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17.6

OPTISWIRL 4200 – The All-in-One Solution Vortex flowmeter with online density compensation


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17.6

On the Cover... The KROHNE OPTISWIRL 4200 Making processes more efficient while reducing costs The rise of raw material and energy means that now, more than ever, companies have to deal with the topic of energy management. On the one hand it is important to reduce energy costs and save over long term and on the other hand you can benefit from certification according to the ISO 50001 regulation.

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Nov/Dec 2014 Volume 17.6

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 11420 Vorna Valley 1686 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

PTISWIRL 4200 is suitable for the flow measurement of a wide range of media. It provides its special strength when it comes to the measurement of density-sensitive media: Already the basic version of the OPTISWIRL 4200 is equipped with a temperature compensation for saturated steam applications; this is an excellent way to ensure sustainable economic success for your company. With the optional pressure sensor the OPTISWIRL 4200 has an integrated density compensation available, which even allows an exact measurement of all kinds of gases and superheated steam with varying process conditions. The electronics of the OPTISWIRL 4200 consist of a highresolution graphic display and an electronic plug in module. The device can be operated by touch of a finger or – with closed housing - with a Magnetic wand. Alternatively the configuration can be carried out comfortably on the PC via Pactware. The configuration and calibration data are stored twofold, in the electronic module as well as in the display memory. This Redundant Data Management prevents the loss of data in the unlikely event of an electronics failure. The replacement part can easily be installed without any re-programming The precise measurement of the volume flow and the process conditions in only one single point combined with an online density calculation based on the standards established by international associations of specialists (i.e. NIST for gas applications and IAPWS for steam applications) results in an excellent system accuracy and makes the OPTISWIRL 4200 perfectly suited for the measurement of energy carriers. As all-in-one solution in auxiliary and supply processes the OPTISWIRL 4200 proves itself as reliable partner to support advanced energy management systems. The OPTISWIRL 4200 was designed for the safety-related applications from the very beginning. It was developed according to the standard IEC 61508 edition 2. The certification is effected within the scope of a Full Assessment by TÜV Süd. Thereby the OPTISWIRL 4200 can be used for continuous volume flow measurement in safety-related applications with classification SIL2. Save costs on installation by using OPTISWIRL 4200 compact measuring systems. In order to measure fluctuations in pressure and temperature, measuring systems consisting of a vortex flowmeter, a separate pressure sensor and a separate temperature sensor as well as an additional flow calculator are generally installed. This results in high costs for assembly and installation. However, with the installation of a vortex flowmeter featuring integrated pressure and temperature compensation such as the OPTISWIRL 4200, there is no need to install separate sensors, cables and in feeds. This makes it possible to save up to 50 %! Using a vortex flowmeter with integrated pressure and temperature compensation such as the OPTISWIRL 4200 allows you to not only lower installation costs but also increase the measuring accuracy of the measuring point. In this case the accuracy is ±1.5 % of the measured value. www.za.krohne.com . salesza@krohne.com . 011 314 1391


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17.6 Contactless flow measurement for critical media

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eliability and precision are key characteristics of the C38 SonicLine® flowmeter from. The device, which was originally developed for the semiconductor market, is perfectly suited to applications in other sectors of industry, thanks to the high standard of quality and versatile basic functions. The ultrasonic sensors integrated in the SonicLine® log up to 250 measured values per second. This means that heavily fluctuating flow rates can also be precisely detected. All medium wetted

components are manufactured from ultra-pure PFA. The electronic measuring equipment comprises a housing made of PP material and is encapsulated during production. This means that all electronic components are hermetically sealed to the outside. This type of manufacturing ensures that the device is especially insensitive to corrosive ambient conditions. The GEMÜ C38 SonicLine® flowmeter is especially suitable for use in conjunction with ultra-pure media, such as DI water, for example. However, corrosive chemicals, such as sulphuric acid, caustic potash solution or hydrofluoric acid, can also be conducted without any problems. The device can also be used in processes which need to be completely metal-free. In addition to pure flow measurement, SonicLine® is also used for dosing applications. The valve actuation required for this can be carried out by the integrated electronic system. This also offers additional functions, such as an empty pipe signal or limit value alarm. Users can make use of an additional interface package, allowing connection to a PC, which can also serve as a power supply. Multilingual software is available to enable individual adaptations by the customer. In addition to an integrated totalizer, the current flow can also be displayed, and all of the basic settings that are required for the operation can be checked and changed. Neels.kloppers@gemue.co.za

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Dates & venues for

THE CONTROL

ROADSHOW Cape Town - 5 February Durban – March (TBA) Windhoek – 2 June Walvis Bay – 4 June Steelpoort – 14 July Phalaborwa – 16 July Port Elizabeth - 27 August Secunda – 17 September Vanderbijlpark – 3 November

Contact Roxanne 0861 776 237 / roxannewnip@mweb.co.za to book your stands


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17.6 PLC and robot control seamlessly integrated

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t Automatica 2014 Beckhoff and KUKA presented a new common interface. The PLC library under TwinCAT 3.1 supports the mxAutomation interface to KUKA. Using the mxAutomation library, commands can be sent directly from the PLC to a KUKA robot with a KR C4 controller. It is thus possible for the first time ever to program the controller and robot simply – i.e. without knowledge of a special robot programming language – on one system. Communication takes place via EtherCAT, with the TwinCAT EtherCAT master and the KR C4 controller from KUKA exchanging data via the EL6692 or EL6695

EtherCAT bridge terminal. In doing so, drive commands are transmitted from the controller to the robot and actual values from the robot to the controller. Commands can be transmitted very quickly from the PLC to the robot thanks to this efficient, high-performance communication. Not only that, the PLC programmer has access to the robot position data at all times in real-time. With extended functionality, the direct and close interaction also enables the implementation of applications where highprecision synchronisation is required. mxAutomation for TwinCAT

3.1 revolutionises the cooperation between PLC and robot. PLC programmers can program movements directly in

the PLC and monitor all actual values of the robot in real-time.

transmitter. Features of CALOG’s remote large displays are: • Excellent visibility with the ultra-bright 125 mm LED digits • IP65 steel housing with 125mm LED display • Display range push button programmable via integrated indicator/transmitter • Full range of output options available on indicator • CALOG’s remote large displays offer a wide range of applications where high visibility and viewing from long distances is required. Typical applications include: • Downtime, time and production control in large factories. • Clock and shift timing applications for manufacturing areas. • Batch or product counting in manufacturing. • Speed timing and control

in manufacturing or service delivery. For example, the time a customer’s car is in a wash bay or on a lift for a tyre fitment. • Remote large display for load cell batch quantities or crane overload protection. • Remote large display for belt weigher rate or total indication. • Weigh bridge weight indication for both driver and operator. • Remote temperature indication for furnace and oven applications where an operator cannot get close to the furnace due to the high temperature. • Temperature indication for baking applications were the speed of a conveyer is controlled based on the temperature of the oven. For example, a tile or bread-baking oven utilising a conveyer to control the time the product is run through the oven.

kennethm@beckhoff.co.za

Remote large displays

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local designer and manufacturer of high quality process control instrumentation and industrial electronics is offering a wide range of remote large displays that includes digit sizes of 20 mm up to 125 mm. These are available in both Polycarp and metal housings

for 3, 4, 5 and 6 digit displays, marketed under the CALOG brand. Standard input to the remote large display is RS232 or optional RS485, with inputs of mA, mV, V, A, Frequency, RTD, Thermocouple and load cell made possible with an internal add on indicator/

sales@instrotech.co.za

Mitech relocates to bigger premises

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itech, the local manufacturer of a wide range of valves and related accessories has relocated to Kempton Park. The new facility provides an improved working environment for staff and a significant amount of additional space for the changing requirements of the company’s growing business and increased order book. Mitech’s new factory is 3 800 sqm in size, which is 1 000 sqm more than its previous premises. The machine shop and assembly areas feature overhead cranes, and with air conditioning throughout the factory, employees enjoy a much improved work environment. The factory floors are epoxy coated making them easier to keep clean, while the security in the Denel factory park is world class. The new address is 3 - 8 Altas Road, Denel North Entrance (D4), Kempton Park. The new telephone number is 011 927-4850. enquiries@mitech.co.za


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17.6 Force monitoring for manual presses

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erman instrumentation specialist Burster, has introduced the new economically-priced ForceMaster 9110 that can monitor both complex and simple press insertion of manual presses in manufacturing and assembly processes. The device monitors force/time or force/displacement/time and is particularly suited for application in chemical and pharmaceutical, food industries, production in assembly or mechanics manufacturing and medical engineering, providing 100% checks. The smart autoconfiguration, combined with automatic sensor recognition, means that even trainees can learn to use the ForceMaster 9110 within a few minutes. “Card & Go”, the SmartCard management system provides tamper-proof operation with access rights for handling bad parts as well as administration of all sorts of different press tools using tool data. In case of recurrent parameters for tested items, this data can be quickly and reliably loaded into the system. Setup and configuration is reduced to a minimum, therefore preventing possible errors when connecting the sensors. The integrated visual and acoustic signally devices indicate whether the produced parts are OK or NOK. The adjustable tone and volume control allows differentiation between several ForceMaster machines in the production facilities and also provides support even with monotonous manufacturing processes. Additionally, integrated stroke and unit counters means that external counters are unnecessary. Simple control tasks can be optionally implemented using a special sequential control function. This can be used for additional tasks such as pneumatic clamping and release of work pieces, blowing out pressed parts, blocking and return stroke of the press or control of OK/NOK sorting diverters. The option of saving measurement curves on a USB flash drive

Meter for compressed air consumption

provides the user with an extremely cost-effective method of storing curves at the machine as well as archiving for evaluation later on a office computer. The parameterization and evaluation software are FMControl, which is included in the system, and can be used to read out the measured values stored in the ForceMaster 9110 and to display and configure the active evaluation elements. The curve data can be stored in an archive. The measurement curves on the USB can also be imported, displayed and archived. info@asstech.co.za

New hygienic point level sensors

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local company offers compressed air users the ability to keep a tally of exactly how much of this expensive resource is being used or wasted. With the efector Metris compressed air consumption meter, ifm provides the user with a low-cost opportunity to precisely measure the current compressed air consumption as well as the total consumption. To do so, the sensor is mounted and adjusted in a pipe length at the factory. Due to the high sensitivity even minute quantities, like those that, for example, occur in case of leakage, are detected at an early stage and can be repaired. Binary, analogue and pulse outputs, the display of current and accumulated flow as well as further functions provide a variety of options to gain informative measurement data and to process them in the control system or in the process.   The fast response time of 100 milliseconds also permits the detection of quick changes or compressed air peaks. Furthermore, Metris distinguishes itself by its high measurement dynamics of, for example, 1:300.   The measuring principle, as well as the constructive design of the sensors, make a measuring accuracy of 3% of the measuring value + 0.3% of the final value of the measuring range possible. Available for pipe sizes from 12,5 mm to 250 mm, efector Metris incorporates a numeric display showing the throughput. For ease of interface with existing systems the outputs are available as analogue, pulsed or switched alarm points.

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info.za@ifm.com

info.za@ifm.com

erfect suppression of stubborn deposits, flexible installation, simple plug & play due to factory setting, as well as maintenancefree PEEK seals are only some features of the new LMT sensor family. Furthermore, the sensors provide a reliable, fast switching and ideal alternative to tuning forks.Precise level monitoring in storage tanks or run-dry protection of pumps are two important tasks for point level sensors. The different lengths and process connections of the new LMT series allow application-specific and orientation-independent installation. Even in difficult conditions with limited space the very compact design allows simple installation. The robust high-grade stainless steel housings are shock and vibrationresistant and the sensors meet all requirements for hygienic areas. The LMT sensors can be adjusted to almost all liquid and viscous media as well as powdery bulk materials. The distinction of two media is possible due to the two switching outputs which can be set independently. The parameters can be set via IO-Link or USB interface. ifm’s new LMT point level sensors are ideal for particularly demanding applications, but at the same time, are easy to use.


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17.6 What’s so special about a “Custody Transfer” flow meter?

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his is the question that is on everyone’s mind when a customer has a unique application that requires a custody transfer meter to be the cash register of a business transaction. The seller and the customers need to trust these meters to be accurate. Always! The preferred custody transfer flow meter has changed with time, technology, and application. Mechanical meters have long been used in most fiscal systems. Positive displacement flow meters were commonly used for small pipelines, load racks and truck mounted applications. Large transfer pipelines commonly used differential pressure orifice metering; pneumatic and later electronic systems.In recent years, linear electronic flow meters have replaced more and more traditional custody transfer systems. Modem flow meters, like the Coriolis mass flow meter, the Promass 84F, for example, has no mechanical moving components to wear or replace over time. The self-contained electronics and the multivariable

aspects of Coriolis flow meters can require less peripheral devices like temperature and pressure compensation sensors. In some applications, meters like the Promass can also eliminate the need for strainers and filters that would otherwise be used to keep metal burrs and solids from mechanical metering systems. Components like strainers, check valves, air and vapour eliminators may still be required regardless of metering technology in order to satisfy national regulations.The requirements for flow meters used in trade vary slightly around the world. However, there are requirements that are uniformly applied. Custody transfer, commercial or

retail trade, flow meters must have a redundant security method to prevent tampering with the calibration adjustments. The first level of security is commonly an internal switch or jumper which enables the access to the calibration physical mechanisms or electronic programming. The access to the internal switch, jumper or software programming must also be limited. The second level of security is a security seal that must be broken to show evidence of access. In the past it has been a wire seal applied through an eyelet screw and the housing or other mechanical system. Newer designs of electronic devices incorporate tamperproof

Boiler feedwater valves for severe startup

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oiler feedwater valves face require feedwater flow control to the most severe startup make up for the steam that leaves conditions to be found anywhere the boiler. within a power plant, a situation Mitech’s Boiler Feedwater that can become highly significant valves are particularly suitable for in terms of costly trim damage, use in power plants as the high expensive leakage and difficult pressure valves control the boiler control. Because feedwater feedwater into an existing boiler. valves are critical to a plant’s The Boiler Feedwater valves operation and performance, it is ensure an improved performance essential that they be specified during start-up, better control properly. This relates both to the and longer life. valves’ ability to control and to The main valve has a special provide tight shutoff, factors that Valve trim featuring Mitech’s ZZ design Trolleyat low openings and cavitation often are overlooked in the valve selection process. All boilers control at large openings. This ZZ

HONEYWELL

HELUKABEL

mechanism eliminates cavitation resulting from the high pressure drop experienced during startup, while the cavitation control design handles the normal running conditions, where the flow rate is high and the pressure drop is low.Good control during start-up is provided by tri-linear characteristics without the need for sacrificial bypass valves installed in parallel. All valves are rated to ANSI # 1500 and feature butt-weld ends. enquiries@mitech.co.za

AT TECHNICAL SERVICES Valve Trolley

➢ 011 805 1201 Boni.Magudulela@honeywell.com

➢ 011 462-8752

➢ 086 100 2887 www.atts.co.za

reporting software called an audit trail that retains memory of changes made to the meter as well as the date and time of the event. The custody transfer meters are tested by national metrology laboratories to verify the security of the design and the performance, this process is called type approval. The flow meter is approved for use in suited applications. A marking label is applied to each meter containing the approval reference information. The flow meter is then allowed to be sold into the appropriate applications.Finally, critical service and custody transfer applications require that the flow meter is proven against a traceable reference standard. In some countries the manufacturer’s calibration certificate is deemed acceptable. In other countries, the flow meter must be proved as used. The performance requirements vary slightly with national regulations often dependent upon the value of the traded liquid or gas. info@za.endress.com


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17.6 New rugged outdoor zoom IP camera

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he new VPort 56-2MP series is a rugged 1080P H.264 zoom IP camera designed for mission-critical video surveillance applications. The camera can operate in an extreme environment of -40 to 75°C without the need for a cooling fan, and is tailored to increase system reliability in extreme conditions and decrease maintenance costs for system operators. With an optional built-in fiber interface and positioning PT scanner accessory, Moxa’s VPort 56-2MP camera can be transformed into an IP positioning system with PTZ capability. Extreme Reliability for Outdoor Applications The VPort 56-2MP is part of Moxa’s new generation of extreme weather IP cameras designed to operate without a fan, making the VPort 56-2MP suitable for both blistering hot deserts and sub-zero snow covered outdoor environments. In addition, the camera supports a higher EMC protection level, and with an optional robust IP68 or Class 1, Division 1 compliant housing to provide exceptional weatherproofing, dust, and explosive atmosphere protection, the camera is well suited for demanding railway, public security, and extreme weather applications, including oil and gas, railway, border fence security, ITS, and mining, that operate 24 hours a day, 7 days a week in harsh environments. Optimal Full HD Image Quality The VPort 56-2MP delivers 1080P Full HD resolution (1920 x 1080), supports up to 3 video streams, and can handle complex scenes easily since the camera preserves rich color contrasts and produces crisp, clear images. With an advanced optical technology featuring 10x optical zoom (6.3mm to 63mm) and 16x digital zoom, 3D DNR, sense up, ICR, and image stabilizer technology to overcome poor lighting conditions, images can be displayed in a wide dynamic range of dark to light, even when operating in extreme environments. Interoperability and Integration The VPort 56-2MP supports ready-to-use NVR and VMS software for video surveillance

systems, and provides a variety of software development kits for use with third-party VMS and SCADA software. Moreover, the VPort 56-2MP supports industry standard ONVIF specifications for simpler and faster integration. Key Features and Benefits • Industrial-grade extreme weather 1080 full HD zoom IP camera • Operates in extreme temperatures without a fan for

long-term durability • Full HD 1080P resolution, H.264 encoding, with 10x optical zoom and 16x analog zoom • High quality video images with day-and-night viewing, 3D DNR, BLC, and image stabilizer • Optional fiber Ethernet port for easier installation and lower costs, especially for longdistance applications • Outdoor-ready with an optional IP68 or Class 1 Division

1 external housing to ensure protection against dust, rain, explosive atmospheres, and corrosion rob@rjconnect.co.za


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17.6 Compact IR camera for glass manufacturing

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lass manufacture requires special equipment for non-contact temperature measurement due to its physical properties. In addition to the special infrared thermometers, Optris GmbHrecently introduced the thermal imaging camera optris® PI 450 G7 with 7.9μm filter to the market. OPTRIS cameras are highly regarded in the industry due to their compact design and the excellent price-performance ratio and with the new G7 model of the PI series, processes in the glass industry can now be regulated by even more highly accurate temperature measurement on glass surfaces. The license-free optris® PI

Connect software, which is included in delivery, has a line scan camera function (line scan mode), which, for example, measures pane temperature during transport of glass panes on conveyor belts. This is a particularly important quality factor for tempering processes. At an ambient temperature of up to 70 °C, the infrared camera is fully operational without a cooling jacket. With a jacket size of 46x56x90 mm3 and a weight of 320 grams (including the lens), the optris® PI 450 G7 is particularly suited for applications in confined spaces and for installation in industrial facilities. Due to an

imaging frequency of 80 Hz, glass products can be continuously tested, even in fast processing. The camera is shipped with

an extensive thermographic analysis software package. sales@instrotech.co.za

MXstudio 2.0 network management suite with comprehensive device support

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he new version of the network management software suite, MXstudio, can now supports a variety of devices, including Ethernet switches, wireless AP/Bridge/Client, Ethernet gateways, serial device servers, and IP cameras, aiming to deliver a easy management experience to automation network administrators

The MXstudio software suite includes Moxa’s well-known MXview network management software and two new tools— MXconfig mass configuration tool for initial mass deployment, and N-Snap network snapshot tool for quick troubleshooting. This one suite allows you to handle almost every task at each stage of the network management life cycle, including

installation, operation, maintenance, and diagnostics. Moreover, with its intuitive interface design, MXstudio empowers automation engineers to easily run a high availability network, reducing the total cost of ownership. Moxa has worked with automation engineers for over 25 years, and to date the MXview network management software has been used to monitor about 70,000 nodes worldwide. As industrial networks get more complex, engineers encounter bigger challenges at keeping networks operating non-stop. They need to spend time learning different software for different tasks, while trying to eliminate human error through time-consuming maintenance processes. Moreover, with larger networks, it takes longer to pinpoint the root cause when errors occur. MXstudio industrial network management suite includes the following software: • MXconfig industrial network configuration tool reduces setup time for initial mass deployments • MXview industrial network management software displays real-time network status information in an intuitive graphical interface • N-Snap industrial network snapshot tool serves as a standalone utility for collecting and comparing network data for quick troubleshooting info@rjconnect.co.za


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17.6 Solution for pump motor protection

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range of electronic motor protection and control relays, especially designed to protect pumps and motors from a variety of faults associated with this market is available from a local manufacturer. The entire K series is aimed at rendering assistance to pump users and consultants that specify protection requirements for pumps. What makes these relays unique is that they incorporate features such as dry-run protection and phase reversal protection which are basic requirements for the protection of pumps. A model exists for every budget. The more upmarket models also include built-in features that allow for a user-selected pump priming time, as well as a user-selectable pump operating time slot. Automated re-start times for dryrun trips are available together with selectable automatic overload trip resets. A useful asset on some models permit the user to measure dryrunning conditions by means of power factor

measurements instead of conventional current measurement so that greater accuracy can be achieved. The range includes the most basic features that need manual adjustments directly by the user to the more sophisticated that can only be programmed by the supporting software avoiding possible setting interference by users. These include the monitoring of statistical information such as the number of starts, trip faults and pump efficiency. Motor protection is achieved by the usual current measurement methods and userselectable phase voltage measurements. Some of the relays in the range also include earth leakage protection, as well as earth insulation lock out protection. The range is very user-friendly and has no limits on current range. These are, in order of sophistication, the KB, KA, KC, KD and KE relays. sales@newelec.co.za

Laser sensor delivers highly optimised performance for positioning and measuring

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he L-Gage LE family of laser sensors has been expanded with the new LE250. Optimised for measurements ranging from 100 mm to 400 mm, the LE250 features superior measurement precision and a small laser spot size. The sensor’s linear array allows for reliable detection and measurement across a wide range of difficult targets, from black rubber to shiny metal. With a resolution of 0.02 mm out to 250 mm and a resolution below 0.2 mm out to 400 mm, the LE250 provides the repeatability and accuracy for solving applications where precise dimensional measurements or positioning are needed. The LE250 also features a smaller spot size, approximately one millimetre, which is ideal for small part detection, and provides more consistent measurements for applications that present varying colours, including

multicoloured packaging. Designed with the same robust housing, intuitive user interface and linear array technology as our LE550 sensor, the LE250 offers the performance features customers have come to depend on. However, with

the smaller beam size and better resolution, the LE250 allows customers to solve a wider range of applications. The LE250 operates with an intuitive two-line, eight-character display, allowing for easy readability, quick adjustments

New appointment

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hris CronjĂŠ has been appointed managing director at Shorrock Automation. Chris has had many years of experience in the automation of measurement and control applications and was sales manager for many years at ifm electronic SA before his new appointment. Both companies have had a long and successful business relationship for many years.

and simple menu navigation. The visible red, Class 2 laser beam and small spot size ensure quick setup and alignment. Features like delay timers and averaging trigger functions can reduce PLC programming time and help get an inspection up and running sooner. The LE250 is also available with an optional metal, rotatable connector and multiple mounting bracket options, allowing operators to save time and money while accommodating flexible application requirements. Enclosed in a rugged, diecast zinc housing and IP67rated polycarbonate lens cover, the LE250 ensures optimal performance in demanding environments. All models meet Military Standard 202 G requirements method 201A, in addition to IEC 60947-5-2, to withstand applications subject to vibration or shock. rodneyt@retauto.co.zaÂ


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17.6 Fit for purpose solution incorporate the latest technology

The MLD type multiple light beam safety device is an example of the latest sensing, measuring and monitoring technology available.

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he replacement of original sensing, measuring and monitoring devices represents a perfect opportunity to assess a specific application and the suitability of the equipment. A more fit for purpose solution, based on the incorporation of new technology, could be considered at this stage. It is entire possible that selection of the original units occurred with one particular machine, rather than the entire process, in mind. When replacing these units, it is then possible to achieve a more holistic overview of the process. In so doing, the supplier will be able to provide a far more cost efficient and plant related solution. This is becoming ever more critical as process plants and manufacturing operations are facing increasing pressure to cut costs.

The Leuze Rotoscan RS4 shows how far sensing, measuring and monitoring technology has advanced.

Business methodologies have had to adapt as sensing and measuring technology itself has developed. In keeping with this transformation, a local company has evolved from being a supplier of technologically superior sensing and monitoring devices to a solutions provider offering advanced technology packages that incorporate high level support. This is underpinned by assistance in both the selection of application appropriate and cost effective solutions, as with the installation of total systems.

Their philosophy is that when one considers a customer’s application, it is best to look beyond a single problem area. A more structured approach is needed in order to obtain a general overview of the customer’s specific requirements. By considering the overall operation of the plant, one will be able to find a solution that will encompass any unforeseen needs within the process. It is important to comprehend that selecting sensors is not as simple as matching a model number to a requirement. One needs to assess the operating environment and gain a comprehensive understanding of the elements that need to be monitored and what would be the most appropriate product from a ‘big picture’ perspective. Parameters that need to be taken into account include the range of the sensor, the speed of the automatic process, the background conditions and type of product, auxiliary equipment and the circuits within the process. An example is selecting a photo electric sensor that is suitable for various switching distances within a plant. The customer then has the option of standardising on one sensor type, as opposed to having different devices throughout the process, which will reduce parts inventory and associated operating costs. A failure to understand the full capabilities of a specific device could result in the selection of a far costlier sensor, when a more cost effective option would suffice in a particular application. Technical acumen and

The recent launch of an enhanced range of Leuze safety switches, safety locking devices and safety command devices follows the call for further flexibility in the range.

experience play a large role in reducing the effects of human error, which could result from uninformed product choice and the absence of appropriate technical counsel. This is where a dedicated technology and solutions provider plays a vital role. Each application has unique, specific needs. In order to provide a balanced solutions driven approach, it is advisable to select a supplier with extensive industry knowledge and a diverse portfolio of customers. bryant@countapulse.co.za

Laser distance sensor with two-line display

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new laser measurement sensor featuring an intuitive two-line user interface display has been introduced by Banner Engineering. The LE550 sensor offers a combination of range, repeatability, accuracy and ease of use not previously available at this price point. Its 8-digit display shows the exact distance to the target as well as the signal of the analog output. Via pushbuttons next to the display the user sets all functions of the sensor or inverts, if applicable, the display’s orientation. The sensor’s linear array provides accurate

measurements from 100 to 1000 mm on a wide range of challenging targets from black rubber to shiny metal. Typical applications include roll diameter, loop control, object measurement and position. The switching output and the analog output can be parameterized independently. For most precise measurements multiple sensors can be installed in close proximity. The die-cast housing is rated IP67, NEMA 6 for use in harsh conditions. rodneyt@retauto.co.za


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17.6 Severe service energy dissipating disk stack trims

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he locally manufactured severe service Energy Dissipating Disc Stack Trims are designed for use in high pressure drop and high flow rate conditions. As the liquid moves through the passages in the trim stack, the energy is dissipated through wall friction, swirling, sharp direction changes and a series of expansion chambers and restrictions. Compact in design, each trim is specially designed for the application and can be combined with cavitation control, resulting in a high rangeability with a 200:1 turndown. Suitable for cavitation elimination on liquids and low noise on gases, the disk stack trims can be separated and cleaned due to the loose disk design. The trims can be designed for flow directions of either over or under the plug, depending on the flow conditions. The trims are available in various body sizes from 50 mm to 600 mm. enquiries@mitech.co.za

New temperature sensor enables reliable soldering

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local company can now supply a platinum temperature sensor sourced from Jumo in Germany with pre-tinned connection wires to ensure reliable soldering. The PCA ET is perfect for applications ranging from the medical field to heating and air-conditioning technology. In humid environments, it is possible to install this sensor in combined humidity and temperature measuring transducers. Platinum temperature sensors are regarded as robust, long lasting and are characterized by good vibration resistance and fast response qualities. They can also record in high temperature ranges of several hundred degrees. In some instances however, the soldering of the nickel connection wires for the sensors can prove problematic. Jumo temperature sensors had previously only been available without tinning as usually a soldering process is qualified by the end user where the exact flux is specified. By pre-tinning, any soldering process, irrespective of the used flux, can be applied. The Jumo PCA ET is available in sizes of 1.5 x 5 x 1 mm and 2 x 5 x 1.3 mm. The temperature sensor is supplied with rated values Pt100 and Pt1000 with tolerances of F0.1, F0.15 and F0.3. A special feature is the version in the F0.6 tolerance class which is supplied “on tape” and is suitable for automatic mounting. As a result, this sensor can be applied very economically and efficiently. info@asstech.co.za

Locally manufactured diffuser plates

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ocally designed and manufactured diffuser plates are used with Globe Control Valves on high pressure drop applications for gases and vapours. Installed downstream from the valve, the diffuser plates are designed to create a back pressure at the valve. 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 while still keeping the velocity within acceptable limits. Special trims are 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. Usually the valve size can be reduced to less than half the size it would have to be without the plate, resulting in significant savings, particularly when the sizes involved are large. Several diffuser plates can be installed in series in an expanding pipework system, or they can be built into a single holder for ease of installation. A steam pressure reducing station is a typical application that can utilise this technology. enquiries@mitech.co.za

HONEYWELL

Valve Trolley

AT TECHNICAL SERVICES

HELUKABEL

Nozzle Remover

➢ 011 805 1201 Boni.Magudulela@honeywell.com

➢ 086 100 2887 www.atts.co.za

➢ 011 462-8752


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17.6 Smart power box with data logging function directly on the machine

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he EP9224 smart power box offers internal current and voltage measurement in addition to the possibility to connect four EtherCAT Box power supply branches. The values are available to the controller via EtherCAT and support the preventive maintenance of machines and plants as well as error diagnostics, especially in conjunction with the data logging function. The power consumption for the control and peripheral voltage is monitored, limited and if necessary also switched off in each 24 V supply branch of the smart power box. The input voltage and current values as well as all output currents can be transferred by EtherCAT to the controller as process data and evaluated. In case of an error a continuous data log can be retrieved, allowing the cause of the error to be identified more easily. For this purpose the last 40 values of the input voltage/current, the output current per channel, the I²t warning level and the internal temperature are stored in a ring buffer. This information is recorded every 1, 10, 25, 100 or 1000 ms as required. The current and voltage measurement plus the data logging provide a deep insight into the machine and considerably simplify and accelerate service. In this way the monitoring of the momentary current values minimises the response times to any errors. As a form of Condition

Monitoring, this transparency in the system and thus the early identification of deviating machine states also supplies the ideal basis for preventive maintenance. Higher total current simplifies system wiring EtherCAT Box modules with IP 67 protection typically use M8 plug connectors for the supply of power, but these are only suitable for a maximum current of 4 A. Therefore it may no longer be possible to simply loop the supply through where modules have a large number of outputs. A further limitation concerns the cables: as the M8 plug connectors can only be used up to a maximum cable cross-section of 0.34 mm2. This results in a considerable voltage drop over larger distances. The EP9224 smart power box offers the ideal solution for this. Equipped with 7/8-inch plug connectors, it allows a total current of 16 A for each control and peripheral voltage with cable cross-sections of 1.5 and 2.5 mm. Even considerably higher starting currents are briefly permissible at the outputs, so that the trouble-free start-up of the connected devices is guaranteed. This gives rise in the field to significantly simpler and cheaper plant wiring compared to the otherwise necessary additional terminal boxes with fuses. kennethm@beckhoff.co.za

Temperature transmitters for food and beverage applications

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he TD Series temperature transmitters for food and beverage applications are designed, developed and manufactured to thrive in the harshest environments. The integrated transmitter electronics, process connector and Pt1000 Class ‘A’ RTD probe are laser-welded, IP69K-sealed which meet the stringent requirements of 3A standards.  Robust and durable, the unit is corrosion-resistant against chemicals and harsh industrial cleaners. The two-wire loop powered transmitter is pre-scaled for use in the 0 to 100 °C range. Applications requiring different ranges can be scaled with a programming tool via IO-Link.  A bright digital LED display indicates measured temperature directly at the instrument for easy verification of proper operation. Temperature measurement uses high accuracy Pt1000 class A RTDs (resistive thermal detector). The highly engineered tip design reduces thermal mass and precisely locates the RTD element with a constant position and force. The benefit of the tip design is very fast reaction speeds of 1 s to 50% and 3 s to 90% of the temperature change. There is no calibration or matching of the RTD with the transmitter module. The TD comes fully assembled and factory calibrated for the highest degree of reliability. This saves both installation and commissioning time. The TD temperature transmitter product line is available with probe lengths of 30, 50, 100 and 150 mm. Units are available with 37.5 mm or 50 mm tri-clamp fittings.

The 18 - 32 VDC units have a 4 – 20 mA analog output. Maximum measuring range is -50 to 150 °C. info.za@ifm.com


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17.6 Taking kinematics to the next level

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winCAT Kinematic Transformation enables machine manufacturers and users to control robots and their own kinematic constructions directly from within the TwinCAT software platform. This function has been further developed so that also highly complex kinematics can be implemented. TwinCAT Kinematic Transformation offers numerous kinematics that are divided into three different product levels, depending on their complexity. These include 2-D, shear, 3-D delta and SCARA kinematics. The new Level 4 version represents a consistent extension of the range of functions, now also allowing more complex kinematics to be implemented. Examples are serial 6-axis kinematics and the Steward platform. TwinCAT performs the set value generation and necessary kinematic transformations. The set values for the axes are cyclically transferred via EtherCAT to the drive amplifier, e.g. an AX5000 servo drive. The robot movements are programmed directly from the PLC. Path movements for the following of contours can, of course, also be implemented with TwinCAT NC I according to DIN 66025. With TwinCAT Kinematic Transformation an additional robot controller and thus the learning of a special robot programming language is not required. Accordingly, the entire machine can be operated with just one control CPU. kennethm@beckhoff.co.za

Self-priming jet pumps

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he AJm self-priming jet pumps can be used to transfer clean water or other liquids similar to water’s physical and chemical properties. Reliable and low maintenance, they are suitable for lifting water from wells, irrigation and pressure boosting of running water. The pump has a stainless steel body and support, both treated with a special anti-rust substance. It has a stainless steel impeller and an AISI 304 shaft and is suitable for temperatures up to +40°C. Various types are offered from 0,3 kW, 220V to 0,9 kW, 220V.The motor is C&U bearing, has copper winding and a built-in thermal protector for single phase type motors. It meets insulation class F and IPX4 protection requirements. enquiries@raptech.co.za

A bull’s eye in quality. Point level switch for liquids in the food sector Liquiphant FTL31 / FTL33

R1916*

Safe and convenient • Compact or short tube version • IP 65/67 with M12 connector and external function test • Leakage detection, WHG approval • Product temperatures up to 150 °C (optionally) Liquiphant FTL31 / FTL33 Version

11–35 pcs.

Price/piece in R Temp.

1–3

4–10

11–35

FTL31, Compact, 10…30 V DC; ≤100 °C R2060 R1978 Plug M12; ISO 228 G½" ≤150 °C R2353 R2259

R1916

FTL33, Ra<    1,5 µm; 10...30 V DC; ≤100 °C R2800 R2688 Plug M12; G¾ flush-mounted ≤150 °C R3093 R2969

R2604

*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

R2188 R2876


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17.6 Encoders for dynamic pitch control on wind energy turbines

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ntroducing a range of encoders for sophisticated pitch control on wind turbines. Wind energy turbines are not only exposed to strongly fluctuating winds but have to use these forces as efficiently as possible. Therefore dynamic pitch control is essential to boost the efficiency of this renewable energy technology by adjusting the rotor blade to the required angle. At low wind speeds, the rotor blades are directed towards the wind and turned away again as the wind forces increase, so as to ensure that the wind turbine continues to operate safely even at high wind speeds. Just as for many applications involving rotational movements, there are different approaches enabling the use of encoders â&#x20AC;&#x201C; starting from simple solutions with only one incremental encoder right through to a combination of two redundant absolute encoders. The gear motor positions the rotor blade while an additional brake ensures that the required position is maintained safely even in the event of a power failure. Since the encoder is mounted directly onto the drive, it has to return reliable positioning values within the temperature range from minus 40 to plus 100°C. The optical gear based multi turn Acuro AC58 encoders from Hengstler have proven to be the best and most suitable solution in this regard.

The position is determined by means of an optical rear illumination method. The mechanical multi turn gear is also scanned optically so that it is not necessary to test the magnetic effects which may be caused by the drive brakes in particular. Such scanning is not susceptible to magnetic interference and therefore suitable for direct mounting on all motors that are provided with brakes. In addition, the encoder offers high resolution values and is able to indicate both absolute and incremental signals which can be used as reference values and/ or for speed adjustments. As a result, no additional resolvers or tachometers are necessary. Another alternative is to mount the encoder directly on the slewing ring of the rotor

blade. In this case, it is coupled by means of a cog wheel mounted on the encoder shaft. Since the mechanical stresses on the sensor are significantly higher than in the case of motor installation, this application places totally different demands on the encoder. To reduce the encoder bearing load, bearing modules have often been used in the past. This installation variant calls for a specifically robust encoder such as Acuro AR62. Featuring a compact design and extremely sturdy ball bearings, it is suitable for very high axial and radial loads. With a maximum admissible load of 300 N (both axial and radial), it not only surpasses most of the common load module types, but also offer ten times the load capacity of commercially available encoders.

Similar to AR58, AR62 is an electronic multi turn encoder that also exhibits wear free pulse wire technology. Magnetic single turn and multi turn scanning ensure high shock and vibration resistance. It is also resistant to environmental influences such as humidity and wide temperature ranges. Offering protection class IP69K this encoder type is suitable for complete outdoor installation. Finally the encoder can also be mounted onto a limit switch box. On-site installation is facilitated by a complete, preadjusted component assembly. In this approach the mechanical requirements are not as high as compared to the direct installation on the rotor blade. Meeting all the demands for high precision and sturdiness the Acuro AR58 magnetic absolute encoder is a cost-efficient solution due to its mechanical design. Both in the single turn and multi turn variant, this encoder type needs only one single magnet. The multi turn encoder uses pulse wire technology, which means that it operates completely wear free without battery and gear. The energy required for position detection is produced from the rotational movement alone, a significant advantage of this technology. bryant@countapulse.co.za

Control valve re-design to increase productivity

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his entire control valve range has undergone a complete re-design resulting in a modular system to increase productivity in the process, food, chemical and petrochemical industry. The construction of the control valves is based on the standard cavity-free plug valve with PTFE-sleeve or chemical resistant PFA/FEP-lining. Furthermore, a wide range of different materials are available for various applications. Heat jacketed control valves are also available as well as different types of actuations such as pneumatic, electric and hydraulic systems.In case of a high flow velocity, a high pressure drop or solid-containing

mediums, a protection insert can be added to increase the service life of the control valve. To control the pressure,

flow or temperature as precisely as possible, 10 different plug forms are available per valve size, consisting of 5 linear and 5 equal percentage control characteristics. In case of very large flow rates, the full bore valve

can be recommended and if there is a specific flow rate needed, the plug can be designed and manufactured according to the requirements. sales@az-armaturen.co.za


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17.6 Eliminating downtime caused by impact torque conditions

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echanical damage to equipment can be avoided eliminating costly downtime and repairs to chains, couplings, screw conveyors and a variety of mechanical fractures. Impact torque occurs when an electric motor / gearbox combination attempts to deliver the necessary power and torque to overcome sudden jamming conditions. By fitting a NewElec OLR 84 protection relay to the motor protection circuit these problems may be totally avoided. The relay has two settings: the first designates the total start time for the given motor in seconds through a range of up to 50 s; the second designates the load trip threshold. The latter setting is percentage calibrated from 30 to 120 % of the selected CT ratio XXX:1. The user must select an appropriate ring CT that will cover the expected trip threshold current. A general rule is that if the motor load maximum current is x A, the user must use a current transformer where 3 x A is about mid scale. The reason for this is that a stall or jam condition usually manifests itself at about three times motor full load when the motor develops an output torque in the region of 2,5 to 3 times its normal rated torque. This output torque will then be amplified through a factor dependent on the gearbox ratio. The OLR 84 permits the starting current for the motor start but will cause a trip in 100 ms if the motor load suddenly exceeds the upper trip threshold where the motor enters a stall condition after the starting sequence. OLR 84 will interrupt the supply to the motor by means of the main holding contactor and prevent mechanical fractures in the production process. sales@newelec.co.za

Valves for severe service applications

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evere plant conditions can quickly turn into severe concerns. Severe Service Valves operate in the harshest of environments to solve the most demanding applications in the power, oil and gas 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 1â&#x20AC;? to 16â&#x20AC;? and on request up to 24â&#x20AC;?. 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. The valves ensure process integrity, up-time reliability and personnel safety. enquiries@mitech.co.za


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17.6 Innovative product range for fluid engineering

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ntroducing a new state-ofthe-art sensor measuring product range dedicated to fluid engineering. Based on a patented process which is unique in the field of flow sensor technology allows the WenglorFluid devices to be mounted regardless of position and flow direction and still provide precision measurements. Extremely user-friendly due to their uniform design concept, ease of operation and

connection, the WenglorFluid sensor’s watertight plastic and stainless steel housings assure accurate performance. The large 7-segement display provides for easy, intuitive operation. The separate LED allows for quick recognition of the switching status.All of the sensors have a switching output which can be configured as either normally closed (NC) or normally open (NO) via the menu. If required, the sensors can be additionally

equipped with an analog current or voltage output. The range consists of: UniFlow Sensors These ascertain the flow velocities of oily and aqueous media in closed piping systems. They don’t have to be aligned to the direction of flow during installation as heating and the temperature sensor are located in the tip of the device. Even if the sensor is turned around, the switching point does not have

to be readjusted. In addition, the UniFlow sensors can be mounted either parallel or perpendicular to the pipe which makes this installation option provide for maximum flexibility. UniBar Pressure Sensors The sensor measures the relative pressure of any desired media in closed systems within a range of -1 to +600 bar. Wenglor pressure sensors with metallic membrane are highly suited for areas with strict hygiene requirements such as in food and pharmaceuticals. They are flush-mounted and therefore compatible with pipe cleaning devices. UniTemp Temperature Sensors The measure the temperature of liquid and gaseous media and make it possible to monitor temperature within processes. They can be used under greatly varying ambient conditions as the switching points can be individually adjusted within a measuring range of 0 to 200º C. info@asstech.co.za

More than SIL – risk control starts with reliability

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ny process management system is efficient with reliable instrumentation. Reduce the risk in basic process control as well as safety applications with safe instrument design. Safety should always come first and starts with safe design and manufacturing based on certified products, people and processes. Benefits • Products: SIL devices are extensively tested and independently assessed • Process: intensively pursued functional safety development process • Sustainability: strategic functional safety management with continuous improvement Certified products level increase safety and availability Since 1999 the safety oriented instrument offerings have been extended to include Safety Integrity Levels up to SIL3. Time-of-Flight level measuring instruments, vibronic point level switches and hydrostatic level

devices are examples of our broad portfolio developed according to IEC 61508 and independently assessed by TÜV Rheinland. Features include selfdiagnostics and proof testing that help to increase process safety and plant availability. Certified people and processes for systematic improvement Certified functional safety management includes a quality and safety policy to allow permanent and systematic verification and improvement. For hard- and software development they have implemented standardised measures to avoid systematic faults and control random failures. During installation of SIL devices, requirements and restrictions are clearly described in the product safety manuals. Proven in numerous tests they are allowed to select a suitable safety device following the IEC 61511. Security in case of device failure The R&D team systematically

develops measuring devices certified up to SIL3. They also consider fail safe behaviour in case of device failure. With Liquiphant FailSafe for example, more than 100,000 operating hours, 500,000 start-ups and 1.7 million demands have been simulated and tested. More than 14,000 test cases have been generated and in excess of 2,500 documents have been created to verify the capability of the sensor – and that’s even before a single device has been sold. Mechanical integrity reduces operation risks During design and manufacture their experts follow clear rules and calculations, often defined in standards like EN or ASME. Material selection for targeted industry and applications is as crucial as virtual simulations, practical stress tests or the Finite Element Method. Sealing concepts such as single, dual or factory seal are achieved through sophisticated mechanical design. Tests such as

Positive Material Identification are as important as material traceability or welding documentation. info@za.endress.com


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17.6 Quality assurance made easy

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he Ecograph T RSG35 records data securely. With the help of the redesigned web server, all the important values can be seen at a glance. The ability to see the chronological history of a remote station at any time Is one of the advantages of the new Ecograph T RSG35 with Its redesigned web server. The device sets a benchmark in the economical price category for data recording and quality assurance. With Its Input configuration of 4/8/12 universal Inputs, the Ecograph T offers the possibility of replacing two recorders with one. Alternatively, the screen recorder Is also available with MOOBUS RTU/ TCP Slave. Remote access The web server provides complete access and complete parameter configuration externally. Settings can be stored locally or saved settings can be uploaded to the device. The remote access not only allows current values but also historical data to be visualised on the web server. The Field Data Manager evaluation software offers users further advantages. The automatic function is configured as a Windows service, for example, so that data is called up in the background. A Microsoft SQL Server or an Oracle SQL database can also be used for data archiving. The basic version, which Includes all the Important features, is supplied free of charge.

E-mail function The Ecograph T is particularly well-suited to the waste water management industry due to its integrated e-mail function that comes standard. It allows alarms and messages generated in outdoor structures to be transmitted to a smartphone as an e-mail using GPRS, DSL or Ethernet. Mobile access to the web server is also possible if configured appropriately. info@za.endress.com

Multiprotocol in-cabinet, block I/O stations for Industrial Ethernet

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popular line of in-cabinet, block I/O stations has been expanded with the addition of the FEN20 I/O stations for Industrial Ethernet. This station incorporates TURCK’s Industrial Ethernet multiprotocol technology into a fixed, economical, in-cabinet I/O product ideal for applications where digital I/O needs to be elevated to an Industrial Ethernet layer such as EtherNet/IPTM, PROFINET® or Modbus TCPTM. This first release in a family of FEN20 I/O stations is available with 16 configurable I/O, power isolation between I/O zones, and an embedded Ethernet switch to

support a variety of application topologies. The station can be addressed via an external rotary switch or via a webserver which makes troubleshooting easier, quicker and more cost effective. The FEN20 supports DHCP, LLDP and includes LEDs for status and basic troubleshooting. TURCK’s Industrial Ethernet multiprotocol technology is an innovative approach to Ethernet applications. A single station can operate on a Modbus TCP, EtherNet/IP or PROFINET network. Upon power-up, the station automatically recognizes the protocol of the master that tries

Profibus DP shaft encoders

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or the choice of an absolute PROFIBUS-DP shaft encoder, the user usually has to specify which shaft encoder operating profile is required. However, if the requirements and desired functionalities change in the course of time, a profile change then frequently makes it necessary to replace the existing shaft encoder.Nonetheless, Wachendorff Automation offers machine builders and system operators an alternative designed around sustainability and investment security. The WDGA

series of absolute shaft encoders for PROFIBUS-DP enables the user to load the preferred encoder profile quickly and easily via the device master file. This means that, purely in terms of software, the user determines which class (1, 2, 3 or 4) is needed for operating the absolute shaft encoder. It is thus possible to switch to another class at any time without the need to reinvest in a shaft encoder and without the installation effort which this would require. For Materials Management and

to connect to it, and dedicates the outputs to that master while still allowing other protocols to access the input data and diagnostic information. The FEN20 in-cabinet I/O module employs a unique housing that makes it perfect for uses in light tower, push button or operator panels. The FEN20 I/O station completes the family of incabinet, block I/O stations that can also be used in PROFIBUS-DP, DeviceNet, AS-Interface and now multiprotocol Ethernet fieldbus applications. rodneyt@retauto.co.za

for the Maintenance and Repair Departments, this is naturally an advantage, as the administrative effort and stocking only consist of a single shaft encoder type for different system generations or functionally different system designs.Different designs and versatile connection facilities via bus terminal box or plug ensure optimal integration of the WDGA shaft encoder to suit the required application. Thanks to the EnDra® technology of Wachendorff Automation, the extremely compact size of the

absolute encoders supports the trend towards miniaturisation in machine design. With their robust mechanical construction and very high bearing loads, they are designed for use in a harsh industrial environment. sales@vepac.co.za


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17.6 Family of level and distance sensors

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he ToughSonic LVL family is a range of level and distance sensors designed for ease of use and reliability that offers non-contact level or distance measurement up to 10.7m, depending on the model. Housed in a small PVDF package, these sensors withstand exposure to chemically aggressive and benign industrial environments, survive submersion (protection to IP68), and include a potted-in cable. Threads are provided at both the top and bottom to allow either suspended or flange installation. The LVL operates over a wide temperature range of -40 to 70ºC and humidity range of 0 – 100%, and the sensor includes multiple simultaneous analog and switch outputs. Other user-adjustable functions are filters,

timers, time delays, switch setpoints and polarity, condition response of all outputs and synchronization. The SenixView visual software which is included, provides adjustment, viewing, analysis, maintenance and cloning without recalibration whether for one or a network of sensors, making it ideal for OEM or maintenance operations where time saving is important. Serial data communications is via RS 485 modbus protocol. The sensor network can link to LAN or internet. With all the features available for the LVL Series, the user can create complete “mini” systems without additional external hardware. A typical application example is driving a pump or valve to control liquid level. sales@instrotech.co.za

Valve designs in chemical and high purity media supply

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n high purity applications and in critical fluid management, high quality and product purity are essential. In many industrial processes, chemical substances in any state of aggregation have become indispensable. One company offers its customers a wide range of services in chemical supply, particularly in critical fluid management. The highly resistant valves from the GEMÜ CleanStar® and GEMÜ iComLine® series can be used in all kinds of applications to meet various system requirements. Furthermore, the sealing technology of the iComLine® valve series allows the valves to be assembled as a multi-port valve block solution. As well as providing a layout that makes the most of both space and resources, it also allows the integration of measuring and sensor technology. Strict purity requirements must be met in all production processes involved in the

manufacture and supply of chemicals. The high purity acids and chemicals required for the manufacture of microchips are produced by specialist companies under ultra pure conditions. Valves, tubing systems and measurement devices for the control and monitoring of the media are also subject to these requirements. In this regard, GEMÜ can rely on its own modern cleanroom plant in Switzerland. For resistance purposes, all medium wetted parts are made of high-quality PFA or PTFE. In addition to valves from the GEMÜ CleanStar® and GEMÜ iComLine® series, other high purity products are available, for use in chemical supply systems among other things. The company offers a wide range of PFA fittings and PFA tubing for the distribution and connection of valves and components. The GEMÜ TubeStar® tubing is available as a 400 metre spool and as a 6 metre

straight piece in ¼ to 1¼ inch sizes. The GEMÜ FlareStar® fitting range offers over 1,200 variations for creating the appropriate connections in the supply installation.

The GEMÜ SonicLine® ultrasonic flowmeter allows extremely precise measurements, even with very small flow rates.

The pressure measurement devices from the GEMÜ HydraLine series have a high-quality

pressure sensor and a patented 3-fold diaphragm, which enables a very high degree of accuracy. There are no movable or fixed components in the measured length of any flow meters or pressure gauges, so that the medium can flow unhindered. The product range is completed with automation components such as position indicators and positioners or process controllers. Neels.kloppers@gemue.co.za

Triple eccentric valve with superior operating characteristics

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ith its triple eccentric design and metal-to-metal sealing, the TRI-CON Series guarantees an ideal valve design. • True cone in cone sealing • Frictionless operating • Low torques • Constant closing angle on the total circumference The operating characteristics and the tightness of the valve are not influenced by high differences

in temperatures and pressure fluctuations because of the triple eccentric geometry and the valves’ special features. Maximum service life is achieved by eliminating any “rubbing” between the laminated seal around the total circumference during seating which enables a frictionless opening and closing. This guarantees full tightness and low operating torques. fred.venter@valve.co.za


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17.6 A smaller and tougher 802.11n WLAN solution for industrial automation

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nnouncing the release of the AWK-1131A, a new 802.11n wireless AP/client that features a smaller housing with advanced protection technology, making continuous wireless connections a reality for your industrial applications. The new AWK-1131A is designed with galvanic isolation technology to protect devices from the electrical disturbances commonly found in industrial environments. In addition, it supports 802.11n MIMO technology to reduce multipath effects and increase data rates up to 300 Mbps for bandwidthhungry applications, and features millisecond-level roaming to minimize packet loss for seamless connections with mobile applications. There are many benefits to adopting wireless devices for industrial applications. Not only do wireless devices reduce deployment costs

compared to wired devices, they also increase mobility for hardto-wire applications and enhance scalability when expanding your network backbone. However, operators must consider wireless reliability and availability when choosing wireless devices for missioncritical applications. Industrial wireless devices require a rugged design that includes advanced EMS protection against the electrical disturbances found in harsh industrial environments, and seamless WLAN roaming to increase network availability for rolling stock industrial applications. By offering better wireless communication than what you’d expect, the new AWK1131A series can meet all of these requirements. The new AWK-1131A series features 802.11n technology, which is perfect for video surveillance applications that require up to a 300 Mbps

data rate and Gigabit wired transmissions. With the release of the AWK-1131A, Moxa now offers a comprehensive portfolio with both single-radio and dual-radio IEEE 802.11n industrial wireless solutions for the bandwidthhungry systems found in industrial applications. AWK-1131A Series Features • Advanced EMS protection against electromagnetic interference • Galvanic isolation technology on all interfaces for device reliability and longevity • 802.11n MIMO technology reduces multipath effects and increases data rates up to 300 Mbps • Moxa client-based Turbo Roaming with millisecond level roaming capability • Palm-size, cost-effective solution for easy installation in space-restricted locations info@rjconnect.co.za

Inspection system for human fever (Ebola) detection

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he Ebola fever and other diseases are highly dangerous and transferred by sick people or contaminated objects. Given the ease modern-day air travel, aircraft are a surefire way to export this dangerous virus worldwide. Africa, for instance, has around 60 airports, so it’s an important international challenge to identify infected people amongst travellers in a crowd at airports, and thus be able to prevent ill people from travelling and potentially spreading the virus across borders. Virus epidemics like the Swine influenza in 2009/2010 and the Ebola virus disease in 2014 has created a worldwide demand for suitable screening techniques allowing a fast non-contact detection of travelers with potential fever. Optris’ fever inspection system is purpose designed for this application. The installation of the whole system including the infrared camera and its extensive software package is simple. Also it can be re-located and set up in minimum time. The system is password-protected to prevent unauthorised changes. Because of a reference radiator built into the infrared camera there’s an automatic and constant IR calibration of the camera itself. The temperature resolution of 0.1 °C detects the smallest of temperature variances. The system works discreetly. The software singles out the people whose skin temperature exceeds the predefined value. The visual alarm gives airport employees the possibility to identify and isolate suspects from their co-travellers so that a medical examination can be done discreetly. If necessary the software offers the possibility to take automatically IR image snapshots when a person trips the alarm. sales@instrotech.co.za


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17.6 Controllers for all applications

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he TTM-J series is TOHO’S baseline basic temperature controller. Even though it is the most basic offering of their many ranges it is a very powerful controller packed with advanced features, excellent value for money and is based on one of TOHO’s most reliable and robust platforms to date. This amazing little controller features a standard thermocouple and RTD input range selectable via software, three control outputs and a fantastically simple software interface. The ease of use of the software or “menu” system allows users to switch between heating, cooling or even motorized valve or “heat/cool” modes at the touch of a button. Full PID and autotuning are also a standard feature as well as two alarm relay outputs that can be configured to just about anything. Included in the array of available features is a timing system that can be set to time out and shutdown when a process reaches a target temperature or to activate an alarm after a period of certain variables being achieved, the possibilities are endless. This little controller packs a titan punch in value, features and quality all at a fantastically low price point. The TOHO TTM-000 series of

controllers is based on the same robust platform as the J-series mentioned earlier. However with the 000-series TOHO have expanded on the modular nature of the platform to create an extremely powerful and cost effective range while still retaining the user-friendly interface and impressive feature set. This range is available in multiple sizes from 48x48 up to 96x96 and can be spec’d to suit the needs of almost any process application. These controllers can be specified with an almost universal array of input and output types in almost any combination. RS-485 Modbus, analogue retransmission and digital inputs are just some of the options available in the range. This range has been in production for over 10 years and has held its own against gruelling operating environments, difficult applications, dramatic market changes and intense competition. Building on the success of the TTM-000 series TOHO introduced the TTM-200 series of advanced microprocessor based controllers to the market. The 200 series is based on an all new advanced modular platform allowing TOHO to build a wide variety of feature sets to tackle hundreds of often difficult and complex control

solutions. The fundamental principles behind the 200 series are those of user friendliness, flexibility and stability. TOHO’s development engineers spent thousands of hours of development to create a flexible software based feature set that can be adapted to suite almost any application on the fly. One such feature is the ability to “bank switch”, this allows a process engineer or operator to quickly “bank” a set of parameters to be changed on the fly. For example the Set value, input offset, and P, I & D values can all be “banked” and have up to 7 different profiles that can be switched to via the touch of a button or a digital input from a PLC. Another feature is the ability to select the role of a given output, an alarm relay can be re-assigned as a PID output and a 4-20mA PID output can be re-assigned to retransmission mode, all on the fly in a matter of seconds. Alongside these powerful software features TOHO also included a software based loader system. This PC based software allows engineers and operators alike to create, download and restore software profiles of all the controllers settings, allowing them to make backups, fine tune settings

and replace controllers within minutes, eliminating the need to program and make records of each setting by hand. Coupled with a universal input and all standard din sizes from 48x48 through to 96x96 this new range is quickly growing in popularity and becoming a formidable force in the world of process control. The TTM-339 is a truly unique ramp and soak or profile controller series. These units are based on TOHO’s new TTM-200 series platform allowing them take advantage of many of the features mentioned previously. With up to 99 SV (set point) steps available, multiple programs or “profiles” can be configured to suite a multitude of product types. The 339 has been developed to tackle all multi-stage processes from heat treatment to drying processes and everything in-between. All 339’s come equipped with a set of digital inputs allowing programs to be run, paused, stopped and even selected from a remote device such as a PLC or switch. This allows engineers to eliminate the need for operators to interact with the unit all together and for a temperature process profile to be truly automated. roy@temptek.co.za

Modular tower light provides enhanced customization and inthe-field modification capabilities

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ntroducing the EZ-LIGHT™ TL70 modular tower light - offering superior flexibility, the TL70 can be customized as needed, and allows for easy position changes in the field. The big, bright 70-mm tower features advanced LED drive technology, providing highly visible

operator guidance and equipment status indication. The tower light can display up to five colours—plus an audible alarm module—in one tower, which allows for multiple colours to be lit simultaneously. The loud 92 dB adjustable alarm offers four userselectable tones, including pulsed, chirp, siren or continuous. For optimal performance, each light segment can be selected solid ON or flashing, and appears gray when off to eliminate false indication from ambient light. The new TL70 modular tower light is one of the most versatile indicator lights for industrial environments. With the ability to fully customize the indicator light with multiple colors, sounds and configurations, in addition to quickly changing positions in the field, the TL70 is ideal for a wide range of applications. Banner’s TL70 modular tower light is available as modular segments, allowing users to build a custom device. For user-friendly installation, the TL70 is up and running in just three easy steps, which include assigning the module settings, assembling the device and applying power. The TL70 is also available as a preassembled configuration. For use in harsh environments, the TL70 modular tower light features rugged, water-resistant IP65 housing with UV stabilized material. Housing is available in black or gray, which allows users to match the device to their application. rodneyt@retauto.co.za


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17.6 Energy monitoring in compressed air systems – simple cost effective packaged solutions

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onitoring the efficiency of compressed air system pays off. Compressed air is used as a power source for many food and beverage operations or any related compressed air system, as it is a versatile, safe and flexible way to transmit energy.

However, many operators do not actually realize that it is very costly to produce and it is often misused. Typical processes where compressed air is needed: • Product handling - Product transport with high speed within the production process • Filling systems - for food or bottles • Liquid pumps - transport of liquid products in the production and filling process • Processing - cutting and peeling of products such as fruits and vegetables • Packaging – packaging processes Below is depicted a very simplified and typical layout of a compressed air system with ideal measurement components. In relation to the system shown, ask yourself these questions: • how much energy is needed to produce compressed air in your process? • where is your compressed air consumed? • how efficient is each of your compressors? • do you lose compressed air, and if so where is it lost? If you cannot answer some or all of these questions, the chances

are that you are wasting energy in the system. With a well designed and implemented monitoring system you will generally reduce energy consumption, detect blocked filters, identify losses in your system and reduce maintenance costs by using alarms. Using a monitoring system, savings of up to 30% can be made using the below techniques: Monitoring and evaluating the system performance against a known baseline • Balancing the compressed air system • Detecting leakages early • Doing maintenance at the right time • Quantify and reuse waste heat Some examples of areas or components that need compressed air and their functions are listed below: • Process air — for cleaning, aeration and transport of products • Control valves and cylinder — to manage production lines • Extraction Technology — air operated liquid pump systems are used in volatile environments. • Generating Nitrogen — air is filtered by using a membrane for the production of nitrogen for a variety of chemical applications. • Air curtains - distinction of a safe and clean area • Drying products - air is mixed with products, in order to accelerate drying processes. The Endress+Hasuer Smartscale solution for compressed air monitoring Components of the Smartscale solution as depicted in the layout are • RSG40 Memograph M energy data manager • T Mass thermal mass flow meters • Pressure transducers and transmitters • RV Energy meter Using the RSG40 to analyses system performance and trends can be achieved by using the following performance indicators: • Compressor efficiency • Leakage loss • Filter supervising with maintenance alarm • Specific air consumption • Cost and efficiency for air drying • Process, equipment or line air consumption monitoring This data can be visualised in real time and exported to any higher level reporting system, including the Endress+Hauser Field Data Manager package or eSight energy monitoring and reporting system. In using a simple packaged solution such as the Endress+Hauser Smartscale compressed air solution, you can easily and quickly implement a monitoring system that will show quick returns on your investment, and realize energy savings in the short term. info@za.endress.com

Small but powerful HMI

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2I Corporation has announced the launch of their new XTOP 4” HMI, which has been specifically designed to meet the requirements for the monitoring and controlling of industrial plants. The 4.3” TFT Colour display supports 65 536 colours and has a backlight life of 50 000 hours. This touch screen has an analog resistive film type and a 1 million times or more touch life and comprises Serial COM2 that has support for RS-232C and RS-422/485.

This HMI has a built-in real time clock with a screen memory of 6MB.M2I’s free multi-functional design software (XDesignerPlus) is included for ease of graphic design. These HMI’s have a large protocol database which incorporates the popular Modbus RTU, Siemens MPI and Mitsubishi FX and Q Series PLC’s, to name a few. M2I’s new powerful and multi-functional design software, XDesignerPlus, can be downloaded for free at http://www.m2i.co.kr/eng/ info@rjconnect.co.za


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17.6 Three-phase drives with universal Ethernet capability bring new flexibility to high-power and continuous machinery applications

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he integrated features of the new MotiFlex e180 range means that the drive platform can be used - without additional hardware - in almost any type of application: with a host of different control systems architectures and communications and motor feedback schemes. At the heart of this universal system integration capability is flexible real-time Ethernet compatibility and feedback interfacing, built-in functional safety, and the ability to be used in many different types of control system architectures - from centralized control to intelligent stand-alone motion solutions. The drives may even be configured using a range of different continuous/peak power output modes to optimize them for applications with different precision, dynamic performance and duty cycle requirements. Thanks to this flexibility, ABB expects the new MotiFlex drives to appeal to OEMs and automation engineers designing for an exceptionally broad range of continuous and heavy-duty application sectors including printing, papermaking, converting, textiles, plastics and steel production. MotiFlex e180 is an all-new

design, but one which builds on the success of ABB’s earlier three-phase Ethernet Powerlinkcompatible e100 drive range, and offers a flexible upgrade path. In total, nine new drives offer a choice of continuous power outputs up to 90A, and peak outputs up to a maximum of 120A. Four different continuous/ peak output level and time combinations can be selected for each of the nine power levels, providing great scope for matching drive performance to specific applications - including extended lifecycle operation in 24/7 environments. At the heart of the drive’s flexibility is a universal Ethernet communications capability. MotiFlex e180 drives may be software-configured for EtherCAT, Modbus TCP, Ethernet/IP or Powerlink based systems - with further options in development. The drives also support many different forms of feedback including incremental and digital absolute encoders with different output formats, resolvers and the new generation of Hiperface DSL encoders which combine motor power and feedback in a single cable and offer significant cost savings on cabling and installation time for companies building large multi-axis systems.

Integrated safety is another core feature of the design, and MotiFlex e180 drives feature dual-channel support for Safe Torque Off (STO) functional safety, conforming to PL e SIL3. Each drive also comes with a substantial range of built-in I/O including six digital inputs, two fast latch inputs, four digital outputs, two analog inputs and an analog output, a high power relay output, and a PTC sensor for motor thermal protection. MotiFlex e180’s extensive built-in functionality allows drives to be employed in many different control system architectures. The software-selectable Ethernet communications capability makes it easy to build systems using PLCs from any vendor. Alternatively, the drives’ intelligence can be used in more decentralized architectures, performing profiling locally on the drive and reducing the load on the central controller. Unusually for this kind of architecture, ABB’s generic drive interface can be customized easily, making it easy for machinery OEMs to create application-specific functionality. In addition to working with centralized PLC or PC controllers, ABB offers its own embedded machinery controllers including

the NextMove e100 - which is ideal for Powerlink-networked systems - and a brand new highperformance addition to ABB’s well-known AC500 PLC range for EtherCAT-networked systems. MotiFlex drives may also be used as intelligent motion control solutions in process automation applications or distributed systems - again, without any additional hardware. The drives’ extensive built-in I/O makes it easy for developers to create really economic stand-alone solutions, and the availability of ABB’s rich MINT language makes it possible to program the drives to perform highly sophisticated motion control tasks. MotiFlex e180 offers OEMs and automation engineers a drive range that is almost limitless in its applications potential. It can be configured in so many different ways, for different control architectures, feedback schemes and communications networks - that it really represents a universal platform for high power applications. The integrated flexibility is also provided with great economy, thanks to an intense focus during the design phase on modularity and design for manufacturing.

coated fully lugged valve bodies in nodular iron with integrated purge ports. The reinforced seats are flexible in an axial way and seal towards each other in the bore when the valve is in the open position, thus protecting internal parts and the gate from the abrasive high pressure media. Upon closure, the seats are displaced axially, forming a seal with the gate until it forms a complete closure of the bore and gives a bi-directional tight shutoff. The seats also form a sealing face on the valve flanges saving the need for gaskets. The gate is supplied in high strength stainless steel, coated to give a

hard and high wear and corrosion resistance surface. For security reason the valves are always supplied ready to be locked in either opened or closed position. The gland box, with three layers of TwinPackTM and a box bottom scraper, gives the gate guidance during operation and makes sure that a first-rate sealing is preserved. Both SLH and SLX have solid top works to give excellent stability during operation. Regardless of what was originally supplied with the valve, any exchange of actuator and/or accessories can easily be performed on site.

info@za.abb.com

New high pressure slurry valves

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he SLH and SLX high pressure slurry valves are designed for really demanding applications with slurry and other abrasive media. The SLH is able to cope with pressures up to 20 bar, while the SLX can cope with pressures as high as 50 bar. They are designed to give a tight shutoff, independent of pressure direction. The flow capacity is maximized with a full bore and minimal seat cavity, and at the same time stresses and wear on the equipment are minimized, resulting in long service life of the valve and related process equipment. The SLH and SLX have epoxy

fred.venter@valve.co.za


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17.6 Multi-function wireless adaptor allowing wired field instruments to function as ISA100TM wireless devices

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newly developed multifunction wireless adaptor enables wired devices that transmit/receive digital ON/

OFF signals or receive 4–20 mA analog signals to function as ISA100 WirelessTM* field wireless devices. Field wireless systems enable plant field devices and hostlevel monitoring, control, and other systems to communicate wirelessly with each other. Driven by the need to improve productivity and safety, companies are looking for ways to collect more data on their plant operations. Consequently, there is a rising demand for field wireless devices as they can be installed in difficult-to-wire locations. Field wireless devices have the added advantage of having a lower installation cost. In addition to ISA100 Wirelessbased field devices and systems, Yokogawa offers multi-protocol wireless adaptors that enable HART® and Modbus devices to function as ISA100 Wireless devices. The development of this new multi-function wireless adaptor demonstrates Yokogawa’s

ongoing commitment to promoting the spread of wireless communication technologies. Plants use communication protocols such as FoundationTM fieldbus, HART, Modbus, and PROFIBUS to facilitate the exchange of data. In addition, digital ON/OFF, 4–20 mA analog input, and other types of signals are used for a variety of purposes. This multi-function wireless adaptor has been developed with this latter category of signal types in mind. The mounting of this adaptor on a wired device that transmits/receives digital ON/OFF signals or receives 4–20 mA analog signals enables it to function as an ISA100 Wireless device. This increases the variety of devices that can be used with field wireless systems, and is expected to lead to a wider use of such systems in plant operations. The world’s first ISA100 Wireless system devices and wireless pressure and temperature transmitters were released in July

2010. In addition to enabling sophisticated control techniques in continuous processes, this gave customers a wider range of devices to choose from. In line with the Wireless Anywhere concept for field wireless solutions, Yokogawa will continue to expand its lineup of ISA100 Wireless transmitters and other devices such as adaptors to develop best-in-class solutions that provide higher value to customers, and promote the use of field wireless technologies. * ISA100 Wireless A technology that is based on the ISA100.11a standard. It includes ISA100.11a-2011 communications, an application layer with process control industry standard objects, device descriptions and capabilities, a gateway interface, infrared provisioning, and a backbone router. Christie.cronje@za.yokogawa. com


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17.6 Protection for the Fieldbus where it is really needed

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here is always a risk of faults and failures when installation technology is used for process automation, and even reliable and robust communication via fieldbus can be affected. To implement protective measures for fieldbus communication that are both effective and efficient, it is vital to pinpoint the actual level of availability and potential causes of failure. So what is the experience with availability of fieldbus installations in practice? And which potential causes are actually responsible for failures? Without knowing the answers to these questions, it is hardly possible to increase fieldbus availability long-term by adopting specific protection measures. However, availability calculations are based on descriptions, assumptions, and observations from the theory of probabilities. And here at Pepperl+Fuchs, we have discovered from many years of interaction with users that these calculations are derived from sometimes unrealistic, sometimes even plain incorrect, assumptions. As such, the results are often not a true reflection of reality either. Discrepancy between Theory and Practice It is often, and wrongfully, the case that only the probability of component failure (i.e., the inverse of the actual failure rate) is used to calculate availability. The probability of component failure represents the potential for random failure due to aging and wear of the component. However, this means that important systematic criteria are not being taken into account. In practice, these criteria play a decisive role in availability: When environmental influences and the mode of operation, and their effect are not accounted for in the calculation, a significant discrepancy arises between the mathematical theory and the effect in practice when it comes to process automation. However, a brief glance at alarm and failure statistics makes it very clear that it is precisely

the effects of the mode of operation and environmental conditions that are responsible for faults much more frequently than random faults that cause component failure. To increase availability longterm, it is therefore crucial to identify the typical causes of faults. As part of a long-term project fault conditions and their causes and effects on the fieldbus infrastructure were studied. The results of the project indicate that systematic failures are the most likely causes of failure in plant operation. In addition to the poor design and planning of segments or failures in the installation, typical causes of failure include: • Shorts circuits, contact bounce, and overloading that occur as a result of work on the segment. • Surges caused by lightning strikes and a reduction in the performance of lightning protection that has previously gone unnoticed. • Water penetration in field devices and junction boxes as a result of environmental influences or mode of operation, i.e., through heavy rainfall, condensation due to high humidity levels, use of high-pressure cleaners, and incorrect or faulty seals. If the assessment of fieldbus technology is reduced only to competition among manufacturers to provide lower failure rates, the assessment is not accounting for maximum availability and is thus puts the user at a disadvantage. Heuristic Assessment of Availability As the purely mathematical calculation of the actual availability of a plant is not a realistic representation, the actual failure rates can be evaluated in another way. The actual or possible fault conditions of plant operation must be recorded for each assessment. A table in which the causes, their probability of occurrence, and impact are recorded has proven a very practical means of assessment. The product of the probability of occurrence and the impact represents the risk indicator.

This analytical approach similar to an FMEA analysis (Failure Mode and Effects Analysis) and makes it possible to take all potential causes of failure into account. In the table, the failure scenarios are assigned to possible protection methods as a solution. Taking a heuristic approach, each solution—regardless of whether it is a particular feature, component, a redundant design, or an operating procedure to avoid failures—is given a key performance indicator calculated using the associated risk indicators. A high indicator means that the measure prevents several or very critical failures. This approach makes it clear which action protects against which potential causes of failure. The extent of the failure risk can also be compared with the cost and complexity of the solution. The efficacy and efficiency of the protective actions are therefore guaranteed to the same degree. Purely mathematical calculations are not suitable for representing the complex array of potential causes of failure in practice. Consequently, the measures derived are also not tailored to the actual failure itself. In practice, it is often the more expensive and, in fact, irrelevant measures and redundancy concepts that are implemented, which ultimately do little to improve availability. The Right Solution for Every Failure The correct method for determining availability and actual causes of failure is of little help, of course, without the technical solutions that can effectively protect against the fault scenarios identified. Based on the in-depth studies that it has conducted regarding fault conditions in the fieldbus infrastructure, Pepperl+Fuchs has developed a new generation of components, specifically tailored to typical failure scenarios. The new intelligent components bring diagnostic capability into the field and thus allow continuous error detection. A wide range of new diagnostic functions and faulthandling features limit faults

in such a way that the process automation system remains in operation thus increasing overall plant availability. As a result, all information can be transferred via normal fieldbus communication, without additional costs being incurred. • The main feature of the new technology is the wellknown Advanced Diagnostic module. This module monitors the physical layer, detects notifications from the downstream components capable of diagnostics, and forwards the notifications to the control system. • The Segment Protector, which is capable of performing diagnostics, offers progressive short circuit protection with excellent fault isolation. The intelligent diagnostic function detects and isolates faults such as contact bounce at spurs. • The Advanced Diagnostic Gateway acts as an interface between the Advanced Diagnostic modules and the control system, responding quickly and reliably to each error. A new I/O function also allows the control system cabinet itself to be monitored. • The diagnostics surge protection offers lightning protection with a selfmonitoring function. It protects the fieldbus and field devices from lightning strikes or voltage spikes and emits an alarm signal when its function reserve is exhausted. • The intelligent leakage sensor can be connected to field devices as well as in marshalling cabinets, providing fast and reliable detection of the slightest change in moisture. All new components are suitable for FOUNDATION Fieldbus H1 and PROFIBUS PA protocols. The new technology is incredibly easy to implement. The components are simply connected and then run without any further configuration— without fieldbus addresses or integration within the control system. The diagnostic functions can be put into operation quickly, easily, and economically. mbracco@za.pepperl-fuchs.com


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Latest retro reflective sensors reliably detect both small and large objects

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he new RK 46C.DXL VarOS retro reflective sensor features a wide light band to reliably detect both small and large objects, even with gaps. A handy ‘teach me’ function allows the sensor to be adapted easily between two object sizes greater than 8 mm at the touch of a button. These sensors are ideal for when the objects to be detected or the associated environmental conditions deviate from the norm. The objects can be round, angular or both, with glossy surfaces, have transparent shrink wrapped film or even be totally black, with gaps or with high ambient light levels. Depending on the application, Leuze can

bring a range of technologies to bear to ensure reliable detection of such objects. The new Leuze RK 46C.DXL VarOS retro reflective sensor is particularly effective in this regard as it responds to objects with the entire width of its light band, which gives it the capability to be able to handle interruptions. The wide light band allows for detection over a 45 mm to 60 mm wide area. The sensitivity and/or resolution of the sensor can be adjusted easily by means of a button located on the rear housing. The use of this sensor does away with the need for expensive light barriers or multiple individual sensors. The new Leuze sensor has the following features: • A homogenous light band • Teachable, preset sensitivity levels • Calibration to transparent, perforated or small objects • Precise alignment due to the special shape and form of the light band • Maximum system availability due to automatic readjustment of the performance reserve • Reliable detection even with depolarising media such as foil packaging • Light/dark switching by means of the ‘teach’ button bryant@countapulse.co.za

Capacitive sensors with single-click teach

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CT sensors, primarily used for level measurement, offer maximum user friendliness with teach buttons and LED back end. Instead of using a potentiometer as before, the sensors can be taught for the relevant medium via a teach button. The BCT here automatically defines the switchpoint so that any deposits on the tank wall or contamination of the sensor cap does not cause any incorrect switching. A logical testing of the selected setting also prevents programming errors with difficult to detect media. Turck offers the BCT series as a universal NO/NC contact in a cylindrical design as an M18 and M30 variant. This not only enables users to effectively reduce the number of device variants that have to be kept in stock but also to implement fail-safe underfill and overfill protection of tanks with a single sensor type. The output behavior can also be set via a pushbutton. All versions are available with a PNP or NPN output. For applications that require protection against the unauthorized sensor adjustment, or in which the sensor can no longer be reached after mounting, a variant is also available with a teach output that can also be taught just as easily with a teach adapter as the pushbutton models. rodneyt@retauto.co.za

Cables, Wires & Accessories

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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

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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17.6 Overcoming obstacles of Industrial Network management

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very industrial network has a life cycle consisting of four basic stages: installation, operation, maintenance, and diagnostics. Even with careful network planning and design, network management throughout all four stages of the industrial network lifecycle can still present many challenges for integrators and operators. To optimize network efficiency, maximize system uptime, and minimize total cost of ownership, industrial automation networks not only require rugged hardware well suited for harsh environments, they also require user-centric software tools to enhance the user interface for efficient network deployment, monitoring, maintenance, and troubleshooting. In this white paper, we discuss the inherent obstacles of each industrial network life cycle segment, and how industrial-tailored network management software can assist you in overcoming these obstacles and reduce the total cost of ownership. Each stage of the industrial network management life cycle— installation, operation, maintenance, and diagnostics—is not only vulnerable to human error, but also susceptible to time-consuming inefficiencies. To maintain non-stop operation, industrial engineers often need to perform countless tasks manually or use different software to run and manage the network at each stage. For example, engineers may use one utility to do troubleshooting but another piece of software to monitor the status of field devices. Fortunately, industrial network engineers can now leverage the power of a centralized network management software suite that allows them to manage their automation network throughout the entire network life cycle. In this white paper, we investigate the management obstacles that must be overcome at each stage of the network life cycle, and explain how advanced network management software can overcome these obstacles. The Four Stages of Industrial Network Management 1. Installation Stage With mass-configuration software, system integrators can deploy a large number of network devices easily and efficiently. The MXconfig network configuration tool, which is included in the MXstudio network management suite, allows users to configure all network settings, including IP address, password protection, redundancy protocols, and even wireless settings, at one time, reducing the initial deployment time to next to nothing, and essentially eliminating the possibility of human error. According to our field testing, MXconfig can be used to successfully configure 100 switches in just 12 minutes, which in many cases could represent a 90% reduction in configuration time.

According to Moxa’s own lab tests, MXconfig can significantly reduce the initial setup time compared with the traditional hands-on, one-at-a-time approach

2. Operation Stage It takes automation-friendly software that allows network operators to monitor network status accurately and in real time. Moreover, it should be easy to configure the software for use with third-party network management software or SCADA systems, to give industrial operators better control of the entire networking system. The MXview industrial network management software included in the MXstudio suite is a GUI platform that allows operators to easily monitor and manage industrial networks of up to 2000 nodes—in real time. Due to MXview’s smart visualization feature, the software autodetects and displays the network topology, shows color-coded VLAN/ IGMP settings, and supports a virtual device panel that displays port status, PoE power consumption, and port-level link traffic, accurate

to four decimal places.MXview supports advanced integration with existing SCADA/HMI systems as well as third-party NMSs. For SCADA systems, MXview supports a built-in OLE for Process Control (OPC) server that can integrate SNMP data to SCADA systems and alert network operators of any network anomalies. Moreover, MXview OPC server supports a unique OPC tag, called the Group Health tag, which indicates the status of the entire network using three simple levels of severity. This unique OPC tag not only reduces the tag cost for SCADA users, but also represents system-level information. Network operators can easily check the health of the network by using the unique Group Health OPC tag. For third-party NMS integration, MXview can send SNMP traps, including link down, power off, and network traffic status, to another network management platform that focuses more on endto-end service availability rather than physical network connectivity.

For third-party NMSs, MXview can send SNMP traps, including link down, power off, and network traffic status, to enterprise network management software.

3. Maintenance Stage The industrial network management system should also serve as a central platform for configuration/firmware management. MXview’s configuration center allows you to select a group of devices and export their configuration files simultaneously for backup, saving a significant amount of time during maintenance. You can also use the job scheduler to perform regular configuration backups. What’s more, MXview supports comprehensive report functions, including event log history, inventory/availability reports, and device property reports, increasing the productivity of maintenance staff. 4. Diagnostics Stage Network event details are important for engineers to quickly analyze where the problem originated, which network segments/ nodes are affected, how to resolve the problem, and whether or not to send an engineer to the affected remote site. MXview supports a highly-intuitive event playback feature that can record network events, and replay past network incidents in the order they occurred. By selecting a specific event or a particular time frame, network status can be played back for event review, topology changes, and sequence analysis.N-Snap, an industrial network snapshot tool provided with the MXstudio suite, allows you to collect your network status, both before and after problems arise, for comparison. Important network data captured by N-Snap includes redundancy settings, VLAN tables, IGMP tables, routing tables, and switch configurations. Conclusion As networks continue to grow, network operators are facing a tough challenge to keep their systems up and running. Moxa’s MXstudio industrial network management suite delivers three key features—easy configuration, smart visualization, and quick troubleshooting—to help engineers monitor and manage their automation network. Moreover, with this one suite, you can perform all key network management tasks for the life of the network, including installation, operation, maintenance, and diagnostics.

MXconfig Industrial Network Configuration Tool

rob@rjconnect.co.za

MXview Industrial Network Management Software

N-Snap Industrial Network Snapshot Tool


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17.6 WirelessHART - the easiest way of connecting to a process control system

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his WirelessHART gateway can now be connected to a process control system via EtherNet/IP or Modbus. Connection is quick and easy whichever of the two options you choose, thanks to the integrated web server and the 3D simulation tool, both of which make using the wireless network with WirelessHART much easier and save the user time and therefore money. Effective planning for faster commissioning For anyone wanting to use a WirelessHART network for wireless measurement of process variables, planning seems an unavoidable chore. Investing the time pays off, however, since having a well thought-out network concept will shorten commissioning time significantly. Only finding out at the commissioning stage that the operating range of nodes has been incorrectly estimated and that some nodes are not included in the mesh network makes for time-consuming and difficult troubleshooting. Pepperl+Fuchs offers a 3D simulation tool called Wireless Network Checker (WiNC) as a standalone software tool so that this scenario can be avoided altogether. With WiNC, existing 3D plant data can be imported, or entire plants can be created from scratch in the tool itself. The required WirelessHART devices are then positioned as needed before the network is simulated in the tool. This allows the user to see which devices are communicating with each other and where there is no connection. This prevents any unpleasant

surprises during commissioning, since the network has been checked prior to installation. Easier connection to process control systems with flexible Modbus mapping and full integration with EtherNet/IP Once the WirelessHART network has been simulated, the user can be reasonably confident that it will work as a mesh network. The reason for this is that the simulation is not simply based on empirical values; it uses a mathematical race tracking algorithm, which enables the planned network to be calculated with a very high degree of accuracy. But the WirelessHART network still has to be connected to the process control system. The Pepperl+Fuchs gateway provides two ways of doing this: connection via Modbus or connection to the process control system via EtherNet/IP. Simple tools and ways of establishing the connection quickly and effectively are available in both cases. With Modbus, the most complicated part is the Modbus mapping. The process control system must know the address where the WirelessHART gateway makes the different data available. The WirelessHART gateway from Pepperl+Fuchs offers flexible Modbus mapping in integrated web servers for this. It enables easy Modbus mapping by variables or sorting and addressing of nodes. The data generated in this way can also be exported in the form of a CSV file. This can be used for documentation purposes or imported into Excel for further editing there. The edited file can then be re-imported by the

gateway. During the import, the gateway indicates whether any inadvertent errors such as duplicate addresses have occurred. This provides for a quick and easy way of checking the Modbus mapping. Modbus mapping is not necessary when the gateway is connected via EtherNet/ IP. In the case of the Rockwell process control system LOGIX, the WirelessHART gateway from Pepperl+Fuchs is fully integrated. Nevertheless, the process control system needs to know the addresses of the various nodes. The gateway uses the HART descriptor for this purpose. Here, the EtherNet/IP address in the WirelessHART station are stored according to a simple structure. This is best carried out together with configuration of the WirelessHART device with the network ID and join key. The gateway itself has a default address and does not therefore need to be mapped. All that then remains is to tell the process control system the IP address of the gateway and the number of WirelessHART network nodes. The WirelessHART network is then connected to the process control system. There is no easier way of connecting a WirelessHART network to a process control system. The stage after connection and before commissioning is where the diagnostic tools come in. Once the network has been successfully connected it is commissioned. The WirelessHART network usually builds itself. But wireless connections are not

Horizontal multistage stainless steel pumps

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he versatile EDH range of stainless steel pumps from LEO is designed for general industrial use as well as farming, mining and water supply applications. The horizontal multistage pumps feature an AISI304 shaft and they are suitable for use in liquid temperatures up to +85°C and in altitudes up to 1 000 m. Offered in single- and three-phase types from 0.37 kW up to 1.1 kW and from 0.5 HP up to 1.0 HP, the EDH range has a maximum suction of 8 m. The pump body is constructed from AISI 304 stainless steel making it suitable for use in harsh environments. The motor meets IP44 protection requirements and is suitable for use in ambient temperatures up to +40°C. It has copper winding and a built-in thermal protector for the single phase type motor. enquiries@raptech.co.za

visible to the naked eye, which makes troubleshooting very difficult. But not with the gateway from Pepperl+Fuchs, which offers graphical network diagnostics directly in the web server. This enables the user to see a device’s connections with other network nodes at a glance. The quality of the connection is indicated at the same time by a color code. Red means no connection, yellow an acceptable connection, and green a very good connection. The intensity of the data traffic on the path can be indicated graphically by the path width. The option also exists to view this data as a list in the web server, since all the information is also available in a list. This can be exported as a CSV file for documentation purposes. The WirelessHART network is thus fully transparent and visible. These handy tools do not just help during commissioning; they can also be used for diagnostics during operation if the user simply wants to know what has changed in a WirelessHART network. Changes happen because the WirelessHART network is selfoptimizing and seeks out the optimum paths during operation. These diagnostic tools in the web server are, of course, also available in the Modbus and EtherNet/IP WirelessHART gateway. Together with the simulation tool WiNC, they make WirelessHART visible and transparent for the user, regardless of which process control system the network is connected to. mbracco@za.pepperl-fuchs.com


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17.6 Sealed bearing prevents failures in triple offset valves

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earing failures are the highest root cause of failure in Triple Offset Valves (TOV) for tight shutoff. This issue is directly attributed to the need to have metal bearings with very tight tolerances when accepting the shaft diameter. Properly designed TOV’s are metal to metal torque seated type of valves. Therefore, very little shaft deflection can be tolerated in order to properly torque the seal ring into the seat. Additionally, properly designed TOV’s should have the bearings located as close as possible to the centre line of the disc, which helps to deliver a rigid support of the shaft when torqueing into the seat. In clean services, such as air or water, the chances of the bearings fouling are small. However, in the world of hundreds of petrochemical, power, and other applications there are many potential problems with bearing failures. Many of these problematic situations are obvious, such as Sulphur Tail Gas and Acid Gas services within refineries and gas processing plants. Sulphur in the gas state will have a phase change to a solid in temperatures below 115°C. If the gas phase sulphur is trapped in the bearing cavities and there is a drop in the Tri-Con valve with steam jacket temperature, the sulphur will become a solid. This causes bearing to shaft seizure, locking the disc in one position. When this situation occurs, the end user must apply a heat gun of some sort in order to unlock the valve. This procedure is not the best practice when operating a modern process facility. Most TOV valve manufacturers offer a welded on steam jacket in order to use the steam’s latent heat to deliver heat to the bearing area. While this is good design practice, human error has negated this benefit when plant personnel simply turn off the steam to the jacket or unhook the connections to perform some maintenance and do not reconnect the steam to the fittings. In addition, every turnaround of a processing plant can be dangerous if media is still in the bearing cavity and that cavity has not at the right temperature. Other chemical applications such as butadiene and styrene have the same issues as described above, except when these chemicals become trapped and dormant it causes a phase change and popcorn, or polymerization, resulting in seizing of the bearings. Additional situations also attribute to foulings, such as simple pipe scale. Furthermore, during the start-up phase in new constructions when the pipes have not been properly flushed, debris can migrate into the bearing cavities. Improper designs can also add to bearing failures once in service. If a certain design has not taken into effect the thermal coefficients of both bearing material and the tolerances accompanied by the cross sectional Standard bearing design in the industry thickness then the bearing could lockup during quick changing thermal conditions. TOV valve manufacturers have been keenly aware of this potential problem and in the early 90’s some manufacturers introduced the Bearing Protection Ring, which has now become the industry standard. However, this feature has proven not to be the solution. A single ring

72in triple eccentric Tri-Con process valve

of die-form graphoil installed into a groove in the ID of the bearing without a compressive load will flatten out and quickly become even after a small amount of cycles under pressure. Graphoil has no memory. It might keep some of the heavy debris from entering the bearing cavity but will allow the process to enter. Other manufacturers offer a dual packing set with a lantern ring sandwiched between them, in addition to a flush port with grease fitting located on the bonnet to allow for flushing of the bearings. Certain manufacturers offer O-rings at the bottom of the bearing cavity. This design would be a good solution, but in the petrochemical market FireSafe designs are mandatory, and an O-ring in the bearing cavity would not be considered Fire-Safe. The TRI-CON Series is available in sizes DN50 (2”) DN1800 to (72”) and pressure Design of patented classes from PN 10 – PN 160 or ASME Class 150Sealed Bearing 900. Very successful derivatives of the TRI-CON Series are the metal seated check valve, TRI-CHECK, and the DoubleBlock and Bleed version, and TRI-BLOCK. An example of efforts being made to find a solution to this issue is the mechanical design that ensures that both the ID and OD of the bearings are protected, and would also not violate the Fire-Safe design criteria. The design incorporates 3 rings of die-form graphoil packing ring at the very end of the bearing ID, and then 3 rings of the same on the OD, both are captured by machined edges and loaded by the packing load which keeps the graphoil rings from flattening out. This patented design is called the Sealed Bearing feature. Besides the fact that this design prevents any media from entering into the bearing cavity, the advantageous design to minimize shaft deflection of Zwick’s standard bearings can be kept in the special design. Another plus is the fact that every standard Zwick valve can be upgraded with the Sealed Bearing design. Besides the protection of the bearing in this design, it functions as an additional seal to the packing and minimizes fugitive emissions to a minimum which makes this bearing system also very attractive for applications in ethylene oxide or propylene oxide. The patented Sealed Bearing has been proven for more than 12 years in many applications such as butadiene, styrene, sulphur, sulphur tail gas, ethylene oxide, polyethylene oxide, high viscosity applications like thermal oil and acid gas. fred.venter@valve.co.za

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