VOLUME

NO 12 DECEMBER 2011

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Chemicals & plastics | Wireless | Operator interfaces & HMI Temperature | IT in manufacturing

contents

VOLUME 27 NO 12 DECEMBER 2011

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COVER STORY
EDGE-TO-CORE INDUSTRIAL ETHERNET SOLUTIONS

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CHEMICALS & PLASTICS

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BUILDING MANAGEMENT

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WIRELESS

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RELAYS

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IT IN MANUFACTURING

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OPERATOR INTERFACES & HMI

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TEMPERATURE

GENERAL

04 06 16

News digest News & events SAIMC news

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Jim Pinto System Integrators Product news

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OUR COVER
For over 20 years, industrial system integrators have relied on Moxa products in device networking applications around the globe. See this month’s cover story on page 24 for more on the latest additions to Moxa’s extensive range of edge-to- core switch solutions for comprehensive industrial Ethernet platform implementation.

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welcome

VOLUME 27 NO 12 DECEMBER 2011
MANAGING EDITOR Graeme Bell NHD Elec Eng (L.C.), MBA gbell@technews.co.za EDITOR Steven Meyer Bsc (Elec Eng), IMM (Unisa) steven@technews.co.za DEPUTY EDITOR Kim Roberts MSc Chem kimroberts@technews.co.za CONTRIBUTING EDITORS Andrew Ashton NHD (Elec Eng), GCC (Elec Eng Factories), GCC Mech Eng Factories, B Com (Unisa) andrew.ashton@technews.co.za Michael Brown BSc (Eng) (Rand), CEng MIEE MSAIEE ADVERTISING Sales manager Jane van der Spuy jane@technews.co.za Tel: +27 (0)31 764 0593 Gauteng Tina van Kerckhoven tina@technews.co.za Tel: +27 (0)11 543 5800 KwaZulu-Natal Jane van der Spuy jane@technews.co.za Tel: +27 (0)31 764 0593 DESIGN AND LAYOUT Technique Design Tel: +27 (0)31 764 0593 SUBSCRIPTION SERVICES For address changes, subscriptions, renewal status or missing issues, call +27 (0)11 543 5800, subs@technews.co.za or write to: Technews Publishing (Pty) Ltd, Box 385, Pinegowrie 2123 SUBSCRIBE ONLINE www.technews.co.za PUBLISHERS Technews Publishing (Pty) Ltd, Box 385, Pinegowrie 2123 PRINTED BY: Intrepid Printers (Pty) Ltd 9 Grix Road, Willowton, Pietermaritzburg LETTERS TO THE EDITOR Letters to the editor should be addressed to Steven Meyer at steven@technews.co.za. Sending material to this publication will be considered automatic permission to use in full or in part in our Letters column. Be sure to include your name, e-mail address, city and zip code. We reserve the right to edit all letters.

Emerson Exchange 2011 does the business in Tennessee
Nasville’s Opryland resort provided a close-knit venue for this year’s annual Emerson User Conference. Process Management president, Steve Sonnenberg, opened the show with a keynote address that spoke volumes about the organisation, its values and management’s optimism for the future. Sonnenberg said that 2011 brought double digit growth for Emerson and that management is optimistic about the future, despite the current gloomy economic news. This optimism is evident in the three cornerstones that underpin Emerson strategy for the future – investment, listening and trust. For me, Sonnenberg’s message resonated 21st century customer orientation. “Emerson is in it for the long haul,” he told the audience. “Investment in people, plants and service centres is essential for our long-term growth and survival. This year, we added 1000 jobs in North America, 650 in Europe, 320 in Latin America, 1800 in the Asia/Pacific region and 200 in Middle-East & Africa.”The fact that not all the technical positions could be filled, despite a sea of unemployment, was this year’s major disappointment. Listening drives the investment direction. Sonnenberg explained that some customers give Emerson high marks in people and products, but indicated that the organisation is sometimes slow to respond, while others said that products are great, but sometimes users have trouble getting the most out of the technology. “Our customers want technology that is easy to use. In response, the new Human Centred Design Initiatives are aimed at transforming our system and field device interactions, making them as easy to use as an iPhone.” The company also continues to expand its I/O on demand, the world’s first electronic marshalling technology initiative. Trust, the third point, is the benefit management earns for getting the first two right – trust in the market and the loyalty of employees. “Trust is not static; rather it is something we have to earn every day,” Sonnenberg said. “Building a listening culture is therefore key to Emerson becoming your trusted adviser.” The upbeat opening address was ably supported by a number of new technology launches. First up was the latest in smart energy initiatives. This holistic approach ensures the greatest efficiency in energy production plus reduced waste and inefficiencies wherever energy is used. At the heart of it is Emerson’s True BTU technology, a patent pending innovation for calculating the actual BTU values of different fuel sources, making energy production more predictable and also reducing greenhouse emissions. Tata Steel’s Andrew Rees was on hand to present on how this technology is helping the Port Talbut steel mill generate savings through better use of ‘ingenious’ fuels such as blast furnace and coke oven gas – by-products of its manufacturing process. The project is expected to reduce powerhouse energy consumption by 3 to 5 percent and help Tata Steel achieve its vision of energy self-sufficiency. Linked to the energy management initiative was the launch of the Rosemount 708 wireless acoustic transmitter designed to help processing plants reduce energy costs by providing visibility into the health of steam traps and pressure relief valves. The device utilises acoustic measuring to identify the ‘hiss’ of leaking steam and then corroborates by making a temperature measurement. Only if a suspicious new noise is accompanied by a corresponding increase in temperature is a potential fault reported. Darren Goodlin, manager of inline instrumentation at St. Louis brewery, Anheuser Busch, called it his ‘bionic ear’ as he explained the downfall of human inspection of steam traps. Emerson’s newest technology is helping reduce fuel costs associated with leaks in the facilities some 1000 steam traps. There was plenty more on offer in the form of short courses, workshops and a crammed exhibition area; safety, wireless and subsea solutions being some of the other technologies in focus during the weeklong event. Run by end-users for end-users Emerson says this year’s Exchange broke all the records – it certainly wowed the crowd in Nashville. In closure for this year, a vote of thanks to all our advertisers and readers for the support you have given us this last 12 months. On behalf of the team at SA Instrumentation and Control I wish you and your families all the very best for the holiday season. Whether you are heading for the beaches, the hills or just spending quality time at home – be safe, enjoy and come back rested next year.

Steven Meyer Editor: SA Instrumentation & Control steven@technews.co.za

All rights reserved. No part of this publication may be reproduced, adapted, stored in a retrieval system or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of Technews Publishing (Pty) Ltd, Reg No. 2005/034598/07

Disclaimer Editorial contributions relevant to the focus of this publication are welcome but the publishers cannot accept responsibility for unsolicited material. While every effort has been made to ensure the accuracy of the information contained herein, the publisher and its agents cannot be held responsible for any errors contained, or any loss incurred as a result. Articles published do not necessarily reflect the views of the publishers. The editor reserves the right to alter or cut copy. Articles submitted are deemed to have been cleared for publication. Advertisements, inserts and company contact details are printed as provided by the advertiser. Technews Publishing (Pty) Ltd cannot be held responsible for the accuracy or veracity of supplied material.

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NEWS DIGEST

EMERSON BOILER CONTROL AT TATA STEEL
Tata Steel’s Port Talbot facility in Wales has upgraded control of its largest steam boiler using energy management technologies and services from Emerson Process Management. The new controls enable Tata to increase energy efficiency and maximise use of waste fuels, reducing emissions as well as reliance on purchased fuels. The Port Talbot facility is Britain’s largest integrated steel mill, making over four and a half million tons per year of high-quality sheet steel for the automotive, construction and household appliance markets. It includes two blast furnaces and a basic oxygen furnace, as well as continuous casters and a strip rolling mill. To date, Emerson has upgraded controls on three of the site’s seven steam boilers.

HONEYWELL SIGNS AGREEMENT WITH BAYER TECHNOLOGIES
Honeywell has announced an agreement with Bayer Technology Services (BTS), a leader in operator training systems. Together the companies will cooperate to deliver dynamic process simulation and other training systems for deployment in the chemical and pharmaceutical industries. BTS has developed multiple simulation studies and training systems in response to the growing need in the chemical industry for safe, reliable and efficient design and operations, BTS’ experience in developing and commissioning training simulators combined with Honeywell Process Solutions’ software and consulting services results in a unique offering for customers who will benefit from priority HPS support and solutions. Acting as a single point of contact, the partnership will support BTS for faster project execution and will give both parties flexibility in staffing.

SUBSEA SUCCESS FOR SKF

NORM GILSDORF HONOURED BY PURDUE UNIVERSITY

S2M, an SKF Group Company, has announced the signature of a 2-year contract with MAN Diesel & Turbo, Aker Solutions Norway and Statoil. S2M will equip subsea compression trains with SKF magnetic bearings and their associated electronics in a first of its kind project for the Åsgard gas field in the Norwegian Sea. The project will involve placing 2 compressors on the seabed to maintain discharge pressure in the pipeline and compensate for the falling suction pressure as the reservoir is depleted in the next few years, thereby boosting the gas flow. SKF magnetic bearings were selected for their capability to operate in these severe conditions with very high reliability, including remote monitoring. They will maintain the motor compressor shaft systems in position and are oil-free, frictionless and virtually maintenance-free: features which are vital in compressors installed at a depth of between 200 and 300 metres, rendering them too deep for divers and accessible only by remote operated vehicles.

Norm Gilsdorf (r) at the awards ceremony.

Honeywell executive Norm Gilsdorf was recognised at this year’s centennial celebration of Purdue University’s School of Chemical Engineering. Gilsdorf, president of Honeywell Process Solutions, already awarded the title of Distinguished Engineer Alumnus in 2010, was honoured with an Outstanding Chemical Engineer Award, and is a featured speaker in the school’s Centennial Seminar series.

His presentation, titled “Have Chemical Engineering Degree – Will Travel,” will highlight the often-overlooked career benefits of pursuing chemical engineering degrees and the important role engineers can have in advancing technology that will be energy efficient, safe and sustainable. In addition to being named a top alumnus, Gilsdorf is also being inducted into the College of Engineering Cooperative Education Hall of Fame.

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NEWS & EVENTS

EMERSON’S FIRST EUROPEAN GLOBAL USERS EXCHANGE

With the theme ‘Exchanging Ideas. Creating Solutions,’ Emerson’s first European Global Users Exchange will be held from 29-31 May 2012 at the Hotel Maritim, Düsseldorf, Germany. Tailored to meet the needs of users in Europe, the Middle East and Africa, delegates will learn about best practices and see how colleagues are meeting new regulatory requirements, increasing yields, improving efficiency and reducing costs with enhanced automation. The European event will follow the same format as the October 2011 Emerson Global Users Exchange held in Nashville, USA. The event will include workshops, presentations, industry forums, short courses, technology exhibits and product roadmaps. Delegates will be able to choose from themed presentations in English, German and Russian.

“We are delighted to announce the details of the first Global Users Exchange for our many users across Europe and others who will join us from other regions,” said Bob Sharp, President, Emerson Process Management Europe. “The Emerson Global Users Exchange is much more than an industry leading technical conference. It is a community of manufacturing leaders committed to extracting the most from their automation investment and sharing their learning with each other.” The event also provides an opportunity for delegates to understand what their peers, other suppliers and customers in the industry are doing to compete in these dynamic times. Attendees will be provided with a unique opportunity to touch and experience the breadth of innovative Emerson technologies – all in one place. An important element of the event is the opportunity it provides to network

with other delegates and industry leaders to make the right connections. Delegates will also be able to meet with the experts behind the technologies and learn how innovative technologies can be put to work. The Emerson Global Users Exchange organisation is now looking for users to share their experiences and expertise with their process automation peers by giving a presentation, workshop or short course at the event. Presenting at the Global Users Exchange provides a unique opportunity for users to showcase their company and its successful operational practices.
For more information contact Mark Tapson, Emerson Process Management, +27 (0)11 974 3336, mark.tapson@emerson.com, www.emerson.com

YOKOGAWA ANNOUNCES NEW MD FOR SOUTH AFRICA
Yokogawa has announced the appointment of Johan Louw as managing director for South Africa (including Anglophone African operations). He succeeds Herman van den Berg, who has been promoted to head up the European and African engineering operations in Amersfoort, The Netherlands. Johan has a degree in chemical engineering and an honours degree in management of technology. He has 15 years process engineering and project management experience in the southern African mining, oil and energy sectors, and has executed capital projects for Sasol, Eskom, Angola LNG and PetroSA. He has business development, operations, design, construction, project control, financial management and information systems experience, and has worked for companies such as Anglo Coal, Weir Envig, KBR and most recently Forbes & Manhattan. Johan brings a wealth of project management and engineering experience from projects related to key Yokogawa customers in South Africa as a basis to direct the SA operation to the next level in organisation, personnel and business development, as well as in competitive positioning.
For more information contact Charles van Haght, Yokogawa SA, +27 (0)11 831 6300, charles.vanhaght@za.yokogawa.com, www.yokogawa.com Johan Louw.

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NEWS & EVENTS

EATON COMPLETES MOELLER INTEGRATION

SIEMENS LAUNCHES JUNIOR CYBER JUNKYARD CHALLENGE

In July 2011 Moeller and Eaton, two established and respected names in the electrical sector, came together as Eaton, a global organisation delivering solutions to support customers in running their systems more productively and cost effectively. The Moeller logo is being replaced by the Eaton logo on all products and packaging. These changes will flow through the supply chain throughout 2011 with a target completion date of 1 January 2012. The products will have the same form, fit and function and carry the same order codes, providing customers with the reassurance of continuity of supply and build quality. The former name will appear as the Moeller series on the product rating and carton labels in recognition of the value the Moeller brand has brought to Eaton. In terms of organisation, product and production techniques, Moeller has been fully integrated into Eaton over the last two years. Moeller facilities have been adopting the Eaton Business System, a single continuous improvement system covering work processes, tools and tooling during this time. The two companies are now well on the way towards unifying their product branding and packaging.
For more information contact Rob Hare, Eaton Electric, +27 (0)11 824 7400, robhare@eaton.com, www.eaton.com

The winning entry from Daniel Pienaar High.

Further entrenching its commitment to bridging the skills gap in the field of electrical engineering, Siemens has taken its Cyber Junkyard Challenge to schools in the Eastern Cape. This Junior Cyber Junkyard Challenge has been undertaken in partnership with Port Elizabeth’s Nelson Mandela Metropolitan University (NMMU). Says Martin Taverner, BU manager motion control at Siemens: “In 2011, our aim is to establish a relationship between Siemens, NMMU and high schools and colleges in the area, hence the introduction of the challenge at a school level. Our hope is that these relationships will help to encourage learners at this level to consider electrical engineering as a career path after school.” In the Junior Cyber Junkyard Challenge, learners had to design, build and programme a fully functional water tank system. They needed to implement the principles of flow rate and volume calculation in addition to basic logic and the principles of level control. “By taking part in this project learners gain

hands-on experience that will assist them when applying to universities, they learn about electrical design, mechanical manufacture, level control within a tank process, industrial automation programming and closed loop control systems – all at a junior level,” Taverner explains. “Nine schools entered the challenge and through our partnership with NMMU, each team was allocated R10 000 to design and manufacture its system.” Final judging took place in October with the winning teams receiving a host of electrical equipment, as well as bursaries donated by NMMU. The Eastern Cape served as a pilot, Taverner’s ultimate objective is that the Junior Cyber Junkyard Challenge will be held annually and open to schools nationwide.
For more information contact Keshin Govender, Siemens Southern Africa, +27 (0)11 652 2412, keshin.govender@siemens.com, www.siemens.co.za

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NEWS & EVENTS

SCHNEIDER ELECTRIC UPGRADES WINDER AT HARMONY
Schneider Electric South Africa, has been commissioned by Harmony Gold Mining Company to upgrade the 106 level sub-vertical winder at its Doornkop mine outside Johannesburg. According to Helgard Honiball, general manager of the Drives Competency Centre at Schneider Electric South Africa, the current winder control is a ‘PowerReg’ system, a slip-ring motor controller with resistor controls in steps. “As the winder is an integral part of the emergency evacuation plan of the mine, the winder control system is critical. Schneider Electric South Africa will therefore optimise and upgrade the current control system to variable speed drive (VSD) control and replace the motor with a more efficient squirrel cage induction machine. Once upgraded, the VSD control will run at a unity input power factor, irrespective of the load on the motor, improving overall system efficiency. Furthermore, it will also be able to run from a backup diesel generator,” he says. The project, to be completed by fourth quarter 2011, requires Schneider Electric South Africa to design, supply and install the winder control system upgrade. “We have a great deal of expertise in replacing systems with VSDs and Schneider Electric South Africa’s established installed base as well as superior technology proved to be a firm motivation in Harmony selecting us to realise this upgrade project,” concludes Honiball.
For more information contact Jacqui Gradwell, Schneider Electric SA, +27 (0)11 254 6400, jacqui.gradwell@schneider-electric.com, www.schneider-electric.co.za

SEWEURODRIVE BEERFEST

From left: Ute Bormann, Managing Director; Tobias Nittel, SEW-Eurodrive Germany; Renee Rose, General Manager of Communications.

SEW-Eurodrive’s annual Beerfest is held each year at venues across the country to say thank you to all the company’s customers for their support. The event has grown over the years and this year the Johannesburg gig moved offsite for the first time – to Rand Airport. The offsite venue allows SEW to grow the event in line with its customer base. Approximately

800 people attended the customer event in Johannesburg. It was also held in Cape Town and Nelspruit. In total 1400 SEW customers were entertained with good music, good food and good beer.
For more information contact Renee Rose, SEW-Eurodrive, +27 (0)11 248 7000, rrose@sew.co.za, www.sew.co.za

EMERSON ANNOUNCES SMART ENERGY INITIATIVE
Emerson Process Management has announced the Smart Energy Initiative, a global programme designed to combine its industrial energy expertise with advanced energy management technologies to enable customers to leverage more renewable fuels, lower energy costs, and reduce emissions. Emerson’s new Industrial Energy Group will focus on modernising and improving the performance of powerhouses, the onsite utilities that provide steam and electricity to power industrial operations, while also improving how the manufacturing process consumes energy. This holistic approach ensures the greatest efficiency in production of energy, plus reduced waste and inefficiencies where energy is used. Emerson technologies and expertise provide the industry’s only turnkey energy optimisation programme to help refiners, chemical producers and other manufacturers significantly reduce energy costs and emissions. “With industrial manufacturers consuming an estimated 50% of the world’s energy, combined with rising fossil fuel prices and global mandates for reduced emissions, our customers need more than incremental efficiencies in energy management,” said Steve Sonnenberg, president of Emerson Process Management. “With the Smart Energy Initiative, Emerson is introducing a fundamentally new platform that can change energy economics globally.” Rennie, director of Industrial Energy for Emerson. “This brings about a reinvention of combustion models, which will make the use of low cost fuels like biomass achievable and sustainable.” For the first time, Emerson’s proprietary suite of software, combined with field control technologies, enables the powerhouse to interchangeably use the most available and affordable renewable or waste fuels – wood waste, food byproducts, animal waste, or manufacturing byproducts such as petcoke or off-gases – to consistently create steam to power their operations. It also delivers 21st century combustion solutions for greater efficiency and reliability when using waste and other renewable fuels which burn and deliver energy at variable and unpredictable rates.
For more information contact Mark Tapson, Emerson Process Management, +27 (0)11 974 3336, mark.tapson@emerson.com, www.emerson.com

NEW PATENT PENDING INNOVATION
At the heart of Emerson’s integrated technology platform is its True BTU technology, a patent pending innovation for calculating the actual BTU values of fuel sources, which makes reliable energy production predictable and repeatable. “Our True BTU Combustion Control platform reinvents the current model of combustion management, which has been around since the 1920s and is still in practice today,” said Chip

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CEMENTING THE FUTURE TOGETHER

Svanesso, known locally as the braai angel, surrounded by staff before being put into storage.

On 10 October 2011, Endress+Hauser officially launched its new Sandton head office building project: Cementing the future together. Svanesso, a sculpture by Swiss artist Claire Ochsner donated to the Sandton office by Klaus Endress at the official opening of the Conference Centre in October 2004, has been removed for safe keeping. The project was originally intended to begin

in 2010, but due to the economic crisis had to be postponed. “For a long time now it has been clear that we would outgrow our current building and in order for us to meet the growing demands of the market, we needed to invest in a state-of-the-art building for sales and services in Sandton,” says MD Rob MacKenzie. “Over the past 25 years, the ‘people for process automation’ has developed from a niché

provider of level instruments, sold via an agency, to a R300 million Broad Based Black Economic Empowerment (BBBEE) company and a major supplier of products, services and solutions for process measurement technology.”
For more information contact Hennie Blignaut, Endress+Hauser, +27 (0)11 262 8000, info@ za.endress.com, www.za.endress.com

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NEWS & EVENTS

MESA CONFERENCE SUCCESS
MESA SA held its third annual conference at the Indaba Hotel in Fourways in October. The theme was “Innovation and Flexibility in Manufacturing Execution“. It was the biggest MESA Conference to be held in South Africa to date, with over 60 registered delegates from all areas of industry. Returning delegates commented on the quality of the presentations, which they agreed was far superior to those of the year before. The keynote speaker of the day was Craig Simpson, a lead analyst at IDC Manufacturing Insights, CEMA, Prague. He talked about driving business innovation through systems thinking. His presentation was full of valuable statistics and trends, and delegates clamoured to get hold of his material. The rest of the day was taken up by the following presentations: • Gerry Geertshuis from Eskom and Machiel Engelbrecht from Bytes PMC talked about the implementation of an integrated decision support centre for the Eskom generation fleet. • Eddie Botes, Planning Manager at SCAW SWR, covered the Haggie Steel Wire Rope (SWR) scheduling and execution system implementation. • Shueyb Vally and George Webster from Hulamin presented the implementation and rollout of OEE at Hulamin. • Deon Smit, Production Integration Manager at Eskom, had the whole audience eating out of his hand with an entertaining and valuable presentation on remote monitoring and diagnostic centre implementation at Eskom return to service plants. The final talk was by Aleksandra Paton, a Process Specialist at Hatch, and Dr Kobus van der Merwe from Industrial Management Enhancement, on developing new performance measures to improve production process management. The conference closed off with a networking session where delegates could relax, discuss trends and ideas, and conduct a little bit of business in a more relaxed atmosphere. The pre-conference MESA GEP training was held two days before the conference and was one of the biggest MESA GEP courses held in the world this year. The MES/MOM skills shortage within southern Africa and globally is recognised as a major barrier to plant and supply chain optimisation and global operations excellence. Since the programme launch, MESA has experienced a remarkable worldwide response. GEP Programs are ongoing, and the next Bytes Systems Integration sponsored GEP CoC course scheduled for southern Africa will be held on February 28th to March 2nd 2012 in Midrand. Other GEP courses are scheduled at locations throughout the world, and companies can have them at their locations or host public GEP courses at their site.
For more information contact Gerhard Greeff, Bytes PMC, +27 (0)11 205 7663, gerhard.greeff@bytes.co.za, www.bytessi.co.za

DESSOFT HONOURED AT ACHIEVER AWARDS

At a special ceremony during the Skills Development Summit held at the CSIR in September, DesSoft was among the companies and individuals who were honoured with Achiever Awards for outstanding contributions to skills development. “At a time when the shortage of skills has reached almost crisis proportions in a number of areas of the national economy, now more than ever those who are making a difference by providing South

Africa with the necessary skills pool must be recognised for their leadership and applauded for their efforts,” said Awards director, Dylan James. The summit was sponsored by the world’s top mining group, BHP Billiton.
For more information contact Justin Alberts, DesSoft, +27 (0)12 644 2974, justin@dessoft.co.za, www.dessoft.co.za

LEADERSHIP AWARD FOR BECKHOFF AUTOMATION
According to Frost & Sullivan, major challenges exist within the South African PLC market including a shortage of engineering skills, market dominance by large multinationals and declining customer loyalty. Despite these challenges, Beckhoff Automation has managed to penetrate the South African PLC market successfully and lead the way in terms of product innovation and solutions using PC-based control technology – the foundation of its continued success. “The company has grown its market share in a highly competitive South African market through continuous development of innovative products and solutions using PC-based control technology,” notes Frost & Sullivan’s industrial automation and process control research analyst, Grant Greyling. “This has been reinforced by high quality customer service and support. “Since its inception in 2006 Beckhoff Automation has increased its market share substantially,” states Greyling. “It has achieved the highest percentile growth in an extremely competitive industry; an industry where the top 5 participants make up over 82 percent of the market. An exceptional sales and technical support team has been integral to this success and market penetration. A high percentage of engineers among its personnel enable the company to provide outstanding customer support service and offer highly efficient and economical solutions.” The Frost & Sullivan Award for Market Penetration Leadership is presented each year to the company that has captured the fastest measured rate of change of market share within its industry. This award recognises how fast a company increases its penetration of a market, either in terms of revenues or of units.
For more information contact Conrad Muller, Beckhoff Automation, +27 (0)11 792 3374, c.muller@beckhoff.com, www.beckhoff.co.za

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HONEYWELL AND VIRTHUALIS TO DEVELOP SIMULATION SOFTWARE

Honeywell has signed a memorandum of understanding with engineering and research firm Virthualis to develop a 3-D simulation solution to improve operator training and plant safety. Under the agreement, Virthualis’ 3-D visualisation technology, MindSafe, will be linked to Honeywell’s UniSim simulation tool, providing a holistic virtual environment that can be used to design, analyse and verify plant operations, as well as to prepare operations teams for safe, reliable and efficient manufacturing. “We see many of our clients struggling to recruit operations staff with the right mix of skills, so we are pleased to be in a position to deliver a strong engineering and training solution that can bridge the competency gap,” says Elgonda La Grange, global consulting services director, Honeywell Process Solutions. “The fusion of Honeywell and Virthualis technologies enhances our existing simulation business with additional expertise and a 3-D learning environment to evaluate and train operators to respond to critical plant conditions.” “Honeywell is the ideal partner because our offerings are complementary and we share the same passion for process safety, reliability and efficiency,” says Simone Colombo, president, Virthualis. “Together we are delivering a solution that can support the lifecycle of a plant, from design through to decommissioning, by empowering engineers to design and implement, and operators to learn and test their skills to control the process safely, prevent accidents and manage emergencies in a realistic environment.”
For more information contact Debbie Rae, Honeywell Southern Africa, +27 (0)11 695 8000, hsa@honeywell.com, www.honeywell.co.za

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NEWS & EVENTS

OMRON LAUNCHES SYSMAC AUTOMATION PLATFORM
Omron Industrial Automation Business has announced the release of a new machine automation platform: Sysmac (system for machine automation control). Sysmac stands for one machine control through one connection and one software, and represents a milestone in Omron’s ten-year plan aiming to strengthen and globalise its position in the machine automation business segment. The guiding principles behind the Sysmac automation platform are: • One control for the entire machine or production cell. • Harmony between machine and people. • Open communication and programming standards. The result is a powerful and robust automation platform with a new machine automation controller (Sysmac NJ), that integrates motion, sequencing, networking and vision inspection and a new software (Sysmac Studio) that includes configuration, programming, simulation and monitoring and a fast machine network (EtherCAT) to control motion, vision, sensors and actuators. industrial environments with fanfree operation and runs under the RTOS a real-time operating system. It is scalable with a choice of 16, 32 and 64 axis CPUs. A response time of less than 1 ms can be achieved for applications of up to 32 axes, unheard of with conventional hardware based control.

ONE MACHINE SOFTWARE
Created to give machine builders full control over the automation system, Sysmac Studio integrates configuration, programming, simulation and monitoring into one software. Sysmac Studio delivers a true integrated development environment and offer a new experience in terms of ease of use and speed of programming.

ONE MACHINE NETWORK
One connection via the Sysmac NJ series controller allows seamless control and communication with both the machine and the factory. The new NJ series controllers are designed for open communication via EtherCAT, the fastest emerging network on the market for machine automation. EtherCAT is Omron’s de-facto machine network for its wide range of field and motion devices. It is a 100 Mbps industrial Ethernet network compliant with IEEE 802.3 frames, capable

of handling up to 192 slaves with refresh time down to 100 μs and less than 1 μs jitter. It achieves high accuracy for multi-axis synchronisation thanks to its distributed slave clock mechanism. It is simple to set-up with automatic address assignment for slaves and cost effective to install as it uses standard shielded Ethernet cables and connectors. In line with Omron’s social and global policy, Sysmac meets global standards such as EC Directives, cULus, Lloyd’s and NK and is designed and manufactured with clean and recyclable material.
For more information contact Terry McIntosh, Omron Electronics, 086 066 7661, terry_lynn_mcintosh@eu.omron.com, www.industrial.omron.co.za

ONE MACHINE CONTROLLER
The heart of the new automation platform is the Sysmac NJ 501 machine automation controller, which is designed for high speed and flexibility. It incorporates an Intel processor proven for harsh

ENDRESS+HAUSER PARTNERS WITH FINESSE SOLUTIONS
Endress+Hauser has acquired a stake in Finesse Solutions, a US based company that develops, produces and distributes sensors, hardware and software for bioprocess engineering. The two companies intend to cooperate closely on product, market and customer development in a way that is complementary to each. “Endress+Hauser and Finesse Solutions have many common customers who can profit from this cooperation,” said Finesse CEO Barbara Paldus. “Furthermore Finesse Solutions will profit from leveraging the know-how of the new strategic relationship to extend its product portfolio and to enhance its global sales and service capabilities.” “Biotechnology procedures will play an increasingly important role in the future, not only in the life sciences industry but also industries such as chemicals by manufacturing products in a more environmentally friendly and economic fashion,” said Klaus Endress, CEO of the Endress+Hauser Group. “Our partnership with Finesse offers us the possibility of gaining experience in this area without neglecting our core business.” Previous majority shareholder, Skymoon Ventures, now has an equal share in Finesse Solutions to Endress+Hauser. The rest of the shares remain with the company’s staff.
For more information contact Hennie Blignaut, Endress+Hauser, +27 (0)11 262 8000, info@za.endress.com, www.za.endress.com

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December 2011 www.instrumentation.co.za

OMRON TRAINING: DECEMBER 2011 TO MARCH 2012 JOHANNESBURG
PLC Introduction 1 (PL1): 23-24 Jan Enhanced PLC 2 (PL2): 25-27 Jan Advanced PLC 3 (PL3): 5-6 Dec Logic Systems 1 (LS1): 5-6 and 12-13 Dec Logic Systems 2 (LS2): 7-8 Dec Enhanced PLC 2 (PL2): 15-17 Feb Logic Systems 1 (LS1): 30-31 Jan Logic Systems 2 (LS2): 1-2 Feb

PORT ELIZABETH
PLC Introduction 1 (PL1): 5-6 Mar Logic Systems 1 (LS1): 13-14 Feb Logic Systems 2 (LS2): 15-16 Feb
For more information contact Terry McIntosh, Omron Electronics, 086 066 7661, terry_lynn_mcintosh@eu.omron.com, www.industrial.omron.co.za

DURBAN
PLC Introduction 1 (PL1): 30-31 Jan Enhanced PLC 2 (PL2): 1-3 Feb Logic Systems 2 (LS2): 14-15 Dec

CAPE TOWN
PLC Introduction 1 (PL1): 13-14 Feb

JOURNAL OF A C&I ENGINEER IN TRAINING
In April, South African Instrumentation and Control announced the award of the first Ray Beaumont technology scholarship to Yokogawa C&I internee, Merone Ramuhashi (http://instrumentation. co.za/38312n). Since then we have received progress reports from her that impressed the team to the extent that we decided it would be beneficial to publish these online. We hope they inspire other young engineers to join the profession. The second set of entries can be found at http://instrumentation.co.za/papers/ communicationprotocols.doc, http://instrumentation. co.za/papers/PID&PCItraining.doc
For more information contact Jane van der Spuy, Technews, +27 (0)31 764 0593, jane@technews.co.za, www.technews.co.za Merone Ramuhashi.

IDC TECHNOLOGIES WORKSHOPS AND WEBINARS IN DECEMBER
Practical control valve sizing, selection and maintenance 5-6 Dec Practical earthing, bonding, lightning & surge protection 8-9 Dec
For more information contact Cheryl Reyneke, IDC Technologies, +27 (0)11 024 5520, cheryl@idc-online.co.za, www.idc-online.com

APPOINTMENTS

Clinton Seager.

Elizabeth Graskie.

Gys Snyman.

Honeywell has appointed Clinton Seager as Automation Training College leader: sub-Saharan Africa.

The OMSA Group has appointed Elizabeth Graskie as financial manager.

Schneider Electric SA has appointed Gys Snyman as vice president: energy efficiency.

www.instrumentation.co.za December 2011

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SAIMC NEWS

From the President’s desk
MYTH BUSTING
Myth: Albert Einstein did not fail mathematics in school, as is commonly believed. Truth: Upon being shown a column claiming this fact, Einstein said “I never failed in mathematics... Before I was fifteen I had mastered differential and integral calculus.” Myth: Searing meat does not “seal in” moisture Truth: Searing of the meat may actually cause meat to lose moisture. Generally, the value in searing meat is that it creates a brown crust with a rich flavour. Myth: The Great Wall of China is the only human-made object visible from the Moon. Truth: The city lights on the night side are easily visible from the moon but the Great Wall of China starts to disappear from sight from only 300 km up. Myth: Speed kills. Truth: If speed alone was the cause of death, all aircraft would have been death traps. However, it is true that if we all reverted back to donkey carts that there would be fewer deaths on the road. “Speed kills” seems to be a slogan to justify making money from motorists in a very easy way rather than try and make an effort in getting the taxi drivers under control. Myth: Global Warming. Truth: It does not really matter if this is a myth or not. It does not really matter if some people are getting rich from “Global Warming”. “Global Warming” has done more to make people aware of the pollution of our planet than any other single issue raised in the past. At last some companies are being forced to reduce their carbon footprint, use energy more efficiently and generally leave our planet in an acceptable state for our children and their children. Myth: It is not a question of what the SAIMC can do for you, but what you can do for the SAIMC. Truth: The SAIMC has implemented a few plans to serve you better. The only problem is that it is for the most part a self-help organisation. However, there are a few places where the SAIMC is contributing towards your well-being without you having to do anything: • We have implemented a website to which you can contribute as well as obtain answers to questions about the industry, technology and professional registration. You never have to work alone. • We answer changes to legislation to ensure that your qualifications will still be valid tomorrow and that you will be able to do your job without getting somebody else to sign off all your work. • We discuss training with educational institutions to ensure that your children and grandchildren will be able to fit into our industry more easily. • We enable you to register professionally by way of CPD training courses. There are still many items on our to-do list, but that will have to wait until 2012. In the meantime I urge everybody who has great ideas to register on our website, go to the Forum > Council > Strategy and let your voice be heard.

Johan Maartens.

VACATION
Many of us will be taking leave over this Christmas period. May you have a safe journey and come back revitalised for the work that lies ahead in 2012. Ina and I would like to wish each and every one a blessed Christmas and may 2012 bring you the desires of your heart as you continue on your way through this life. In the greater scheme of this, our time on earth is short but worth every second. Make the most of it. To the Committees: I would like to thank you from the bottom of my heart for the wonderful work you have done this year. We had our differences but as they say: “If everybody agrees only one person is doing the thinking”. To the families of the committees: I would like to thank your families for putting up with your participation in the SAIMC. Without your support the SAIMC would not have been able to look back on a very successful year in which all three of our targets were reached – well, we are still working on one and that is the First Lego League trailer that still needs some modifications to accommodate all the equipment.

Secretariat SAIMC, Tel: 08610 SAIMC, +27 (0)11 431 3802 (international callers only), Fax: 086 616 0141, admin@saimc.net

www.saimc.net

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December 2011 www.instrumentation.co.za

Durban branch
At the October technology evening, which was kindly hosted by Honeywell, account manager Tony White took us through ‘Virtualisation in Industrial Control’. We learnt about the key benefits and value that it can bring to business and Tony also shared some practical experience for builds and migrations of existing physical platforms to a virtual server.

FORTHCOMING ATTRACTIONS
The December Technology Evening will be hosted by Yokogawa who will provide specialist speaker, Bruce Bonte. Bruce is a qualified instrument mechanician with 22 years’ experience in the process control and instrumentation arena. He joined Yokogawa earlier this year and is currently training facilitator for Africa. It is in this role that Bruce will be looking at ‘A Model to Combat the Skills Shortage’. Wednesday 7 December 17:30 for 18:15 Westville Country Club 1 Link Road Westville Please contact Kevin McElroy on 0832519993 or kevin@eastcoast.co.za if you have any queries.

Howard Lister thanking Tony White for his contribution.

YEAR-END FUNCTION
The Durban branch annual function was held at The Heritage Theatre on 22 October. It was a complete sell-out and gave companies the opportunity to entertain customers in a relaxed and fun networking atmosphere. Committee member Paul Sikhakhane did a fine job as Master of Ceremonies, introducing acting Chairman Vinesh Maharaj, guest speaker Ed Boje and SAIMC President, Johan Maartens, all of whom had some interesting things to say about the industry, education and of course the role of the SAIMC in the past year. The Durban committee introduced a new award this year to recognise contributions from industry and it went to Nico Marneweck from Yokogawa for Best Technology Presentation 2010/2011. The food was great and the entertainment was a tribute to the much-loved country rock group, The Eagles. The band really entertained on the night doing justice to one of the biggest-selling US acts in history.

Vinesh Maharaj congratulating Nico Marneweck.

Vinesh Maharaj addressing the audience at the year-end function.

www.instrumentation.co.za December 2011

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SAIMC NEWS

SAIMC Secunda branch
David van Eeden from Proconics presented a topical discussion on the different flowmeters and their applications in industry. David is a design engineer and his presentation highlighted a number of practical tips which may not always be found in textbooks. The networking after the presentation allowed members to debate the pros and cons of which technology is most appropriate in different applications. The Secunda branch of SAIMC also visited the library of the local branch of the Vaal University of Technology (VUT) to assess the reading and reference material available to students. The branch has undertaken to ensure that Instrumentation & Control magazine is available in the library. The branch would also like to appeal to members and other interested readers to donate books and other technical material for use by students. If you have a donation to make please contact Dennis Hoffman, dennis. hoffman@sasol.com and we will ensure the library receives this.

Peter Zietsman thanking David for his presentation.

Constance, VUT librarian, with an I&C magazine.

SAIMC Banquet
Members spent an enjoyable evening at the prestigious Rand Club where they were wined and dined in style. The guest speaker was Dr Anthony Turton, an expert on water resource management, who was named Environmentalist Of The Year in 2010. He gave an entertaining and thoughtprovoking exposé on the strategic water quality challenges that South Africa is facing. Seen here enjoying the banquet are President Johan Maartens and his wife Ina as well as Past President Johan van Jaarsveldt and his wife Beverley.

President Johan Maartens and his wife Ina.

Past President Johan van Jaarsveldt and his wife Beverley.

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Cape Town branch
The Cape Town branch felt at the beginning of the year that in order to deliver a good service to members it needed to fill key vacant positions within the existing leadership. The nomination and voting process was, however, poorly supported, but it did manage to obtain the services of two industry people to assist with key branch activities until the 2012 AGM. The new members are events coordinator Raymond Cloete and branch treasurer Izak Muller. “Having a solid team where everyone is available and working towards the same goals is important to us as it enables SAIMC Cape Town to deliver on members needs,” says branch chairman, Selvan Murugan. “The branch’s sole purpose for 2011 is to ensure consistent technology evenings as well as building close ties with learning organisations such as CPUT and Northlink College.” September – Gareth Davies from CBI Electric gave a presentation on the past and future of automation engineering. The engineering of automation systems has been evolving for a number of years, starting with simple automation systems such as looms and punched card machines to today’s sophisticated DCS and PLC hybrid systems. The actual engineering and deployment of these systems from a business view point, where systems need to be deployed in a fraction of the time normally acceptable, was perceived as a great topic by members. Gareth provided a thought provoking session that focused on engineering standards, evolution, usage and methodologies used in the selection and deployment of systems and the focus on real world tools to cater for current and future engineering environments. October – Nico Marneweck from Yokogawa SA gave a presentation on methods to combat the skills shortage. Yokogawa SA has developed a 3-year internship model that the organisation would like to share with SAIMC members, particularly members who are part of learning institutions. Yokogawa has battled to find appropriately skilled people to employ in South Africa and thus implemented this novel approach in order to produce the skilled human resources they require.

TECHNOLOGY EVENINGS DURING 2011
This brief summary of the year’s activities has been included to provide members with a history of the year as well as to thank our sponsors without whom the branch could not have fulfilled its purpose. May – Ken Irwin from Motorman SA gave a presentation on robotics and its history and use within industrial environments. This was a welcome break from the tradition of conventional control and instrumentation presentations as was evident from the varied fields of expertise in the audience. July – Evan Willemse from Beckhoff Automation gave a presentation on EtherCAT, the open real-time Ethernet platform developed by Beckhoff. EtherCAT sets new standards for real-time performance and topology flexibility and was therefore considered an excellent technology topic for members. August – Gary Friend from Extech Safety Systems gave a presentation on intrinsic safety. IS is the preferred protection technique for many instrumentation installations within hazardous environments and the content of this presentation by Gary was extremely informative. The presentation looked at the origins and principles of IS, including hazardous area zoning and the implications for dusty environments.

SITE VISIT TO SIMONS TOWN NAVAL BASE
An initiative is underway to arrange a site visit to the naval base in Simons Town during the week of 14-18 November. The naval base has agreed to accommodate us within this week to view automation in operation at the navy.

GENERAL
Members are requested to update their contact details (especially cell phone numbers) in order to be kept informed about branch activities. We also urge our members to communicate directly with the branch leadership in order to voice opinions, direct queries and make requests for improvement. The leadership is there to serve members, but needs members to contribute towards this initiative. The 2012 AGM process will be underway shortly.

Cape Town: Selvan Murugan at selvanm@ssi.co.za, Mobile: +27 (0)83 297 7620 Durban: Vinesh Maharaj at vmaharaj@cubetech.co.za, Mobile: +27 (0)83 792 6518 Johannesburg: Andrew Bharath at Andrew.bharath@za.yokogawa.com, Mobile: +27 (0)83 758 1908 Richards Bay: Vinesh Maharaj at vmaharaj@cubetech.co.za, Mobile: +27 (0)83 792 6518 Secunda: Peter Zietsman at Peter.Zietsman@eskom.co.za, Mobile: +27 (0)83 310 7925 Vaal: Solly Mabitsela at solly.mabitsela@sasol.com, Mobile: +27 (0)83 381 9962 Zambia: Rodgers Kayombo at rodgers.kayombo@kcm.co.zm Council: Ina at Admin@saimc.net, Mobile: +27 (0)82 440 8957

www.instrumentation.co.za December 2011

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JIM PINTO

Sensors
JIM PINTO
Jim Pinto is an industry analyst and commentator, writer, technology futurist and angel investor. His popular e-mail newsletter, JimPinto.com eNews, is widely read (with direct circulation of about 7000 and web-readership of two to three times that number). His areas of interest are technology futures, marketing and business strategies for a fast-changing environment, and industrial automation with a slant towards technology trends.

Smart, networked sensors will soon be all around us, collectively processing vast amounts of previously unrecorded data to help run factories, optimise farming, monitor the weather and even watch for earthquakes. Many people (including me) think that wireless sensor networks can become as important as the Internet. Just as the Internet allows access to digital information anywhere, sensor networks will provide remote interaction with the physical world.

FROM LARGE, EXPENSIVE AND DUMB TO TINY, CHEAP AND SMART
Sensors are already everywhere. But most sensors used today are large, expensive and dumb – they lack the intelligence to analyse or act on their measurements, simply reporting for remote processing. Soon, MEMS and nanotechnology will yield tiny, low cost, low power sensors. Tiny is important because they can be scattered around to measure just about everything that you can imagine. Low power because they won’t need to carry a large battery and may even be solar powered. Low cost because the numbers required will be enormous.

Against the backdrop of the war on terrorism, work is progressing on a nationwide sensor network that someday could provide a real-time early-warning system for a wide array of chemical, biological and nuclear threats across the US. With a $1 billion budget in 2004, the US Department of Homeland Security is doing a significant amount of new development, plus coordinating the efforts of key scientists at national labs. The core technology relates to materials, sensors, networks and chips. Field trials of prototype networks are already starting. MEMS and nanotech will be used to create several low cost, highly accurate biological and chemical sensors. On the networking front, peer-to-peer networks with multilevel security and quality of service guarantees will span wireless, wired and satellite links. Within a few years, these technology developments will impact commercial markets, bringing huge new opportunities in other areas.

EMBER’S WIRELESS SENSOR NETWORKS
An MIT spin-off, Boston-based EMBER is achieving significant advances in this field. MIT-Tech Review recently interviewed Ember CTO Robert Poor about his visions of a world filled with wireless networked devices. Interesting stuff – worth reading. Ember sells radio chips with embedded processors that can organise themselves into networks to manage real world data from sensors. The EmberNet self-organising, self-healing mesh algorithms produce networks that are reliable, flexible, secure, and easy to use. Adding devices only makes EmberNet sensing and control networks stronger and more efficient. As its markets expand, Ember envisions literally thousands of tiny sensors scattered profusely all over the environment for monitoring, surveillance, control, resource management, optimisation, forecasting and prediction.

COMBINATION OF THREE HOT TECHNOLOGIES
There are three basic technologies involved in sensor networks: • Micro miniature, ultra-low-power sensors (today these are usually MEMS; soon nanotech sensors will come on the scene). • Embedded chips and firmware for P2P communications and self-organising systems. • Software for communications, control and optimisation for thousands of nodes. Together, these new developments are bringing intelligent, wireless sensors that talk with each other, forming intelligent networks spread over wide areas. Together, the sensors network process information into an overall analysis. Indeed, wireless sensor networks are one of the first real world examples of “pervasive” computing – small, smart, cheap sensing and computing devices that will permeate the environment.

APPLICATIONS
Immediate markets include industrial automation (process control), defence (unattended sensors, real-time monitoring), utilities (automated meter reading), building automation (HVAC controllers). Within the next few years, distributed sensing and computing will be everywhere – homes, offices, factories, automobiles, shopping centres, supermarkets, farms, forests, rivers and lakes. Even accurate weather prediction will be revolutionised through widespread wireless sensors. In a flat or declining industrial automation marketplace, expect big growth from wireless sensor networks. Get your company involved. Or, join a company that is involved.

SENSOR NETWORKS COUNTER TERROR THREATS
Once tiny, low power sensors are available and the measurements are communicated and coordinated through peer-to-peer wireless links, the technology moves to whole new software arenas: pattern-recognition, heuristic analysis, self-organising systems, and complexity science. The funding required to develop this significant new technology synthesis quickly is becoming available.

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www.instrumentation.co.za December 2011

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SYSTEM INTEGRATORS

Cube Technologies assists with boiler control
A SUCCESSFUL CUBE TECHNOLOGIES AUSTRALIAN PROJECT IS NOW A CLIENT REFERENCE SITE.
Australian Country Choice (ACC) is a vertically integrated supply chain organisation dedicated to the supply of high quality beef and veal products to Coles Supermarkets and other export customers, and maintains a ‘plate to paddock’ philosophy. ACC’s central processing facility is located in Brisbane and incorporates beef and veal primary processing, further processing and retail ready meat packaging operations for delivery of shelf ready fresh meat products. Weekly production capacities include the processing of 5 000 yearling, veal and Certified Organic beef carcasses. In September 2010 ACC approached Cube Technologies to assist with the problems being experienced with the Bailey Network90 system which controls the boilers in the plant. Issues raised were the unacceptable failure of the system and the loss of I/O cards for the control system on the plant’s two fluidised bed boilers, refrigeration plant and coal conveying system. “Cube Technologies was selected due to its extensive experience in boiler control systems. ACC’s original requirement was for the possible repair of the Bailey system. However, we determined that the resultant additional cost to ACC for running on diesel for 26 weeks would have been $2.34 million (R18.8 million). In consultation with ACC we agreed that they required a state-of-the-art process control automation,” says Dirk Swart, General Manager at Cube Technologies in Australia. The client’s original intention was the simplification of its existing control strategy without compromising performance and functionality. This entailed allowing operators to easily view and control the boilers, coal conveying, hot water and refrigeration operations; and to have fully integrated alarm management and trend displays. In addition it had to make all known faults and waiting times visible to operator and reduce the fault finding time. “In the initial discussion stages we needed to convince management that the replacement of the old system was necessary from both a time and cost saving perspective in the short and long term,” says Swart. “In addition, decisions between the choice of a PLC or DCS as the control system were debated but because of the cost implications we agreed on the implementation of a Siemens PCS7 distributed control system,” says Swart. Cube Technologies project managed the new system and was responsible for the detailed design (in collaboration with ACC on site), drawings, panel manufacturing, commissioning (via Pac Technologies) and commissioning. “The project was quite challenging in terms of the lack of documentation. We were therefore forced to extract and interrogate the Bailey programs from the existing controllers. In addition, we had to physically trace all existing field wiring by hand,” Swart explains. Cube Technologies overcame communications issues by setting specific goals at the outset and holding weekly progress meetings and project schedule updates with ACC. “We issued monthly reports to manage and control cost variations. All software and procedures were tested via simulation before implementing and all plant operators were trained to ensure their thorough familiarity with this completely new system,” says Swart. Future plans for the boiler plant automation upgrade include automation of the steam delivery control; investigation of hot water rendering return storage; investigation of turning excess energy into usable electricity; optimising coal combustion; investigation of steam and water wastage; and investigation of diesel usage and losses. The project was delivered on schedule (six months from conception to commissioning) and on budget, without a major commissioning shutdown or impact on existing operations. “ACC says that this is the best major project implemented by any external company they have experienced. Due to its successful implementation, the ACC project has been opened as a reference site to potential Cube clients on many occasions,” Swart concludes.
For more information contact Vinesh Maharaj, Cube Technologies, +27 (0)31 764 6081, vmaharaj@cubetech.co.za, www.cubetech.co.za

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SYSTEM INTEGRATORS

SYSTEM INTEGRATORS
The full System Integrators tables can be found in the 2011 Instrumentation & Control Buyers’ Guide under the section Services (Industrial). Please contact Jane 031 764 0593, e-mail: jane@technews.co.za or Tina 011 543 5800, e-mail: tina@technews.co.za for more information on inclusion in this section.

SYSTEM INTEGRATORS

ABACUS AUTOMATION
Tel: (031) 702 5767 sales@abacus-automation.co.za www.abacus-automation.co.za

FESTO
Tel: 08600 FESTO (33786) sales.interaction@za.festo.com www.festo.com

SYSTEM INTEGRATORS

PSY SYSTEMS
Tel: (011) 782 5449 paul@psysystems.com www.psysystems.com

ALTECH ALCOM MATOMO
Tel: (011) 235 7640 sales@alcom.co.za www.alcommatomo.co.za

HYBRID AUTOMATION
Tel: (031) 573 2795 info@hybridautomation.co.za www.hybridautomation.co.za

SAM – SYSTEMS AUTOMATION AND MANAGEMENT
Tel: (011) 803 0570 info@sam.co.za www.sam.co.za

AUTOTRONIX
Tel: (031) 705 0400 or (016) 422 7644 sales@autotronix.co.za www.autotronix.co.za

IRITRON
Tel: (012) 349 2919 marie.herbst@iritron.co.za www.iritron.co.za

SMS INDUSTRIAL SERVICES
Tel: (013) 697 0702 sales@smsholdings.co.za www.smsholdings.co.za

BIGWAVE AUTOMATION SYSTEMS
Tel: (011) 452 1546 bigwavesa@telkomsa.net www.bigwave.com

MOORE PROCESS CONTROLS
– TRADING AS MATRIKON MOORE Tel: (011) 466 1673, www.moore.co.za info@moore.co.za or info@matrikon.co.za

SYSTEMS ANYWHERE
Tel: (011) 024 5491 info@systemsanywhere.com www.systemsanywhere.com

CUBE TECHNOLOGIES
Tel: (031) 764 6081 info.rsa@cubetech.co.za www.cubetech.co.za

PROCESS DYNAMICS
Tel: (011) 394 5412 systems@process-dynamics.co.za www.process-dynamics.co.za

WELKOM INDUSTRIAL CONTROLS
Tel: (057) 357 5724 zentae@wic.co.za

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www.instrumentation.co.za December 2011

COVER STORY

Edge-to-core industrial Ethernet solutions
NEW ICS 10GBE CORE SWITCHES JOIN MOXA’S COMPREHENSIVE PORTFOLIO.
Moxa’s wide portfolio of industrial Ethernet infrastructure solutions has become even more comprehensive with the addition of the new ICS industrial core switch family. The ICS series joins a suite of powerful edgeto-core switches and the MXview industrial network management software (iNMS) to create advanced industrial Ethernet platforms with excellent scalability, performance, reliability and ease of maintenance. Moxa’s industrial edge-to-core Ethernet switch solutions have the high performance needed for the core layer of the network infrastructure plus the flexible media selection needed for the edge layer. The Moxa switch portfolio now includes over 500 models, including the ICS series 10GbE core switches, the IKS and EDS-700/800 series modular rackmount and DIN-Rail distribution switches, the EDS600/500/400/300/200 series DIN-Rail edge switches, and the TN and PT series industry-specific Ethernet switches. All of these switches are built specifically to operate within the harsh environments and exacting requirements of mission-critical industrial applications such as railway, ITS, smart grid, oil and gas, factory automation and maritime applications. Moxa’s MXview iNMS enables total network management with simple, user-friendly browser UI that can track the network status of all Moxa managed Ethernet switches in real-time, quickly identify failure points, and reduce troubleshooting response time in complex and critical network operations. The new ICS series industrial core switch family enables customers to deploy a high-capacity converged automation network with extreme 10GbE performance, network resilience and fanless durability. These core switches extend carrier-level availability throughout the entire industrial network to provide a stable multi-service backbone that can support a large amount of Ethernetbased services such as video, voice, command and data transmissions. Benefits of Moxa’s edge-to-core industrial Ethernet switch solutions: • Ultra-reliable fast network redundancy across three layers of an industrial network with Turbo Ring/Turbo Chain self-healing Ethernet technology. • Faster communication speed and quicker network response with Gigabit performance.

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• Complete solutions support converged applications such as video surveillance. • Industrial-grade reliability, completely fanless, with industrial certification and approvals. Core layer - high bandwidth 10GbE industrial core switches: • Full Gigabit L2/L3 networking capability. • Up to 24 or 48 1GbE connections. • Up to 4 10GbE ports. Distribution layer – industrial modular rack mount and DIN-rail switches: • Flexible modular design.

• High port density. • Ideal for control room and outdoor cabinet operations. Edge layer compact, standalone DIN-rail switches: • 5 to 19 ports, FE to full GE, managed and unmanaged switches. • Cost-effective solutions. • Advanced L2 networking capability.
For more information contact RJ Programmable Techniques, +27 (0)11 781 0777, info@rjprogtech.co.za, www.rjprogtech.co.za

www.instrumentation.co.za December 2011

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CHEMICALS & PLASTICS

Measuring vessel contents in the chemical industry
DURING THE PRODUCTION OF CHEMICALS IT IS NECESSARY TO STORE WIDELY DIFFERENT PRODUCTS.
FROM LIQUID TO SOLID FORM
Raw materials must be stocked in order to ensure continuous production; intermediate products have to be temporarily stored before being further processed; and finished products have to wait somewhere until they are shipped. All this makes accurate measurement of vessel contents an absolute necessity. Specialist level sensor manufacturer Vega has the right products for different applications in this industry. position, rod or cable versions are available. For products with poor reflective properties or for extremely high accuracy requirements, the Vegaflex 65 with coaxial rod has proven to be an exceptionally good solution.

LEVEL DETECTION OF POWDERY SUBSTANCES
The Vegawave 62 is the ideal solution for reliable level detection of all types of powdery substances. The switching point of the sensor can be adapted precisely to individual requirements by using customised cable lengths.

GUIDED MICROWAVE FOR BULK SOLIDS CONTAINERS AND SOLVENT VESSELS
Some basic products used in the production of chemicals come in powder or granulate form. Vega’s guided microwave sensor, the Vegaflex 61, is particularly suitable for level measurement of these materials in medium sized silos. The sensor is completely independent of product characteristics, dust generation and air currents from pneumatic filling. The robust sensor version Vegaflex 62 is available for applications in which strong extraction forces arise. Modern facilities in the chemical industry are often geared for the production of a number of different products. Irrespective of product characteristics, the implemented level sensor must deliver accurate, reliable measurement data. This is where the Vegaflax 61 can also be used, and depending on the application and mounting

LEVEL DETECTION WITH VEGASWING 63
Beside continuous level measurement, level detection constitutes an important security feature on storage tanks. Many new sensors for continuous level measurement are now certified for overfill protection, but a second physical measuring principle ensures optimal safety as well as redundancy. Because of the many ways it can be applied, the vibrating level switch, Vegaswing 63, is ideal for all measurement tasks connected with the storage of liquids. The recurring test according to the Water Resources Act is performed simply by pressing a key on the signal conditioning instrument. The sensor then corresponds to SIL requirements.
For more information contact John Groom, Vega Instruments, +27 (0)11 958 1901, john.groom@vega.com, www.vega.com

Vegaswing 63 with non-contact radar sensor

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CHEMICALS & PLASTICS

Mettler Toledo’s Good Weighing Practice
THREE SIMPLE STEPS TO SIMPLIFY BALANCE TESTING.
Weighing equipment must be inspected and tested at regular intervals to ensure consistently accurate results. Many laboratories, however, test too frequently or perform unnecessary and even incorrect tests. The combination of Metler Toledo’s GWP Verification, GWP Excellence and weight sets is an easy-to-implement solution that simplifies correct routine testing strategies. Based on market demands for increased guidance, Mettler Toledo has developed Good Weighing Practice. This global, riskbased weighing guideline allows companies to reduce testing costs while keeping safety a priority. There are three steps to simplifying the routine testing: • GWP Verification: the improvement potential of even the most rigid quality system (in terms of quality assurance, cost reduction and the increase of employee productivity) has been validated by multinational companies. GWP Verification provides a colourcoded executive summary, which illustrates the status of each balance in regard to the potential risks of inaccurate measurements. Specific recommendations for each balance or scale are then derived from this report. This includes information on how to maintain accurate results with minimal testing efforts, such as routine tests types, frequencies of checks and calibrations, required test weights and the control limit for each test. • CarePac Weight Sets: the GWP Verification assessment provides details on which weights should be used for each test. GWP states that routine testing with just two test weights is sufficient. CarePacs contain two carefully selected certified weights to test close to the minimum and the maximum capacity of the balance. Handling only two weights simplifies routine testing and saves on considerable purchase and re-calibration costs. • GWP Excellence: The third step is to put the optimal testing regimen into practice. Using the information from the GWP Verification report, all testing procedures can be implemented directly in the balance firmware, which is a built-in safety feature in all new XP, XS, and XA balances. This includes which tests to carry out, how often and using the correct CarePac weight set. Whenever a test is due, the balance user is prompted to perform the relevant test and is given step-by-step instructions directly on the balance display. Finally, the combination of GWP Verification, GWP Excellence and CarePac weight sets is an easy solution to simplify a routine testing strategy. This allows users to save by eliminating unnecessary testing. Thorough documentation of the balance performance and routine tests, the balance firmware helps to avoid out-of-spec results, negative audit findings or even warnings.
For more information contact Chris de Jager, Microsep, +27 (0)11 553 2300, chris.dejager@microsep.co.za, www.microsep.co.za

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BUILDING MANAGEMENT

TOP FIVE PLACES TO LOOK FOR ENERGY LOSSES

Infrared to detect energy wastage
on clear, windless evenings after dusk or before dawn, when thermal differentials in the roofing materials are in a transient state. Not all roofs can be effectively inspected using infrared thermography. What to scan Roofs: Wet roofing insulation loses its R-rating. Scan the roof surface and follow temperature differences to possible entry and exit areas for conditioned air. Spot repairs are less expensive than replacement and old roofs are often a challenge to dispose of because of their contents. Walls between conditioned and unconditioned spaces, including outside walls: Concentrate on the top and bottom of conditioned spaces and also look for indications of missing or wet insulation. Construction joints and connections: At floor slabs that extend outdoors, there are often heating or cooling losses by conduction through the slab. Penetrations of the building envelope (pipes, conduits, chimneys): Uninsulated gaps often exist around roof and wall penetrations. Door and window frames and seals: Look for leaks due to poorly fitting doors and windows but bear in mind that spot repairs to major losses such as roof leaks usually offers faster payback than fixing door and window seals. Anticipated savings The Department of Energy estimates that following up on the findings of an energy audit of a building’s envelope saves most facilities at least 15%.

Hot or cold air leaks from buildings, systems and equipment result in energy wastage. However with a small amount of training it is possible to use a thermal imager to spot the abnormal temperatures which lead to energy waste. Unlike regular digital cameras that capture images of the visible light reflected by objects, thermal imagers create pictures by measuring infrared energy or heat. The thermal imager then assigns colours based on the temperature differences it measures. This works best when the imager is in the hands of someone with a good working knowledge of the structures and systems being scanned, who can then interpret the temperature variances seen on the camera. A typical scan can show energy saving opportunities of up to 15%, with varying degrees of repair investments. Thermal imaging experts suggest that building owners, building managers and facilities engineers inspect the following systems to identify energy losses.

BUILDING ENVELOPE
Building envelope refers to the building structure as well as the climate controls within it. The envelope is what separates the outside environment from the inside, and it is frequently imperfect. The degree of temperature variance may be very small – one or two degrees. The best time to scan is when the outside temperature is at least 10°C higher or lower than the inside temperature. Thermal loading or other environmental factors could also mask or distort potential problems. Exterior walls should not be scanned when the sun is shining on them and roofs should be dry and free of water or ice. Inspections should be performed

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BUILDING MANAGEMENT

HVAC SYSTEM
The heating, ventilation and air conditioning (HVAC) system is usually one of the biggest energy consumers within a facility. What to scan Ductwork and registers: Even the highest rated HVAC system wastes energy without a well sealed duct system. With

infrared technology the thermal pattern of air loss or gain in ducting can be seen and registers can be monitored to determine whether heating or cooling output is optimal. Fans and blowers: These mechanical elements are motor driven. Mechanical imbalance will manifest itself in overheated bearings and other components.

Thermal images of these systems can also identify shaft misalignment in couplings between the motor and fan. Electrical connections: A loose or corroded connection increases resistance at the connection, resulting in overheating. Anticipated savings Studies indicate that

commercial buildings with constant air volume systems often experience energy losses from air leakage of as much as 33%. Also, studies indicate that air supply temperature differentials due to conduction losses can be as great as 6°C. Considerable savings can be achieved with duct sealing and insulation remedies.

MOTORS AND GENERATORS
Electrical motors are one of the biggest energy consumers in any facility. Overheating and malfunctioning motors and generators result in mechanical or electrical inefficiencies that lead to more energy use and ultimate failure. Since generators are actually “reverse motors,” diagnostics are similar for both kinds of units. What to scan Airflow: In fan cooled motors, a restricted airflow will cause general overheating on the entire housing. Electrical unbalance: A high resistance connection in the switchgear, disconnect or motor connection box, can usually be pinpointed by an infrared inspection and confirmed using a multimeter, clamp meter or a power quality analyser. Bearings: When thermal images reveal bearing housings with abnormally high temperatures, either lubrication of the bearing or its replacement is called for. Insulation: Look for higher than normal housing temperatures in areas associated with windings. Electrical connections: As with electrical connections in HVAC systems, look for loose or corroded connections that increase resistance. Anticipated savings With motors and generators, specific energy losses are usually of less consequence than failure of the unit. The impact of a motor or generator failure will be contingent upon the nature of the enterprise and the systems affected. The best ways to reduce motor energy expenditures are to keep motors well maintained and operating at maximum efficiency and to size them appropriately and operate at constant speeds.

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BOILERS
Boilers are the heart of steam and hot water heating systems. What to scan Refractories: Thermography makes possible in-service monitoring of the condition of refractory linings. Leakage of outside air: This condition is difficult to pinpoint with diagnostic technologies other than thermal imagers and it can lead to substantial inefficiencies. Boiler casing insulation: Look for heat loss from damaged insulation. Fan motors: Check for impeded airflow, electrical unbalance, overheated bearings and failing insulation. Pumps: Look for hot bearings, leaking seals and motor faults. Valves: Thermography can identify blocked valves that are nominally open and leaking valves that are nominally closed. Electrical connections: Look for loose or corroded connections that increase resistance. Anticipated savings In boilers, major energy losses associated with stack losses as well as radiation and convention losses typically represent 10 to 20% of fuel input, depending upon fuel type. Insulation and boiler economisers can reduce these losses.

ELECTRICAL SYSTEMS
Electrical systems can waste money as components degrade and resistance increases. What to scan Distribution panels: Check for unbalance in circuits and loose and corroded connections at breakers, contacts, fuse clips and busses. Transformers: Monitor high and low voltage bushing connections, cooling tubes and cooling fans and pumps. Look for overheated connections, comparatively cool cooling tubes and hot or cool pumps. Be aware that if the temperature of one electrical leg on a transformer is significantly hotter than the others that leg may be failing. Lighting control circuits: Check all wiring splices and connections at fuses, switches, and fixtures. Be aware that thermography can also be used to monitor low voltage control circuits. Anticipated savings According to some estimates, lighting accounts for about 20% of all electricity use in the USA and more than 40% of electricity use in offices, stores, and other commercial buildings. While complete retrofits of lighting systems are producing phenomenal returns on investment, keeping lighting controls such as time clocks, photo sensors and occupancy detectors operating properly will help save energy.

CONCLUSION
Thermal imagers have come down so far in price that most facilities can recoup the cost in terms of energy savings within six months. Incorporating thermal imaging into a regular maintenance programme contributes to efficiency as well as helping a maintenance team to identify and prevent expensive electromechanical failures.
For more information contact Val Verwer, Comtest, +27 (0)11 608 8520, info@comtest.co.za, www.comtest.co.za

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WIRELESS

One way wireless
IN SPITE OF MOVES TO CONVERGE INDUSTRIAL WIRELESS STANDARDS, TAKING THE PLUNGE STILL INVOLVES SOME UNQUANTIFIABLE RISK.
Andrew Ashton, contributing editor, SA Instrumentation and Control.
In the years leading up to the end of the 2001 – 2010 decade end-users who were considering the adoption of industrial wireless technology for instrument signals were faced with two options, each gathering their own proponents, and each coming from a different perspective: these were (in the blue corner) the WirelessHART (IEC/ PAS 62591) team and (in the red corner) the ISA100 (ISA-100.11a) team. In the last three years a third player, WIA-PA (IEC/PAS 62601), originating from China, has joined the fray. Various commentators have likened the battle of the industrial wireless standards to that between VHS and Betamax in the dim and distant past. And for all the hot air that was generated, both those technologies got overtaken by rotating optical storage solutions which themselves may soon disappear. So should you wait to adopt wireless or should you make an informed decision now and live with that?

CONVERGENCE DRIVERS
Large end-users have put pressure on the IEC/PAS 62591 and ISA100 groupings to provide a convergence route map. There are sound commercial and operational reasons for such convergence and the advantages of such convergence appear to be mutually beneficial for both end-users and vendors. From an end-user perspective the benefits include: • A wider choice of field instrumentation since the vendor

Table 1. Comparison of devices and roles: WirelessHART vs. ISA-100.11a.

WirelessHART Device
Field device Adapter

ISA-100.11a Role
2

Device
Field device. Adapter.

Role3
Data provider and/or consumer. Converts the (wired) legacy device protocol to ISA-100.11a protocol enabling the combination to become a data provider and/or consumer. Provisions devices that are set to factory defaults to enable them to join a wireless network. Provides, inter alia, wireless network range extension. Provides the interface between the wireless network and the backbone (plant) network Gateway Forms the interface between the wireless industrial sensor network and host network (Typically Ethernet). Also acts as a protocol converter for the host protocol (Foundation Fieldbus, HART, Modbus ...). Responsible for overall network, device and communications management. Implements either Router or Backbone router role. Facilitates secure system operation. Key management and authentication. Often the security manager and system manager will be implemented in a single device.

Native WirelessHART device. Typically functions as data producer and/or consumer and router. Adds wireless capability to existing wired HART device Adapters and field devices. Typically functions as data producer and/or consumer and router. Used to join a new instrument to an existing WirelessHART network and possibly to read field device PV and/or diagnostics.

Handheld

Provisioning device.

Router. Access point Provides the interface between the wireless mesh network and the Gateway. Provides the connection between wireless and the host network. WirelessHART to host interfaces such as Modbus – Profibus – Ethernet. May also perform network manager and security manager functions. Backbone router.

Gateway

Gateway.

Network Manager

Builds and maintains the mesh network. It identifies the best paths and manages distribution of slot time access. Manages and distributes security encryption keys. It also holds the list of authorised devices to join the network

System Manager.

Security Manager

Security Manager.

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pool becomes the totality of IEC/PAS 62591 and ISA100 manufacturers. • A more competitive supply side environment, for the same reason. • Lower on-site maintenance spares holdings because (large) end-users would not need to hold both IEC/ PAS 62591 and ISA100 field instrument spares. • Reduced investment in training since they would not need to train on both systems. • Reduced investment in infrastructure since they would not need to hold, for instance, hand-held devices for provisioning wireless devices. • Overall reduced lifecycle costs. From a vendor perspective the benefits include: • Faster global adoption of wireless technology since endusers would not be stuck in the choice dilemma. In an October 2010 report1 from ARC Advisory Group the potential revenue increase resulting from faster adoption was postulated at up to hundreds of millions of US Dollars. • A larger potential market since they would be able to market to all potential instrument purchasers.

Figure 1. WirelessHART typical system architecture.

CONVERGENCE STATUS
Both ISA100 (Working group WG12) and NAMUR have active programs in place to determine roadmaps to convergence and there is a working communication channel between NAMUR and ISA on the subject. The ISA100.12 convergence subcommittee initiated a Convergence User Requirements Team that submitted reports both to ISA and to NAMUR in 2010. NAMUR produced report NE133: Wireless Sensor Networks: Requirements for convergence of existing standards, addressing the issue. In 2010 NAMUR also entered into discussion with WIA-PA with a view to that standard also being included in convergence discussions. Can 1 340 000 000 (that’s approximately 20% of the world’s population) ever really be wrong?

Figure 2. ISA-100.11a typical system architecture.

WHAT ARE THE DIFFERENCES?
Perhaps the starting point to answering this question is to look at where WirelessHART and ISA-100.11a originated. In the case of WirelessHART, at a simplistic level, it was developed as a wireless extension to the existing wired HART communications protocol. That has some impact on its applicability, design and even on the level of security incorporated into the standard. In the case of ISA-100.11a it evolved as probably the most obvious member of the ISA100 standards family. That means that it was envisaged as a part of a much greater whole than WirelessHART. For instance, ISA100 also embraces the use of wireless for real-time field-tobusiness systems for interfacing work order systems, Control LAN, business LAN and voice. It was also in its infancy as the greater need for security for plant control systems was rearing its ugly head and while the world was busy running out of IPv4 addresses. That means that

“ISA100.11a offers a vaster coverage and broader view of process automation solutions” Gengyun Wang

Table 2. Blue team and Red team – key players in each corner.

WirelessHART ABB Elpro Emerson Endress+Hauser Pepperl+Fuchs MACTek Phoenix Contact Siemens

ISA-100.11a Fuji Electric Gastronics GE Honeywell Nivis R3 Sensors Yamatake Yokogawa

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WIRELESS

perhaps more emphasis was put on embedding security into the standard and that IPv6 addressing is embraced. Unlike WirelessHART, ISA-100.11a supports the concept of sensor network subnets, offering greater expansion potential. A detailed technical comparison of WirelessHART and ISA-100.11a performed as part of Gengyun Wang’s MSc thesis4 concludes that “ISA100.11a offers a vaster coverage and broader view of process automation solutions” and cites aspects such as latency minimisation, management of QoS, security and object orientation. Table 1 shows typical devices and device roles for each of WirelessHART and ISA-100.11a. Unfortunately, with the final draft of WIA-PA only released in October 2011, there is insufficient information in the public domain to include comparative details for WIA-PA. Figures 1 and 2 respectively show typical system architectures for WirelessHART and ISA-100.11a. The terminology and purpose of devices differs a little between the standards, and in many cases a single device may perform multiple roles (for instance a WirelessHART Gateway may actually embody Adapter, Gateway, Security Manager and Network Manager), so Table 1 and Figures 1 and 2 should be considered as comparative guidelines only. Readers should refer back to the standards themselves for a deeper understanding of these roles.

At the same time there is the growing concern about eavesdropping on industrial wireless for the purpose of sabotage. Over and above the use of 128-bit security keys, which help to foil eavesdropping attempts, secure industrial wireless uses channel hopping, slow channel hopping, channel whitelisting and blacklisting. These channel hopping communication strategies are handled by the Network Manager or System Manager and there are some significant differences in the complexity and configurability of channel hopping strategies between WirelessHART and ISA-100.11a.

ABOUT THE AUTHOR

TAKE THE PLUNGE
At the start of this article I posed the question: “So should you wait to adopt wireless or should you make an informed decision now and live with that?” Here is my take on it. If I had a plant where it made economic sense (based on total lifecycle cost) to install a wireless sensor network for some field instruments – perhaps for location reasons (say an effluent plant some distance away from the main operations), or for environmental reasons (signal cabling being damaged by heat / vapours / corrosion ...) or by virtue of moving parts (where sliding contacts, rotary kilns, catenaries and the like can be eliminated) – then I would take the plunge. Which technology would I plump for? If the majority of my wired field instruments were already HART devices I would stick with HART. Otherwise I would go the ISA-100.11a route. Would I bet on complete convergence and interoperability between WirelessHART and ISA-100.11a field instruments and infrastructure in the next five years? No. Would my investment be maintainable and the technology selected supportable for 10 years? Almost certainly. So what are you waiting for?

CHANNEL HOPPING
One of the challenges that secure industrial wireless communications has to address is that of ever-increasing traffic on the unrestricted 2,40 GHz ISM band on which all of these industrial wireless standards are built. This same band is shared by Zigbee, Wi-Fi, Bluetooth, smartphones, wireless telephone handsets, security cameras, baby monitors, remote controls and a plethora of other devices. Simply put: the airwaves are crowded in this band.

Andrew Ashton has electrical, mechanical and business qualifications and has been active in automation and process control since the early 1980s. Since 1991 he has headed up a company that has developed formulation management systems for the food, pharmaceutical and chemical manufacturing industries and manufacturing solutions involving the integration of various communication technologies and databases. Developed systems address issues around traceability, systems integration, manufacturing efficiency and effectiveness. Andrew is a contributing editor for SA Instrumentation and Control.

REFERENCES
Reference Organisation 1 ARC Consulting 2 3 4 Resource ARC Brief: ISA100 and Wireless Standards Convergence HART Communication Foundation The Components of WirelessHART technology International Society of Automation ISA-100.11a-2009: Wireless Systems for Industrial Automation: Process control and related applications Chalmers University Of Technology Report No. EX036/2011: Comparison and Evaluation of Industrial Wireless Sensor Network Standards ISA100.11a and WirelessHART URL http://www.arcweb.com http://tinyurl.com/5rm2zmv http://tinyurl.com/6dg3jas http://tinyurl.com/6bo6dnc

SOURCES & RESOURCES
Organisation HART Communication Foundation International Electrotechnical Commission Resource General information on HART and WirelessHART IEC 62601: Final Draft: Edition 1.0 2011-08: Industrial Communication Networks – Fieldbus Specifications – WIA-PA Communication Network and Communication Profile ISA100, Wireless Systems for Automation Background, registered devices, FAQ. URL http://www.hartcomm.org

International Society of Automation ISA100 Wireless Compliance Institute

http://tinyurl.com/66ht4p8 http://www.isa.org/ISA100 http://www.isa100wci.org

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WIRELESS

Wireless Ethernet communications
IN THE INDUSTRIAL, UTILITY AND ITS INDUSTRIES, THERE HAS RECENTLY BEEN A MIGRATION TOWARDS USING ETHERNET AS THE NETWORK OF CHOICE.
As a world standard, Ethernet is the logical choice as more and more manufacturers start to develop hardware with Ethernet interfaces. With the mechanisms inherent in Ethernet, a network can be installed and configured for almost any application. Ethernet provides redundancy, prioritisation, VLANs, and many other options that can enable a single network to be used for everything from critical applications such as control and automation to less important applications such as email or simple file transfers. However, at times Ethernet connectivity will be required in remote locations or areas where it is difficult or impossible to lay physical cabling for connectivity. This could be due to existing structures, terrain or a variety of other factors. Also at times connectivity is only required for a single device to send very small amounts of non-critical data, and then it is sometimes not feasible to lay cable. using wireless rather than physical cabling, and these need to be taken into consideration.

STABILITY OF THE LINK
One of the biggest disadvantages when using wireless communications is the stability of the link. Wireless links are adversely affected by external conditions such as weather or surrounding buildings and this must be taken into account on installation. 802.11 links require line-of-sight between the antennas and so must be kept away from surrounding buildings. Common misconceptions when using wireless are that the signals travel in a completely straight line without dispersion, and that wireless antennas that can “see” each other through very tight gaps should still be able to connect strongly. This is not the case, and is due to a phenomenon with wireless communications called the Fresnel zone. If a direct lineof-sight (DLoS) line is drawn between the antennas, the Fresnel zone will occupy a large area around the DLoS, sometimes also called the Radio Line of Sight. As a rule of thumb 60% or more of the Fresnel zone must always remain clear of obstructions to achieve a strong, stable link. Besides fixed obstructions such as buildings or trees, temporary obstructions such as low lying cloud cover or heavy rainfall must be considered. In the case of adverse weather, the stability of the link could be greatly affected or it could drop completely. High winds can also pose a problem if antennas have not been properly installed . Shifting antennas can cause the link to fail completely, especially in the case of long distance links. An antenna shift of a couple of centimetres can put it completely out of alignment.

ETHERNET ALTERNATIVES
In cases like these it is necessary to look at an alternative communication medium to copper or fibre optic cabling, such as wireless. Wireless communications come in various forms. Wireless can be used for relatively short distances up to approximately 3 km, in which case 802.11, more commonly known as WiFi, will be recommended. To set up wireless over slightly longer distances than WiFi, up to around 12 km, WiMAX, also known as 802.16/e, is the common choice. To reach distances greater than this, cellular or satellite connections can be investigated. These allow connectivity to reach almost any location on the globe, depending on the application. One of the most obvious advantages when using WiFi, or any wireless communications technology, is the lack of cables. When an overflow meter 3 km away from the main network needs to be connected in order to send an update once every hour, it is not feasible to lay thousands of rands of cabling. In these situations wireless communications can save time and money. However, there are disadvantages to

ADVANTAGES AND DISADVANTAGES.
These are the common advantages and disadvantages that need to be considered for any wireless scenario, whether basic 802.11, WiMAX, cellular or satellite wireless.

WI-FI
802.11 wireless communications do not need to be licensed, which can be both an advantage and a disadvantage. Other advantages are that there are no hidden costs, and 802.11 hardware can simply be purchased and installed at the user’s discretion. The disadvantage, however, is that interference can be caused by other

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surrounding wireless devices as it is legal for anyone to setup their own wireless. For this reason a site survey including a wireless frequency scan is essential when planning for a wireless installation. A frequency scan will show what frequencies are being used in the area, and the installer can then determine which frequency to use so as to avoid interference. In more populated areas it is worth performing frequency scans every few months to make sure that no new wireless systems have been put in place that could cause interference. WiFi is not considered the strongest or most stable of links, and so should not be used for critical applications where a link failure could cause major problems, site shutdowns or even death. However, in cases where noncritical remote connections are required, 802.11 wireless can be an excellent time and money saver.

WIMAX
WiMAX, or IEEE 802.16, provides a wireless mesh network with a much greater range than 802.11 wireless – up to 12 km radius or more, depending on the hardware. WiMAX also does not require line-of-sight, although bandwidth and performance may be affected in a non-LoS scenario, depending on the environment. The 802.16e Enhanced standard also calls for an allowance for WiMAX subscribers to be able to travel at up to vehicular speeds of 120 km/h and to be able to cross over to different WiMAX base stations without renegotiating the link. This is different to 802.11 wireless which has to renegotiate the link to each new access point as it moves around. This means that for applications such as VoIP (Voice over IP), 802.11 it is not suitable if users need to hold calls whilst moving around the site. However, 802.16e will allow this movement between different WiMAX base stations without dropping the call. The disadvantage to 802.16 (which again could also be an advantage) is the requirement that frequencies be licensed for specific areas before they can be used. This licensing is handled by ICASA, the regulator for the South African communications sector, or the equivalent body in countries other than South Africa. This licensing can prove to be a time consuming task, and also raises the cost of the solution. However, having a licensed frequency means that interference from an outside source cannot happen legally. This means that interference on a WiMAX link is less of a concern than with 802.11 WiFi. Finally WiMAX will require regular renewals of subscription fees for the licensing of the frequencies, unlike WiFi which is a once off payment for the hardware (not counting spares or possible repairs on the hardware).

addition if any one of the links has a problem, the end device would be unreachable. The use of WiMAX or WiFi is not even an option in this case. In these situations either cellular or satellite links would be an option, both having their own advantages and disadvantages. They can be used almost anywhere to gain network connectivity. Cellular communications will still require a cellular tower within range to get a connection, but nowadays most areas will have cellular towers in range. For satellite, all that is needed is an unobstructed view of the sky. However, both of these technologies come with disadvantages. Unlike WiFi they incur monthly costs. Cellular connections require the user to pay for the amount of data transferred, whilst satellite connections require a monthly rental cost. Also, both of these technologies rely on a third party and the end user does not have direct control in the case of problems.

WIRELESS
Although wireless might not always be the first choice, especially in mission-critical applications, it can be one of the best methods when transferring non-critical data from remote sites, or areas where physical cabling is not feasible. However, the use of wireless links should only be considered after proper planning and consideration of all the factors involved. Site surveys are essential in order to properly assess the installation requirements prior to purchasing of equipment, and professional installers must be used to ensure the antennas are correctly mounted so as to provide a strong and stable link.
For more information contact Tim Craven, H3iSquared, +27 (0)11 454 6025, info@h3isquared.com, www.h3isquared.com

CELLULAR OR SATELLITE
In some cases WiFi or even WiMAX cannot achieve the distances needed. A single camera or PLC in a remote area 100 km away from a network would need many different WiMAX links, all back to back, in order to use WiMAX. The expenditure required to set this up and the ongoing maintenance required would not be feasible. In

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WIRELESS

Wireless technology in industrial automation
YOKOGAWA WHITE PAPER.
The use of wireless technology in industrial automation systems offers a number of potential benefits, from the obvious cost reduction brought about by the elimination of wiring, to the availability of better plant information, improved productivity and better asset management. However, its practical implementation faces a number of challenges: not least the present lack of a universally agreed standard. This article looks at some of these challenges and presents the approach being taken by Yokogawa. of distributed control and plant asset management spread throughout the plant. Another important benefit is improved workforce productivity. The fact that there are no wires leads to reduced installation and commissioning effort, while the fact that workers – whether operators or maintenance engineers – can now be truly mobile. Improved plant management results from the improved availability of video surveillance and people tracking for better safety and security, along with a reduced need to access hazardous or remote plant areas. Of all the elements highlighted above, wireless sensor networks are currently attracting the most attention as most of the benefits directly relate to this area. Apart from the benefits of eliminating signal and power wiring, wireless sensor networks open up measurement applications in sites that are hard to access, or where the wiring cost cannot be justified. They can also prove invaluable for the modernisation of existing facilities, for temporary installations, or for locations where a power source is not available. Wireless sensor networks offer enhanced plant asset management through the freeing up of cable resources for higher-priority measurements in existing installations, the replacement of many traditional pressure gauges and temperature indicators and the ability to make measurements that could not previously be justified. There is also a reduction in ‘blind spots’ through the ability to make measurements on rotating or moving equipment and in remote locations. A further point is that, once established, wireless sensor networks are scalable: additional sensors can be added at low cost and temporary measurements can be incorporated for process diagnostics and optimisation.

THE WIRELESS LANDSCAPE
In order to understand the ways in which wireless technology can aid the implementation of industrial automation systems, it is first important to clarify what is meant by the word ‘wireless’ in this context. Essentially, wireless can act at several levels within a plant: • RFID – at the simplest level, radio-frequency identification can aid asset inspection and tracking, safety, security and location. • Wireless sensor networks – this is possibly the area where most attention is currently being focused and embraces aspects such as condition monitoring, wireless instruments and measurements. • Wireless LANs, covering areas such as mobile operator terminals, data-logging, security, maintenance and IT. Wireless WANs, including long-distance broadband backhaul and high-bandwidth video applications. When implemented within a typical plant, each of these aspects can bring benefits as well as new opportunities. For example, the fact that plant and process information is available anywhere via wireless sensor networks leads to greater quality of information, with the benefits

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WIRELESS STANDARDS
In developing a universal standard for industrial automation wireless networks a number of challenges emerge, not least because most licence-free wireless networks use the same 2,4 GHz bandwidth and many sensor networks are based on the IEEE 802.15.4 standard. Clearly there are concerns about co-existence and interference leading to reliability and latency problems and about multiple protocols sharing the same bandwidth.

OBSERVATIONS
In open terrain with no obstacles a range of ±600 m can be expected in pipeline applications, a higher antenna position improves communication quality, a range of 50-100 m can be expected near to plant steelworks, a range of >50 m can be expected inside infrastructure and inside plant steelworks a range of <<50 m can be expected. Users have concerns about security with the potential for jamming, sabotage and the compromising of network privacy, but also want systems that are open, backwards compatible, interoperable and cost effective to implement. One thing is certain: the industry must strive to establish a global standard that covers communication from sensor to control room, is designed with security in mind and is end-user driven. Unfortunately, this ideal scenario is unlikely to occur in the immediate future since two standards are currently being used by different industry players –Wireless HART and ISA100.11a. Although the two have some features in common, in reality they are very different. In particular, the scope of ISA100.11a is much wider. Whereas Wireless HART focuses on monitoring from WI HART enabled field instruments, ISA100.11a offers the scope to cover everything from field instruments to control-room integration. Moreover, it is compatible with a variety of protocols including Foundation Fieldbus, Profibus, Modbus and others as well as HART. It allows over 1000 devices in a network compared to only around 250 with Wireless HART. Yokogawa is committed to supporting ISA100.11a as a preferred single international standard. In addition the ISA99 Security for Industrial Automation and Control Systems standard will be implemented to warrant overall security and privacy.

have been carried out to establish the characteristics of 2,4 GHz wireless transmission within typical environments such as refineries and chemical plants, from which a number of important lessons have been learned: 2,4 GHz radio is sensitive to the presence of obstacles (pipe work and other metal structures, for example); wireless is unlikely to be affected by the local climate and response time is a useful indicator of the radio transmission conditions. As a result of this experience, Yokogawa is pressing ahead with the development of wireless-based field instruments and access points as the initial stage of a ‘total solutions’ approach. It is implementing partnerships with other organisations to facilitate aspects such as the integration of auxiliary sensors as well as mobile worker networks, integration of surveillance camera systems and long-haul inter-plant connections. A lesson learned from conducted wireless sensor field trials and real project implementations of mobile worker networks is that obstacles may affect the reliability and hence the quality of service of the network. Specifically, the proper location of access points and other devices and the possible need for inclusion of repeaters should be assessed beforehand. This is particularly critical for the successful operation of the mobile worker network where roaming is essential. It is expected that wireless sensor networks will gradually be adopted by the process industry. Although ISA100.11a is designed to accommodate control applications, initially the majority of applications will be for monitoring due to battery life limitations. In existing installations the benefits are obvious: measurements for process monitoring and condition monitoring can be added where the existing infrastructure cannot accommodate them. State of the art Greenfield sites are expected to be equipped with intelligent instruments that are mostly connected through wired instrumentation systems such as Foundation Fieldbus, but with several wireless networks for process and condition monitoring present.

SUMMARY
Yokogawa is committed to the emerging wireless technologies as a way forward in implementing total solutions with wireless sensor networks as a key element in providing DCS and plant asset management ‘Anywhere, Anytime’. The Yokogawa values of openness, inter-operability and reliability will be provided by systems based on the ISA100 standard with Yokogawa assuming total wireless solution responsibility.
For more information contact Johan van der Westhuizen, Yokogawa SA, +27 (0)11 831 6300, johan.vanderwesthuizen@za.yokogawa.com, www.yokogawa.com

WIRELESS STRATEGY
Yokogawa has developed Star, Mesh and a combination of the two networks, with the emphasis on self-healing network configurations and high security levels. It is also investigating long battery life for field operation and longer sensing ranges (up to 5 km). Field trials

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RELAYS

Omron’s new solid state relay
Omron has introduced a range of industrial high-power solid state relays (SSRs) that offers extended life and greater reliability thanks to a unique surge pass circuit. Omron’s SSRs are often required for heating control in industrial processes where products require drying or baking, for example within the food and beverage industry and also in the production process of flat-panel display equipment in the semiconductor industry. In such instances, furnaces and ovens are heated electrically using high currents passed through Ni-Cr alloy wire elements, or by halogen lamps.

IMPERVIOUS TO POWER SURGES
SSRs, are known to be susceptible to (power device) damage in the event of high surge noise. As continuity is vital for productivity, Omron has made available an SSR which is able to handle surge noise. The new G3PH industrial high-power solid state relay offers superior resistance to surge voltages thanks to an original surge-pass circuit that gives the G3PH outstanding endurance and protects it against surge voltages in excess of 30 kV.

COST EFFECTIVE SOLUTION
The non-zero-cross version of the G3PH, in combination with the Omron EJ1 modular temperature controller and the G3ZA multichannel power controller, offers a cost effective solution compared to the more expensive option of using a standard power controller. The G3PH series also offers other benefits, including replaceable power device cartridges for ease of maintenance, zero-cross load switching, built-in heatsinks and operational indication. It conforms to all current safety standards, including CE, cULus, and TUV.
For more information contact Terry McIntosh, Omron Electronics, 086 066 7661, terry_lynn_mcintosh@eu.omron.com, www.industrial.omron.co.za

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Advanced standalone motor protection relays

In order to meet the increasing demand for safety standards in modern industries, many end-users are looking for methods to eliminate the need for electrical staff to open MCC cubicles in order to determine the nature of a motor trip or to adjust motor protection setting parameters. NewElec’s KE range protection relay can have an optional door mounted fault indication display as well as an infrared data acquisition and transfer facility (IRDA) that is both inexpensive and easy to use. A transceiver IRDA is simply attached to a communications cable that connects to a laptop. The housing on the IRDA is magnetic to fasten to the door mounted RDU so that the operating staff may adjust, read and save data directly. The KE is an advanced motor protection relay that is also capable of recording real versus apparent power utilisation for analysing motor efficacy. It has outstanding protection benefits that include earth insulation lockout, user selectable instantaneous or IDMT earth leakage tripping characteristics, programmable limitation to start attempts and up to 2000 event records as well as a separate listing of the last 60 faults together with current and voltage details. In flameproof applications, the IRDA saves time since the flameproof door need not be removed to achieve the results mentioned. For utilisation underground, NewElec has developed an explosion proof version of the IRDA that allows the operator to download motor information to a USB memory stick device.
For more information contact Luc Dutrieux, NewElec, +27 (0)12 327 1729, sales@newelec.co.za, www.newelec.co.za

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Seal of approval for Imana Foods
HACCP ACCREDITATION WITH HELP FROM WONDERWARE.
Since its inception in 1984, Imana Foods has expanded in leaps and bounds but to realise its dream of ‘Redeeming Eden’ through caring for its consumers, traders, suppliers and employees, the company needed to gain certification in internationally recognised quality and food safety standards such as ISO 9001 and HACCP (Hazard Analysis, Critical Control Point Methodology). This in turn, required detailed traceability of production processes and materials. Imana Foods is a member of the Kwaden Investments group and is supported in systems development by a sister company, IT Dynamics, which was tasked with providing a systems solution for product traceability. The scope of the project was to include scada, MES and enterprise integration initiatives that would place Imana Foods in control of its existing production and ready to meet future business and operational challenges.

SOLUTION REQUIREMENTS
To achieve the expressed goals, Imana Foods would rely on a scalable system design where there was to be minimal data duplication between the ERP and production systems. The ERP system would still be responsible for the queuing and prioritising of work orders. All incoming raw materials needed to be lot managed and scanned into their respective storage locations for tracking into the blenders. This would need to be done for all materials used in the more than 150 recipes in Imana Foods’ range of products. Bags of work in progress from the blenders needed to be individually weighed and tagged with bar-coded labels for tracking through to the packing lines. Full traceability would then be achieved by ink jet coding the finished product. One of the most important requirements of the system was that it should guide operators on ‘what to do when’, so that printed instructions would no longer be necessary. “The scada system would verify all transactions and would be the source of daily shift reports,” says Irvine.

BACKGROUND
Prior to this project, team leaders had no clear visibility into the blending operations. “Blenders worked from instructions printed manually from the ERP system,” says Murray Irvine, project engineer at IT Dynamics. “This meant that the work schedules depended on the reliability of a printer, and the recipe integrity on the reliability of the operator. On the ingredient side, while every effort was made to stick to a first-in-first-out transfer of raw material, this was not always guaranteed and stock discrepancies were identified at the end of every month. There was no real traceability.”

SOLUTION SELECTION PROJECT GOALS
For the Imana Foods’ leadership team, faced with an expanding marketplace demanding increased food safety focus, there was a need to review its production operations. This led to the launching of a blender project with the following goals: 1. Full traceability of all materials entering and leaving the savoury powders blending process. 2. Visibility into the blending process. 3. Production data (from Wonderware) to be linked with the company’s ERP system for the automation of realtime work order administration. • HACCP certification. • Improve the quality of finished goods. • Reduce inventory discrepancies. “A small InTouch application was already in use monitoring PLCs in the factory,” explains Irvine. “However, that was not the deciding factor for solution selection. For Wonderware, the availability of the PEM (Production Events Module), FMM (Formula Management Module) and the Sequencer objects were core to the solution. The decision was made to go with Wonderware and the purchase of all the other Wonderware solutions necessary to this project (System Platform, ActiveFactory, Historian and Information Server). Paul Alcock, Imana Foods’ MD also believed that Wonderware’s technology was a very good match for the company’s future goals.” PEM enables users to record production events into a standard database and to know the exact process conditions at a certain step. Users can also report forward

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and backward genealogy of materials, equipment and production events. The Sequencer object coordinates tasks that must be executed in a certain sequence or order of operation. It is designed to configure, execute and manipulate a sequence of operations associated with attributes from multiple application objects running within an industrial application. The Sequencer exposes a comprehensive set of attributes that allows users to create SmartSymbols and regular InTouch animations to monitor and control the Sequencer operation. PEM, FMM and Sequencer are now all part of Wonderware’s Equipment Operations Module. Mobile computers for use by the operators and mobile label printers were both sourced from Intermec due to good service levels, pricing as well as being the only supplier that could support both narrowband and broadband. On the technology front, Imana Foods chose barcodes over an RFID solution. This decision was based on price and the fact that RFID as a technology is not yet mature enough to give an easy, viable solution. For wireless networking with the mobile computers and printers, broadband was chosen because narrowband could not cope with the InTouch-based operator interface even though graphics and complex displays were eliminated.

Figure 1.

IMPLEMENTATION
Because of the scope of the project, many disciplines and skills would be required including a project manager, engineers, business analysts, software developers, network engineers, instrumentation technicians, network administrators and technical support personnel. Figure 1 shows the system topology. The MPI network was expanded to include the blenders, resulting in 22 PLC nodes being connected to the Wonderware system. The blending area was set up for a wireless infrastructure with handheld PCs and wireless label printers. The handheld PCs are running a managed InTouch application through Microsoft Terminal Services which resides on the Application Object Server. The office computers are connected via the Wonderware Information Server portal to allow viewing of custom and PEM reports. The system is fully integrated with the company’s ERP system which passes the recipe information to the formula manager which is queried for each ingredient on a bag-by-bag basis in order to load the blender. The PEM objects store acknowledged data from the operators and provide the traceability for lot-tracked raw materials as well as for finished goods. The Sequencer object is used to sequence the blend process. The ERP system is sent the resultant blending process information in order to close the loop and monitor stock levels and any accounting variance anomalies. In addition, custom reports calculate equipment utilisation from time data captured in the Wonderware production database. “The most important item of information supplied by the system is the raw material lot tracking data as fed into the blenders,” says Irvine. “This is giving Imana Foods a far greater level of control than previously.”

On the handheld units, the blender operators are shown the recipe details as well as an ingredient by ingredient breakdown of what they have to scan or acknowledge as having been fed into the blender. The blender is on load cells which register its weight increase as it is loaded. There are built-in timers that capture the total blend time as well as any additional mixing times that may be required. When being unloaded, platform scales underneath the blenders register the weight of the offloaded bag and this data is captured by the PEM objects.

BENEFITS
• HACCP certification was achieved within three months of going live. • Better insight into the blending operation in the factory from a material usage variance point of view. • Improved raw material stock control. • Real-time blend closure in the ERP system. • Factory procedural deviations are highlighted. • More consistent product quality from following recipes exactly. • Improved management of the physical blending process. • Proper temperature control of sensitive blends.

CONCLUSION
Imana Foods has achieved all its initial project goals and has ambitious plans for expanding and extending the capabilities of the system. This was made possible through the use of a flexible platform in the hands of a very capable project team which amply demonstrated that technology is no longer a barrier to achieving business and operational objectives.
For more information contact Jaco Markwat, Wonderware Southern Africa, 0861 WONDER, jaco.markwat@wonderware.co.za, www.wonderware.co.za

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EtherCAT-based CNC solution from Beckhoff
TWINCAT 3  CONVENIENT EMBEDDING OF CNC IN THE OVERALL SYSTEM.
The TwinCAT automation software forms the universal platform for the control of PLC, motion and CNC functionalities, visualisation, safety, measurement technology, condition monitoring and robotics. In version 3 of TwinCAT, the engineering is facilitated by the integration of all tools into one development environment based on Microsoft Visual Studio, into which the configuration and the programming environment for IEC 61131 are integrated. Further languages are available for programming in C and C++. Likewise, Matlab and Simulink can be used as a development platform for controllers and filters. Microsoft Visual Studio offers the possibility to use modern tools for software engineering. This way, using Team Foundation Server, it is possible to track both changes in the source code or to manage software projects. An editor for the convenient configuration and programming of safety applications is also integrated. The safety programs can be written in function block language or in C; in addition, the safe drives can be configured here. Calculation tools for the new machine directive are integrated and facilitate the necessary calculations. The PC and EtherCAT-based CNC solution from Beckhoff integrates all machine functions into one hardware and software platform, characterised by high performance, openness and flexibility. The universal TwinCAT automation software and the fast EtherCAT fieldbus system, Industrial PCs, control panels, I/O components and drive technology combine to offer a complete solution for CNC machining. This way, the productivity of manufacturing facilities can be increased, the controller design becomes ‘leaner’ and the costs for hardware, commissioning and maintenance are lowered. The Beckhoff CNC platform is suitable for all industries, processing technologies and machine kinematics: from compact dental machining centres and woodworking machines to complex plasma cutting and welding machines. The CNC solution from Beckhoff is scalable to meet the exact requirements of modular and multifunctional machine concepts.
For more information contact Conrad Muller, Beckhoff Automation, +27 (0)11 792 3374, c.muller@beckhoff.com, www.beckhoff.co.za

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Schneider Electric’s StruxureWare for Data Centres
Schneider Electric has introduced StruxureWare for Data Centres, a management software suite designed to address all aspects of the data centre physical infrastructure needed to maximise availability and efficiency. The product combines Schneider Electric’s Data Centre Infrastructure Management (DCIM) and Data Centre Facility Management (DCFM) software tools to provide data gathering, monitoring, automation and planning and implementation functionalities enabling an integrated and multifaceted view of all the mission critical physical systems of the data centre. This new offering empowers managers by giving them access to all the data and tools they need to operate a more reliable, efficient and productive facility. “Data centre environments traditionally rely on isolated management tools that require the knowledge and experience of numerous IT and facility professionals leveraging specialised management dashboards to obtain the information they need,” says Kevin Brown, vice president, data centre global offer and strategy, Schneider Electric. “With StruxureWare for Data Centres, Schneider Electric is providing a toolset from which the data centre manager can access and manage across the domains of the IT room. This management software suite delivers comprehensive, accurate real-time data enabling action to be taken based on the complete picture of the data centre.”

STRUXUREWARE OPERATIONS SUITE
StruxureWare Operations is an enterprise DCIM framework providing a scalable and fault tolerant solution encompassing all aspects of modern data centre management, ranging from asset and capacity control over dashboards to smart phone integration. The framework provides the ability to forecast future budgets for expanding and consolidating data centre operations as well as the impact these changes would have on various aspects of the facility. Through transparency into data centre key performance indicators (KPIs), customers are assisted in making informed decisions about service level agreements and controlling operational costs. StruxureWare for Data Centres provides users with multiple options to create and share a variety of management dashboards. These range from very detailed, domain specific dashboards for electrical power and cooling to higher level perspectives relevant to overall data centre and single site energy management. Additionally, the dashboards offer multi-site options to support comparisons and corporate energy governance activities.
For more information contact Jacqui Gradwell, Schneider Electric SA, +27 (0)11 254 6400, jacqui.gradwell@schneiderelectric.com, www.schneider-electric.co.za

STRUXUREWARE MONITORING SUITE
The StruxureWare for Data Centres monitoring suite offers a series of core and advanced options for real-time visualisation, notification and reporting of the physical facility and data centre systems. • StruxureWare Central: a fundamental, vendorneutral software system that provides a unified view and analysis of complex IT physical infrastructure that communicates with building, power, enterprise and network management systems to ensure quality and increase energy efficiency. The new StruxureWare Central for Blackberry and iPhone apps provide data centre managers with the same active alarms, alarm history, device groups and current sensor values found in the StruxureWare Central desktop user interface without being tied to a computer screen. • StruxureWare Power and StruxureWare Cooling: these advanced options build on Schneider Electric’s existing power monitoring and cooling automation offerings by adapting to the unique conditions within a data centre.

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Westermo announces the release of its Lynx DSS
DEVICE SERVER SWITCH PROVIDES IP CONNECTION TO LEGACY SERIAL DEVICES AND ROUTING FUNCTIONALITY.
Westermo has announced the release of its Lynx DSS compact device server switch for connecting legacy serial control and telemetry systems to the latest IP networks. With low data rate serial communications being replaced by higher bandwidth IP networks, the Lynx DSS helps to preserve any investment in existing systems and add functionality by supporting new equipment that requires additional bandwidth. Lynx DSS is an industrial Ethernet switch for managing applications with a combination of IP and serial connections replacing the need for multiple units. Powered by an updated version of the Westermo WeOS operating system, the device delivers enhanced serial to Ethernet connectivity support for dual serial networks, modem replacement functionality and Modbus gateways. Legacy devices can be connected via two serial ports; one configured for RS-232 and the other for either RS-232 or RS-422/485. Two versions are available, the L208-F2G-S2 and L108F2G-S2. The L108 supports a range of layer 2 switching functions that provide resilient, rapid recovering redundant ring Ethernet networks. The unit has four 10/100 Mbit/s ports and two further ports can be fitted with either Gbit or 100 Mbit SFP transceivers. In addition to these functions the L208 provides additional layer 3 networking functionality including routing, firewalls and VPN remote access. These functions support users wanting to communicate over potentially insecure networks and also help to prevent users inadvertently connecting to the wrong network. Suitable for deployment in extreme operating conditions, the device is type-tested to meet industrial EMC, isolation, vibration and shock standards and approved for use in industrial applications including Cenelec EN 50121-4 certification for railway trackside installations. The Lynx DSS has a

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wide operating temperature range from -40 to 70°C, no fan or other moving parts and a full metal IP40 enclosure. The WeOS operating system has been developed as a cross platform solution. Available on the Westermo RedFox, Wolverine, Lynx and Falcon products, it provides a future proof and scaleable solution for industrial networking requirements. Low power requirements results in a reduction in running cost over the life of the unit and a footprint size

of only 100 x 50 mm makes the unit easy to incorporate into machines and existing applications. A wide operating range of 19-60 VDC increases the scope of suitable applications.
For more information contact Bob Petrie, Throughput Technologies, +27 (0)11 705 2497, bob@throughput.co.za, www.throughput.co.za

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Siemens expands Ethernet switch range
EFFICIENT SWITCHES CONNECT AUTOMATION NETWORKS TO THE COMPANY’S IT SYSTEM.
The Siemens Industry Automation Division has expanded its range of industrial Ethernet switches with a new range of 19-inch rack devices. The Scalance-X-500 switches are especially suitable for configuring large automation networks and connecting them to the company’s IT system. Typical areas of application are network configuration and coupling in production and process systems in industry sectors such as mining, logistics and transport. The new switches are equipped with fully modular ‘Hot swappable’ 4-port technology for electrical and optical media modules. Scalance XR528-6M with two height units has six slots for 4-port media modules, Scalance XR55212M has three height units and twelve slots. Up to 24 or 48 end devices and network components with speeds of 10-1000 Mbit/s can be connected. In addition, both device versions offer four slots for SFP+ (Small Form-factor, pluggable) transceivers with a 10 Gigabit/s Ethernet. The new switches have functions for industry-specific communication and offer layer 2 and layer 3 functions, such as static and dynamic routing for communication with networks on the company’s IT system. The devices provide numerous redundancy functions, such as ring redundancy, RSTP (Rapid Spanning Tree Protocol) and MSTP (Multiple Spanning Tree Protocol), supplemented with standby functions and VLAN. The external 300 W power supply unit, PS598-1, supplies the Scalance-X500 switches with power. This is either installed above or below the switch or docked on the back directly using a plug-in connection. The availability of the switches increases when two redundant network devices are used. To activate layer 3 functions, an optional removable medium with key function (Key Plug) is used. This contains the activation licence and allows configuration data to be saved.
For more information contact Keshin Govender, Siemens Southern Africa, +27 (0)11 652 2412, keshin.govender@siemens.com, www.siemens.co.za

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Honeywell’s Experion Batch Manager
Honeywell has launched its Experion Batch Manager R410 solution, a comprehensive enhancement to the Experion platform, which is designed to improve batch process throughput and efficiency and reduce waste. It pushes batch control closer to the process by directly embedding it within the controller, reducing complexity and improving availability and overall system performance. Experion Batch Manager R410 offers increased throughput by reducing batch execution times through reductions in system latency by up to 80%. The solution is unique in its ability to execute a complete procedure within a redundant controller. Applicable to any process sequence, Experion Batch Manager not only functions 3-5% faster, but is more reliable and easier to maintain than typical server based solutions . A key new capability of the R410 solution is the native batch summary displays that are embedded directly into the system. These improve operability and reduce engineering effort. Improvements also include class based master recipes, which reduce the total number of recipes that must be created and maintained. Experion Batch Manager covers all levels of procedure heirarchy in the ISA S88 model. “With an increased demand for product specialisation, batch manufacturers need to be able to produce a wide range of products with different specifications, available on demand, and be able to quickly take advantage of new trends. Having a more flexible operation, which means being able to respond to changing customer needs quickly, helps batch manufacturers stay competitive,” said Steve McGeorge, product marketing manager at Honeywell. “Experion Batch Manager R410 delivers this flexibility by reducing cycle time as well as lifecycle and production costs.”
For more information contact Debbie Rae, Honeywell Southern Africa, +27 (0)11 695 8000, hsa@honeywell.com, www.honeywell.co.za

Ten Gigabit Ethernet
The new CAT6A connectors from Phoenix Contact with the integrated Quickon and Piercecon quick connection systems provide reliable data transfer rates of 10 Gbps, in conformance with the Ethernet CAT6A standard. These high performance components ensure fast and reliable connections locally. The new coding of the M12 connectors with Piercecon connection prevents incorrect insertion into existing M12 solutions. The connector profile for the Quickon quick connection system remains the same as for the commercially available RJ45 connectors. These freely configurable connectors can be connected without requiring any special tools. The extensive CAT6A product line includes M12 and RJ45 connectors for the cable and device ends. These are available with IP20 protection for office applications and a high IP6X degree of protection for industrial environments. The preassembled cables are available in different versions.

The difference between the CAT6A and CAT6A components that are available in the market should be noted. In a 10 Gb network a reliable and high quality data transfer channel is only obtained when using CAT6A components.
For more information contact Sean Hadley, Phoenix Contact, +27 (0)11 801 8200, seanh@phoenixcontact.co.za, www.phoenixcontact.co.za

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OPERATOR INTERFACES & HMI

HMI platforms evolve to take on new roles
The worldwide human machine interface (HMI) platform market continues to evolve to meet the needs of both discrete and process manufacturers and the OEMs that serve these markets. Rather than being just a standalone component, the HMI device is evolving into a platform that helps solve manufacturing problems to improve business performance. Furthermore, users are turning to open systems and commercial off-the-shelf technologies to meet their increasing demands for high performance, ease-of-use, and lower total cost of ownership. Although technological advancement will continue to be an important factor, the focus of manufacturers, processors, and OEMs has moved toward seeking solutions that help them manage their manufacturing operations, while dealing with the reality of having to pare back their in-house engineering and automation system support capabilities. In addition, global competitive pressures require users to increase integration of automation with other enterprise applications. Suppliers have responded to these requirements by providing HMI platforms that use object-based technologies and provide Internet access to move their solutions from standalone, application-specific platforms to become a key component of an automation solutions portfolio.

By Craig Resnick, Research Director, ARC Advisory Group.

MARKET DRIVERS
Increasingly, HMI platforms help users visualise key metrics and KPIs, such as overall equipment effectiveness (OEE) and energy savings, to help them quantify the benefits of

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their automation investments. These users are all too aware of global competition and escalating energy costs, as well as the need for automation equipment that can help them achieve more flexible production, while reducing environmental impacts. However, users must go through a business justification process before they can replace their existing, less efficient equipment. This business justification requires clear metrics regarding the return on investment (ROI) and return on assets (ROA) of each purchase. Increasingly, they use their new HMI platforms as the digital dashboard to visualise and quantify these metrics.

THE EMERGING DEMAND FOR HMI PLATFORMS
Today, HMI platforms – in conjunction with programmable logic controllers (PLCs) or more highly functional programmable automation controllers (PACs) – have become a primary building block for industrial automation systems in many manufacturing plants. Increasingly, however, users want the HMI platform to serve not only as an operator interface window into the application, but as an enterprise integration tool. As the trend toward open systems in the automation and enterprise markets continues to unfold, the HMI platform emerges as a single device to support a wide range of applications. At the low end of the market (characterised by small, fully integrated, low-cost products), HMI platforms can form the basis of an embedded control product for a wide range of OEM product applications. At the high end of the market (characterised by manufacturing processes integrated to global operations), HMI platforms provide data and information visibility across the plant floor and throughout the enterprise.

components and performing extensive burn-in testing, so reliability should not become an issue until well along in the platform’s service life. Software reliability, however, is not measured as a direct function of time. It is achieved by eliminating design faults and performing extensive functionality testing and debugging. Unlike hardware, software reliability does not diminish over time. However, software reliability can be affected each time an upgrade is made. This has been an argument that bodes well for the HMI platform, as the embedded software has been included as part of the extensive functionality and burn-in testing is performed prior to delivery to the user. As a result, the HMI platform is not subject to continuous software upgrades that could negatively impact reliability.

OPERATIONS MANAGEMENT
End user companies are increasing their agility by accessing and visualising real-time information and applying it to speed up and improve operations. They are also integrating business, manufacturing, and production within the operations management realm. These users are deploying operations management solutions based on industry standards to standardise visualisation and IT infrastructure across multiple facilities. This standardisation of visualisation is a driving force in the growth of HMI platforms. These users seek to reduce IT and engineering costs by implementing rapidly deployable and easy-to-manage visualisation applications. They want to take the pain out of expanding and managing disparate systems by transforming their HMI platforms into enterprise-wide collaboration tools, without disrupting their current operations.

REDUCED WIRING AND SPACE PLUS EASY DESIGN AND MODIFICATION
Over the past 15 years, HMI platforms have displaced conventional operator input devices and display elements – such as hardwired push buttons, lights, and LED numerical displays – providing substantial savings in wiring and space. The tremendous cost efficiency of graphical display devices and commercial software technology has largely displaced hardwired panels and pushbuttons. The simplicity of the design and the flexibility afforded by the easily modified software programs also drive the market toward scalable HMI platforms in lieu of panels and pushbuttons.

MAINTENANCE
A key reason that HMI platforms are growing in popularity is their ability to lower maintenance time and expense for OEMs and end users. HMI platforms that support automation and enterprise applications can provide the control room operators and maintenance technicians with information to speed up maintenance operations and reduce interruptions. These HMI platforms provide maintenance crews with access to the company’s maintenance management system at either the control room level or directly at the machine, equipment, or unit level. Some HMI platforms are configured to incorporate HMI, configuration procedures, programming languages, and maintenance procedures. This provides a common interface, and allows the user to achieve the operational benefits of transparent integration between each domain. ARC’s upcoming latest worldwide HMI Software study, along with ARC’s worldwide Operator Interface Terminal study, addresses in depth many of the issues and trends relating to HMI platforms.
For more information contact Paul Miller, ARC Advisory Group, +1 781 471 1126, pmiller@arcweb.com, www.arcweb.com

HIGHLY RELIABLE HARDWARE AND SOFTWARE
With continuously shrinking component costs and improved designs, processors, and software-based systems, today’s HMI platforms offer compact configurations, flexible handling, rich features, and competitive pricing. They can also offer increased reliability, with mean times between failures (MTBF) for hardware components typically measured in years of continuous operation. Hardware reliability is achieved by minimising physical faults by eliminating failure prone

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Weather resistant panel PCs

Phoenix Contact has expanded its range of VMT 3000 panel PCs to include a device with a 26 cm (10.4 in) high resolution display with IP65 protection. This display was specifically developed for use under harsh industrial conditions and has a resolution of 1024 x 768 pixels. The panel PCs have an attractive enclosure manufactured out of solid die-cast aluminum. As a result of the dust protected and waterproof enclosure with IP65 protection, these panels are weather resistant and are insensitive to humidity and moisture. They can also be used in extreme temperatures ranging from -20 to 550C, which allows them to be employed outdoors as well as in refrigeration systems. Another option is a sunlight readable display which allows them to be used in direct sunlight. The panels are especially energy efficient thanks to their Intel-Atom platform, a combination of a highly integrated chipset and a power saving processor. The Atom processor can either be clocked at 1.1 GHz or 1.6 GHz, and has a thermal design power (TDP) of 2.5 W. The lower power consumption is also noticeable in the lower amount of heat generated. The device does not require a fan. This means that users get a fully fledged industrial PC equipped with an industrial grade touch screen and all of the relevant interfaces. It can be used for years as an energy efficient operating console for machine related use.
For more information contact Andre Kemp, Phoenix Contact, +27 (0)11 801 8200, andrek@phoenixcontact.co.za, www.phoenixcontact.co.za

Low cost graphic operator interfaces
Pro-face has introduced low cost HMI Ethernet graphic operator interfaces to its GP4100 series. The new models feature full graphic and touch operation capability and are equipped with 85 mm, 16-greyscale and high-resolution 200x80 pixel displays and USB interfaces. The series offer high quality screens with expanded support of Windows images and Bitmap fonts can be made even on a small HMI display. Two types of three-colour LED backlights, green, orange and red or white, pink and red can provide operators with easy to see operational status. There are three types of communication models, RS-232C, RS422 and RS-485, with selectable isolation for the choice of controller and application requirements. Useful new functions such as scrolling display of alarm messages, history logging of alarms, recipe functions and clock synchronisation with controller data, support the HMI. Two USB interfaces, Type A and mini-B are standard, as well as support for data transfer from a PC via the mini-B port. Support for a USB memory data transfer via the Type A interface does not require a setup engineer to take a PC to the factory floor to update its programs. The Type A interface can be used to connect various devices, such as a USB code reader and serial communication device via a USB-SIO conversion cable. GP4100 Series is supported by new GP-Pro EX Ver. 2.6 editor software. A limited edition of the software can be tested using the free download service from the Pro-face web site.
For more information contact Dino Singh, Shorrock Automation, +27 (0)12 345 4449, sales@shorrock.co.za, www.shorrock.co.za

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TEMPERATURE

New portable infrared thermometer from Raytek
According to Raytek, it is important to choose the correct IR wavelength if reliable, accurate temperature measurement is desired. It is best to use the shortest possible wavelength for the temperature range: for temperatures over 900°C it is not advisable to use 8-14 μm, but a 1 or 2 μm wavelength; less than 900°C, 8-14 μm is used. These factors are extremely important when choosing the correct infrared thermometer. To this end, Raytek has upgraded its ST range to include the new ST61 which has gone through a shape change and offers more features than its predecessor the ST60. Its IR temperature range is from -32 to 600°C with operation using the 8-14 μm wavelength, well suited for this temperature range. The unit also has a K-type thermocouple input with a range up to 1372°C. The normal input manipulations: instantaneous, average, min and max are still available along with a 20 point data gatherer installed and simple recall via the screen. The unit includes precision, high-resolution optics with excellent resolution (D:S ratio) of 30:1.
For more information contact R&C Instrumentation, 086 111 4217, info@randci.co.za, www.randci.co.za

Temperature transducers from ifm electronic
Three more temperature transducers have been launched by ifm electronic to augment its already extensive selection. The new compact versions of the TA series provide either a 4 to 20 mA output signal, or connect directly to AS-interface. As long as the master is at least to specification 2.1 the built-in AS-i slave in the temperature sensor is recognised immediately and data transferred with no need for further intervention. The value is transmitted as degrees Celsius, so no conversion is required. All three TA units incorporate a Class A Pt1000 sensing element for accuracy and speed of response, reacting as quickly as 1 s. Measurable temperature ranges start at –50° and extend to 150°C. Housings are completely sealed and welded to provide IP68/IP69K protection and excellent mechanical stability. Mounting is via the integrated thread and electrical connection via an industry standard M12 connector.
For more information contact Chris Cronje, ifm electronic SA, 086 143 6772, chris.cronje@ifm.com, www.ifm.com/za

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TEMPERATURE

Compact temperature transmitter design
Labom recently launched its compact multifunction temperature transmitter and switch, MiniTherm GS2700. The probe operates on a resistance thermometer principle, offering IP67 protection in a small footprint for minimum mounting space. Probe lengths can be ordered from 15 to 250 mm, with electrical connection made by the on-board M12-socket termination for quick and easy installation and removal. The transmitter is equipped with a 4-digit LED display that can be rotated through 300°. The 4-20 mA process signal transmits the temperature range of -50 to +200°C to a control panel via the sealed M12-connector. Additional PNP or NPN switching outputs offer further versatility to the user. The GS2700-probes are also available with a USB-interface and Comline.S programming kit and hygienic versions are available for the food and pharmaceutical industries.
For more information contact Current Automation, +27 (0)11 462 4253, etienne@switches.co.za, www.rectifier.co.za

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PRODUCT NEWS

Compact non-contact linear inductive sensors

Turck’s Q-track family of linear position sensors has been expanded to include the newest QR14 and the Q17 models. Measuring just 14 mm and 17 mm in height, the compact, non-contact inductive sensors deliver dependable, repeatable measurements in applications with spacing limitations and harsh environments. Operation is based on the RLC resistance inductance capacitance principle. Unlike potentiometric or magnetostrictive technologies, the sensors incorporate precisely manufactured printed emitter and receiver coil systems. The emitter coils are activated with a high frequency AC field and produce an inductive RLC circuit with the positioning element. The element is inductively coupled with the receiver coils, which are arranged so different voltages are induced in the coils, depending on the position of the actuator. The voltages serve as a measure for the sensor signal. Q-track sensors deliver maximum measuring

spans, with minimal blind zone and high resistance to EMI/RFI noise interference. “The low profile design and rugged housing make the Q-track sensors the preferred choice for versatile linear positioning applications,” said Marty Cwach, Product Manager, Turck. “Our ability to repackage technology into new housing designs enables us to deliver smaller sensors that suit the widest variety of application and spacing requirements.” Superior to alternative technologies, the innovative design, linearity and repeatability of the Q-track sensors eliminate the performance failures commonly experienced with other technology options. The RLC principle of operation used in the Q-track linear position sensor is highly immune to noise interference and is inherently weld field immune. Since the position element does not contain a magnet, it can be used in metalworking applications because it will

not attract ferrous debris, which would affect the operation of a magnetostrictive sensor. Additionally, the inductively coupled position element provides noncontact position feedback. This is ideal for use in applications with constant motion, such as pinch rollers, cylinder position, web tension control and pitch control. Along with these advanced design features, the compact, durable construction increases functional flexibility. The QR14 and Q17 include both current and voltage outputs, eliminating the need for two separate sensors and offering greater convenience and cost efficiency. The fully potted and sealed IP67-rated housing protects against moisture and dust in demanding environments.
For more information contact Rodney Topham, RET Automation Controls, rodney.topham@retautomation.com, +27 (0)11 453 2468, www.retautomation.com

www.instrumentation.co.za December 2011

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PRODUCT NEWS

VERSATILE VARIABLE AREA TECHNOLOGY FROM KROHNE

BEARINGLESS ENCODERS FROM BAUMER

The H250 M40 flowmeters, based on the variable area principle, are versatile and can be used for gases as well as conducting and non-conducting liquids. The sturdy all-metal version ensures high resistance to pressure, temperature and product, and can withstand extreme usage and ambient conditions. The device features a completely modular design enabling it to be individually configured for virtually any requirement, from pure analogue use without auxiliary power to integration into a fieldbus system. The H250 is available in nominal sizes DN15 - DN100 in various materials and connection variants. Typically, variable area flowmeters are installed upright in rising mains and the product must flow through them from bottom to top which can lead to extra expense. The H250 M40 on the other hand, offers freedom in terms of layout as there are special versions of the device that can be used for horizontal and even fall pipes. All electronic components are designed to be intrinsically safe and non-sparking and can be used in gas and dust explosive areas. Optionally, the same components – with a safety lid – can be installed as devices in explosion-proof enclosures. In this way, a single device can comply with different regional explosion protection strategies. All product variants offer category IP66/IP67 protection.
For more information contact John Alexander, Krohne SA, +27 (0)11 314 1391, johna@krohnesa.co.za, www.krohne.com

The wide selection of compact, bearingless encoders presented by Baumer at the Interlift trade fair provides particularly promising solutions for lift engineering. The absolute encoder MHAD (photo) is one of the highlights in the Baumer portfolio of rotary encoders without integral bearings. It combines the product benefits of narrow dimensions with the functional capabilities of an absolute encoder. The unit is easy to fit into tight spots where installation space is confined and thanks to its large through-hollow shaft the encoder does not consume any space at the shaft end while allowing installation anywhere on the motor shaft. MHAD is a member of the HDmag encoder family which excels through non-contact magnetic sensing, absolute reliability and maximum availability. MHAD unites high-precision absolute and incremental signals in a single device. The

current position will be output as absolute value with 16-bit resolution, while an additional incremental signal (8192 steps per turn) provides speed feedback. The large permissible tolerances of 1 mm on radial and axial displacement as well as air gap allow for safe and quick installation. An LED provided at the encoder acts as activity indicator and at the same time as an installation aid. The encoder platform provides IP67 protection in its standard configurations, withstands operating temperatures between -40 and +85°C and due to its robust design andmmagnetic sensing technique provides dependable operation not only in dust and humidity but also during severe shock and vibration.
For more information contact Temperature Controls, +27 (0)11 791 6000, sales@tempcon.co.za, www.tempcon.co.za

LOW COST PRESSURE TRANSMITTER FROM ALLPRONIX
The PB11xx range from EMA is rugged, IP67 rated and tamper proof for use in gas and liquid applications. Transmitters in the range 0-400 bar are available in measuring units of bar, psi, kgf and Mpa; all are equipped with overload, short circuit and reverse polarity power protection. The unit is powered up from 18-36 VDC and can operate in a temperature range of -25 to 80°C

with one output either 0-10 V in a 3 wire system or, 4-20 mA, in a 2 wire system for continuous monitoring.

For more information contact Allpronix, +27 (0)11 795 9500, sales@allpronix.com, www.allpronix.com

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December 2011 www.instrumentation.co.za

AC/DC CURRENT PROBE

PRESSURE TRANSMITTER WITH USB OR CANOPEN OUTPUT
WIKA’s P30 pressure transmitter for precision measurements is now also available with USB or CANopen output signals for quick and easy connection to a PC and convenient data acquisition. For the instrument, working with measuring rates up to 1 kHz, WIKA is also offering new software tools such as a data-logger. Via the ‘EasyCom’ configuration program, the pressure transmitter can be adjusted easily and extensive technical documentation, including interface protocol and DLL, also enables operation with customer specific software. The compact and high-quality P-30 delivers measured values with an accuracy of 0,1% (TEB), without additional temperature error in the range of 10-60°C. There is an optional variant with an accuracy of 0,05% FS available. The precision instrument is also available, as model P-31, with a flush diaphragm.
For more information contact WIKA Instruments, +27 (0)11 621 0000, sales@wika.co.za, www.wika.co.za

Universal Technic of France has expanded its range of AC/DC current probes. The large jaw clamp can accommodate circular conductors up to 83 mm in diameter and busbars of 100 x 64 mm or 122 x 54 mm. Current ranges are up to 7500 A. The mid-size jaw can accommodate circular conductors up to 50 mm in diameter and has the capability of measuring currents up to 2000 A. The smallest clamp has a jaw which can accommodate conductors up to 15 mm in diameter and measure currents up to 300 A.

Clamps are available operating off their own internal batteries or alternatively they can be powered by the analysing equipment via a cable. Various terminations can be supplied such as BNC, D01 and 4 mm safety plugs. Hall effect techniques are employed, ensuring high accuracy and a wide frequency response.
For more information contact Mervyn Stocks, Denver Technical Products, +27 (0)11 626 2023, denvertech@pixie.co.za, www.denvertech.co.za

NATIONAL INSTRUMENTS EXPANDS SMART CAMERA FAMILY
National Instruments has expanded its NI Smart Camera I family by introducing seven new models, including s, colour and high-resolution options. The new NI 177x Smart Cameras feature a 1,6 GHz Intel Atom processor for om increased processing power and an IP67 rating to protect the hardware from dust and water, making the cameras ng ideal for industrial inspection applications that require s high-performance in a rugged form factor. Additionally, or. the cameras have a real-time operating system to deliver the reliability and determinism needed on a production floor. Using the Intel Atom processor, the new cameras ew deliver processing speeds four times greater than ater other NI Smart Cameras. They also add new ew sensor options, including VGA, 1,3 MP and 2 MP in colour and monochrome as well as 5 MP in monochrome. The new sensor options make the cameras well suited for applications that require higher resolution image acquisition such as metrology and detection of small defects as well as colour imaging such as LED validation for electronics. The new cameras are the first National Instruments products to offer an IP67 rating.

For more information contact National Instruments, +27 (0)11 805 8197, ni.southafrica@ni.com, www.ni.com/southafrica

www.instrumentation.co.za December 2011

59

PRODUCT NEWS SENSOR DEVELOPMENT

HANSFORD PRODUCTS FOR THE METAL INDUSTRY

ULTRASONIC SENSORS FOR SANITARY ENVIRONMENTS

As the steel industry continues to strive for more effective plants with 100% availability, Hansford Sensors remains are committed to helping customers monitor plant machinery effectively. Typical areas include rolling mills, drives, gearboxes and cooling towers. Before getting too involved in what technique is to be applied, consideration needs to be taken to whether the application requires offline or online monitoring. Within the Hansford Sensors range of products, the AC sensor (HS-100 Series) has been designed to withstand the harsh conditions that exist in the steel industry. There is also supporting hardware that can be used to connect to a local interface box (HS-SE) for offline readings using a data collector or permanently installed equipment (420 mA accelerometers, HS-420 Series) that can be connected to a PLC for trending and logging. More sophisticated systems involve looking at velocity and bearing conditions. In this example, the standard AC sensors (HS-100 Series) connected back via a vibration module (HS-500 Series) can be used to protect the machine. When used with the vibration module (HS-510), the output can be displayed and alarmed locally and also connected back to the PLC. Wireless options are also available. Within the Hansford range of accelerometer products there are a selection of different mountings and connection methods, including armoured, silicon and fire retardant styles. Consideration must also be made to the practicality of the installation and in areas where the machine may need to be accessed it is recommended that sensors with a separate cable assembly are used.
For more information contact Temperature Controls, +27 (0)11 791 6000, sales@tempcon.co.za, www.tempcon.co.za

Banner Engineering has introduced the U-GAGE M25U ultrasonic sensors. These are opposed mode ultrasonic sensor pairs specifically designed for use in sanitary environments. The sensors, rated IP69K and IP67 (NEMA 6), are constructed of heavy duty 316 stainless steel, allowing them to withstand the high pressure washdowns, severe temperatures and aggressive cleaning chemicals common in food and beverage applications. With a smooth barrel housing – free of threads, gaps or seams that could accumulate debris – they allow thorough cleanup with minimal effort. IP68-rated washdown cordsets and FDA compliant brackets are also available to ensure reliable, long lasting performance in the harshest environment. The M25U is the ideal solution for challenging applications such as cleanin-place procedures that require reliable sensing in washdown environments. It

delivers all the advantages of conventional ultrasonic sensors – utilising sound waves to detect the presence of targets – while providing the most durable, robust design on the market. The ultrasonic technology also allows the sensor to reliably detect clear objects. M25U sensors can be wired for either normal or high speed. Normal speed offers a longer sensing range, while high speed provides a shorter response time, ideal for high speed counting applications. Applications include presence detection of clear or coloured containers during sanitising; food process monitoring; position monitoring; and aseptic bottling in contained environments.
For more information contact Rodney Topham, RET Automation Controls, +27 (0)11 453 2468, rodney.topham@retautomation.com, www.retautomation.com

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PC BOARD CONNECTORS UP TO 125 A

ROBUST PRESSURE SENSOR FOR GENERAL APPLICATIONS
Labom has introduced the rugged Pascal CS2100 pressure sensor and switch for general applications. These sensors feature IP65 protection in a compact design for less mounting space than traditional pressure gauges. CS2100-sensors have a measuring range of 0-40 bar with a 4-20 mA output signal. This signal is displayed on the sensors 4-digit LED display, which is rotatable through 300°. These sensors also feature optional PNP/NPN switching points, which can be programmed through the display’s buttons, or via optional PC-software. Mechanical fitting is achieved through a rugged thread connection. And electrical termination is made simple through the convenient M12-socket connection.
For more information contact Current Automation, +27 (0)11 462 4253, etienne@switches.co.za, www.rectifier.co.za

With a current-carrying capability of up to 125 A and cable cross-section sections of up to 35 mm², the PC 35 series of PC board connectors from Phoenix Contact have one of the best specifications in the market. Since the plugging and unplugging forces of these connectors are quite low, the connectors can be connected to devices – even those with high power rating – in a user-friendly manner. The conductor connection is implemented by screwing the tension sleeve tight. The two- to six-pin plug connectors are factory equipped with a screw flange that reliably connects it to the base strip. The screw flange can also be used as a panel feed-through on the base strip side and

provides an additional hold within the device. For pitch sizes of 15 mm, the connectors have received unrestricted 600 V UL approval in compliance with UL1059 (1000 V in accordance with IEC). Using the inverted versions of the IPC 35, shockprotected device outputs as well as free hanging cable-to-cable connections and board-to-board connections are possible. The plug connectors and base strips are also available in a four-pin version with a professional-grade shield connection.
For more information contact Sean Hadley, Phoenix Contact, +27 (0)11 801 8200, seanh@phoenixcontact.co.za, www.phoenixcontact.co.za

INCLINATION AND ACCELERATION SENSORS FROM PEPPERL+FUCHS
Pepperl+Fuchs’ F99 series inclination and acceleration sensors offer accurate and easily programmable sensors for inclination and acceleration monitoring in the areas of mobile equipment, renewable energies and factory automation. The new generation sensors are easily configured to provide incline or tilt angles between 0 and 360° on a standardised 4-20 mA or 0-5 V analogue interface. Switch outputs are also provided in order to monitor limit angles. F99 sensor highlights: • Customer-specific configuration of measuring ranges and outputs. • Innovative mounting concept provides protection against mechanical shock and vibration. • High protection rating IP68 and IP69K. • Robust housing suitable for outdoor use. • Extended temperature range -40 to 85°C. • Increased noise immunity 100 V/m. • CSA approval for worldwide use. Applications are found in commercial and construction vehicles, transport and loading units, solar panels, automotive and production plants, rail and marine vessels and metal processing.
For more information contact P&F Products, +27 (0)11 609 8188, sales@pandf.co.za, www.pandf.co.za

www.instrumentation.co.za December 2011

61

PRODUCT NEWS SENSOR DEVELOPMENT

LOW COST DRAW WIRE SENSORS FOR A MEASURING RANGE OF UP TO 5 M

OMRON’S EASY TO USE VISION SENSORS

The new wireSENSOR MK-88 extends the Micro-Epsilon portfolio of ultra compact draw wire sensors. As a low cost alternative to the aluminium based standard industrial range, the MK series excels in its compact design, its glass fibre reinforced plastic construction and its low price for large quantities. In particular it offers an outstanding balance of sensor size and measuring range. Wire lengths of 2,3 m, 3,5 m or 5 m open the door to applications that used to be exclusive to larger and more expensive sensors. Sensors with potentiometer based interfaces are available (4…20 mA, 0-10 V, 0-1 kΩ). For OEM projects, all common incremental and absolute digital interfaces or fieldbuses may be used.
For more information contact Elton Murison, Esteq Engineering, +27 (0)12 809 9500, e.murison@esteq.com, www.esteq.com

Vision sensors in Omron’s new FQ range consistently deliver crystal clear images even with the most challenging of targets. They feature one-touch control via a simple and intuitive menu system that eliminates the need for complex instructions and specialist know-how and offers outstanding simplicity of installation and set up. The first products of this type to employ HDR (high dynamic range) technology, FQ vision sensors incorporate full colour processing with up to 16 million colours, built-in polarising and halation filters and integrated high-intensity LED lighting. These features enable them to provide stable inspection even with highly reflective, low contrast and similarly difficult targets. They also cope easily with piece-to-piece variation between targets, and with target misalignment.

So that users can select a sensor that accurately meets particular requirements, Omron supplies its new FQ vision sensors in versions with fields of view from 7,4 to 300 mm. All models have an IP67 ingress protection rating, making them suitable for use in the tough operating environments. As an aid to integration with modern industrial control systems, Omron FQ vision sensors feature industry-standard connections for trigger and I/O signals, as well as Ethernet connectivity. For applications requiring more than one vision sensor, multiple units can readily be networked together and controlled from a single point.
For more information contact Terry McIntosh, Omron Electronics, 086 066 7661, terry_lynn_mcintosh@eu.omron.com, www.industrial.omron.co.za

NEW ANALYSER FROM YOKOGAWA
Yokogawa has introduced a new gas analyser to the South African market. The TruePeak TDLS measures gas concentrations inside the process using a tuneable diode laser for increased efficiency in boiler and gas furnace applications. As the laser travels through the process, the amount of light absorbed by the process gas is measured to determine the gas concentration. Traditional analysers have to extract a sample which adds cost, slows down the response time and often compromises the accuracy, whereas the Yokogawa TruePeak TDLS analyser measures in-situ and offers improved accuracy with a real-time response at a reduced cost. The analyser measures O2, CO and CH4 in and across the combustion zone thereby minimising distribution errors and process oxygen analysis can be measured directly using a rapid 5 second measurement. The process is analysed in-situ with no analyser shelter required, resulting in a lower installation and maintenance costs.
For more information contact Johan van der Westhuizen, Yokogawa SA, +27 (0)11 831 6300, johan.vanderwesthuizen@za.yokogawa.com, www.yokogawa.com

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December 2011 www.instrumentation.co.za

GIGAVAC’S NEW LATCHING CONTACTORS

MINIATURE PRESSURE TRANSMITTERS FROM INSTROTECH
Using the chip-in-oil technology developed by Keller, miniaturisation of OEM pressure transmitters is now made possible. Apart from an extremely compact design, the devices also offer impressive advantages in resistance to electrical noise fields of 250 V/m and high frequency resistance of up to 4GHz. The Series 4-9 LC with housings starting at a diameter of 11 mm, is an embedded system with the entire transmitter electronics in the transducer housing hermetically embedded in oil and all the key pressure measurement components protected against risk from humidity and condensation. These OEM transmitter capsules are ideal for integration in higher-order systems due to the selectable analogue and digital output signals. The CiO pressure transmitters are designed for 5 V applications and provide constant protection against overvoltage and polarity reversal on all lines up to 33 VDC. With an analogue output, the series is characterised by fully integrated compensation and signal standardisation over the temperature range -40 to 150ºC. The full scale pressure ranges extend from 1 to 1000 bar.
For more information contact Pieter Deysel, Instrotech, +27 (0)11 462 1920, info@instrotech.co.za, www.instrotech.co.za

Gigavac has announced the new GXL14, the first release in the GXL line of latching contactors able to switch voltages from 12 to 750 VDC and AC. With a continuous duty rating of 350 A, the GXL14 expands on Gigavac’s GX line of EPIC sealed contactors that feature a compact, lightweight design in an environmentally sealed package. The GXL14 latching line of contactors, operate without continuous coil power. This feature is preferred in applications such as solar power, power backup systems and vehicle systems operating on battery power. By conserving the power normally required to operate a standard relay, the GXL series allows the user greater flexibility in design. The GXL14 was developed for the transportation and bus industry including

recreational vehicles, emergency vehicles and mining equipment, as well as solar power and power back-up systems. The GXL14 measures 57x60x115 mm and comes with easy-connect chassis level power terminals that allow for installation without the need to bend large power cables or develop special bus bars. It can be mounted in any position and used in harsh environments at temperatures from –55 to 85°C. An optional SPST-NO auxiliary contact driven off the main armature gives true indication of the main contact position.
For more information contact Denver Technical Products, +27 (0)11 626 2023, denvertech@pixie.co.za, www.denvertech.co.za

EARTHING AND SHORT CIRCUITING DEVICES
Earthing and short-circuiting devices must be optimally adapted to the situation if they are to work reliably in emergencies and safely prevent danger to personnel. Surgetek’s comprehensive range of locally manufactured portable earthing and short-circuiting devices is designed to ensure the safety of personnel from dangerous voltages. The devices are rated in accordance with SANS 1934 to withstand full system fault current conditions for the total duration of the fault. Suitable for a wide range of applications, including overhead lines, switchgear systems and LV distribution systems, devices are tested to simulate the worst possible conditions and comply with the electrical, mechanical and humidity penetration requirements of SANS 61230. Single-pole and three-pole earthing and short circuiting devices, tubular busbar clamps, phase clamps, earth clamps, fixed phase and earth connection points and various accessories are available to meet all earthing and short circuiting requirements.
For more information contact Johan van Staden, Surgetek, +27 (0)11 792 1303, info@surgetek.co.za, www.surgetek.co.za

www.instrumentation.co.za December 2011

63

PRODUCT NEWS SENSOR DEVELOPMENT

SKF’S AFFORDABLE VIDEO ENDOSCOPES
SKF’s new video endoscopes are first line inspection tools that allow technicians to visually assess a machine’s internal condition without the need to disassemble, saving time and money. “The TKES 10 endoscope range has been designed around the needs of technicians”, says Steve Gething, Business Development Manager – Maintenance Products. “With a tip diameter of just 5,8 mm and powerful variable LED lighting, the endoscope allows good vision of machine components in dark, normally inaccessible areas”. The entire range features a common display unit with a bright 9 cm (3.5 in) backlit screen, with the capability of saving images and video and allowing transfer to a PC or sharing with others. Supplied with a standard 1 m insertion tube, which is either flexible, semi-rigid or flexible with a steerable two way articulating tip, the range is suited to numerous applications. All models are equipped with a side view adapter to allow inspections of applications such a pipe walls. A high resolution miniature camera at the tip of the tube, with up to 2X digital zoom, gives a clear and sharp full screen image. The tube can be inserted into water and most lube oils, and has a high ingress protection level of IP67. To facilitate ease of use, the display unit is equipped with powerful magnets as well as a tripod mount on the back, allowing the display unit to be used hands free. Each endoscope is supplied in a sturdy carrying case complete with all necessary cables, universal mains charger and cleaning kit.
For more information contact Samantha Joubert, SKF, +27 (0)11 821 3500, samantha.joubert@skf.com,www.skf.co.za

HYGIENIC OPTICAL SENSOR SYSTEM

As each component is a part of an innovative modular system, Wenglor’s InoxSens range of hygienic optical sensors is ideal for use in the food, beverage and pharmaceutical industries. The system integrates sensor, mounting and connector technology to save time during installation, cleaning and maintenance. There are no recesses or crevices so water, chemicals and contamination run off completely without damaging the shell. The housings are of rugged medical quality V4A stainless steel. InoxSens is rated to IP68 and IP69K

protection and also provides mechanical protection for all standard cable types. A wide variety of Wenglor sensor devices make up systems such as scanners, OCR readers or vision sensors, illumination devices, colour sensors., print mark sensors, reflex sensors for measuring tasks or contrast recognition or retro-reflective light barriers for recognising clear glass.
For more information contact Anastas Schnippenkotter, ASSTech Process Electronics & Instrumentation, +27 (0)11 708 9200, info@asstech.co.za, www.asstech.co.za

THREE PIECE MODULAR CONTROL SYSTEM
The ecomatmobile Basic Line from ifm electronic is a new control platform for mobile vehicles. The Basic Line is a threepiece modular system that is easy to wire, simple to install and reduces the amount of space needed for visualisation on a dashboard. The Basic Line control platform includes three compact units – controller, relay and display – that together control the automation of mobile vehicles. The Basic Controller is a compact module with 32-bit processing power and two CAN-bus ports. The mini controller replaces conventional relay logic and complex process controllers. Electronics are integrated into a compact, plastic housing that provides connections for inputs and outputs, communication and programming. A status LED indicates the current operating status of the module. The Basic Relay module is designed to simplify wiring and battery connection and eliminate external terminals. The easily expandable relay streamlines wiring and becomes a decentralised ‘control room’ for mobile applications. Installation is simple and the compact relay module can be installed in areas with limited mounting space and those with splashing water. Basic Display is a full-colour high-resolution display that replaces conventional analogue displays and traditional gauges on a dashboard. The display provides a resolution of 320x240 pixels and a colour depth of up to 256 colours.
For more information contact Chris Cronje, ifm electronic SA, 086 143 6772, chris.cronje@ifm.com, www.ifm.com/za

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quickfind december 2011

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AC/DC Dynamics Allpronix ARC Advisory Group ASSTech Proc. Elec. & Instr. Beckhoff Automation Bytes Systems Integration Comtest Distribution Cube Technologies Current Automation Denver Technical Products Eaton Electric Endress+Hauser Esteq Engineering H3iSquared Honeywell Southern Africa ifm electronic SA Instrotech Krohne SA Microsep National Electronics Week 2012 National Instruments SA NewElec Omron Electronics SA P&F Products Phoenix Contact R&C Instrumentation RET Automation Controls RJ Programmable Techniques Schneider Electric SA Shorrock Automation Siemens Southern Africa SKF South Africa SmoothEdge Surgetek Temperature Controls Throughput Technologies Varispeed

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info@acdc.co.za sales@allpronix.com pmiller@arcweb.com info@asstech.co.za c.muller@beckhoff.com gerhard.greeff@bytes.co.za info@comtest.co.za vmaharaj@cubetech.co.za ettienne@switches.co.za denvertech@pixie.co.za robhare@eaton.com info@za.endress.com e.murison@esteq.com info@h3isquared.com hsa@honeywell.com chris.cronje@ifm.com info@instrotech.co.za johna@krohnesa.co.za info@microsep.co.za info@neweventsltd.com ni.southafrica@ni.com sales@newelec.co.za terry_lynn_mcintosh@eu.omron.com sales@pandf.co.za info@phoenixcontact.co.za info@randci.co.za rodney.topham@retautomation.com info@rjprogtech.co.za jacqui.gradwell@schneider-electric.com sales@shorrock.co.za keshin.govender@siemens.com samantha.joubert@skf.com info@smoothedge.co.za info@surgetek.co.za sales@tempcon.co.za bob@throughput.co.za drives@varispeed.co.za john.groom@za.vega.com sales@wika.co.za jaco.markwat@wonderware.co.za info@za.yokogawa.com

www.acdc.co.za www.allpronix.com www.arcweb.com www.asstech.co.za www.beckhoff.co.za www.bytessi.co.za www.comtest.co.za www.cubetech.co.za www.rectifier.co.za www.denvertech.co.za www.eaton.com www.za.endress.com www.esteq.com www.h3isquared.com www.honeywell.co.za www.ifm.com/za www.instrotech.co.za www.krohne.com www.microsep.co.za www.new-expo.co.uk www.ni.com/southafrica www.newelec.co.za www.industrial.omron.co.za www.pandf.co.za www.phoenixcontact.co.za www.randci.co.za www.retautomation.com www.rjprogtech.co.za www.schneider-electric.co.za www.shorrock.co.za www.siemens.co.za www.skf.co.za www.smoothedge.co.za www.surgetek.co.za www.tempcon.co.za www.throughput.co.za www.varispeed.co.za www.vega.com www.wika.co.za www.wonderware.co.za www.yokogawa.com/za

55* 58 50,51 64 44 12,45* 29,30,31,47* 22 56,61,stitched insert* 51*,59,63 8,21* 7*,11,14 62 35*,36,37 13,49 54,64 63 41*,58 27*,28 11* 59 40*,41 40,62 61 49,52,61 28*,54 IFC*,5*,13*,57,60 OFC*,24,25 10,45,53* 52 8,9*,48 64 26* 63 56*,58,60 46,47 30* 26 3*,59 42,43,OBC* 6,31*,38,39,62

*denotes advertiser

Vega Instruments SA WIKA Instruments Wonderware Southern Africa Yokogawa SA

For more information on these and other suppliers please see www.ibg.co.za

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