What's New in Processing Sept/Oct 2014

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RET Automation Controls www.retautomation.com |

Tel: +27 (0)11 453 2468

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sales@retautomation.com

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Experts in Automation

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Founded in 1945, Pepperl+Fuchs today is one of the world’s leading providers of technologies for factory and process automation.

Industrial Sensors: Focus on the Market Developments in industrial sensors are driven by market-specific requirements. From the inductive and capacitive to the photoelectric, Pepperl+Fuchs produces sensors across all types of functionalities.

Process Interfaces: Secure Applications Technologies for use in hazardous areas are also designed for specific applications in specific industries. For all types of explosion protection systems, high performance products and customized solutions are available in many different applications.

Leading technologies from Pepperl+Fuchs are readily available in markets all around the world.

www.pepperl-fuchs.co.za

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On the Cover...

MultiCon = Meter + Controller + Recorder + HMI in one package

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RET Automation Controls www.retautomation.com |

Tel: +27 (0)11 453 2468

|

sales@retautomation.com

he MultiCon series devices are advanced meters, controllers and recorders closed in one compact case. They have been designed for both advanced and less demanding applications in industrial automatic control engineering.

They feature a colour TFT display with a touch screen (3.5 or 5.7 inch, depending on version).

Such a GUI is a pleasure to work with, and the operation of the MutiCon playing the HMI role is intuitive and comfortable. The kernel of the software is LINUX operating system, which ensures stable operation and enables installing advanced software.

Sept/Oct 2014 Volume 17.5

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

Fig. 1: Possibility of operation via a touch screen, a keyboard or a mouse

Possibilities At first glance, the absence of any keys on the instrument front panel comes as a surprise. However, operation using the touch screen is much more efficient and comfortable.

The operation philosophy is analogous to generally known windows systems: hitting (clicking on) appropriate menu keys, sliders to move the screens, etc. If, however, you are not happy with the touch screen, a traditional keyboard and a mouse can be connected to the instrument through USB ports to make the operation extremely simplified.

P O Box 11420 Vorna Valley 1686 South Africa

Tel: 0861 PROCES (776 237) Fax: 086 723 5321 Printed by: Raptor Print Views expressed in this publication do not necessarily reflect the opinions of the publisher.

Copyright reserved on all material

Fig. 2: Example of input/output hardware configuration

Despite its compact dimensions the instrument has huge application possibilities. A well-thought-out modular design allows precise adaptation of the CMC to various specific needs and requirements of all customers. Available is a wide array of input and output modules

(current, voltage, universal, thermocouple, RTD, digital, counting, relay, SSR and other). In its most expanded version, a single, compact CMC-99 instrument can include modules which provide in total up to 48 physical inputs and outputs (analogue, digital and relay).

Its slightly bigger brother, CMC-141, can have fifty percent more inputs and outputs. Figure 2 shows the CMC-99 rear panel for one of the most typical configurations often ordered by our customers. You do not need to use all slots; what’s more, when a modification becomes necessary all you need to do is send the instrument to an authorized distributor who will introduce the changes, adding, removing or replacing modules.

The most demanding users, for whom a single RS-485 interface in the standard version is not enough, can choose the ACM (Advanced Communication Module) with additional communication interfaces: Ethernet, USB, RS-485 and RS232 shared with another RS-485.

Using the Modbus RTU, the MultiCon CMC can read data and control outputs of other devices in the network.

External inputs/outputs (i.e. inputs and outputs for other devices) are particularly useful when there is a need to control a large number of physical execution units or collect data from distant sources.

The number of these inputs/outputs is counted independently of the inputs/ outputs available on the built-in modules.

This additionally augments the potential of MultiCon which is powerful already.

In this way, using a MultiCon CMC you can build an advanced network system where you can monitor the operation of the whole from any place on the planet, e.g. via Internet.

Each MultiCon can work also as a data recorder. Its internal memory of 1.5 GB is sufficient for over 125 million of samples, meaning that even in the intensive sampling mode (every second) you can record data, for example, from 24 channels for 2 months.

Block internal design In order to understand why such a small device meets so many different requirements, it is necessary to have a closer look at its internal design.

The heart of the device is a powerful, 32-bit ARM9 processor to which typical peripherals are connected: flash memory with firmware, flash memory for data recorder, RAM, TFT graphic display with a

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Fig. 3: Block diagram of the device

touch screen, power supply systems, basic communication interfaces, etc. Please note, however, the way the I/O modules are connected.

To reduce the load on the CPU and ensure fast implementation of system tasks, including immediate response of the TFT display (the laboratory tests of hardware possibilities have proved that e.g. viewing films or cooperation with a USB internet camera with advance processing and image displaying in real time is not a problem), all optional measurement and communication modules are equipped and supported by their own efficient RISC processors (AVR family) and they are connected with the main processor via a fast serial bus.

Therefore, all tasks related to e.g. A/D processing, calibration, transmission frames support, etc. are performed directly on the modules. As a result, even with the maximum number of modules connected, the device speed is not affected, and expanded internal firmware of the modules ensures very good accuracy and stability of measurements.

Such a design solution allows also an easy introduction of a very

important element: galvanic separation of all external connections in all modules to significantly increase the device functionality and flexibility.

Software After powering on, the operating system is loaded from the flash memory to RAM, followed by the application software.

The before-mentioned, specially designed bus connecting the modules, including an internal communication protocol, allows an immediate detection, identification and recording of each newly installed module.

Suitable configuration modules are activated simultaneously which ensures full implementation of the PnP function.

The device system is based on Linux, which allows – with suitably thought-out software - to use MultiCon to implement even many independent tasks at the same time (also in large multi-channel systems).

For detailed description of more interesting software functionalities (including logical channels, mathematical operations on channels, timers, profile generators, single and multiple PID controllers, etc.) please refer to part III of the articles on MultiCon CMC. As a result of cooperation with the users, the software is constantly developed and new, useful functions are added.

Interesting additions or solutions are quickly implemented as firmware updates.

A free update feature is provided so that all MultiCon CMC users always have the latest firmware version installed on their devices.

The update procedure cannot be simpler: just download the latest files from our website, write them on a pendrive, connect the pendrive to CMC and start the process - the rest is fully automatic. rodneyt@retauto.co.za

Alarm management technology making plants and pipelines safer, more productive

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ynAMo™ alarm management technology is improving safety and productivity at more than 100 process plants and pipelines around the world by helping operators better and more quickly evaluate alarm situations in control rooms. Plants and pipelines are increasingly relying on numerous automation systems, which can produce more than 1,000 system alarms in a given day. The number of alarms can often overwhelm operators, a problem that leads to lower production and increased safety incidents that cost the process industry billions of dollars every year, according to the Abnormal Situation Management® (ASM) Consortium, an industry group dedicated to advancing process technology The DynAMo solution, which was launched in November 2013, allows plant operators to tune out noise and focus on critical situations by more efficiently managing and evaluating alarms. This allows operators to more easily detect and prevent problems, and to develop and implement effective alarm management strategies aligned with industry-recognized guidelines and standards.

DynAMo is based on Honeywell’s 20-plus years of alarm management experience in the process industries. DynAMo reduces control room alarms by up to 80 percent by allowing operators to create customizable dashboards on computers or mobile devices that allow them to view the alarm system health at a glance. This allows operators to better and more quickly diagnosis alarms and their causes and consequence on one console.

Honeywell has licensed DynAMo technology at plants in Australia, Canada, Japan, Saudi Arabia, and the United Kingdom, among others, as companies work to increase the efficiencies of their control rooms.

Richard Wawrzon, process engineering and control team leader for Qenos Pty Ltd., Australia’s leading supplier of polyethylene and polymers, said, “High quality tools to manage and maintain process alarm systems are critical to running petrochemical plants. Honeywell’s DynAMo Alarm Suite has sensibly integrated analysis, documentation

and notification tools to provide support engineers with an efficient way to stay in control of process alarm systems. Once process safety is being looked after, key resources can focus on production efficiency.”

Honeywell recognized the severity of alarm problems at industrial sites and delivered an effective tool for assisting in optimizing alarm management programs, which are intended to prevent alarm floods and reduce operator loading. With the DynAMo Alarm Suite, personnel can monitor alarm issues based on their specific roles and take action before abnormal situations escalate. A new, customizable, role-based dashboard enables operators, engineers and managers to view the health of their alarm system at a glance. The software has added mobile device compatibility for viewing alarm metrics at any time, from almost any location. Chris Lucas, gas control team leader for Alliance Pipeline in Canada, said, “We chose Honeywell to provide our alarm management solution because its DynAMo Alarm Suite will help us meet our alarm philosophy and control room management plan objectives. Honeywell’s involvement with the ASM Consortium and the American Petroleum Institute also weighed into our decision, as did integration with the control system of our choice.”

DynAMo Alarm Suite works with any control system as well as complementing Honeywell’s Experion® PKS system. The alarm software provides a single window into alarm system performance and regulatory compliance, helping companies adhere to industry standards such as ISA 18.2, EEMUA 191, API 1167, and PHMSA. boni.magudulela@honeywell.com

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17.5 Selecting and sizing instruments just got easier

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here are many challenges in instrumentation engineering in a plant. Planners have to combine know how in application and instrumentation to arrive at safe decisions.

Calculations are complex and the variety of products is difficult to master. Since release of the improved Applicator 10.11, complex engineering is made simpler.

Benefits • New Applicator start page for direct access to the different engineering modules • Intuitive navigation with a fresh, new look • New features in the Selection module including industry specific parameters, result indicator and a new segmentation of the input parameters • New Proline flow products in the Sizing Flow module added. Advanced order code determination of selected, checked and calculated order options • New industry applications added to Applicator: Rectification for the Chemical Industry and Juice production for the Food & Beverage Industry Provides planning reliability, speed and flexibility Applicator is a convenient selection and sizing tool to aid your planning processes.

Using the entered application parameters, Applicator determines a selection of suitable products.

You may choose from Endress+Hauser’s product portfolio for level, flow, density, pressure, analysis, temperature and registration as well as system components.

Select, size and configure the best-fit instruments After entering the application parameters, such as measuring point specifications, suitable products and components are recommended.

The transfer of selected products to the sizing and thereafter to the product configuration function supports basic engineering.

Industry Applications within Applicator are for product selections based on an

application-oriented navigation, such as in the Food & Beverage, Waste water/Potable water, and Primaries industries.

By a process map from your industry, you can choose the relevant measuring point. You are then directed to the measuring task and to an overview of suitable products.

Available online or on DVD including Applicator ProjectApplicator is available online with free access and on DVD for installation to your PC, including regular software updates via the Internet.

On the installed software you can find the Project module. This module enables you to manage

your projects from the beginning and store the relevant parameters and data for reuse in future projects.

Export and import functions allow the easy transfer of the projects between different systems. info@za.endress.com

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17.5 Slim design highly efficient power supplies

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part from the particularly space-saving housing, this new 24V power supply family is distinguished by a high degree of efficiency. Depending on the version, output voltages range from 3.3 to 20 A. In addition, the units possess high power reserves and reliably switch off the circuit breaker in case of a short circuit.

Thanks to innovative technologies, the new power supplies require considerably less space in the control cabinet. Another advantage is the above average efficiency of up to 94 per cent. This reduces waste heat and saves energy costs. Instead of using a NTC resistor, a microprocessor controller keeps the inrush current low, making it easier to protect the wiring.

The positioning of the components allows permanent operation even at the limits of the specification. This results in excellent MTBF values ranging from 0.89 to 1.4 million hours. All power supplies offer sufficient power reserves to reliably deal with load current peaks while the voltage supply is ensured for several milliseconds in case of short failures of the mains voltage. For the optimisation of AS-i technology, ifm electronic also offers newly developed switched mode power supplies for the range between 2.8 and 8 A. alwyn.skelton@ifm.com

Intelligent image processing

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n most industry sector new applications are evolving that require high performance, easy to use image processing solutions. Wenglor’s new VisionSystem+ meets all expectations.

The device offers flexible functions that provide solutions for simple shape and position detection right up to complex measuring tasks. With the automatic tracking feature, functions such as object differentiation, bulk goods analysis and optimized orientation

correction are made possible.

The modular system design – consisting of control unit and camera – is distinguished by the new Teach+ function which allows users to record the affective segment of the production process to a data file and transmit this to a service technician via Wenglor’s website. Project settings are optimized and sent back to the user. After reading the parameters, production can be continued uninterrupted at full speed.

The entire process is completed without accessing the customer’s network.

The new VisionSystem+ is supplemented with an extensive range of illumination technology such as luminous floodlights and ring illuminators and spotlights in various sizes. A variety of light and operating modes (through-beam operation, flash mode, diffuse light dispersion etc) provide for perfect contrast conditions. info@asstech.co.za

Steam conditioning valve

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his steam conditioning valve is a modular system which can contain a combination of Cavitation Control, ZZ or Twister trims and diffuser elements, combined with a steam atomising desuperheater nozzle.

The design incorporates an angle-style body which allows for substantial differences in inlet and outlet, both in terms of size and pressure rating.

It is also primarily designed to incorporate the well-proven Mitech Twister trim, flowing from the inside outwards for maximum efficiency of space utilization.

The body is further designed to have a large annulus around the stack, such that even relatively high trim exit velocities cannot cause significant erosion damage to the body.

However, the plug configuration is such as to give the best possible shut-off with the smallest possible actuator.

Furthermore, the plug is guided by the trim, and the trim and plug are designed to have a relatively long stroke, thereby maximizing the turndown of the system.

The desuperheater nozzle is fitted to the centre of the valve outlet in an area of highly turbulent flow, to minimize the risk of water impinging on either the valve body or downstream pipework.The moment the valve is cracked open, steam is introduced to the desuperheater nozzle at full upstream pressure, in order to maximize the atomization of the cooling water.

The water supply to the

desuperheater is arranged in such a way that the valve body is not in contact with the cooling water, thereby removing the risk of thermal cracking caused by severe temperature gradient, which is the Achilles heel of most

steam conditioning systems.

In fact the only component that is simultaneously in contact with both water and steam is the desuperheater nozzle itself. enquiries@mitech.co.za

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17.5 New dual-range torque sensor with USB interface

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he latest dual-range torque sensor from German company Burster sets new standards for measuring static and rotational torques in laboratory testing, production and quality assurance.

The powerful features of the 8661 sensor can be fully exploited especially in the fields of industrial automation, engine testing, medical technology and electrical engineering.

The instrument can be used, as example, not only for measuring constant-load torques and starting and breakaway torques, but also for detecting transient values such as load spikes. No time is wasted in changing sensors or readjusting the test bench for a new sensor.

The new 8661 covers a wide load range. By using different

factors for ranges 0‌5 Nm to 0‌200 Nm, the user can measure loads with a linearity deviation of less than 0.05% FS. With the

speed and angle measurements and computed mechanical power on up to 32 measuring channels. The powerful formula

optional USB interface and convenient DigVision PC software, the sensor is ideal for both stationary and mobile measuring tasks. Depending on the model and software version, it is possible to visualize, log and assess torque,

editor allows for mathematical operations to calculate numerous variables, including values such as efficiency and smoothing averages.

The plug & measure software design with auto-scaling

functions enables an ultra fast set-up phase. Results calculated using the mathematical formula editor can be displayed and classified numerically or graphically as required. Via the supplied driver package, the sensor can be easily integrated in LabView or the user’s own software. Via the speed and angle measuring option (angle resolution to 0.09%, extra processrelevant reading in addition to torque can be recorded. The dual-range model also includes the built-in LED status indicator, which can indicate numerous operating states as well as the currently active measuring range. info@asstech.co.za

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17.5 Steam monitoring pays off in less than two years

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the different internal customers was only calculated according to empirical standards.

As prerequisite for any efficiency gain actions, the Energy Plant Department needed to: • Monitor steam production and consumption in real time • Have meaningful data centrally available

Application details The steam fluxes (in tons/h) are measured using a vortex flow meter, a temperature and a pressure sensor. Each of the overall 39 measuring points also include an energy application manager (EngyCal) providing power (heat flow) and energy (in GJ).

The device is not only able to do calorimetric calculations according to relevant standards, its also operates as a gateway and supplies the data via a fibre optic network to the workstation located at the energy centre building.

Here the values are visualised and stored in an OPC database.

Finally they are processed again to provide precise and conclusive figures, instead of pure process value.

Customised reports including valuable information such as real consumption in each cost centre, amount and location of losses and overall efficiency of the steam process are now available in userfriendly format for management review.

Solution: Integrated a turnkey steam monitoring solution into the company’s existing energy monitoring system.

HONEYWELL

HELUKABEL

rom manual calculations to automated measurement, turnkey steam monitoring solution enables the systematic reduction of energy costs.

Customer challenge; although steam consumption is very important to the profitability of the company, consumption by

Valve Trolley

The solution included: • Instrumentation 39 steam measurement systems (Prowirl 72F vortex flow meter + TR15 temperature sensor + Cerabar PMP51 pressure transmitter with syphon and shut-off valves) • Energy application managers (EngyCal RS33 including cabinets, cables and required system components) • Data acquisition and visualization (P View software, OPC server and workstation PC) • Mechanical installation (flanges and reducer pipe works, insulation)

• Endress+Hauser also performed all the associated services that were required.

Main steps 1. Energy site survey: A site survey was performed and several concepts were discussed and offered.

2. Consulting: The detailed technical solution was developed together with the customer and local partners taking into account the site-

PHOENIX CONTACT

specific IT infrastructure.

3. Installation and commissioning: The monitoring solution was installed, commissioned and the Energy Plant Department supported in analysing the measured data.

4. Consulting energy audit: An audit of the steam process was performed in order to evaluate the measuring results and the amount of losses. This was the basis to recommend effective corrective and preventive actions.

The results • Accurate, consolidated data on steam output, transport and consumption • Controlled steam consumption via precise metering of each consumer • Measured transport efficiency and allocated losses in the steam pipe network • Customised reports for management review ArcelorMittal Zenica in Bosnia and Herzegovina produces hot rolled products (rebars, wire rods, mesh, lattice girders, classic construction armatures) mainly for the Balkan, EU and North African markets. “With the solution and services provided, ArcelorMittal Zenica management is now able to make the right decisions to reduce energy costs. Taking into consideration the total amount of losses, the cost of the supplied solution and further investment, the project provides a return on investment in less than two years.” Emir Krgo Head of production sector Energy Plant Department ArcelorMittal Zenica, Bosnia and Herzegovina info@za.endress.com

AT TECHNICAL SERVICES Valve Trolley

➢ 011 805 1201 Boni.Magudulela@honeywell.com

➢ 011 462-8752

➢ JHB: 011 801 8200 DBN: 031 701 2701 CT: 021 930 9666 PE: 041 364 0415

➢ 086 100 2887 www.atts.co.za

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17.5 Stainless steel bypass level indicator

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he BM 26 BASIC and ADVANCED MLI series has an optimal strength-to-weight ratio and combines robustness and flexibility with a long-proven technology, thus providing excellent value for money.

It is easy to install and needs little or no maintenance. The BM 26 series is made of stainless steel. Its bicolour indicator flaps are housed in a 100 % hermetically-sealed, durable glass tube. The BM 26 is suitable for use with highly corrosive, toxic or flammable liquids. Our bypass level indicators are simple, rugged devices designed to indicate or transmit the level of liquids.

They indicate level using a float magnetically coupled to a

column of rotating flaps. Bistable switches can be attached to the measuring tube to detect level.

It can be used in various industries such as chemical, Oil and Gas, Petrochemical and even the water industry.

The Basic version is ideal for measuring liquids with a density ≥0.75 g/cm³ / ≥46.8 lb./ ft³, temperatures up to 150°C / 300°F or pressures up to 16 bar / 232 psig (for more data, refer to Guidelines for maximum operating pressure on page 37).

Level can also be transmitted via an ER analog transmitter.

The Advanced version is ideal for measuring liquids with density range of 0.54...2.0 g/cm³ / 33.7...124.8 lb/ft³, temperatures up to 300°C / 570°F or pressures up

to 40 bar / 580 psi (for more data.

Level can also be transmitted via an ER analog transmitter or Radar/ TDR level transmitters.

Highlights • Rugged stainless steel design – low or no maintenance • Flaps housed in a hermetically sealed rugged glass tube (IP 68 • Large variety of accessories and options: special materials, valves, high and low temperature insulation, hazardous area approvals, limit switches, analogue transmitters, radar meters, interface measurement etc.

• Measuring ranges from 0.3 m/1 ft up to 5.5 m/18 ft (longer on request) i.thushini@krohne.com

New, comprehensive energy logging and reporting

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he Fluke 1730 Three-Phase Electrical Energy Logger is a new logger specifically designed for energy conscious consumers, rated for its simplicity in discovering sources of electrical energy waste. Its ability to profile energy usage across facilities allows the user to identify opportunities for energy savings and provides easy-to-understand data required to take the appropriate action.

The 1730 shows when and where energy is being consumed in the facility, from the service entrance to the individual circuits. It compares multiple data points over time and builds a comprehensive picture of energy usage with the energy analyze software package. It facilitates the rapid understanding of specific points of energy loss, which can in turn reduce energy bills.The 1730 Energy Logger inconjunction with a VT02 Visual IR Thermometer

or the Ti125 Infrared Camera can take energy surveys to the next level, quickly identify opportunities for energy savings both electrically and thermally.

When using an infrared camera or a visual IR thermometer along with the 1730 Energy Logger, users are able to discover potential problems that could be wasting energy and then quantify them electrically with the 1730 Energy Logger.

This combo is touted to be the perfect tool set to uncover hidden operational wastes such lighting, air conditioning and other large loads that could be switched off when not in use.

Some outstanding features of the 1730 are: • Comprehensive logging: More than 20 separate logging sessions can be stored on the instrument. In fact, all measured values are automatically logged and can

be reviewed during logging and before downloading for on-the-go analysis.

• Complete “in-the-field” setup through the front panel: no need to return to the workshop for download and setup or to take a computer to the electrical panel. Battery life:

M12 power connectors

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nnouncing the extension of the portfolio for the M12 power product range with a 2+PE version for the 230 V mains supply.Despite the significantly higher performances in comparison to common M12 connections, the installation geometry of the M12 Power series remained unchanged. No new design of the devices is necessary and common bigger power plug connectors can be replaced by the compact M12 plug connectors.

The range includes molded M12 power connectors with S-coding in straight and angled socket and pin versions.

They are available in PVC cable quality. The cable sets are available in lengths of 1.5, 3, 5, and 10 meters; customer-specific lengths are available on request. seanh@phoenixcontact.co.za

four-hour operating time (backup time) per charge on lithium-ion battery.

• Highest safety rating in the industry: 600 V CAT IV/1000 V CAT III rated for use at the service entrance and downstream. info@comtest.co.za

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17.5 Enabling efficient and visually represented PRP/HSR network management

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reating a network management interface of devices and systems using different protocols can create risks and management issues that can compromise effectiveness and security for Substation Automation Networks. An efficient and visually represented PRP/HSR network using Power SCADA with specially designed management middleware can effectively avoid these problems.

Traditional Substation Automation System (SAS) structure is an end-to-end hard-wired network. This makes sure all communication is in real-time and that responses are quick. However, when the network communication system has been upgraded to an Ethernetbased network, all the devices are connected to Ethernet devices, such as switches and routers. This results in a potential risk of network communication latency due to network topology changes, traffic congestion, or packet queue prioritization. For mission-critical or timesensitive applications, even millisecond long network interruptions cannot be tolerated, as they may severely impact system operation or jeopardize onsite personnel safety. The IEC 62439 standard states that the time that the plant allows for recovery before taking emergency actions (e.g., emergency shut-down, fall-back mode) should be less than 10 ms. In IEC 61850 edition 2, it also clearly states that the communication redundancy times of GOOSE and SMV protocols in substation automation systems are required to be bumpless.

What is PRP/HSR? The Parallel Redundancy Protocol (PRP) and High-availability Seamless Redundancy (HSR) protocols described in IEC 62439-3 are two technologies that provide seamless failover from a single point of failure. PRP achieves active network redundancy by packet duplication over two independent networks that operate in parallel, whereas HSR is designed primarily for ring topologies. Based on these two seamless redundancy protocols, a redundancy box (Redbox) can quickly activate non-HSR or non-PRP end devices connected to HSR or PRP networks with zero switch-over time. Mission-critical applications in SAS communication can benefit from these redundancy technologies to ensure network reliability.

Challenges Faced 1. Redundant network monitoring and troubleshooting Networks commonly use MAC and IP addresses as management units to control the network and various network devices. However, PRP/HSR is a very new technology that duplicates packets on the link layer by using the same MAC address, ensuring that the client end can receive packets even in the event of a communication problem.

Unfortunately, the current network management system is unable to detect that the packet has been duplicated, so the user cannot see whether both packets have been received or not. Detecting whether or not both packets have been received gives important information about the quality of the link and the health of the redundant network.

Hence, managing and monitoring the PRP/HSR network is more difficult because system administrators will not know the redundant network’s real-time status. Troubleshooting for the failed redundant path also becomes another big challenge since the failure point of the network is unknown.

2. Un-unified device and network management interface Manufacturing Messaging Specification (MMS) is the main monitoring and messaging protocol used for communication in IEC 61850 compliant systems. However, as more and more networking devices have been increasingly implemented in the IEC 61850 system, devices that do not run MMS, such as industrial Ethernet switches and embedded computers, have also become important for communication and control. In contrast to IEC 61850 devices, the protocol used today for managing IT equipment is Simple Network Management Protocol (SNMP), a protocol entirely distinct from MMS, based on a wholly different logical structure. As PRP/HSR devices use Supervision Frame for device management, it is difficult to integrate these two systems for monitoring and management.

The fact of there being different device and network management protocols, MMS for IEC 61850 control devices and SNMP for IT or networking devices, results in an incapacity of the central management suite, such as Power SCADA, to manage both control devices and networking devices in a centralized manner. Given the fact that most market-available Power SCADA software suites are compatible only to MMS protocol but not SNMP or Supervision Frame, network management on a single Power SCADA becomes impossible; the networking devices are invisible on the Power SCADA. As a result, IEC 61850 system operators may not be able to efficiently and effectively correct or prevent system failures using the information provided by Power SCADA. Recommended Solutions The solutions outlined below can help establish efficient and effective management for a PRP/HSR Substation Automation Network: Native PRP/HSR substation computers can play an important role in a highly reliable smart substation.

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17.5 Some users have been using a PRP/HSR Redbox to enable a conventional computer to join the PRP/HSR network. However, this could add the risk of a single link/node failure. Instead, using a native PRP/HSR computer can avoid the risk of a single link/node failure.

Control devices and redundant networks can be monitored on a single Power SCADA platform The best use of native PRP/HSR substation computers is to deploy a PRP/HSR-capable Power SCADA management server.With some

specially designed PRP/HSR management middleware built in, the PPR/HSR management server can enable the Power SCADA to collect and analyze the raw data from various distributed devices. The current redundant network status can be fully monitored, and the singlepoint failure can be immediately discovered. This makes real-time troubleshooting a simple task. Even system administrators with little knowledge of PRP/HSR technology can easily manage, monitor, and troubleshoot the PRP/HSR network on a single Power SCADA platform.

The PRP/HSR management middleware should be able to support both SNMP and MMS interfaces, allowing the connection of various substation devices that run different communication protocols. The integration of the middleware and Power SCADA enable all data to be effortlessly used and read in the substation Power SCADA system through MMS protocol. Substation operators find it easy to manage all devices on the PRP/HSR system via the Power SCADA visual tools. In addition, troubleshooting can be easy as any single failure point can be shown on the Power SCADA, making the SAS or any other PRP/HSR applications more reliable and stable.

Enabling Efficient and Visually Represented PRP/HSR Network Management Even though there is a unified standard for PRP/HSR protocol, there is no standard for the network management interface. Using a native PRP/HSR management server with a built-in management middleware can help collect, analyze, and integrate all raw data from various devices on one single management platform. This makes network diagnosis, troubleshooting, and device condition monitoring easier than ever. rob@rjconnect.co.za

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2014-10-OptrisVideo_WNIPRev1-1_190x130 30 July 2014 11:09:17 AM

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17.5 Intelligent surge protection for Blowdown intrinsically safe applications valves for boilers

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he new PT-IQ Ex models from the self-monitoring Plugtrab PT-IQ surge protection system are specifically designed for intrinsically safe applications and can be installed directly in Ex zone 2. The intrinsically safe signal circuits can be routed up to Ex zone 0.

All protection systems consist of a controller and the protection modules themselves.

The controller supplies power to up to ten surge protection devices over mounting rail connectors and establishes contact to the multi-stage remote monitoring system. This means significantly less wiring is required than when

RFID systems

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he constant increase of automation in modern production plants is increasingly supported by identification systems. Their tasks include, for example, the control or release of production steps or the assignment of information about each product. The RF identification system from ifm electronic is a compact and easy alternative for applications in which, for example, optical identification is not possible due to the ambient conditions.

The RF identification system for AS-interface allows reading and writing of code carriers

using conventional installation techniques.

The intelligent monitoring of each voltage-limiting component in a protective circuit allows preliminary damage to be detected and this information to be displayed using a separate yellow status indicator. In this way, pre-damaged surge protectors can be replaced during routine maintenance before they fail.

The newly available Plugtrab PT-IQ Ex products complete the line of intelligent surge protectors for measurement & control and data technology.

lowdown valves are a very popular category of pipe valve, used in a wide variety of applications, in particular in the sugar industry.

They are used for operation in an open position.

The main function of blowdown valves is to control a continuous flow of steam /fluid under high differential pressure.

The outstanding feature of this type of valve is that it can maintain fluid tightness and it is easily operated without the help of any wedging action.

Mitech’s automated Globe Blowdown valves are a recognised standard in the sugar industry as they eliminate the need for the operator to manually blowdown the boiler, typically on Mud Drum Blowdown applications.

The Globe valves are built with a stellited plug and seat, an oversized actuator and extended mounting bars.

Flanges are 600# and they can be either on/off or used in modulating control mode.

Mud drum blowdown valves are used on boilers to clean the drum of soluble and insoluble solids that collect at the bottom during normal operating conditions.

Applications vary from boiler to boiler as each one is designed for specific pressures and temperatures.

tonyr@phoenixcontact.co.za

enquiries@mitech.co.za

(ID tags), benefiting from the advantages of AS-interface. It can be easily integrated into existing AS-i networks and is immediately ready for operation. For reading, the RF identification system uses the AS-i analogue protocol 7.4 for data transfer. Special software modules are not required. Up to 31 read/write modules can be connected to one AS-i master.

The read/write head stores transmission errors which can be retrieved for a targeted fault analysis. Antenna, electronics and AS-i interface are integrated in a compact housing. The voltage is supplied via the AS-i network via a rotatable M12 connector. No additional operating voltage is

required. The ID tag (transponder) provides flexible mounting options for workpiece carriers, tanks etc. The code length is 15 bits.

The RFID system (Radio Frequency IDentification) generates a 125 kHz electromagnetic field for reading and writing of data. The electromagnetic field emitted by the antenna induces voltage in the passive ID tag (transformer principle). This activates the ID tag (transponder) which returns its code. Processing of the code and transmission to the AS-interface are carried out in the read/write head. The advantages when using the system include reliable

data transfer in dynamic reading processes and very small ID tags.

Ethernet, Profinet, and Profibus evaluation units are also available. denzil.hewitt@ifm.com

13

17.5 New non-contact infra-red temperature sensor

T

he new PyroUSB non-contact infra-red temperature sensor connects directly to a PC via a USB cable (included) and operates without the need for any additional hardware interface or power supply.

The CalexSoft software (also included) is simple to install and requires no specialist knowledge to set up and use. It displays temperature in numerical format and on a simulated scrolling chart.

Users can set the temperature range and emissivity, compensate for reflected energy, apply filtering to fluctuating temperatures and use peak or valley-hold processing to measure hot or cold objects on conveyors. The software may also be used to record measurements at any interval from 1 second to 1 week and pre-programmed to start and finish at any time or date. Audible/visual alarms can be set to warn users that the temperature is either too high or too low. The built-in OPC Server

interface allows communication between the sensor and any other equipment with OPC Client capabilities, making systems integration simple and affordable.

In addition to the USB interface, the sensor is equipped with a 2-wire, 4 to 20 mA output, which is linear with temperature.

This output can be connected at the same time as the USB interface or independently. The PyroUSB sensor is capable of measuring temperatures accurately and repeatably from -40°C right up to 1000°C. If a smaller range is required this can be set using the CalexSoft software.

The sensor itself is just 106 mm long by 25 mm diameter and made of polished stainless steel, sealed to IP65, making it ideal for food and pharmaceutical applications. It is held in place by a mounting nut (included).

Fixed and adjustable brackets are offered to simplify mounting and a laser-sighting tool is available to assist in the sighting of the sensor.

The high-quality Germanium lenses used by Calex produce very well defined optical paths.

There are three to choose from; the first provides a field of view with a distance to spot size ratio of 15:1. There is also a lens with a

30:1 ratio and one which focuses on a 5 mm diameter spot at 100 mm distance, which is ideal for small targets such as electrical components.

If the sensor is required to operate in a very high or low ambient temperature (less than 0°C or more than 70°C) it can be ordered with a water/air-cooled jacket built around it.

The temperature inside the sensor can also be monitored from the PC to make sure it doesn’t exceed the ambient limits. For dusty environments, such as in paper or textile mills, an air-purge collar can be fitted to keep the lens clean.

Built-in adaptive filtering provides a very stable signal without compromising the remarkable 250 ms response time, so there is no need to sacrifice a fast response in order to achieve a stable reading. PyroUSB sensors are RoHS compliant and conform to EN 61326-1:2006 for EMC. sales@iqinstruments.com

Power Supplies and UPS For Maximum System Availability Leading technology and high quality our POWER products ensure your system is always reliably supplied with power Power supply units, DC/DC converters, redundancy modules, and uninterruptible power supply units are tailored in their functionality and design to the requirements of various different sectors and always offer the ideal solutions.

For More Information Please Contact Us On:

JHB: 011 801 8200 CT: 021 930 9666 DBN: 031 701 2701 PE: 041 364 0415 www.phoenixcontact.co.za

14

17.5 Automation Interface – the open interface for automatic code generation

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he Automation Interface within TwinCAT 3 automation software enables complete remote control of the TwinCAT engineering system and automatic generation of programs and configurations.

Depending on the degree of automation, manual handling of control projects and any associated errors that go along with it can be reduced or eliminated. The quality of software engineering is increased by automating the project generation, while at the same time saving time and cost.

The automation of machines and plants is becoming increasingly complex and time-consuming. Engineering expenditures are growing in proportion to this, which is reflected, among other things, by the increased costs for the development, configuration and programming a PLC. These costs can be reduced if either the complete software application or parts of it are generated automatically. On top of that, errors in the configuration can be reduced by automated code generation. This is precisely where the TwinCAT Automation Interface

Architecture of the TwinCAT Automation Interface in TwinCAT 3

makes a dramatic impact: it provides a programming interface using the complete TwinCAT system and virtually all offline and online functions can be remotely-controlled. The error-prone and (in terms of personnel costs) expensive generation of I/O configurations and programs is thus simpler to accomplish.

The TwinCAT Automation Interface Various interfaces to different tools that simplify the engineering process have already been available for many years in TwinCAT 2. The TwinCAT Automation Interface is one of these disclosed interfaces that

is based on the Component Object Model (COM) from Microsoft and – in addition to the standard Microsoft .NET programming languages – also supports modern script languages such as Windows Powershell.

This opens up new areas of application and usage scenarios for the TwinCAT Automation Interface.

The TwinCAT Automation Interface is made up of a large number of programming routines that are available to the user in the form of classes and methods. Among other things they enable the loading of TwinCAT projects from a source code database such as the Team Foundation Server. The projects can be modified afterwards and activated on the runtime system. Navigation through a project is intuitive, because the underlying tree structure is the same as in the TwinCAT engineering environment, which facilitates faster familiarization with the Automation Interface.

Configuration nodes can be added, deleted and modified within a project. Appropriate routines are available for this, irrespective of the type of node (PLC, I/O or Motion). The modification of parameters on a node is simple, since almost all the settings are provided in a generic XML format. The configuration of a node is loaded by means of methods available in the Automation Interface; it can be modified by means of standard XML mechanisms such as those provided, for example, by the .NET framework and saved once again in the TwinCAT configuration.

I/O nodes can contain, for example, node addresses or baud rates as parameters, while a PLC node in PLCopen-XML provides the source code (e.g. of a function block) in the corresponding IEC 61131-3 language.

Here, too, the source code can be loaded, modified and saved again.

All elements of the TwinCAT configuration are made available to the outside with fine granularity via the Automation Interface.

This provides a high degree of flexibility for the customer application, since the Automation Interface – as opposed to the step-by-step generation of the configuration “node for node” – also enables the generation of configurations on the basis of templates. For this, the application could access a template pool, Use of templates for generating e.g. a source control system, configurations and successively build up the configuration. Templates can be defined in a range from complete projects right down to the node level; i.e. an EtherCAT device from the I/O area, once configured, could be saved in a template file, imported later via the Automation Interface and added to a new configuration.

The generation of a configuration – especially in the case of I/O configurations – is based among other things on hardware addresses, which are of course only available if access to the corresponding I/O device is possible. The Automation Interface provides the option to prepare a configuration offline, i.e. without connected I/O devices, and to add the parameters later on when the I/Os are present. Alternatively, a configuration can also be accomplished with connected I/O devices using the “Scan function” that is familiar from TwinCAT XAE. Applications of the TwinCAT Automation Interface With the aid of the TwinCAT Automation Interface, complete projects can be generated or changed in a standard and flexible way. The application possibilities that result for the customer are extremely varied: They can range from a simple application for the automated addition of version information to PLC function blocks to complex user-defined engineering tools, which only use the regular TwinCAT configuration environment in the background.

However, officially available TwinCAT supplement/function products also make use of the Automation Interface: for instance, the

15

17.5

Structure of the example application

TwinCAT ECAD import tool, which uses the Automation Interface internally in order to generate a project from an XML file coming from an ECAD tool.

Users can find a detailed description of the Automation Interface, many solution examples and best practice articles in the Beckhoff Information System.

Among other things a downloadable application example is provided that offers the customer a starting point for their own application and thus promises an initial sense of achievement in handling the Automation Interface. The application provides a certain number of different TwinCAT configurations on a graphic interface

written in C# using WPF. These can be specified in detail in an XML file.

The corresponding configuration is then automatically generated in the background at the push of a button and activated when necessary.

The time required for this is just a few seconds – depending on the scope of the configuration to be generated. Such an application offers very high optimization potential for applications where the configuration of a machine must be changed several times a day, for example because tools are to be activated with other I/O systems. A machine operator can then activate the different configurations as required without TwinCAT know-how.

A further demo application shows the possible use of the Automation Interface from a Visual Studio® add-in. The application can be started when a TwinCAT project has been opened. It automatically adds version information (author, version) to all PLC function blocks in the project in the form of constants that can be read later on. Such an application underlines once more the usage possibilities and the flexibility in the integration of applications into the Visual Studio® development environment. kennethm@beckhoff.co.za

Monitoring sensors via the mobile phone network

W

ith the TC Mobile remote signaling and remote control system you can monitor digital and analog inputs cost-efficiently and securely via the mobile phone network.

In addition to the four digital inputs, two analog inputs are now also available for the level sensor, pressure sensor, gas sensor or brightness sensor values. What’s special about this is the fact that the inputs can be used not only for a 0 to 20 mA signal, but also for

voltage measurement up to 60 V. If ever the measured value deviates from the reference value, an alarm is generated via SMS, e-mail or GPRS. With a large voltage range from 10 to 60 V DC or 93 to 250 V AC, the compact signaling system is extremely versatile, particularly when used in buildings and harsh industrial environments. kevinp@phoenixcontact.co.za

16

17.5 Reliably determine actual fieldbus availability

C

ommunication via fieldbus is highly valued in process automation due to its high reliability. Like any installation technology, however, it is not exempt from faults and failures. But what is the actual risk of failure and what availability can be realistically assumed? Calculations often provide an unsatisfactory reflection of the real situation. This results not only in incorrect assumptions, but often in protective measures that are expensive but barely effective.

In practice, to what degree does availability affect whether a fieldbus installation is commissioned? You need to understand what can cause problems and how best to protect against them, so that you can take preventive measures and ensure increased fieldbus availability. However, availability calculations are based on descriptions, assumptions, and observations from the theory of probabilities. Pepperl+Fuchs have discovered from many years of interaction with users that these calculations are based on assumptions that are sometimes unrealistic, and sometimes just plain wrong. Of course, the results of such calculations do not really reflect reality.

What do we mean by actual availability?

The International Electrical Vocabulary (IEV) has 47 different definitions of the term availability and, accordingly, different ways of calculating it. Stationary availability is usually called availability (A) for short. It is defined as the mean value of current availability in a time interval. The mean time to failure, called MTTF, and the mean down time, called MDT, can be used for a simplified calculation of the stationary availability, provided these values are constant. In this case, the following formula is used for the calculation: Often, the inverse of the Lambda failure rate for a product or series of products is mistakenly used to calculate the MTTF, such as for a fieldbus segment. But this procedure reflects only the random failure of the component(s). This means that important systematic criteria are not being taken into account. In practice, these criteria play a crucial role in availability: When environmental influences as well as the mode

of operation and its 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 failures that cause component failure.

An example shows the difference The extent to which this type of one-dimensional view can distort reality when calculating availability is shown by a simple example: If a person in his role as employee is used instead of the process system, the result is an MTTF of 1401 years or 72,800 weeks according to the above-mentioned procedure. But this value takes into account only the “total failure”–i.e., possible death–of an employee, which certainly does not accurately reflect the employee’s actual availability in his professional life. Take a look at the human bathtub curve for the Federal Republic of Germany and we see that this high MTTF is a result of the reciprocal value of the human “failure rate” 0.71375 ‰. If you further assume that a replacement is found for a failed employee after six weeks (=MDT), the availability is calculated as:

Of course, important aspects of everyday working life remain unaccounted for. Much more frequent causes of absence from the workplace are vacation, illness, doctor’s appointments, or business trips, which can occur several times a year. If you assume that a failure of on average two weeks occurs twice a year for these reasons, the availability is calculated as:

This value corresponds to the actual observations in practice– quite unlike the calculation with the inverse of the Lambda value.

Reduction of failure risks Finding the right method of calculating availability is just the first basic step. Once you have calculated reliable figures for the actual availability of a plant, it follows that you must take measures to reduce the failure rates effectively and thus increase availability.

Systematically, there are four methods to protect against a component or part of a system failing and thus positively influence the MTTF: First: Preventive measures and procedural instructions must be given. The correct and protective handling of technology is often enough to help reduce failures significantly.

Second: The predictive, automated handling of faults. With this method, techniques and components are used that have been specially developed to detect and isolate typical faults in a targeted and proactive manner–before they can spread. The impact of the fault remains limited to a deactivated device, while the plant itself remains in operation. For example, if a measuring device connection is deactivated in the case of a short circuit, but the fieldbus segment remains unaffected, because the failure of an individual measuring part is tolerable.

Third: The detection of faults through diagnostics. With this method, discrepancies between the actual status and the best possible status are detected through monitoring and reported to the control room. Before this can have a negative impact on the overall function, proactive intervention can be taken. For example, if you measure a change in the frequency of filling level sensors using a tuning fork, this indicates that the sensor has become jammed. The problem can then be corrected.

Fourth: Redundancy. This protects against failures whose causes have to be investigated in the device itself. Redundancy is indispensable if these faults cannot be avoided in any other way, but must absolutely be controlled to ensure safety or plant availability.

This is the case for power supplies and control technology boards or for field devices where the measuring circuit is required to have a very high level of availability.

Actual fault causes–an outlook What exactly are the typical fault scenarios in fieldbus installations and what specific measures actually protect against these causes of failure? The answer to this question is the basis for correctly selecting components, methods, and procedures. The second part of this article therefore not only explains the results of several years of investigation by Pepperl+Fuchs on the typical fault scenarios, but also presents an innovative and simple method for assigning the protection, which is actually effective, to every cause reliably or for evaluating the available protection objectively.

This method is recommended by the company to ensure a more objective discussion. mbracco@za.pepperl-fuchs.com

17

17.5 Controlling and switching in a highly compact package

P

LC logic, the new programmable logic relay system, is particularly well suited for small automation tasks. It combines the strengths of established relay technology with logic functions in a single package.

The modular design, featuring plug-in relays, enables flexible assembly, depending on the switching task. Pluggable switching elements ensure high machine and system availability thanks to fast replaceability during servicing.

The system consists of logic modules, the PLC-Interface relay system, and the Logic+ software. To start up the system, the logic modules are plugged into eight relay modules. A compact 50 mm wide logic module can process 16 input/output signals. The base module can be expanded with up to two add-on modules for more complex applications, making it possible to process up to 48 input/output signals.

Programming is done using the highly intuitive Logic+ software that requires no previous experience in this area. kevinp@phoenixcontact.co.za

True-rms clamp meter

T

he local Fluke representative claims their Fluke 325 clamp meter is by far the best value-for-money clamp meter currently available on the market. Specifically designed for commercial, light industrial, HVAC, residential and DIY applications, the 325 with its rugged casing is tough enough to withstand a one-meter drop. The ergonomical design features a smaller, tapered jaw, for cramped situations. The 325 is also Category IV 300V/ CAT safety rated and has a 2-year warranty. The 320 Series clamp meters measure: • 400 Amps ac & dc current • 600 V ac and dc voltage • resistance up to 40 kΩ with continuity detection • True-rms ac voltage and current on non-linear signals • Temperature info@comtest.co.za

The first of its kind – a level switch that can handle any environment ... ... temperatures from -196 to +450 °C, pressures from -1 to +160 bar, all liquids.

The new, patented drive of VEGASWING 66 as well as extremely temperature resistant materials make it possible.

▪ ▪ ▪ ▪ ▪ ▪

Point level switch and overfill protection device Liquid gas vessels, boilers and distillation columns Quick function test via keypress More reliable than capacitive probes and float switches Double security (through second line of defence) All approvals, and up to SIL3

www.vega.com/VEGASWING

18

17.5 Capping valve

S

ince 1899 NAF valves have been developing and manufacturing for the process industry integrating traditional mechanical construction with intelligent systems. The new capping valve from NAF ensures safe, time saving processing of wood chips in pulp digesters. he NAF Pro-Cap is a high tech valve for chips filling, one of the most critical applications at a pulp batch digester plant.

It’s crucial that this is done in a safe and time saving way and to control the time of the cooking sequence.

The capping valve is mounted on top of the batch digester for automated filling of wood chips in the digester. During the cooking sequence the valve provides tight shut-off to atmosphere.

The unique design of the NAF Pro-Cap is based on a segmented ball valve. This prevents wood chips from getting stuck between the housing and the ball.

Design and function: The segment is mounted on an upper and lower stem. The uniqueness of the design is that each of the stems is mounted in an eccentric hub. The stems can be moved along the valve by

T

Capping valve left

Capping valve right

rotation of the eccentric hubs.

The upper eccentric hub

is used for a once off manual adjustment of the assembly.

This provides the correct load and scraper function between segment and seat.

The lower eccentric hub is automated with a Turnex actuator to lift and load the segment against the seat. This is done during each cooking sequence, thus providing a tight seal on the upstream side of the valve.

After the cooking sequence is completed, the process is reversed.

NAF Pro-Cap Valve Features: • Batch digester capping valve • PN 16-25 and ANSI 150 • Body in EN 1.4408/ASTM A351 CF8M • Valve Inspection and testing acc to API 598 • Unique design uses the eccentric hubs to load the seat and provide tight shutoff • Jammer device for locking the valve in open or closed (filling or cooking) position • NAF Turnex high performance actuators used for operation and eccentric hub. fred.venter@valve.co.za

USB Modbus data acquisition

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he D8000 series USB interface modules are a complete family of data acquisition modules for use in process control systems.

These modules can measure process signals such as thermocouples, 4-20mA loops, discrete contact closures, and they can generate voltage or current signals for controlling annunciators or valves.

Complete data acquisition systems can be created with ease with the D8000 modules and a host supervisory computer.

The modules provide direct connection to a wide variety of sensors and annunciators.

They perform all signal conditioning and linearization and contain no pots or DIP switches. All user-selectable settings, such as ranges are stored in non volatile EEPROM, which maintains these values even after power is removed.

The D8000 series remote I/O modules are compatible with all commercial software programs and OPC servers that support the Modbus RTU protocol. Commercials software programs from DreamReport, Wonderware, Intellution, National Instruments Labview, Indusoft, DAQFactory and DASYLab all support the Modbus RTU protocol. OPC Servers from Kepware and MatrikonOPC support the Modbus RTU protocol.

Features • Build complete data acquisition systems.

• Analog and Digital I/O models available.

• USB communications interface.

• Modbus RTU Protocol.

• Differential Analog Inputs.

• 500Vrms analog input or analog output isolation.

• 16-bit analog input measurement resolution.

• Continuous self-calibration • No adjustments required.

• Programmable analog input digital filters.

• Requires +10V to +30Vdc unregulated supply.

• Removable screw terminal plug connectors.

• CE marked. sales@vepac.co.za

19

17.5 New technologies for upstream oil and gas boost production performance

D

igital Suites for Oil and Gas, an innovative set of software and comprehensive services, can help oil and gas producers boost production performance by 3 to 5 percent while improving operational safety.

Responding to demands for safer and more productive operations in oil and natural gas production, Honeywell used its extensive experience in the oil and gas and related industries to introduce a unique suite of solutions specifically designed for upstream operations.

The production improvements, which have been validated through customer testing, are driven by a combination of better productivity, higher uptime and more efficient remote operations, and can produce a return on investment in as little as six months.

“Upstream oil and gas producers tell us they have access to more real-time data than ever, but access to that data alone is not enough to improve performance – you also need digital intelligence to make sense of all the data being collected,” said Ali Raza, vice president and general manager, Honeywell Process Solutions. “Digital Suites for Oil and Gas turns data into digital intelligence that helps operators make critical decisions faster by capturing, managing and analyzing the right production information.”

The overwhelming complexity of data in upstream production can make insightful decisions difficult, safer operations a challenge and integrated metrics beyond reach. Digital Suites for Oil and Gas can meet these challenges with data-driven solutions that are ready for new operations or integrated into existing production environments. Digital Suites for Oil and Gas software helps to ensure that essential safety procedures perform as designed, operators are fully trained, alarms are managed and enforced, and production performance is instantly available to detect and mitigate potential events. These software solutions make collaboration through remote operations a reality, helping to manage the number of local personnel, especially as the upstream industry moves farther offshore into higher-risk conditions.

Digital Suites for Oil and Gas is a fully integrated offering, but each suite is also available separately, letting customers address the specific issues they face. The six suites are: Operational Data; Process Safety; Production Surveillance; Equipment Effectiveness; Production Excellence; and Operational Performance.

The new offerings combine Honeywell’s field-proven technologies with new software and implementation methodologies delivered through its new oil and gas center of excellence, which was recently established to better serve Honeywell’s customers in the upstream oil and gas industry.

Digital Suites for Oil and Gas works seamlessly with Honeywell’s complete line of integrated control and safety systems, instrumentation, and industrial products, and can be easily integrated into any multivendor environment. boni.magudulela@honeywell.com

A bull’s eye in quality.

Temperature head and DIN rail transmitters iTemp TMT127 / 128 / 187 / 188 Individual and comfortable • A wide range of fixed measuring ranges for RTD and TC • High accuracy in ambient temperature ranges • Galvanic isolation and ATEX certification (option) iTemp Version for non-hazardous area

R692* 11–35 pcs.

Price/piece in R 1–3

4–10

11–35

TMT187: head transmitter, RTD 3-wire

R744

R714

R692

TMT188: head transmitter, TC

R744

R714

R692

TMT127: DIN rail transmitter, RTD 3-wire R1333 R1280

R1240

TMT128: DIN rail transmitter, TC

R1240

R1333 R1280

*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

20

17.5 Alarm system with integrated GPRS communications to control panel

I

ntroducing a domestic or commercial alarm system using GPRS technology with an important function that allows commands to the control panel to be activated via SMS. This powerful solution is totally developed and manufactured in South Africa which ensures cost-effective local back-up support. The integrated hardware package consists of the ERS 48Z Control Panel, wired and wireless devices, Codex remotes for panic, arming and disarming of the alarm, the GPRS communicator and short range transceiver for remotely controlling an AC switcher.

The ERS 48Z is an 8 zone control panel, expandable to 48 zones, and can take any combination of wireless and hardware zones with up to 8 LCD/LED keypads. The short-range transceiver links to the control panel via a BUS line for communication to a remote AC switcher with relays to switch 220 V lighting on the property perimeter, or to trigger opening of gates, or garage doors. This function can be performed from the control panel installed within a building or through SMS commands and is particularly useful to allow armed response access into a property.

A serial ERS GPRS Communicator device provides for full bi-directional transfer of data from the control panel or a cellphone to the control room of an alarm company, with full uploading and downloading capability. This device supplies full contact ID reporting via the ERS GPRS APN network.

Positive reaction has been received on demonstration of the new end to end ERS 48Z solution from security companies. frankf@ersnetworks.co.za

Fieldbus Foundation and HART Communication Foundation members approve formation of FieldComm Group

T

he final step in constructing a single organisation to lead process automation communications and integration technologies was completed when the members of both the HART® Communication Foundation and Fieldbus Foundation™ approved the merger proposed by their respective boards through a voting process that concluded on August 30. This completes a yearlong study and diligence period by a dedicated team of volunteers representing each of the foundations.

The new corporation, called FieldComm Group, will be led by a board of directors composed of representatives of the collective companies from the current boards of each foundation. HansGeorg Kumpfmueller has been

elected as the inaugural chairman of the board. Mr. Kumpfmueller will lead the direction of the FieldComm Group and oversee the addition of FDI LLC in mid2015.

Mr. Kumpfmueller has served as a leader in setting the course of device integration in his role as chairman of the FDI LLC board and as CEO of Sensors and Communication at Siemens. He is convinced the formation of FieldComm Group is “a major step forward for the process industries by leveraging the strengths of each industry-leading protocol and adding the value of the nextgeneration integration strategy.”

The board has appointed Ted Masters as president and CEO of FieldComm Group. He currently serves in the same capacity with the HART Communication

Foundation. Mr. Masters brings a wealth of instrumentation and controls experience to bear in addition to a deep understanding of the use of data analytics in enterprise systems.

Mr. Masters believes the creation of FieldComm Group is an unprecedented opportunity to build upon existing technologies and develop a single future vision toward harmonisation of standards for the process automation industry worldwide.

He said, “I am excited about the opportunity to work together with distinguished leaders and technologies around the globe to integrate valuable process intelligence from devices to improve the operations of our users.”

During the transition and integration of the two

organisations, Richard J. Timoney will serve as executive vice president of FieldComm Group. Mr. Timoney currently is president and CEO of the Fieldbus Foundation. He commented, “The joining of Fieldbus Foundation and HART Communication Foundation will realise the automation industry’s goal of a single, unified body to support advanced digital technology. The efforts of countless individuals and companies have helped us reach this milestone.” FieldComm Group will consolidate offices in Austin, Texas, and function as a single entity beginning January 1, 2015. Until that time, the HART Communication Foundation and Fieldbus Foundation will continue to operate independently. sue.fielder@fieldbus.org

Plug-in connector housing for EMC applications

E

MC-protected versions have been added to the line of Heavycon EVO heavy-duty industrial connectors. The cable glands with a bayonet locking mechanism make both lateral and straight cable outlet directions possible in a single housing.

This enables a large number of ECM housing and cable gland

variations to be created with just a few components. The cable outlet can also be subsequently adapted on site. The housing material is corrosion-resistant, and all seals are electrically conductive.

This provides a shield attenuation of approx. 40 dB, which is sufficient for industrial EMC applications. The new IP

65/66-compliant housings are available in the B6, B10, B16, and B24 formats with a single or double locking latch. The housings can be purchased individually and are available in stock as complete plug-in connector sets with pushin contact inserts. seanh@phoenixcontact.co.za

21

Automated valves provide infinite control for industrial processes

I

ntroducing a sleek new range of Italianmade valves for process and industrial applications. The valves, manufactured by well-known and respected valve manufacturers, M&M International, are a well priced alternative to existing brands available in South Africa and offer Europeanquality assured performance and durability, while full support and service is afforded by the local distributor.

The range of advanced solenoid and piston actuated valves perfectly complements the company’s popular range of Ashcroft pressure gauges, transmitters and switches, as well as its Fairchild range of pressure regulators, volume boosters and I to P converters.

Full range solution This completes the company’s pneumatics and process control equipment offering and ensures that designers, engineers and plant owners have a singlesource of supply for control equipment.

M&M International is a leader in the supply of solenoid and piston actuated valves throughout Europe. In South Africa they have been made keenly aware of the need

The new range of M&M solenoid and piston actuated valves

to pitch prices competitively and as a result have committed to supply top-quality products at an affordable price.

The range is widely used in a variety of industries worldwide, including the food, agriculture, energy, railways, industrial automation and automotive industries (among others). The valves are suitable for a all-manner of materials from gases to fuels, liquids, steam, powders, chemicals etc. jerry.smits@protea.co.za

What colour is sugar?

T

he colour of sugar liquor is often determined from process samples in a laboratory. This is time consuming, and correcting the process based on old laboratory data can cause production loss.

The solution: inline monitoring.

The decolourisation process removes organic impurities that impart colour to the sugar liquor, such as by using ion-exchange columns or activated carbon columns.

The clear brown syrup is passed through a series of acrylic and styrene resin columns, as well as granular activated carbon columns. Depending on the liquor quality, different resins and/or resin combinations can be used. The resulting light-coloured syrup or fine liquor is used for white sugar crystallisation or, after further treatment, for the production of bulk liquid sugar.

OUSAF22, the colour analyser with the right combination of light source, optical filters, photo detectors, and flow cell path lengths, monitors the colour of a process stream with a readout in colour scales over different ranges. Typical measurement wavelength ranges would be from approx.

400 nm up to but not limited to 520 nm, depending upon the colour application. The sensor is designed for true inline process use and the Memograph CVM40 transmitter allows the colour scale to be read out in the appropriate engineering unit.

The most commonly used sugar colour scale is the ICUMSA scale. The ICUMSA colour

depends on the sugar concentration. The Memograph CVM40 has two universal inputs available for process input like the sugar concentration and, with help of the built-in powerful mathematical package; the CVM40 is able to calculate the true compensated ICUMSA sugar colour value.

The design with two wavelengths also enables the measurement system to compensate for suspended solids that normally will affect the colour measurement. If higher turbidity is present in the process stream a filter can be installed prior to the sensor. In humid or condensing environments the sensor can be fitted with an air purge option to prevent disturbances caused by window fogging.

Due to the flexible path length setup, the Endress+Hauser OUSAF22 can be configured to detect very slight changes in sugar colour. info@za.endress.com

Cables, Wires & Accessories

17.5

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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17.5 New vortex flowmeter for advanced energy measurement

I

ntroducing the new OPTISWIRL 4200 vortex flowmeter for the measurement of conducting and non-conducting liquids, gases and steam.

The new device is targeted at auxiliary and supply applications in various industries, such as internal monitoring of energy flows for saturated and superheated steam or hot water, and heat metering applications. Areas of usage also cover steam boiler monitoring, burner consumption measurement or compressed air network monitoring, including FAD applications.

Based on the experience gained with the predecessor OPTISWIRL 4070, the new flowmeter comes with some advanced features: in addition to gross heat calculation for steam, the OPTISWIRL 4200 now includes net heat calculation for steam and condensate (hot water) as well.

With one temperature sensor integrated as standard, the device can be installed as heat meter in the feed line directly connected with an external temperature sensor in the return line.

The gross and net heat calculation can be fed into a DCS to support advanced energy management.

As established with the predecessor, temperature and pressure compensation options are also available for the new OPTISWIRL 4200 to enable calculation of standard

OPTISWIRL 4200 C: New vortex flowmeter for advanced energy measurement

flow volume under fluctuating pressures and temperatures (online density compensation).

Both compensation functions are based on the standards of NIST (for gas) respectively IAPWS (for steam). Another advantage is that by combining three measurements (flow, temperature and pressure) in one 2-wiredevice, the line has to be opened only once for installation.

In addition to the standard sensor range, a version with integrated reduction of nominal diameter up to two sizes is now available for space-saving

installations and large measuring spans. About 90% of all vortex flowmeters are ordered one size smaller than line diameter in order to increase the flow speed and to get a wider measuring range.

Here, the line has to be reduced before and widened after the sensor, typically including 20DN inlet and 5DN outlet. With the reduction and widening of nominal diameter included in the sensor, this is no longer necessary.

To compensate for no straight inlet between reduction and the vortex bluff body, these devices

New panel PCs for outdoor applications

I

ntroducing new panel PCs in the Embeddedline series for operation and monitoring tasks outdoors.

The new devices are characterized by a UV and IRresistant front combined with a sunlight readable display.

With the wide temperature range from -20°C to +60°C and the dust-proof and splash-proof housing, the range of possible applications has been extended further.

The panel PCs are available in display sizes of 7”, 12”, and 15”, offering a maximum resolution of 1024 x 768 pixels.

They can be operated as usual with your finger even when wearing gloves, using pens or tools, without causing damage to the surface.

Thanks to the backlighting which can be switched off and the efficient CPUs, the panel PCs are particularly energysaving.

All devices are equipped with an Intel Atom processor and can be configured with regard to mass storage, the operating system, and an additional serial interface. kevinp@phoenixcontact.co.za

are specially calibrated and linearised.

The remote version OPTISWIRL 4200 F with field housing converter is now available with connection cable up to 50 m/164 ft. As with the predecessor, a dual version with two independent sensors and two signal converters is also available for multiproduct pipelines, redundant measurement or increased safety demands.

Enhancements have also been made on the electronics side: equipped with new AVFD function (Advanced Vortex Frequency Detection), the newly developed signal converter VFC 200 of the OPTISWIRL 4200 features advanced signal processing and filtering: interferences and disturbances in the pick-up signal are suppressed, and signals apart from the relevant frequency band are filtered out. Redundant data management prevents loss of calibration and configuration data when changing electronics or display.

By default, all OPTISWIRL devices are wet-calibrated at factory (traceable to international standards) and pre-set to match customer specifications.

OPTISWIRL 4200 also comes with an installation wizard to ease installation; e.g. in a steam application it will only show related settings. i.thushini@krohne.com

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17.5 The ideal PoE+ Ethernet solution with optimized power and bandwidth

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oxa unveils the ideal communication solution for high bandwidth Ethernet powered devices (PD) in industrial applications. To complete the line of high performance and extremely reliable industrial Ethernet switches, the EDS E series, the new EDS-G512E-8PoE is released. It features a high power output (up to 36 watts) designed for industrial, heavyduty PoE devices, Gigabit Ethernet capabilities for large bandwidth network transmissions, easy management tools (SmartPoE) for monitoring PDs, and an industrial-grade reliability built to withstand harsh environments.

Due to the increasing adoption of high bandwidth power devices in industrial applications, such as PTZ/outdoor HD cameras and wireless APs with IEEE 802.11n and IEEE 802.11ac capabilities, a switch with IEEE 802.3at abilities while featuring Gigabit Ethernet solutions is essential for a smooth network communication. The new EDS-G512E-8PoE series feature 8 Gigabit PoE+ ports allowing for large bandwidth transmissions and up to 30 watts of power in its standard mode. For heavy-duty PDs (power devices) requiring a higher voltage, the EDS-G512E8PoE series also allow up to 36 watts of power output. The series ensure a sufficient power supply for your mission-critical, powersensitive applications, making it the best Gigabit PoE+ solution to date.

The EDS-G512E-8PoE is designed with a series of smart management tools that simplify the process of remotely controlling and monitoring the power devices. The tools include a power management function to optimize the system accordingly, thus lightening its burden, and a diagnostic function to detect PD conditions with failure detection and LED indicators.

Other features, such as 3 kV LAN surge protection, -40 to 75°C wide temperature tolerance, Turbo Ring and Turbo Chain technology, and Moxa’s industrial network management software, are also included to guarantee network reliability and uptime.

EDS-G512E-8PoE Series

Features • Up to 30 watts of power per PoE+ port in standard mode and up to 36 watts for heavyduty devices.

• 8 Gigabit copper ports and 4 SFP Gigabit fiber slots for large bandwidth data transmission.

• SmartPoE management tools for easy operation and

monitoring of PoE powered devices.

• 3 kV LAN surge protection and -40 to 75°C operating temperature tolerance.

• Supports MXstudio industrial network management suite for large-scale deployments and management. rob@rjconnect.co.za

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17.5 Triple offset rotary process valves for Engen Back of Berth project

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he NMPP overview: To replace the existing 45-year old DurbanJohannesburg Pipeline (DJP – 12 inch) urgently as it is running at full capacity and nearing the end of its design life.

• To increase the capacity on this critical route (Durban-Gauteng) to meet projected demand and to ensure security of supply for the long term • 555km of 24 inch pipeline (mainline) and 160km of 16 inch pipelines NMPP as a hybrid of ‘Greenfields’ and ‘Brownfields’ project executed over long distances with difficult terrain would have significant cost and time delivery issues.

• Upgradeable to meet projected demand to 2035 – assuming high GDP in future • 70 year design life The solution The 30” Class 150 Zwick Tri-Con triple offset rotary process valves supplied to Engen as part of this project are fitted with Auma electric actuators.

• Zwick Tri-Con rotary process valves offer: • SIL 3 • Sizes from 2” (DN50) to 88” (DN2230) • Temperatures from -196OC to +815 OC • Zero leakage bi-directional sealing • Self centering temperature compensating disc • Quarter turn torque seated

• Metal to metal seats • Inherently fire safe & tested • High cycle bearings fred.venter@valve.co.za

Tower light now available in self-contained, compact size

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nnouncing a new selfcontained, compact version of its industry-recognized EZ-LIGHT™ TL50 tower light.

Measuring at only half the height of the standard TL50 models,

the TL50 compact tower lights are ideal for space-restricted applications requiring highly visible operator guidance or indication of equipment status.

Designed to replace

conventional stack lights, which often require time-consuming assembly and complex wiring, Banner’s TL50 tower lights provide bright, uniform lighting. The new TL50 compact version displays up to five stacked colors in one tower with universal ac voltage and up to seven stacked colors in one tower with standard dc voltage, and ten colors to choose from for each segment.

While the TL50 tower lights provide versatile indicator lighting for industrial settings, the manufacturers found equipment designers needing a more compact solution. The new compact configuration satisfies this need, while ensuring the

Space savings across three levels

T

he new UT 4-PE/L/HESI fuse terminal block range with screw connection offers a high degree of functionality on three levels with a pitch of just 6.2 mm.

The double bridge shaft on each level allows all tasks for potential infeed and distribution to be implemented quickly and easily.For switching tasks, especially in MCR technology,

an isolating plug, feed-through metal, component connector for the solder-free installation of electronic components or a fuse plug for 5 x 20 and 6.3 x 32 glass tube fuses can be used in the disconnect zone of the disconnect terminal blocks depending on the application. Feed-through terminal blocks of the same shape complete the range.

All modular terminal blocks in the UT screw terminal block series use the cross-system accessories of the Clipline complete modular terminal block system. In addition to using the same bridge system, marking and testing is identical for push-in, spring-cage, COMBI, and IDC fast connection technology. tonyr@phoenixcontact.co.za

same quality, uniform brightness and reliable performance our customers have come to expect from our other TL50 tower light models. Plus, the TL50 compact tower lights are extremely rugged and cost-effective for indication on smaller pieces of equipment.

Banner’s TL50 tower lights come preassembled and preconfigured, allowing users to save time and money during installation. For use in diverse environments and applications, the TL50 compact tower light is available in audible models with standard, sealed or OmniDirectional audible elements. rodneyt@retauto.co.za

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17.5 The IDENTControl system is always the right fit

T

he IDENTControl concept is unique in terms of connecting RFID systems with LF, HF, and UHF technology. There is only one system that can deal with numerous applications worldwide easily and efficiently, and connect to all common fieldbus environments and control systems. What is particularly important for the user is that the software has an identical structure for all RFID systems. The free RFIDControl software is available to support commissioning, not only guaranteeing easy device parameterization and diagnostics, but also allowing advance test operation before a control system is connected.

The Pepperl+Fuchs RFID range is based on almost 30 years of technology and application expertise across different sectors. IDENTControl is a great example of a versatile RFID system concept. IDENTControl is the perfect solution for many users in material handling and automotive engineering.

Its perfect modularity and comprehensive command structure significantly simplify flexible design, future-proof integration, and functionally optimal application of RFID solutions.

Range of frequency

Applications For users in various sectors, the innovative IDENTControl concept guarantees individuality, easy integration, internationality, and investment security. Selected application examples clearly demonstrate this. In workpiece carrier applications, the compactness and the option of installing tags flush in metal are impressive. In the field of material handling, read heads with ranges of >150 mm are often used. Stainless steel solutions are ideal for the food industry. For mobile solutions, the system offers handheld devices in pocket format. mbracco@za.pepperlfuchs.com

LF, HF, and UHF read/write heads can be connected to an IDENTControl control interface. The system can therefore be adapted perfectly to the respective applications. The RFID frequencies have different performance characteristics. LF is usually used in metal environments—partly for flush installation—while HF is used together with Smart Tags for larger volumes of data, and UHF for greater ranges. Trigger sensors can be connected directly.

IDENTControl is the all-rounder and thus offers great flexibility.

Varied fieldbus connection A variety of fieldbus solutions are available. Having this variety allows standardized application of the system around the globe, and it can be easily incorporated into a wide range of controllers.

Global standardization for RFID is therefore made much easier. Our Ethernet-based systems offer realtime capability with IRT (isochronous real time). The EtherCAT solution is particularly easy to connect and has a high data transmission rate to Beckhoff controllers. The CC-Link connection is often used with Mitsubishi controllers.

The standard command structure for LF, HF, and UHF systems makes it easy to implement a wide variety of solutions in the control environment software.

UHF as a new solution option UHF read/write heads from Pepperl+Fuchs offer much more than the large range and the convenience of using tags. The F190 read head is extremely compact yet powerful, enables selective reading of individual tags, and reading of a tag pulse. Software filters enable specific applications. The horizontal or circular polarization of the read heads improves reading performance. Simple connection via M12 connectors with IP67 protection and the metal housing make the product fit for industrial use.

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17.5 VEGA Instruments SA sponsors school in First Tech Challenge Robotics Competition The First Tech Challenge, which grew out of the First Lego League Challenge, is in its second year of competition.

This year twenty three teams from communities around Gauteng competed against each other to build the best robots. The Thuto Lefa Secondary school was invited by the Sci-Bono Discovery Centre Manager of the Technical and Support Robots Department to take part and they found a willing and supportive sponsor in VEGA Instruments SA (Pty) Ltd. Team VEGAnucs was born!

The school’s team was made up of five students between the ages of 15 and 18, led by a mentor and two team coaches. Staff members at VEGA Instruments played a supporting role by offering technical and practical advice and encouragement.

The final competition was held on August 2, 2014 at the Sci-Bono Discovery Centre and the team VEGAnucs reached the top five, only being eliminated in the semi-finals. However, they didn’t come away empty handed as they were awarded the Best Motivational and Inspirational trophy.

“By supporting the team from the Thuto Lefa Secondary School, VEGA Instruments’ philosophy of giving back to the community was fulfilled once more”, said MD John Groom. “We were excited to play a part in helping young learners to explore the world of science and technology and to grow our future young professionals”. chantal.groom@vega.com

Custom designed pneumatic rotary actuators

A

new range of locally designed and manufactured pneumatic rotary actuators is custom designed to suit various applications. The low maintenance instruments are available with either a double crank mechanism for modulating control or a scotch yoke mechanism for on / off duty. The main shaft assembly on the double crank design is welded together eliminating the need for it to be assembled or disassembled.

The actuator is field reversible from clockwise-to-close to clockwise-to-open allowing the base mounting of the actuator, irrespective of the valve type and fail action. The actuator has a Namur mounting for switch packs or positioners on the top shaft and transfer case lid. This provides a standard bracket for all positioners and accessories with no coupling required.

Engineered and fitted to most valves, the actuators have a pneumatic piston design and are suited for torques up to 250 000 Nm. The choice of either a double

crank or scotch yoke mechanism allows the user to select the best mechanism for optimum control and cost effectiveness. With its square drive, the actuator can

be mounted perpendicular to or inline with the pipework.

Adjustable end stops allow the end position to be externally adjusted in both open and closed position to within 7°.

Pressure seals are all simple ‘O’ rings reducing maintenance costs, and the single spring design, which is pre-stressed in a detachable pack, makes the actuator easy to assemble and dissemble.The double crank design for modulating control provides high run torques, negligible backlash and low friction, while the scotch yoke design for on/off duty offers high end torques.Typical applications for the pneumatic rotary actuators include, for example, petrochemical, mining, breweries, pulp and paper, power generation and iron and steel industries. enquiries@mitech.co.za

New power supply for frequency inverters

T

he new Quint Power power supply is specifically designed for connection to frequency inverters. In the event of mains failures it is used as a compact buffer solution and ensures that the machine can be restarted quickly and without errors when the supply voltage returns.

If a mains failure occurs, the DC intermediate circuit voltage of the inverter continues to supply all connected 24 V loads without interruption. To do so, the power supply is connected to two outer conductors of the three-phase system and to a DC voltage. This can be the DC intermediate circuit

voltage of a frequency inverter or a supply unit.

The controller then continues to be supplied with the kinetic energy of the motors. This enables a controlled machine stop to be performed. tonyr@phoenixcontact.co.za

27

Blockage detected - danger averted!

Flexibility is the main principle

17.5

I

n order to ensure a continuous flow of recycled material to the melting furnace, blockages must be detected. The Solimotion FTR20 bulk solids motion detector is the perfect candidate to be put in charge of monitoring.

More than a third of copper production at Aurubis, the world’s largest recycler of copper, is achieved as a result of processing debris containing copper and precious metal such as dross, slag and dust as well as PCBs, electronic scrap, used catalytic converters and materials from the waste industry. The recycling materials are first checked for consistency and chemical composition and then comminuted. The raw material is then fed into a bath smelting furnace via an enclosed conveyor belt. The material can get jammed here, which could lead to a blockage - but not when the Solimotion FTR20 bulk solids motion detector is on guard!

This non-contact device based on microwave technology works with an operating frequency of 24GHz and a transmission power below 100mW. For detection of the bulk solids movements, microwaves are transmitted and then reflected by the material. The Solimotion measures the strength of the reflected, frequency-shifted energy (Doppler Effect) and creates from it a display value, which is indicated via LED bars. The FTR20 operates like a binary switch, Le. it detects two states: material movement and no material movement. The optional analog 4-20mA output signal also allows continuous detection of changes in the mass flow. With an unobstructed beam path, the range of the Solimotion is up to 20m, dependent also on the reflection characteristics of the particular bulk solids.

At the push of a button Initial commissioning can be performed quickly and easily due to the automatic alignment function and just one push of a button.

The manual alignment option of the FTR20 also enables individual adjustment to the application with the help of customisable functions. In addition to an adjustable hysteresis, a switching delay and attenuation, the detection range or the gain can be adjusted so that even bulk solids with very low relative permittivity (dielectric constant, such as expanded polystyrene, can be detected reliably. The configuration is stored internally and is maintained even if the supply voltage is interrupted. When in operation, no further input is necessary. To check, a PLC may be situated downstream or a data logger is available, the FTR20 provides the option of simulating an output signal.

Applications The Solimotion FTR20 is ideal for the continuous monitoring of pneumatic and mechanical bulk solid transportation processes. The compact device can be used wherever cost-effective monitoring of bulk solids movements (flow/no flow) and changes to the flow behaviour is required, e.g. in metering systems, silos, above conveyor belts, before strainers and filters, after discharge and at bucket conveyors. info@za.endress.com

Searching for a modular solution?

OPTIFLEX 2200 C/F is the answer.

The OPTIFLEX 2200 C/F – TDR level meter is available with either a horizontal or a vertical housing to fit into installations of many industries and applications: It can measure in nearly all process applications with temperatures up to +300 °C / +570 °F and in tanks of maximum 40 m / 130 ft height. The remote converter can be installed and operated as far as 100 m / 328 ft from the probe. Intelligent software eliminates false reflections caused by environmental disturbances and product build-up – we call it DPR (Dynamic Parasite Rejection). To ensure safe operation, the TDR level meter is SIL2-compliant (HFT=0) according to IEC 61508 for safety-related systems.

So, who needs the OPTIFLEX 2200 C/F? For one,it’s all about chemicals. The device often replaces RF capacitance, displacer, float and pressure meters, but also older TDR meter generations. The OPTIFLEX 2200 C/F is easy on the budget while ensuring economic value that meets the highest requirements.

You can count on us: Our robust level meters feature high accuracy and reliability to suit your needs.

KROHNE – Process engineering is our world.

KROHNE South Africa 8 Bushbuck Close Corporate Park South Randtjiespark, Midrand Tel.: +27 113141391 Fax: +27 113141681 Cell: +27 825563934 John Alexander j.alexander@krohne.com www.za.krohne.com

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17.5 Stainless steel safety hinge solution for food and beverage industry

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new stainless steel safety hinge switch offers an ideal solution for mechanically and hygienically challenging problems in sectors such as the food and beverage, pharmaceutical or cosmetics

industries. These are all industries that require strict cleanliness and hygiene control, which is where the high safety level of the Leuze S420 stainless steel switch comes to the fore.

Safety hinge switches essentially unite the safety switch and door hinge functions in a single component.

They are used for the position monitoring of hard guards such as protective hoods that can rotate by means of a monitoring switch (without guard interlocking) integrated into the hinge.

Due to the fact that external actuators are not required with these switches, they can also be used problem free in environments with high dust concentration levels or with heavy particle loads.

Fault-free function is ensured even with warped or misaligned doors by means of a repeatable setting (switching angle alignment). The actuator is integrated into the housing while electrical connection is by means of either a cable or an M 12 plug with optional cable entry from above, below or on the wall or mounting side.

This allows for the monitoring of all types of doors, hoods and flaps. The safety hinge switch has an opening angle of up to 180° which can be adjusted as many times as needed.

The Leuze S420 stainless steel switch offers optimum cleaning options even with high pressure cleaning, thanks to a wall side cable outlet, a high grade surface with a roughness of less than 0.8

micrometres and an IP 67, IP 69 K level of protection. In addition, covered tamper proof screws reduce the risk of contamination by a considerable margin.

This safety hinge switch is also recommended for the woods product industry in situations where high availability is critical under dust and particle loads.

Through the six-point bolting of the joint, even heavy doors can be guarded reliably and with extended service intervals. Users can select from device versions featuring contact blocks or safety related switching outputs (OSSDs). This makes it possible to have a series connection of 32 devices without compromising the safety level. bryant@countapulse.co.za

Vision sensor series for advanced communication and inspection capabilities

A

nnouncing the release of the iVu Plus TG Gen2 and iVu Plus BCR Gen2 vision sensor series.

Designed from the industryrecognized iVu Integrated Vision Sensor family, the Gen2 series offers faster response times and multiple inspection resolution choices.

Banner’s iVu Plus Gen2 touch screen vision sensors advance inspection performance with Ethernet connectivity and multiple inspection capability.

Ethernet connectivity enables sensors to share inspection data directly with PLCs, PCs or other factory devices, making communications and control even easier on the plant floor.

The iVu Plus Gen2 vision sensors are designed with the same intuitive interface and reliable functionality of the original iVu sensor, but now offer expanded inspection performance to solve a wider range of applications.

With the ability to better detect small features and provide significantly faster barcode read rates, the new Gen2 platform provides enhanced inspection capability for future application development.

For optimal detection of small parts and features, the iVu Plus TG Gen2 vision sensors offer the option for full 752 x 480 resolution.

The iVu Plus Gen2 model can also be configured to operate using four different sensor types.

These types include Area, which verifies the presence of a feature or features of interest; Blemish, which identifies flaws on a part, such as scratches on a disc; Match, which verifies that a pattern, shape or part in any orientation matches a reference pattern; and Sort, which recognizes and sorts as many as 10 different patterns of parts, such as nuts, bolts and washers.

With advanced barcode reading capabilities, the iVu Plus BCR Gen2 offers enhanced traceability with an integrated touch screen for easy setup and monitoring.

Featuring a new coarse mode option, the iVu Plus BCR Gen2 sensors allow for faster barcode read rates, especially for 2D barcodes.

The Gen2 series is available in four models: • iVu Plus TG Gen2 Integrated: An intuitive interface and functionality with enhanced

remote communication, multiple inspections and complete sensor set.

• iVu Plus TG Gen2 Remote: A unique remote screen interface with an exceptionally wide viewing angle, high-speed processing and separate touch screen display for remote mounting.

• iVu Plus BCR2 Integrated: A barcode reader with accurate traceability in a compact, rugged package with integrated touch screen for

easy setup and monitoring.

• iVu Plus BCR2 Remote: A barcode reader solution for applications where the vision sensor location makes it difficult to use an integrated display.

Each iVu Plus Gen2 model is housed in an IEC IP67-rated housing, making the sensors rugged and versatile to suit a broad range of application environments. rodneyt@retauto.co.za

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17.5 Positioners for stable process control

A

range of pneumatic, electro-pneumatic and smart positioners deliver stable process control at an exceptionally low price.

The rugged, durable design makes the positioners ideal for harsh

environments while maintaining precise, accurate positioning of the control element. Units can be easily changed from direct to reverse action, or vice versa. Low air consumption keeps operating costs at a minimum, while still responding quickly and accurately.

The range of pneumatic and electro-pneumatic positioners is easy to set up and calibrate and their modular design makes them versatile and suitable for almost any pneumatic application. The positioners are available in rotary, linear, single and double acting versions. With Ex ia as a standard, the positioners are suitable for a 20 - 100 kPa, 4 - 20 mA signal and an air supply of up to 10 bar.

The range of Smart positioners is microprocessor-controlled, providing rapid, high-precision signal processing for input and position feedback. Rotary and linear types are suitable for 4 - 20 mA, HART, Profibus and Fieldbus protocols. The Smart positioners can be mounted remotely, and with their two-wire communication, many units can be linked onto one loop, saving installation costs.

The conventional positioners offer two alternative supply ports and two alternative signal ports. They are instrinsically safe with ATEX approval and no regulator is required making them suitable for 1 000 kPa operation. The positioners can be mounted to linear actuators to DIN/IEC 534, mounted to linear power cylinders, and mounted to rotary actuators to VDI/VDE 3845. enquiries@mitech.co.za

Mechatronic flow switch

T

he SBN flow switch is ideal for applications that include detecting cooling water flow in welding furnace cooling loops and monitoring cycling coolant flow in machining applications.

A fast response time of 10 ms is ideal for cycling applications and the durable switch has a minimum of 10-million switching cycles.

The switch is immune to rapid temperature changes of the media and an integrated check valve prevents back flow. The switch is able to be bench setup and has an accuracy rate of +/- 5% of the full range.

The compact flow switch includes an inductive proximity switch mounted in an adjustment dial that senses the position of a springsupported piston.

When the adjustment dial is turned, the position of the inductive sensor moves closer or farther away from the top of the piston. The position of the piston is proportionate to the flow rate.

The spring resets the piston to its initial position with decreasing flow of the media.

This allows the sensor to be mounted in any horizontal or vertical position and function as a check valve. The switch can be set up to 26 gpm and LED indication provides operating status at a glance. chris.cronje@ifm.com Valve Trolley

HONEYWELL

AT TECHNICAL SERVICES

PHOENIX CONTACT

HELUKABEL

➢ JHB: 011 801 8200 DBN: 031 701 2701 CT: 021 930 9666 PE: 041 364 0415

➢ 011 462-8752

Nozzle Remover

➢ 011 805 1201 Boni.Magudulela@honeywell.com

➢ 086 100 2887 www.atts.co.za

30

17.5 Measuring water flow is child’s play...

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hether it’s drinking water, process water or waste water, in urban or rural areas: water has become a scarce and valuable commodity. The aims of sustainable water management have been clearly set: supplying sufficient quantities, with area-wide distribution, allocation and optimum cleaning.

The result is an increase in the demands placed on the facility operators. And not least in terms of proving the quality of the plant, for example in accordance with self-check and self-monitoring ordinances, and growing safety requirements in accordance with the Operational Safety Ordinance.

Integration and intelligent data management are becoming increasingly important on account of the growing degree of automation in water and waste water treatment plants.

However, what is crucial is the precise measurement of water flows.

The Promag 400 family- the perfect measuring device for any application: Tried-and-tested Promag To do this, plant operators require sensors and the new Promag 400 transmitter (second device from the right). robust, high-quality flow meters.

The Promag 400 meets the basic requirements without any ifs or buts and provides new, cutting edge climatic conditions. Even more of a challenge is permanent use technology. This device series represents industry-optimised design underwater or underground. Promag W400 is specially designed for and impresses with its simplicity and reliable operation. these harsh conditions and guarantees consistently reliable operation Where accurate measurement of water quantities is essential, the without any additional protective measures or costs: Promag 400 is the key to optimal quantity balancing, process regulation • Certified corrosion protection (EN ISO 12944) for device installation and billing for measuring points. Compliance with guidelines for underwater (satisfies Im1 & Im2 in accordance with EN ISO 12944), custody transfer (MI-001, OIML R49) and the provision of industryunderground (Im3 in accordance with EN ISO 12944), in regions with relevant drinking water approval goes without saying. a saline environment (C5 M in accordance with EN ISO 12944), with The device configuration and checking is ingeniously simple strong moisture or temperature fluctuations (deserts, tropics). and the latest web server technology enables time-saving operation • Reliable long-term operation due to robust, fully-welded sensors and without additional software.

IP 68 protection.

Upload and download of parameters can be easily performed for • Anti-corrosion connection housing made from Lexan polycarbonate data storage and fast commissioning of multiple identical measuring with a multi-sealing concept. points.

Whatever the application, the right Promag device is available.

Data storage (HistoROM) with trend analysis and process • Promag L, the versatile standard instrument, with its unique loose monitoring is carried out automatically. This ensures rapid recovery of flange concept (DN ≥ 300), Promag L offers maximum flexibility for device data in the event of servicing and enables simple replacement installation, regardless of the orientation of the tube flange pitch of electronics without readjustment. diameter. The weight-saving design with short installation lengths is Extensive self-diagnosis functions increase the plant reliability and available in the nominal diameters DN 50 to 2400. provide maximum transparency. The verifiability of the measurement • Promag W, the specialist for every occasion, with certified corrosion results is based on traceable verification concepts, permanent fault resistance and IP 68 protection. Approval for custody transfer in monitoring and clear fault categorisation for specific maintenance accordance with MI-001 and OIML R49 is available for nominal measures. diameters DN 25 to 2000.

Analog output signals, HART®, PROFIBUS® DP, MODBUS RS485, • Promag D, the compact intermediate-flange device with a spacethrough to Ethernet/ IP enable seamless integration into existing saving design for use in the smallest spaces. process control systems, including documentation. Since the • The innovative housing design, available in DN 25 to 100, enables firmware/device drivers are available throughout the entire life cycle, perfect-fitting and quick centring. This saves time and offers reliability compatibility between the field device and the process control system each time it is brought into commission. is guaranteed at all times.

Electromagnetic flow meters from Endress+Hauser have been used The tried-and-tested W@M information system provides efficient successfully for over 35 years in more than 1.5 million applications. life cycle management for design, maintenance and service.The Compliance with high quality standards ensures guaranteed power supply is also new: the same device can be used for alternating measurement results for all users in long-term operation, as every voltages of between 18 and 260V and for DC voltages of between 18 device is traceably tested on an accredited calibration rig (ISO/IEC and 30V. By using just one wide-range power unit, the risk of damage 17025). due to incorrect wiring in the field is ruled out.Measuring devices are often installed outdoors and are exposed to heat, dust and fluctuating info@za.endress.com

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17.5 World’s first native PRP/HSR computer World’s first native PRP/HSR

computer

A the launch of the DA-820 series of Quad core i7 high performance rackmount computers. The Announcing

nnouncing the launch of the DA-820 series of Quad core i7 high • Highly reliable redundant design: Dual power, RAID 0/1/5/10, and PRP/HSR technology performance rackmount computers.

The DA-820 rackmount embedded computers are the world’s first • Patented fanless thermal design DA-820 rackmount embedded computers are the world’s• first native PRP/HSR management IEC 61850-3 certified (Temperature Class C3 and EMCservers level 4) with native PRP/HSR management servers with slot-in PRP/HSR expansion Detect errors faster module that provides bumpless redundancy, enabling efficient, slot-in PRP/HSR expansion module that provides bumpless redundancy, enabling efficient, visualized • PRP/HSR monitoring and control intelligence visualized PRP/HSR network management.

PRP/HSR network substation management.

• SNMP-based self-health management Multi-function computer Optimize error reparability The DA-820’s main operating system runs on the lntel Quad core i7-3612QE CPU and QM77 chipset, which supports standard X86, VGA • OS Smart Recovery API handles system crashes automatically Solutions for PRP/HSR substations: Enabling a scalable and x 2, USB, 2 Gigabit LAN ports, and 2 RS-232/422/485 3-in-1 serial ports.

The DA-820 is equipped with a 4 SATA disk interface and by default manageable PRP/HSR infrastructure In addition to the DA-820 native PRP/HSR computer, Moxa is also supports RAID 0/1/5/10 functionality. going to launch the PT-G503 CPU PRP/HSRand redundancy (RedBox) which in In addition, theoperating DA-820 is specifically for the substation The DA-820’s main systemdesigned runs on lntel Quad core i7-3612QE QM77box chipset, applications that require precise time synchronization and compliance 2014 Q4, the world’s first integrated PRP/HSR RedBox with Coupling supports X86, VGA x 2, USB, 2 Gigabit LAN ports, and 2Moxa’s RS-232/422/485 3-in-1 serial The & QuadBox. PT-G503 RedBox and DA-820 nativeports.

PRP/HSR with standard IEC 61850-3 standards. server allowRAID your PRP/HSR substations to collect, analyze, Theequipped DA-820’s flexible makes itdisk suitable for local SCADA, DA-820 is withdesign a 4 SATA interface and bymanagement default supports 0/1/5/10 functionality.

In environmental monitoring, video surveillance, protocol conversion, and integrate raw data from various devices on one single management addition, the DA-820 is specifically applications that require precisePRP/HSR time network platform, enabling efficient and visualized and PRP/HSR redundancy applications. designed for substation management and making network diagnosis, troubleshooting, and In addition, the DA-820’s cyber security function it an ideal solution synchronization and compliance with IEC 61850-3 standards. The DA-820’s flexible design makes it suitable device condition monitoring easier than ever. for enabling secure network communications. for local SCADA, environmental monitoring, video surveillance, protocol conversion, and PRP/HSR Benefits of the DA-820 rackmount computer rob@rjconnect.co.za • Minimize error probability

Multi-function substation computer

redundancy applications. In addition, the DA-820’s cyber security function it an ideal solution for enabling secure network communications.

South African Flameproof Association

A

the maintenance of flameproof equipment in mines.

Dario Campetti, of Electrical Another presentation will Association (SAFA) is involved in of concern as and when they Minimize error probability explosion prevention/protection arise. These issues are discussed engineering consulting firm be that of UK-based hazardous techniques for equipment used by SAFA’s executive committee Dario Campetti & Associates equipment specialist Extronics  Highly reliable atmospheres redundant design: Dual power, RAID 0/1/5/10, and PRP/HSR technology in hazardous and, if required, the appropriate will deliver the keynote address. MD John Hartley, who will across all industries. is the subcommittee is called on to His discussion will centre on a present his paper, titled Making  Patented fanless Itthermal design national mirror committee of investigate the issue and report suggested system for the control safe waves in hazardous areas –  IEC 61850-3 certified (Temperature Class C3 and level 4) of explosion- deploying wireless safely. and management the IEC Ex Committee and has its findings to the Ex Steering and EMC This presentation will protected electrical apparatus registered as a voluntary executive committee.

Detectbeen errors faster association with the Engineering The primary objective of that can be installed at coal mines discuss the various approaches  PRP/HSR monitoring andthe control intelligence of deploying wireless networks Council of South Africa. association is to promote to increase operational safety. safely and effectively – from The system outlines the SAFA comprises almost 200 safety best practice in the  SNMP-based self-health management requirements for the first transmissions of radiomember companies from end- hazardous area industries, minimum Optimize reparabilityto develop competencies and inclusion in a coal mine’s frequency signals in hazardous users error and manufacturers relevant government bodies and promote training, influence the management system to ensure areas when exploring mine  OS Smart Recovery API handles system crashes automatically equipment testing houses. With formulation and implementation that the mine complies with and mineworker protection branches already in Gauteng, of national and international the legal requirements and to detailing how new design Kwa Zulu Natal and Cape Town, standards and regulations, and reasonable safe working practices methods and changes in safety SAFA has become the recognised improve and maintain excellent when using explosion-protected standards have allowed for current technology to be more electrical apparatus. authority in South Africa on stakeholder relationships. explosion prevention technology.

This year, SAFA will be holding Other key speakers to easily and efficiently adopted.

All the details pertaining The association has several its annual symposium on the deliver presentations, include the PT-G503 SAFA Symposium are mining solutions provider Joy to the subcommittees including native the 13th of November 2014 at theMoxa In addition to the DA-820 PRP/HSR computer, is also going to launch PRP/HSR representative Paul available on the SAFA website, Intrinsically Safe sub-committee Graceland Casino in Secunda, Global redundancy (RedBox) in 2014 Q4, the Province world’s first PRP/HSR with Coupling & Meanwell, who will focus RedBox on www.flp.co.za and thebox Master Installation Mpumalanga and integrated s a non-profit body, the Electrician sub-committee, includes safety in PetroChem, Oil Benefits of African the DA-820 South Flameproof rackmount amongst others, tocomputer tackle issues & gas, mines etc.

Solutions for PRP/HSR substations: Enabling a scalable and manageable PRP/HSR infrastructure

QuadBox. Moxa’s PT-G503 RedBox and DA-820 native PRP/HSR management server allow your PRP/HSR

Page 1

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17.5 Fibre optic amplifier features world’s fastest 10 microsecond response rate

B

oasting the world’s fastest response rate, the DF-G2 fibre optic amplifier can achieve a 10-microsecond response time with 5-microsecond repeatability.

In addition to quick response rates, Banner’s DF-G2 provides an easy-to-read dual digital display for highly visible signal level and threshold values.

Featuring an intuitive interface, the sensor ensures simple set-up and programming through displays and switches and buttons, or via remote input teach wire. The DF-G2 also offers complete user control, providing manipulation of all operating parameters, including switch point threshold, light operate or dark operate, various output timing functions, electronic gain level and sensor response speed.

With best-in-class response

speeds of 10µs or 15 µs with only 5 µs repeatability error, the DFG2 balances response speed with precision for critical positioning applications.

The DF-G2 amplifier combines amazing speed with greatly increased sensing range

to ensure efficient and reliable detection in diverse applications and industries.

Offering six different expert TEACH and SET methods, operators can achieve optimal gain and threshold selection for each application—particularly

for high-speed or low-contrast environments, such as small part or clear object detection.

The DF-G2 features thermally stable electronics, which help minimize warm-up drift and enable multiple amplifiers to be mounted side-by-side, with no reduction in the ambient temperature limit.

Inherent thermal stability also provides cost-saving advantages by reducing machine start-up time and eliminating production delays due to ambient temperature changes.

For additional flexibility, an intricate cross-talk avoidance algorithm allows two fiber optic assemblies to be mounted in close proximity, sensing different features of the same target. rodneyt@retauto.co.za

Lightweight aluminium power transmission cables

I

ntroducing a cost effective and lightweight aluminium power transmission cable to assist alternative power producers to cost effectively plug into the country’s national power grid.

The cable is ideal for South African conditions and ticks all the boxes when it comes to reducing cost, simplifying transport requirements, ease of installation and even reducing the risk of theft that is associated with copper power transmission cables.

The new aluminium power cables are a small fraction of the cost of copper cables and offers similar performance characteristics and lifespan.

Yet the cable is considerably lighter and as a result is far easier to transport and install. In certain instances the light weight of the cable may even reduce the cost of support mechanisms and cable trays.

Lightweight and flexible The cables also have a special finely stranded aluminium wire construction, which gives them an added measure of flexibility and makes them easier to route in confined spaces and evidently reduce labour cost and man power. The cables have specially

Heluwind WK Powerline Alu cable

formulated heat resistant insulation and are UV and oil resistant for installation in harsh environments.

To meet international sustainable development and environmental requirements the cables are also manufactured from neutral materials and contain no harmful halogen (LSZH) substances.

The new cables are designed to be suitable for installation on wind turbine generators,

photovoltaic systems, generators, combined heat / power plants, transformer stations, as well as a wide spectrum of standard applications where cost and ease of installation are a strong consideration.

Easy to install No other additional specialised equipment is required for installations. A range of aluminium cable lugs and compression connectors are available, as well as aluminium

to copper components to join the two different materials where required.

The range of Heluwind WK Powerline Alu cables are available in 0.6/1KV and 1.8/3KV variants and are designed to fill a niche for small generation plants and perfectly supplement the company’s other aluminium and standard cable ranges. doug.gunnewegh@helukabel. co.za

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17.5 Loading metering skids

L

oading metering skids (singular or stand-alone) or gantries (multiple skids in parallel) are used in fuel loadout applications, either for trucks or rail carts and these applications are generally custody approved or certified according to international accepted standards.

Endress+Hauser Loading Metering Skids (LMS) are designed, manufactured and shipped as a complete solution with a choice of top loading or bottom loading nozzles, in 3-inch, 4-inch or 6-inch.

These Loading Metering Skids are built with proven technologies, utilising the accuracy and long-term stability of Coriolis custody approved meters, batching computers, start/stop valves and a proper grounding system for safety. Loading Metering Skids also come in a choice of vertical or horizontal installations and the use of an optional air eliminator.

The company provides open and standardised interfaces, which means that the Loading Metering Skid is compatible with the Endress+Hauser Terminal Management systems, as well as other “open” tank inventory systems.

In comparison to conventional mechanical PD meters, the Promass Coriolis meters offer a direct mass output. Furthermore, due to simultaneous density and temperature output, we are able to release give aMedia volume output at the same time, which benefits the customer, Media release as trends clearly indicate a shift from volume to mass billing for light hydrocarbons (similar to LPG).

Due to the much lower pressure losses (see attached table) the Promass can operate with much higher flow rates, which results in faster loading times, improved fuel logistics and scheduling and an

Loading Metering Skids Specifications Loading Metering Skids Specifications Model Model

Line Size Line Size

Application Application

LMS50 LMS50 LMS80 LMS80

3” ANSI 150 RF 3” ANSI 150 RF 4” ANSI 150 RF 4” ANSI 150 RF

LMS1F LMS1F

6” ANSI 150 RF 6” ANSI 150 RF

Truck loading Truck loading Truck/rail car Truck/rail car loading loading Rail car/ ship Rail car/ ship loading loading

General Specifications General Specifications Liquids Liquids Pressure Rating Pressure Rating Material Material EX Concept EX Concept Custody Transfer Custody Transfer Equipment Equipment Optional Optional Optional Blending Optional Blending

increase in product volume. This results in improved cash flow and lower operating costs.

Loading Metering Skid benefits: • Standardised metering solutions • Cost saving due to trouble free and easy to deploy solution • The accuracy of the Coriolis meters ensures reduced losses resulting in cost savings vs. the traditional mechanical meter systems for positive displacement • Full MID-EC examination approval for complete metering skid • Lowest re-calibration costs due to long-term stability of the Coriolis meter • Lower pressure loss than positive displacement meters, resulting in much faster loading times • Simple and powerful integration into Tank Vision Tank Gauging system, thereby providing a comprehensive inventory management system.

Custody Custody transfer flow transfer flow rate* rate* kg/min kg/min 50…1000 50…1000 150…3000 150…3000

Flow rate for max 0.5 bar pressure loss Flow rate for max 0.5 bar pressure loss for Diesel EN590 at15°C for Diesel EN590 at15°C vs. PD kg/min l/min vs. PD kg/min l/min meter l/min meter l/min 540 650 500 540 650 500 1500 1800 1300 1500 1800 1300

250…12000 250…12000

4600 4600

5550 5550

3900 3900

For all light hydrocarbons e.g. gasoline, diesel, jet fuel, marine gasoil, viscosity range For all light hydrocarbons e.g. gasoline, diesel, jet fuel, marine gasoil, viscosity range to max. 76cSt (valve limitation) to max. 76cSt (valve limitation) ANSI Cl.150, others on request ANSI Cl.150, others on request Carbon Steel, others on request Carbon Steel, others on request Ex d, armoured cabling Ex d, armoured cabling MID Directive 2004/22/EC (Module D, no verification required), Class 0.3/0.5 MID Directive 2004/22/EC (Module D, no verification required), Class 0.3/0.5 Promass 84Fflow meter, batch controller, digital start/stop valve, Y-strainer, isolation Promass 84Fflow meter, batch controller, digital start/stop valve, Y-strainer, isolation valve, thermal relief valve, frame, piping and cabling valve, thermal relief valve, frame, piping and cabling Air eliminator, Prover connections, pressure sensor, card reader, overfill prevention Air eliminator, Prover connections, pressure sensor, card reader, overfill prevention sensor, grounding system, temperature sensor, blending connection and sensor, grounding system, temperature sensor, blending connection and configuration configuration A 2” blending line can be connected to each loading metering skid and it will be A 2” blending line can be connected to each loading metering skid and it will be controlled by the batch controller, max 3 different recipes controlled by the batch controller, max 3 different recipes info@za.endress.com

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17.5 Sensor interfaces make a PC a measuring instrument

T

he sensor interface PCD400A is an amplifier that can easily carry out measurements simply by connecting to a PC using a USB interface.Directly connect the strain gauge output sensor to the input terminal and input adapter on the back, and start the included dynamic data acquisition software (DCS-100A) to convert the PC to an amplifier.

Operation is fully interactive using the PC, and by connecting the sensor and carrying out a minimal amount of settings, it is possible to obtain engineering unit data.

This is capable of 4 channels of recording from 1 sensor interface unit.Furthermore, connecting the units using a connection connector set enables expansion up to 4 units measuring 16 channels, meaning this is most suited to small-scale measurement.The construction of a compact and highly versatile measurement system provides a measurement tool that can be used in a range of situations, from simple experiments through to high-level measurements. sales@peterjones.co.za

Digital vibration testing

T

he analysis of vibration is the most significant indicator of operating conditions in motors and rotating machinery.

The TAMAT VIB1400 hand-held, digital vibration test meter allows operators to detect anomalies in the bearings as well as balancing and inadequate alignment, before they become significant problems.

Predictive maintenance has proven to be the most convenient and economical practice undertaken by industry, that avoids unnecessary costs associated with preventive maintenance schedules, and goes a

long way to protect the system from unforeseen stoppages.

The TAMAT VIB-1400 is portable and allows for an organised predictive maintenance program based on programmed vibration monitoring. Acceleration, velocity and displacement are indicated on a LCD display for high visibility.

It has an accelerometer with a magnetic base which guarantees stable and repeatable measurements.

Results are stored in an internal memory with up to 500 measurements which can be downloaded later to a PC. This allows for trend analysis development.

Features: • Frequency range 10Hz – 1kHz • Vibration testing for ISO 2954 • RS232 data output • RMS peak value sales@tiafrica.co.za

Programmable universal temperature indicator/controller from RTDs such as PT100. Ni100 RTD is available as

A

local distributor of process control instrumentation and specialised systems manufacturers a 4 digit (-1999 to 9999) LED universal temperature indicator for applications where temperature needs to be displayed and controlled. he model 4003 is designed for highly accurate measurement and display (in ºC, ºF or K) of temperature thermocouples, selectable from the front push buttons, of Type J, K, N, R, S, T, W5 and

an option as well as other thermocouple types.

The thermocouple and RTD signals are accurately linearised by the internal micro-controller.

Options include programmable analogue output, single, dual, three and four alarms, peak hold, and RS232/485 output.

Selected options now feature ‘Plug & Play’ technology, allowing option boards to be ordered separately and field fitted as required.

Model 4003 features: • 1/8 DIN enclosure (45 x 92 cut-out), UL 94 V-0 flame retardant • Touch button programmable • 14.2mm bright red LED display • ‘Plug & Play’ feature with selected options • Other thermocouples and RTDs available as an option • Free keypad lock option available sales@instrotech.co.za

Index of Advertisers with relevant page numbers

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7 8, 25, 29 OBC 19 6, 21 8, 29 11 27 23

Pepperl+Fuchs Phoenix Contact RET Automation Controls RJ Connect Siemens Temp-Tek Valve & Automation VEGA Instrumentation

IFC 8, 13, 29 OFC, IBC inserts inserts 5 15 17

R

T

C

B

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Advanced Ultrasonic Solutions

17.5 Banner’s advanced ultrasonic sensors perform

where other sensors can’t.

• Innovative offering solves virtually any application • New, more affordable ultrasonics with higher resolution and repeatability • Stable and consistent performance with integrated temperature compensation • Models rated up to IP69K • Chemical-resistant models • Models available with minimal dead zone and extended sensing ranges

40-plus years of sensor design experience, quality control, sales support and cost-effective solutions: • Banner quality products with global availability • Rapid customisation with most products shipping in 3 days or less • Industry’s largest force of application engineers to solve your toughest challenges • More than 3,000 factory and local field representatives to serve you

For more information visit: www.retautomation.com

RET Automation Controls (Pty) Ltd Tel:

011 453 2468

Call us for the name and number of our distributor in your area B55

by RET Automation Controls

36

17.5