and crippling unplanned downtime, and a probable decrease in the machine’s useful life. The Fluke 830 Laser Shaft Alignment tool offers simple functionality, fast, accurate and actionable answers. Unlike the straight-edge method or dial indicators, Fluke’s 830 performs complicated alignment calculations automatically, which means users have the answers needed to quickly align the machine. An enhanced user interface provides easy format results that don’t require extensive alignment knowledge. The “All-in-One” result screen shows both coupling results and feet corrections (vertical and horizontal) in real terms, allowing for corrective alignment action. The Fluke 830 features: • Single laser measurement technology -

reduced errors from backlash resulting in better data accuracy • Intuitive guided user interface for easy alignment • Compass measurement mode for flexible, reliable and repeatable measurements using an activated electronic inclinometer • Dynamic machine tolerance check for continuous evaluation of alignment adjustments • Unique extend mode handles gross misalignment by virtually increasing laser detector size • Data protection with auto save and resume capability Since machine downtime is costly, test repeatability is critical. The Fluke 830 uses a patented single laser precision alignment system that provides accurate and repeatable measurement results ensuring that misalignment problems are properly addressed sales@comtest.co.za

Multi-touch HMI range expanded with 11.6-inch widescreen panel

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comprehensive range of Control Panels and Panel PCs offer a solution for complete machines or systems, in an integrated and customisable manner, and provides a top quality look and feel. The new 11.6-inch widescreen display format offers

increased scalability in the range of compact HMI devices. The popular CP2xxx and CP3xxx multi-touch panel series are complemented by new 11.6-inch devices in 16:9 widescreen format. The display range now comprises a total of nine models: 7-inch, 11.6-inch, 15.6inch, 18.5-inch, 21.5-inch and 24-inch in widescreen format; 12-inch, 15-inch and 19inch in the conventional 4:3 format. With this wide range of options, the multitouch panel series now offers the modern widescreen format in the fine scalability offered by traditional 4:3 HMIs. Another bonus is the high resolution of the new 11.6-inch display, at 1366 x 768 pixels. This matches the impressive resolution of the 15.6-inch and 18.5-inch devices, enabling the use of an

existing visualisation on HMIs in three different sizes without additional engineering effort. This is particularly beneficial for machine builders that use a uniform user interface for their machine range and want to scale the operating panel according to the machine size in a simple and cost-effective manner. The new widescreen devices are available as built-in Panel PCs (CP26xx and CP27xx) as well as built-in (CP29xx) or mounting arm (CP39xx) Control Panels. All the multi-touch panels in the mounting arm configuration feature a high-quality housing machined from aluminium with metal perimeter protection for the display front. kennethm@beckhoff.co.za

New highly compact isolation amplifiers with UL certification

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he Mini Analog Pro product family is the first line of 6-mm isolation amplifiers with plug-in connection technology. There are now four new product types that are UL 508 listed and thus can also be used in the USA and Canada. The expansion of the product line includes an analog frequency converter with limit value functionality for converting standard signals to frequency or PWM signals, a limit value switch with converter relay output for switching analog limit values, a constant voltage and current source, and a NAMUR insulation amplifier for proximity initiators and voltage-free and resistive switch contacts. The easy-to-configure modules are available with screw-in or push-in connection technology. The Mini Analog Pro isolation amplifiers can be easily installed and operated in narrow spaces. Easily visible and accessible connection points and power measurements during operation ensure convenient use. kevinp@phoenixcontact.co.za


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18.4 Maximum computing capabilities increase intelligence in the Smart Factory

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mart Factory concepts require more intelligence on machines or the entire production line, placing greater demands on the computing performance of the automation system. More and more functions with ever-shorter cycle times require more powerful centralised control technology. The PC-based control architecture pioneered by Beckhoff is always based on the newest and most powerful IT processors, meaning that the latest generation IT technology will be immediately available for automation applications. In the IT server field, many-core computers are used for particularly complex and demanding computing applications. The new C6670 industrial server generation now makes this technology available for Industry 4.0 applications, too. To accommodate the rising demands posed by the Smart Factory, with its highly intelligent machines and production systems, the company is introducing one of the most powerful controllers in the world with its C6670 industrial server. It features 12, 24, or 36 processor cores and 64 to 2,048 GB of RAM, making the C6670 the ideal hardware platform for the â&#x20AC;&#x153;many-core controlâ&#x20AC;? concept, through which the manufacturer consistently pursues its centralised control philosophy. This means that not only PLC, Motion Control, robotics, and CNC functions, but also the Condition Monitoring and energy management functions of a Smart Factory are integrated into a single software system and executed on a single CPU. However, this immense computing power can only be utilised effectively if each coreâ&#x20AC;&#x2122;s performance is fully leveraged by the TwinCAT 3.1 automation platform. The entire system is governed by a powerful C6670 many-core computer, which performs not only conventional machine control functions, but also controls a linear eXtended Transport System (XTS) and a robot. Measurement technology and Condition Monitoring functions are also integrated into the system. kennethm@beckhoff.co.za


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18.4 New hygienic inductive conductivity measuring system

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Modular marshalling patchboard concept with innovative color coding system

New hygienic inductive conductivity measuring system OPTISYS IND 8100

ntroducing the new hygienic inductive conductivity measuring system OPTISYS IND 8100 for the food and beverage industry. With its fast response time, it is particularly suitable for applications in the field of product separation/identification, or in CIP plants to shorten transition phases and save cleaning fluids. The new 3A and EHEDG certified measuring system offers two 4…20 mA outputs for conductivity, concentration and temperature. Within the conductivity measuring range from 50 μS/ cm…1.000 mS/cm, OPTISYS IND 8100 features 14 preset range/output combinations for convenient commissioning. Alternatively, the analogue output can be set freely via the touch display or via PC with optional configuration tool. For media separation, 4 conductivity ranges can be defined via PC. The concentration output can be used to display the concentration of 4 factory set mediums/ranges, e.g. caustic soda, nitric acid, or a customer set medium, which concentration curve can be programmed via a

30 point linearisation. The short response time of the integrated Pt100 temperature sensor (T90 < 15 sec) allows for fast indication of changes in medium or process conditions. The corresponding conductivity is also indicated (T90 < 2 sec) for fast identification of CIP reagents to prevent blending and save costs. OPTISYS IND 8100 uses a touch display for configuration. It features different selectable display modes and warnings: the background colour can be set in three colours, white, green and red; steady or flashing related to alarm settings. Further there are 2 solid state relay contacts configurable as limit switches. The compact design with IP67/69K housing suits for pipes with small diameters > DN40/1 1/2”. The sensor is encapsulated in a PEEK body for use in hygienic processes or direct in concentrated acids or alkalis. Various hygienic process adapters such as Tri Clamp, DIN 11851, SMS or Varivent N are available. OPTISYS IND 8100 is the successor to the discontinued ACM 500. salesza@krohne.com

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he new push-in PTMC marshalling patchboards achieve up to 20 percent higher packing density with marshalling wiring in process technology, thanks to the modular concept and the compact design. The individual marshalling patchboard elements snap into place easily and securely and can also be coded using eleven different colors. This ensures clearly arranged and fault-free wiring. The precise number of positions and the blocked form design, ideal for various applications, create a stable patchboard construction that is resistant to warping. The 2.3 mm test connections are easily accessible, next to the connection points, enabling convenient testing with standard testing accessories. The pre-assembled marshalling patchboards are available with four or six push-in connections per element in 32, 48

and 80-pos. designs. In terms of mounting type, there is a choice of direct, 19” rack and DIN rail mounting. The PTRV marshalling terminal system is the most compact on the market with a length of just 100 mm. It offers additions options for easy and clearly arranged marshalling wiring. Its key features include freely selectable colors, easily accessible test connections, and large-surface matrix marking. The marshalling terminals and marshalling patchboards are designed for use in Ex i safety circuits up to 60 V and are available as blue versions. The marshalling patchboards, which can be self-assembled, are configured and ordered with just a click of the mouse in the product area on the phoenixcontact.net/ products website. brucep@phoenixcontact.co.za

Index of Advertisers with relevant page numbers AT Technical Services Beckhoff Automation Endress+Hauser Helukabel Honeywell Instrotech ifm electronic Krohne

12,18 15 7 5 12,18 OFC,9 OBC 19

Phoenix Contact Pepperl+Fuchs Prei Instrumentation RET Automation Controls Soliflo (Pty) Ltd Temp-Tek Valve & Automation Vega Instruments

13 25 29 IBC IFC,12,18 23 21 11,12,18


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18.4

HAZARDOUS AREA INDICATORS.

K50L EZ-LIGHT® Bright, long-lasting LED technology for years of maintenance-free operation Fully-encapsulated for harsh environments; IP67 and IP69K Red, Blue, Yellow, Green or White colors with up to three color indication in a single light

www.retautomation.com Models for any zone or classified area. Extensive approvals ensure K50L and K30L indicator lights are safe to use in every zone or classified area, including a worldwide IECEx approval for quick access to countries outside Europe and North America. • 50 mm and 30 mm models • 4-pin integral Euro-style QD, PVC pigtail Euro-style QD, or 2 m integral cable

EZ-LIGHT K50L

®

B71

EZ-LIGHT® K30L

RET Automation Controls (Pty) Ltd P.O. Box 8378 | Edenglen 1613 | Phone: 011 453 2468 sales@retautomation.com


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18.4

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