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FEATURES:Control systems and automation

Drives, motors and switchgear

Standby and back-up

Temperature measurement

Transformers and substations

Energy and enviroFiciency

E+C august 2013 cover.indd 1 2013/07/23 09:09:03 AM

The views expressed in this publication are not necessarily those of the publisher, the editor, SAAEs, SAEE, CESA, IESSA or Copper Development Association Africa

Comment

Electricity+Control is supported by:

I recently had the privilege of joining the Department of Science

and Technology’s (DST’s) workshop set up to plot the research

infrastructure roadmap for South Africa.

Of course the process could be dogged by personal agendas

and stifled by the inability of the participants to collaborate and

think out of the box about the national interest. This is always

a challenge, in particular when dealing with a combination of

industrial and academic participants who all have made a variety

of investments in their own chosen direction of research. So it

takes big people indeed, and deft management of the process.

I was amazed at how much consensus was reached, how folk

put aside their personal wishes and indeed investments – and

tried to find a way forward. A wonderful couple of days by all

accounts – made even more enjoyable because the weather in

Cape Town at the time precluded thoughts of the sun and the

sea… But, most of all, I was impressed with the vision of the DST.

I found it remarkably refreshing, once again, to interact with one

of the most effective departments of government.

Naturally there is much still to be achieved – and everyone knows

that. But this is a department that is quite genuinely committed

to progress. There is, without doubt, a real sense that we can

make the contribution we must in order to see this nation flourish.

As I find myself wearing a number of hats, most recently as the

Transnet Professor of Systems Engineering, I am often asked

to comment, in many cases from a podium, as to why we must

relentlessly strive for excellence – and why elitism is, in certain

cases, not only a good thing, but an essential thing. Well, I have

commented at length on the need for excellent basic education.

Many of my colleagues, like myself, are hopeful that this issue

will in due course be resolved. Of course it is complex, and of

course some immense harm has been done by well-intentioned

(but misguided or misinformed) individuals who have over the

years tried out all sorts of adventurous experimentation.

But excellent basic education is well within our reach. Excellent

basic education ensures that we have a population that can be

trained and educated – and in fact that the economy is able to

absorb the folk we produce. Excellent basic education is the

ticket out of poverty and the ticket to a productive workforce.

But research infrastructure speaks to something well above

that – well above bachelor’s degrees, and into the realm of

master's and doctoral study. To many, the question around

this is not only why, but also that it sounds so damned elitist.

First of all, it has to be about the quality of what you do. The

various statistics about unemployed graduates (notably with

a vanishingly small proportion in engineering) are more about

unemployable graduates – an indictment if ever there was one.

But, the production of excellent graduates is the way you ensure

a stable middle class. Without that, the economy will simply not

be able to raise itself above its current stagnant position.

The production of graduates implies - also - the production of folk

with master’s and doctoral degrees - without a doubt essential if

we are indeed to imagine that we can become competitive. But

competitive we certainly must become if we are to continue to

dominate on the continent, and if we actually want to compete

internationally. If ever there was a case to be made for why we

must make it our business to ensure that our universities are at

the forefront of world research, it is that we need to be able to

generate knowledge and compete.

Much has been said about the nature of the world we live in, and

how we live in the knowledge economy. Knowledge is generated

by research – simple as that. And, as much as we need to be

cognisant of the need to develop many more students with

bachelor’s degrees, equally we need to ensure that our research

grows and is world class.

It is likely that, in time, our universities will, as in many other

countries, begin to align themselves as primarily teaching or

primarily research institutes. Is that elitist? For some observers,

quite probably.

But it is necessary? Well of course – in fact it is essential.

Ian Jandrell

Ian JandrellPr Eng, BSc (Eng) GDE PhD, FSAIEE SMIEEE

1August ‘13 Electricity+Control

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Features

Contents

Control systems and automation4 Illustrating the technology behind industrial-grade NAS By B Chen, Moxa8 Automation migration By G Wilson, Siemens10 Cooling today’s sizzling data centres By K Dunlap and N Rasmussen, Schneider Electric12 Round UP

Drives, motors and switchgear22 Arc-preventative MCCs – safety and protection for personnel and equipment By DB Durocher, Eaton26 When power meets quality By Y Harary, Elspec28 Round UP

Standby and back-up30 Reduce electricity costs and free up capacity By E Solot, Alpha Power Solutions36 Round UP

Temperature measurement38 Non-contact temperature measurement using IR thermometers By B Campbell, Comtest40 Round UP

Transformers and substations46 Proper transformer sizing and copper windings By E Swanepoel, Copper Development Association Africa (CDAA)50 Round UP

Energy and enviroFiciency54 Advantages of polyurethane in industrial applications By T Carolin, UMP57 Round UP

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1 Comment20 Cover article60 Light+Current61 Bizz Buzz62 Social Engineers64 Clipboard


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A network-attached storage (NAS) unit is a computer appliance used solely for data access (read/ write) and back-up, built from the ground up with integrated hardware and software for

storing and serving files. A conventional NAS is usually a relatively large, multiple-drive machine located in a cooled computer room, providing shared data access and storage to all or most of the users of a networked system.

Industrial and commercial grade NAS

A proper NAS appliance conveniently connects to a network to allow multiple users to access data from the same set of drives. A NAS usually has several storage drives attached which can be either hard disk or solid state drives. These drives are usually removable, are often arranged in a RAID, and when combined offer a great amount of storage capacity and data redundancy in a relatively small, easily configured cabinet.

Because these appliances are situated in air-conditioned control rooms, the performance criteria for the storage drives are concerned less with environmental durability and resiliency than with access speeds and mean-time before failure (MTBF). Yet with today’s increas-ingly mobile information technology, there is a rapidly developing market and a growing need for an industrial quality NAS that may be widely used in various mobile applications, or at remote field sites where environmental factors are usually harsh and severe. NAS units are, for example, used on mass transportation vehicles such as buses, railcars, and other rolling stock, while others are being used in power stations where heat, vibration, and overall reliability are a great concern. For these applications, conventional, commercial NAS designs simply cannot withstand the environmental stresses; these designs require upgrading to industrial standards that can accom-modate the harsh effects these demanding environments will inflict.

To be a rugged NAS there are several challenges that need to be addressed from the very outset of the design and development process. Most important among these are vibration and shock tol-erance, hardiness in extreme temperatures of heat and cold, both

redundant power supply and redundant network connectivity, and water and dust resistance.

Vibration and shock

The first challenge for a rugged NAS device is the vibration issue, because this is a particularly significant problem when it is used on a railway, bus or other moving vehicle. Typically, these vehicular applications will use NAS to store surveillance records, and will be mounted in a railcar, or bus. Consequently, in these environments suitable NAS solutions must meet or surpass the vibration standards defined in EN50155 [1] and IEC 61373 [2], requiring careful design of both hardware and software.

Properly designed industrial NAS hardware must have a high re-sistance to damage from the constant vibration and shocks that occur on moving vehicles. This means that engineers must carefully select and test components and PCB designs even before the final shape of the device internals has taken any definite form. More importantly, because one of the fundamental requirements of any NAS is a large and reliable storage capacity, the hard disks used must be both high performance and high capacity, while also resisting industrial-grade shocks and vibration.

Meanwhile, the appliance must also feature software utilities that will supplement the basic hardware priorities by actively adjusting the system to protect the storage drives from extreme circumstances. For example, when vibration or shock levels exceed specified measure-ments, the drives must be capable of protecting the physical disk (if

Illustrating the technology behind industrial-grade NASBy B Chen, Moxa

Network-attached storage that meets and exceeds the definition of ‘industrial grade’ in every way – makes it perfect for industrial applications.

Electricity+Control August ‘134

Abbreviations

should eliminate this point of failure wherever possible, or work to reduce its potential for harm by maximising fan efficiency. Taken together, all of this means painstaking design work with compre-hensive thermal evaluation across all hardware arrays, from the bare component level upward.

On the other hand, guaranteeing system operations in extremely low temperatures is equally challenging. For climates where tempera-tures can drop to well below zero, an intelligent, on-board heating solution is necessary to warm the device to an operative temperature so that the NAS will remain available to the network. Again, this means a sophisticated design combination of an onboard heater with intelligent software controls.

Finally, a properly resilient, industrial-grade NAS should be equipped with the ultimate failsafe: a temperature sensor that will halt disk operations when thermal limits are exceeded, and resume disk accesses when the system returns to a normal operating temperature. This method is similar to the vibration protection described earlier, except that in instances of such extremely high temperatures, non-volatile memory is no longer an option; the drives will shut down to protect the rest of the device from damage. During this period the local network will lose access to its storage system, as if the NAS has gone offline. It is inconvenient, true, but when the system’s internal heat reaches limits greater than 70 or 80°C, a temporary shutdown is the only thing capable of reliably protecting the hardware from burning out.

Network and power redundancy with dual PoE+

Two more critical issues for any network service are data and power redundancy. Network redundancy is a simply achieved solution com-

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disk drives are being used) by automatically shutting down all data access processes. In such an event, a proper industrial-grade NAS will temporarily store all data in a suitably large, non-volatile buffer memory and then automatically write this data to disk once the vi-bration or shock reduces. For this, an independent vibration (shock) sensor, more sensitive than a hard disk’s internal sensor, should be used to initialise vibration protection processes before environmental extremes have the chance to affect the disk. This requires, in turn, sophisticated and detailed software design.

Temperature

Another problem is severe temperature, both at the high and low extreme. Because commercial NAS units are usually located in air-conditioned computer control rooms, these systems have no need to make allowance for temperature extremes: the data centre climate will always be carefully maintained. However, a NAS unit mounted on a vehicle, or in a harsh, remote industrial environment like a power substation or wind farm, will need to endure temperatures a com-mercial system simply cannot tolerate.

To keep a NAS operating in extreme heat, engineers must select components that quickly and effectively dissipate heat, or even bet-ter, maintain system performance while generating much less heat than standard commercial components. Tracking down and testing such parts is not an easy task, but adding to this difficulty is the need for eliminating internal fans: fans break down easily and often, and these events inevitably result in heat-sensitive components quickly and irrecoverably frying themselves. Ideally, industrial-grade devices

Take note

iP – ingress ProtectionmtBF - mean-time Before Failurenas – network-attached storagePCB – Printed Circuit BoardPoE+ - Power over Ethernet PlusRaid - Redundant array of independent disksRnas – Rugged network-attached storageuPs – uninterruptible Power supply

• in certain industrial applications, rugged it devices that may not only be used in a controlled environment are needed.

• Rugged devices, especially storage devices, have very specific attributes – which must be confirmed when purchasing.

• dependable and cost effective solutions are now available.


About the author

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mon to most NAS appliances: equip the device with two Ethernet interfaces to guarantee that the network remains up even should one interface fail. Since two ports are already available, it should also be possible to aggregate the two lines into a single connection, thereby doubling the network load capacity.

Power redundancy, on the other hand, is not so common. Failure of a power input is so rare in control room NAS units that it has never been an issue. For commercial NAS appliances, an uninterruptible power supply (UPS) is really all that is needed. Yet on most vehicles and in many industrial environments space is tightly restricted, mak-ing a UPS not an option.

Once again, good, advanced engineering is capable of providing an efficient, cost-effective solution: by using Power over Ethernet Plus (PoE+), power redundancy is achieved using the same lines and interfaces as used to provide network redundancy. In addition, because power supply over PoE is somewhat restricted, the device will necessarily run on a relatively low power draw, reducing not only the cost of installation (by eliminating extra power supplies), but also reducing its overall cost of operation.

IP Rating

Finally, as any industrial engineer knows, dust and water are ever-present concerns when building machines to run in industrial envi-ronments. Designing the machine to meet a suitable IP rating is thus another crucial factor when building a rugged NAS. IP54 is typically the minimal requirement for networked devices that must remain reliable despite exposure to the elements. An IP54 rating means the enclosure protects against dust, humidity, and splashed water, and NAS appliances which meet this standard can be depended upon to remain functional even when the odd three-year-old dumps his 'sippy' cup over the networking cabinet, or when there are torrents of wind and rain raging just outside the hood.

IP 54• 5 describes the level of protection from solid objects• 4 describes the level of protection from liquids

Conclusion

With more and more industrial applications requiring NAS as part of their core systems, it is important to have a rugged NAS alternative that meets industrial requirements. To fulfil this need, a NAS properly described as industrial and rugged must conquer the challenges of vibration and shock, remain stable in both low and high temperatures, give reliable network and power redundancy (even in remote field sites), and be resistant to dust, water, and wind. RNAS-1200 Series is just such a rugged NAS as it meets and exceeds the definition of ‘industrial grade’ in every way, making it perfect for industrial ap-plications such as rolling stock, buses, power substations, or remote

automated facilities like wind farms. Equipped with Moxa’s Data XPro utility, the RNAS-1200 also comes with a proprietary intelligent heat-ing solution, an automatic cut-off for high temperature thresholds, and protection against vibration and shock that will guarantee reli-able access to your data, even in extreme conditions. Sophisticated hardware and software design make it a dependable, cost-effective storage appliance for harsh industrial environments.

References

[1] EN50155. 2007. Railway applications electronic equipment used on rolling stock.

[2] IEC 61373. 2010. Railway applications: rolling stock equipment - shock and vibration tests.

Redundant Array of Independent Disks (RAID)

RAID is a disk subsystem that increases performance or provides

fault tolerance or both. RAID uses two or more hard drives and a RAID

controller, which is plugged into motherboards that do not have built-in

RAID circuits. Today, most motherboards have RAID built in. In the past,

RAID was also accomplished by software only, but was much slower.

In the late 1980s, the ‘I’ in RAID stood for ‘inexpensive,’ but was later

changed to ‘independent’. In large storage area networks (SANs), floor-

standing RAID units are common with terabytes of storage and huge

amounts of cache memory. RAID is also used in desktop computers by

gamers for speed and by business users for reliability.

Bruce Chen has spent six years with moxa inc – working as a project supervisor and senior technical writer in the field of industrial computing. Enquiries: RJ Connect. tel. 011 781 0777 or email [email protected].


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If you are a factory or process plant technician or electrical engineer, you will know that one of the challenges that faces plant operation is equipment ageing and the incorporation of new technology

into an old plant.As equipment ages the possibility of product failure also in-

creases. Some of the installed equipment could be 10 to 20 years old. Devices like programmable logic controllers (PLCs), human machine interface (HMI) panels, industrial computers, variable speed drives (VSDs), process instruments and intelligent switchgear, are more susceptible to electronic failures due to ageing. One way of making sure such equipment failures do not cause plant stoppages is by replacing these old products. Some of these old products may be available, but at a much higher price, some may be phased out or fully discontinued.

The availability of old parts presents another challenge, as a cus-tomer might be forced to upgrade to a new version product that uses newer programming software or even to a completely new product that has many differences from the old product. Aspects like old to new product cabinet mounting size differences seem trivial, but pose a real problem on site. If the programming or visualization software is also required to be part of the plant, then issues like the Windows operating system changes are also to be considered, as some com-puters might still be running on MS DOS, Windows NT or Windows 2000, which are old. Currently Windows XP or Windows 7 seem to be the norm; Windows 8 is now available; 64 bit computer motherboard processors are also readily available and currently in use.

From a software engineering point of view the biggest challenge when moving from an old product to a new product is software code reusability. For example if you have an old PLC installed that is pro-grammed in LADDER, Function Block Diagram or Statement List, if you have to move to a newer product it would be time consuming and costly to completely rewrite this programming code from the beginning.

An engineer would have to print out the old program, analyse it, understand how the program should work and then rewrite and download the software code for the new product. Another old to new product change example would be HMI panels. Some installed old HMIs have many visualization screens and to re-engineer these screens from scratch without knowledge of how the HMI tag vari-ables, buttons and input/output fields operate together with the PLC controller could also be challenging, time consuming and costly.

Changing from an old installed product that is produced by Com-

pany X to a new product that is designed by a completely different Company Y is even more challenging, as the software programming layout and features might be completely different ie maybe the new supplier does not support Statement List programming or does not support Profibus. End customers should always keep back-up software programs readily available in some type of secure software library, as these will become useful when a migration needs to take place ie some of the online projects kept within installed running products do not have program comments shown, which poses a problem because people constantly change jobs and a new person working on site will have little knowledge of how the online program works.

Migration tools are a key aspect to consider, as they help custom-ers migrate old software projects into new software projects that can be downloaded into the new hardware. Below are some example migration tools that are available from Siemens Industry Automation:• S5 PLC <to> S7 PLC Program Blocks Migration Tool• S7-200 <to> S7-1200 Program Blocks Migration Tool• HMI ProTool Software <to> HMI WinCC Flexible Software• HMI WinCC Flexible Software <to> TIA Portal WinCC• WinCC SCADA old version <to> WinCC SCADA new version• PCS7 DCS old version <to> PCS7 DCS new version• STEP7 V5, ProWORX, Concept, Unity Pro XL, RSLogix5/500/5000

software program symbols <to> TIA Portal software program tags/symbols

Automation system migrationBy G Wilson, Siemens Industry Automation

Migration tools assist in the migration of old software projects into new software projects that can be downloaded into the

new hardware.

Take note

• software is a huge investment – it takes a significant amount of engi-neering design time.

• software can be migrated from older systems to new systems.• migration tools exist – but not for all projects; so be sure to consider

this aspect when designing and building your system.


Other software migration tools are available for customers who plan to build new plants and for plants that exist - these are all important factors to consider. The short term aspect might be a quick cheap solution, however the long term migration and support aspects should also be considered. Technology is always changing and with it comes improvements such as ease of use, more diagnostics, easier installation and improved design; therefore migration to newer technology is not bad thing – it is a good thing. One such example would be the migration from the older type PLC controllers which were programmed via RS232/485 to new PLC controllers that have onboard Ethernet ie the Siemens S7-1200/1500 PLCs.

New standard laptops do not come with RS232/485 ports and therefore an adapter would be required, but Ethernet comes standard on all new laptops. Another example would be if a customer decides to change their installed Windows operating system version throughout their plant. This poses a problem as the older type installed software does not support this new Windows version, therefore purchasing an upgrade software package to the latest software version that does work on the newer Windows version is cheaper than buying a complete new software package.

Conclusion

From this discussion, it can be seen that migration aspects do play a role when selecting prod-ucts that will be installed for a particular application.

About the author

Abbreviations

after completing his national diploma at nelson mandela metropolitan university (nmmu) in 2001, Gary Wilson joined siemens industry automation during which time he has gained much automation product knowledge and site experience. He is currently product promoter for PlC and Hmi products. He obtained a Btech Electrical Engineering degree through unisa and is registered as a Professional Engineering technologist with the Engineer-

ing Council of south africa (ECsa). Enquiries: tel: 011 652 2000 or email [email protected].

dCs – distributed Control systemHmi – Human machine interfacems dos – micro s oft disk operating systemPlC – Programmable logic ControllersCada – supervisory Control and data acquisitiontia – totally integrated automationVsd – Variable speed drive

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Virtually all IT equipment is air-cooled, that is, each piece of IT equipment takes in ambient air and ejects waste heat into its exhaust air. Since a data centre may contain thousands of IT

devices, there are therefore thousands of hot airflow paths within the data centre that together represent the total waste heat output of the data centre, waste heat that must be removed.

With power densities of modern IT equipment pushing peak power density to 20 kW per rack or more, simulation data and ex-perience show that traditional cooling, dependent on air mixing, no longer functions effectively.

To address this problem, design approaches exist that focus on room, row, and rack-based cooling. In these approaches, the air conditioning systems are specifically integrated with the room, rows of racks, or individual rack in order to minimise air mixing.

Key functions of data centre air conditioning systems

Every data centre air conditioning system has two key functions. The first function of providing bulk cooling capacity is the same for room, row, and rack-based cooling. The major difference lies in how each cooling system performs the second critical function, distribution of air to the loads. Controlling the airflow is therefore the main objective of the different cooling system design approaches.

Room-based cooling

With room-based cooling, the computer room air handler (CRAH) units operate concurrently to address the total heat load of the room. Room-based cooling may consist of one or more air conditioners supplying cool air completely unrestricted by ducts, dampers, vents and more; or the supply and/or return may be partially constrained by a raised floor system or overhead return plenum.

The room-based design is heavily affected by the specific con-straints of the room, including the ceiling height, the room shape, obstructions above and under the floor, rack layout, CRAH location, the distribution of power among the IT loads and more. When the supply and return paths are uncontained, the result is that perfor-mance prediction and performance uniformity are poor, particularly as power density is increased. Therefore, with traditional designs, complex computer simulations called computational fluid dynamics (CFD) may be required to help understand the design performance of specific installations. Furthermore, alterations such as IT equipment

moves, add-ons, and changes may invalidate the performance model and require further analysis and testing. In particular, the assurance of CRAH redundancy becomes a very complicated analysis that is difficult to validate.

Another significant shortcoming of uncontained room-based cooling is that in many cases the full rated capacity of the CRAH cannot be utilised. This condition occurs when a significant fraction of the air distribution pathways from the CRAH units bypass the IT loads and return directly to the CRAH. The result is that cooling requirements of the IT layout can exceed the cooling capacity of the CRAH despite the required amount of nameplate capacity.

Row-based cooling

With a row-based configuration, the CRAH units are associated with a row and assumed to be dedicated to a row for design purposes. The CRAH units may be located in between the IT racks or they may be mounted overhead.

Compared with the traditional uncontained room-based cooling, the airflow paths are shorter and more clearly defined. In addition, airflows are much more predictable, all of the rated capacity of the CRAH can be utilised and higher power density can be achieved.

Row-based cooling has a number of side benefits other than cool-ing performance. The reduction in the airflow path length reduces the CRAH fan power required, increasing efficiency.

This is not a minor benefit, when we consider that, in many lightly loaded data centres, the CRAH fan power losses alone exceed the total IT load power consumption. A row-based design allows cooling capacity and redundancy to be targeted to the actual needs of specific rows. For example, one row of racks can run high-density applications such as blade server, while another row satisfies lower power density applications such as communication enclosures.

For new data centres less than 200 kW, row-based cooling should be specified and can be implemented without a raised floor. For existing data centres row-based cooling should be considered when deploying higher density loads (5 kW per rack and above).

Rack-based cooling

With rack-based cooling, the CRAH units are associated with a rack and are assumed to be dedicated to a rack for design purposes. The CRAH units are directly mounted to or within the IT racks. Compared

Cooling today’s sizzling hot data centres By K Dunlap and N Rasmussen, Schneider Electric

Air conditioning systems should be specifically integrated with the room, rows of racks, or individual rack in order to minimise air mixing.


Abbreviations

completely characterised by the manufacturer. This allows simple specification of power density and design to implement the specified density. Rack-based cooling should be used in all data centre sizes where cooling is required for stand-alone high-density racks. The principal drawback of this approach is that it requires a large number of air conditioning devices and associated piping when compared to the other approaches, particularly at lower power density.

Hybrid cooling

Nothing prevents the room, row, and rack-based cooling from being used together in the same installation. Placing various cooling unit in different locations in the same data centre is considered a hybrid approach. This approach is beneficial to data centres operating with a broad spectrum of rack power densities.

Another effective use of row and rack-based cooling is for density upgrades within an existing low-density room-based design. In this case, small groups of racks within an existing data centre are outfit-

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with room-based or row-based cooling, the rack-based airflow paths are even shorter and exactly defined, so that airflows are totally immune to any installation variation or room constraints. All of the rated capacity of the CRAH can be utilised, and the highest power density (up to 50 kW per rack) can be achieved. The reduction in the airflow path length reduces the CRAH fan power required, increasing efficiency. This is not a minor benefit considering that in many lightly loaded data centres the CRAH fan power losses alone exceed the total IT load power consumption.

A rack-based design allows cooling capacity and redundancy to be targeted to the actual needs of specific racks, for example, different power densities for blade servers versus communication enclosures. Furthermore, N+1 or 2N redundancy can be targeted to specific racks. By contrast, row-based cooling only allows these characteristics to be specified at the row level, and room-based cooling only allows these characteristics to be specified at the room level.

As with row-based cooling, the deterministic geometry of rack-based cooling gives rise to predictable performance that can be

Take note

CFd - Computational Fluid dynamics CRaH - Computer Room air Handlerit – information technologyR&d – Research & development

• typically, it equipment is air cooled.• Cooling systems must be specifically designed to cater for the needs

and layout of it equipment in your plant.• Generally, it is useful to get expert advice to ensure that your systems

will be adequately cooled.

The CX8093 Embedded PC from Beckhoff is equipped with a PROFINET RT device

interface designed as a 2-port switch for daisy-chain cabling. A special feature is the added functionality of a virtual device which can be used to double the process data size or to connect a second controller.

When the optional virtual device (slave interface) is activated, the CX8093 Embed-ded PC behaves like two PROFINET devices. Accordingly, twice the maximum input/ output data volume can be processed – with PROFINET approximately 1 000 bytes, ie the CX8093 can process twice the number of PROFINET process data. The network name

of the ‘two’ devices can be set via the address switch or the TwinCAT System Manager. The IP settings are allocated by the PROFINET controller.

A further benefit of the virtual device is the ability to communicate with a second PROFINET controller, which is a simple way to increase system availability. On the one hand, the CX8093 (as a local controller) can verify the two incoming master signals by means of a plausibility check to monitor the function of the cabling, for example. On the other hand, failure of one of the masters can be detected and the second master can re-spond accordingly. The space-saving CX8093

Embedded PC measures only 65 x 100 x 80 mm. It runs Windows CE 6.0 and features a 400 MHz ARM9 CPU, 64 MB RAM and a Mi-croSD card with up to 4 GB storage capacity.

Enquiries: Email K.MCPhersonbeckhoff.com.

Moxa has added to its Gigabit-performance cyber secu-rity family - the EDR-810 series. This new product is an

industrial multiport secure router with Firewall/NAT/VPN and managed L2 switching functions, which allow the EDR-810 to transmit data efficiently while protecting the network and critical devices from cyber attacks. The EDR-810’s integration of security and networking functionality into a single device saves extra deployment cost and effort.

Moxa’s Gigabit-performance security routers can be

deployed in networks that need secure remote access or remote monitoring of field assets, and provides an electronic security perimeter for that protects critical cyber assets, such as pumping/treatment systems in water stations, DCS systems in oil and gas applications, and PLC/SCADA systems in factory automation. Moreover, the EDR series provides enhanced cyber security to address to the three key vulner-abilities of the automation networks.

Enquiries: Tel. 011 781 0777 or email [email protected].

Small local controller integrates virtual device

All-in-one cyber security solution

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ted with row or rack-based cooling systems. The row or rack cooling equipment effectively isolates the new high-density racks, making them ‘thermally neutral’ to the existing room-based cooling system.

Another example of a hybrid approach is the use of a chimney rack cooling system to capture exhaust air at the rack level and duct it directly back to a room-based cooling system. This system has some of the benefits of a rack-based cooling system but can integrate into an existing or planned room-based cooling system.

Conclusion

To make effective decisions regarding the choice between room, row, or rack-based cooling for new data centres or upgrades, it is essential to relate the performance characteristics of the cooling methods to practical issues that affect the design and operation of real data centres

About the authors

neil Rasmussen is the senior vice-president of innovation for schneider Electric. He establishes the technology direc-tion for the world’s largest R&d budget devoted to power, cooling, and rack infrastructure for data centres. neil is currently working to advance the science of high-efficiency,

high-density, scalable data centre infrastructure solutions and is a principal architect of the aPC infrastruXure system. after founding aPC in 1981, neil served as senior vice-president of engineering and Cto for 26 years, assuming his current role after aPC joined schneider Electric in 2007.

Kevin dunlap is general manager of cooling solutions at schneider Electric. involved with the power management industry since 1994, Kevin previously worked for systems Enhancement Corp which aPC acquired in 1997. Following the acquisition, Kevin joined aPC as a product manager

for management cards and then for precision cooling solutions following the acquisition of airflow Company, inc. Enquiries: Eben owen. tel. 011 557 6600 or email [email protected].

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Honeywell has introduced OneWireless Terminal Solution, which brings together a portfolio of wireless-enabled products, services and productivity tools tailored for

terminal operators. Honeywell’s new OneWireless Terminal Solution enables operators of oil and gas terminals to increase their productivity while also complying with stringent health, safety and environment (HSE) regulations, all at significantly lower cost than wired technology.

“There is constant pressure on terminal operators and owners to improve productivity, efficiency, safety and security with limited capital and operating budgets. The OneWireless Terminal Solution helps enable customers to achieve these goals within their budgets,” said Ray Rogowski, global marketing director, Honeywell Process Solutions. “In a com-petitive industry, terminal operators are investing in tank automation to meet new safety regulations as well as continuously looking for ways to manage costs. Wireless-enabled tank gauging is less expensive, at about half the cost of the wired alternative.”

Unique in the industry, OneWireless Terminal Solution includes ISA100-compatible Honeywell Enraf SmartRadar FlexLine, the highest-precision wireless radar gauge avail-able. Requiring no external wireless module, the Flex-Line’s integrated radio sends tank level measurements securely and wirelessly to the central control room. The Flexline is also used as a data concentrator, collecting data from local tank instru-ments and sending the data wirelessly through the same ISA100 network.

Enquiries: Boni Magudulela. Tel. 011 695 8000 or

email [email protected].

The new AXC 1050 controller from Phoenix Contact’s Axiocontrol range

provides excellent performance and easy usage. It is particularly suited for installa-tion in harsh industrial settings.

For the construction of local stations, the I/O modules of the Axioline I/O system can be added on to the controller directly via the built-in Axiobus.

The controller’s Ethernet interfaces en-able integration with existing networks and connection to other decentralised I/Os. A range of communication protocols are available for this: TCP/ IP, UDP, Modbus/ TCP, Profinet.

Thanks to a built-in uninterruptible power supply (UPS), the Axiocontrol controller is particularly resilient against power outages. This means that if there is a power outage, applicative measures to ensure system availability can be in-

stated. Designed for deployment in highly demanding environments, the special AXC 1050/XC mini-controller operates at an extended temperature range of -40 up to +60°C.

Enquiries: Andre Kemp. Email [email protected].

Wireless – safer, more efficient terminal operations

Fast mini-controller with rugged housing

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There is a danger that South Africa’s lack of active participation in many of the MV standards developed by SC 17A and SC 17C now

used extensively in the electricity supply industry, could lead to local standards becoming unique with accompanying cost implications.

The fact that South Africa has not participated in the work of sub-committees or working groups means that we will have to accept what the international community has decided or create our own docu-ments with modifications thought necessary to meet local physical or infrastructure-based conditions.” He adds that the same number does not mean that the content is exactly the same. For example, EN 61008-1 [1] does not have the same content as IEC 61008-1 [1] because the EN standard has common and country-specific deviations. However, SANS 62271-1 [2] is identical to IEC 62271-1 [3].

Internationally all MV standards are developed by sub-committees 17A and 17C of the International Electrotechnical Commission (IEC). The 17A committee is responsible for preparing international stand-ards and specifications for high voltage switchgear and controlgear rated above 1 kV ac or 1,5 kV dc.

The IEC 17C committee is tasked with preparing international standards covering pre-fabricated assemblies that are a combina-tion of one or more parts of switchgear and controlgear exceeding 1 kV ac as well as associated control and power equipment that measures, signals, protects or regulates equipment. Gas-insulated switchgear assemblies fall within the scope of SC 17C.

The 17A sub-committee has three working groups, four project teams, 17 maintenance teams and two ad hoc project teams and has published 21 standards in the 62271 series. It is also responsible for the 1XX series and some 3XX series documents. Sub-committee 17C has four working groups, 12 maintenance teams, two advisory groups and a single ad hoc project team. It has published 14 standards in the 2XX and others in the 3XX series of 62271.

The international trend in recent years has been to rationalise the wide range of standards in the MV field into the 62271 series to provide a coherent and complete set of documents that cover high voltage switchgear and controlgear as well as the related assembly standards.

A document, IEC 62271-200 [4], has recently been published and as the so-called ‘-200’ had introduced significant changes its implemen-tation was reviewed some years later with a view to improvements and corrections based upon market feedback.

The instructions were to avoid major technical changes, particularly those that could challenge equipment already qualified according to edition 1; ensure consistency with the IEC 622271-1 [3] common specifications published in 2007; and reorganise the information within the document to improve legibility.

In August last year a meeting of the SABS Committee 67A took a decision to raise the participation level in IEC SC 17A and SC 17C. As a result a national mirror committee was set up to discuss the docu-ments circulated from SC 17A and SC 17C, enabling South African input into the standards development process of the 62271 series.

The situation now is that South Africa has an obligation to partici-pate in the development of the 62271 series. This is an opportunity to input valuable information from an Africa perspective. There are tangible benefits to being part of the information chain, particularly being able to see where future developments are headed and accom-

modate trends and future changes without crisis. Locally the mirror committee is able to discuss and debate the merits of proposed changes. As an active group it is also building expertise in the field of high voltage switchgear, controlgear and assemblies through contact with the international electrical standards community.

The international trend in MV standards is focused on ongoing adherence to - and maintenance of - standards. Locally the view is that it is a new beginning through which South Africa can participate in the work and development, possibly including the nomination of experts to assist working groups and project and maintenance teams.

References

[1] EN 61008-1. 2005. Residual current operated circuit-breakers without integral overcurrent protection for household and similar uses (RCCBs). Part 1: General rules.

[2] SANS 62271-1. 2012. High-voltage switchgear and controlgear Part 106: Alternating current contactors, contactor based control-lers and motor-starters

[3] IEC 62271-1. 2011. High-voltage switchgear and controlgear - Part 1: Common specifications.

[4] IEC 62271-200. 2011. High-voltage switchgear and controlgear - Part 200: AC metal-enclosed switchgear and controlgear for rated voltages above 1 kV and up to and including 52 kV.

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by Isaac Kruger, Schneider Electric

SA electricity supply industry needs to be more active in setting MV standards

Isaac Kruger

As standardisation manager MV at

Schneider Electric South Africa, Isaac

Kruger is responsible for all standardisation

activities, solutions and applications within the MV field,

with a strong emphasis on the future requirements of

intelligent grids. Kruger has had numerous significant

achievements in his career, holding senior positions in

associations such as SAIEE and the IEC, and the South

African Bureau of Standards (SABS). Enquiries: Tel. 11 254

6441 or email [email protected].


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Manufacturers, particularly those in process industries, can gain increased functionality and an enhanced op-

erator experience with the latest version of the FactoryTalk View Human-Machine Interface (HMI) software from Rockwell Automation. FactoryTalk View Site Edition (SE) and Machine Edition (ME) 7.0 applications, released in early 2013, offer more efficient alarm management, simplified installation, improved user experience, and integrated data sharing in a wide range of production environments.

“To stay competitive, our customers need scalable HMI solutions that are easier to install, enable operator productiv-ity, and are more tightly integrated to company control and information systems,” says Christo Buys, control systems business manager, Rockwell Automation Sub-Sahara Africa. “To meet all these needs, we are leveraging our deep experi-ence to evolve our visualization software.”

FactoryTalk View SE 7.0 software will support larger num-bers of HMI clients and servers in a single system, increasing the size of systems that can support the FactoryTalk View SE alarming sub-system, FactoryTalk Alarms and Events.

The FactoryTalk Alarms and Events alarming sub-system has been enhanced to align with ISA’s Alarming Standard 18.2, and will now support the shelving state. The sub-system now also allows users to configure remote-alarming commands on display faceplates, saving crucial time when an operator needs to react to device alarm situations.

The newest version includes an improved installation pro-cess and design environment. The new installation process in FactoryTalk View SE and ME software saves time with a streamlined work flow that automates installation of Facto-ryTalk View components.

Enquiries: Christo Buys. Tel. 011 654 9700 Email [email protected].

Turck is offering customers that require a 24 V power supply directly in the field a series of switched mode power supply units with IP67 protection.

A large amount of expensive cabling with large cross sections is required if the field device and the control cabinet for the plant are large distances apart. The use of power supply units with IP67 protection is particularly suitable here, since they provide a 24 V power supply directly in the field without any voltage drop. Due to their degree of protection to IP67, the new PSU67 power supply units can also be fitted directly to the machine without any protective measures. The power supply units offer a high level of failsafe performance, thanks to their no-load and short-circuit protection as well as passive air cooling. The devices also automatically bridge voltage dips of up to 50 ms. The high efficiency of the devices ensures a good energy balance of up to 90%. The ac/dc wide range input and an ambient temperature range from -25 to +60°C make the power supply units suitable for worldwide use. They feature a voltage output with a 4-pin 7/8 inch connector. LEDs indicate the actual operating state to the user. Turck is offering the PSU67 series switched-mode power supply units in four variants, A 2 a, 4 A and an 8 A variant, each with one output, and a variant with two 4 A outputs. The power supply units are compliant with the requirements of EN 60950-1 and the cULus and CE approval.

Enquiries: RET Automation Controls. Tel. 011 453 2468. Visit

www.retautomation.com.

Latest software enhances HMI operator experience and data integration

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Power supply units for direct mounting in the field

This FactoryTalk View 7.0 HMI screenshot shows how the software process-system capabilities, information integration and

usability have been improved.

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ELPRO’s new 615M-1 simplifies cellular connectivity for indus-trial applications. The 615M-1 industrial cellular modem and

router offers wireless data connectivity for both Ethernet and serial interfaces over GSM mobile networks at 3G speeds. Easily extend your reach to remote industrial assets wherever cellular network coverage is present, both locally and internationally. The 615M-1 cellular modem is ideal for reliable connectivity with program-mable logic controllers (PLCs), remote terminal units (RTUs) or any other Ethernet or serial devices.

Typical applications include:• Remote connectivity to PLC\ SCADA networks • Water\ wastewater, oil and gas and mining applications • Electricity distribution network monitoring and control • Connectivity to remote renewable energy systems


One of the biggest advances in industrial manufacturing in recent years is the trend of connecting all management processes, as

well as control and field level devices to one network, and operators are looking for economical ways of connecting legacy devices to a network, especially solutions that leverage existing IT manage-ment technologies. In response to this need, Moxa has introduced the MGate 5102-PBM-PN PROFIBUS-to-PROFINET gateways, which feature IT management tools to provide a second level of protec-tion for automation networks. “Moxa’s MGate Ethernet gateways not only provide innovative technology that can bridge PROFIBUS devices (PROFIBUS drives or meters) to PROFINET masters (SCADA or Siemens PLCs) with ease, but also lev-erage IT management tools for effortless management,”said Jun Chuang, product manager for Industrial Ethernet Gateways. In addition, the MGate 5102-PBM-PN has a rugged design with optional built-in optical isolation, -40 to 75°C wide-temperature op-eration, and microSD card for configuration back-up, ensuring reliable performance for use in industrial applications such as oil and gas, power, process automation, and factory automation.


Cellular network coverage for industrial connectivity

IT-friendly Ethernet Gateway

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Honeywell has launched the new RMG Gas Metering Management software

and service solution, which enables natural gas and measuring station operators to monitor operations on-site or remotely, provide data analysis and facilitate remote maintenance. The solution reduces opera-tional costs and improves the accuracy and reliability of measurements.

The RMG Gas Metering Management system supports both RMG by Honeywell and third-party measurement devices, al-lowing users to accurately determine the technical condition of all gas measurement devices in a metering station using a single software package. In addition, the ability to remotely access measuring devices simpli-

fies planning and organisation, and reduces costs as it keeps station visits to a minimum.

“One of our goals in developing this new solution was to give customers the freedom and flexibility to choose the best combination of measuring devices to meet their unique needs, regardless of the manufacturer,” said Frank Michels, general manager, RMG Gas Metering. “The RMG Gas Metering Management solution works seamlessly with both RMG and third-party measuring devices, so customers all over the world can create highly tailored solu-tions, but still monitor everything through one central, reliable system.”

Honeywell has already tested the sys-tem with prospective customers including

Schwaben Netz GmBH in Germany, produc-ing positive results. The Honeywell RMG Gas Metering Management software is available in English and German.Enquiries: Boni Magudulela. Tel. 011 695 8000

or email [email protected].

Mitsubishi Electric has extended the capability of its MELSEC FX3G Com-

pact PLC with the release of a new Ethernet embedded CPU – the FX3GE. This comes in addition to the standard USB and RS422 communication ports. Further, the new CPU also adds two analogue inputs (0-10 Vdc or 4-20 mA) and an analogue output (0-10 Vdc or 4-20 mA). These new analogue and network features, combined with the power and ex-pandability of the MELSEC FX3G mean the new Compact PLC can meet the needs of a wider range of applications.

Further features of the new MELSEC FX3GE include the ability to set two user keywords for secure PLC access, built in

high speed counters and interrupts for system feedback and control, built-in 2-axis positioning capability with dedicated inverter protocol, and a choice of models offering 24 or 40 I/O as standard, expandable to 256 I/O. The FX3GE offers all the power of the FX3G, including large program memory, ample space for data storage, logging or recipes, plus high speed execution to enhance sys-tem productivity. The FX3GE can also use all of the expansion modules and special adapters in the MELSEC FX3 range. With the embedded Ethernet capability, users can take advantage of remote monitoring, maintenance and data sharing with HMI. The FX3GE is ideal for food and beverage

applications, for example where flow control or level monitoring might be important or where control of pumps is required.

Enquiries: Email [email protected].

Subsidiary of Yokogawa Electric Corporation, Yokogawa United Kingdom, has been awarded a multi-million pound contract by

SSE Hornsea for the upgrade of one of the UK's largest onshore underground gas storage facilities, located at Atwick, East Yorkshire.

Yokogawa United Kingdom will supply an integrated control and safety system, together with a metering solution. The order includes the supply and installation of Yokogawa’s flagship CENTUM VP integrated production control system to control the gas compres-sors. Also included in the project is the ProSafe-RS integrated safety instrumented system, which will contribute to ensuring process safety at the facility.

The Atwick gas storage facility comprises nine man-made salt cavities that have been leached into a salt layer 1,8 kilometres un-derground, creating around 325 million cubic metres of gas storage space.

Gas is imported to the site and injected into the cavities for storage. When needed, the gas is then withdrawn from the cavities, dried, and exported to the National Transmission System. According to the British Geological Survey: “When compared to above ground storage tank facilities, underground gas storage provides the significantly greater and cheaper storage volumes required and, when carefully constructed and monitored, added levels of safety.”

This contract is part of an SSE project to extend the life of the site and allow its use for both peak shaving and longer term storage by improving control, compression, and metering. It is the project’s aim to ensure the viability of the asset’s control systems and the commer-cial availability of the facility for the future by replacing the obsolete control systems with modern, maintainable, and supportable control and safety systems.Enquiries: Tel. 011 831 6300 or email [email protected].

Gas metering management system – accurate, reliable

New Ethernet embedded CPU

Major contract for onshore gas storage facilities

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CoVER stoRy



Standby and back-up





ACDC Dynamics - truly leading edge

ACDC Dynamics was founded in 1984 and is a market leader in manufacturing, importing and distributing of quality products in

the electrical, solar power, alarms systems, pumps and tools indus-tries. Our head office is located in Edenvale and we have branches in Germiston, Cape Town and Durban.

Staff: We employ over 420 people countrywide delivering service excellence and making sure we have the right people in the right places. Our field sales personnel, product specialists for each brand and product range and technical support staff, are always ready and able to provide any support you may require. We consider our expert staff to be our greatest asset.

Apprentice school: ACDC Dynamics has just opened its new ap-prentice school with 22 apprentices including six ladies in the first year programme. The two year apprenticeships started in January 2012 - training electricians, electronic technicians and amateur wind-ers in their electrical trade. Our first group of apprentices will qualify in late 2013.

Products: Our product ranges include, alarms, industrial and domestic automation, telemetry systems, pumps, switchgear and instrumentation, energy management and power factor control and correction solutions, solar and wind generators, tools, wire, adhesives and consumables, cable and wire management products, and the most comprehensive range of lighting, making use of new innovative technologies in energy saving solutions applying CFL, Inductive and LED technologies. Some of our leading international brands that we represent include:

Solutions: Our manufacturing operation offers a wide range of solutions from the production of transformers, power supplies, electronic timers, motor starters to power factor correction systems.

Although our primary markets are specifiers, consulting engineers and architects we distribute a wide range of products to OEMs, Panel Builders and through Electrical Wholesalers countrywide, this places ACDC Dynamics products within easy reach for anyone in sub-saharan Africa. ACDC Dynamics products are specified in many projects ranging from stadiums to mines, hotels to homes, farms to breweries and residential shelters.

Sustainability: Many companies talk about sustainability, but few are passionate and committed enough to live it. To address the heightened demand of renewable energy and energy savings, we have drawn together a group of specialists to focus purely on the activities of green solutions.

The Green Team: This team helps business find effective ways to reduce energy use in optimising asset and reducing fossil-fuel consumption and their carbon footprint. The team advises on imple-menting co-generation, managing peak demand energy consumption, power factor correction, lighting, solar panels, variable speed drives for compressed air, fans, motors, and pumping systems. We aim to reduce energy costs of your production environment so you can operate more efficiently and profitably.

Fast, efficient and friendly: ACDC Dynamics is committed to upgrading its existing IT infrastructure during 2013 to the X3 ERP system. We aim to simplify our operations and improve our services to you, our valued customers, by providing easy access to your orders and stock enquiries.

Catalogue: One of the company’s many strengths is its extensive catalogue which is widely recognised as a benchmark in the electrical industry. Truly world class, you will find all the specifications, product ranges and technical details you will require to make the most ap-propriate product selections. It is produced and updated biennially to provide you with the most up to date product detail. The updated catalogue will be available in late 2013.

Enquiries: Tel (sales): 010 202 3400. Tel (technical): 010 202 3500

Email: [email protected]. Visit www.acdc.co.za

• Rhomberg • Gewiss (Italy)• C&S TC (India)• Fuleon (UK)• Datalogic (Italy)• Terasaki (Japan)• Weicon (Germany)

• BM (Italy)• Crown (Japan)• TechnoAlarm• Gave (Spain)• SolarLand• SolarEdge


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The Leuze CML 720 Series, available from Counta-pulse Controls, offers an extremely fast response

time of only 30 µs per beam. This speed of operation allows these light curtains to detect even the fast-est processes with ease. The beam spacing of up to 5 mm means that the Leuze CML 720 light curtain can rapidly detect even the smallest changes in dimen-sion, facilitating extremely accurate positioning. Ca-pable of operating in the range up to six metres with a measurement field length of up to three metres, these light curtains allow accurate measurement of large objects with ease. Not only does the Leuze 720 offer speed of detection, users can also simply com-mission the unit without the need for a PC due to the integrated display in the connection head. A further feature of the unit is the option to use a rear-side mounting for the connection head. This results in a very small dead zone of only 23 mm being created when several light curtains are cascaded.

Enquiries: Gerry Bryant. Tel. 011 615 7556 or email [email protected].

The Integra motor controller has been re-launched nationally under the Suresense Technology banner which is available lo-

cally from OEN Enterprises. Integra can make significant savings on the running costs of applications that use ac induction motors.

The Integra motor controller is unique as it dynamically ad-justs power to a motor as its load changes. It constantly moni-tors the motor's load and calculates the exact amount of power required at any time, reducing the amount of electricity used, increasing the lifespan of motors. Once the motor is running, Integra constantly monitors the load on the shaft of the motor and adjusts the electricity consumption in accordance with the job that it is doing at any point in its duty cycle. Integra is able to shut motors down when they are not required. The timed shut off feature automatically turns off motors that have not been used for a specified period of time. Integra’s stored energy feature takes full advantage of the kinetic energy present in fly wheel applications and can decrease run time of the motor down by as much as 30% in certain cases.

Enquiries: Mike Andrews. Tel. 011 675 4447 or email [email protected].

Detects smallest changes in dimension

Complete fixed speed motor solution

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The risk of an arc flash event is real—an arc flash can instantane-ously generate temperatures about four times the temperature of the sun. An arc flash is associated with the explosive release

of energy caused by an electrical arc, due to either a phase-to-ground or a phase-to-phase fault. These kinds of faults can result from many factors - a dropped tool, accidental contact with electrical systems, build up of conductive dust, corrosion or improper work conditions.

An arc flash event creates intense heat, light and concussive force. For example, a 10 000 A arc on a 480 V circuit is said to have the explosive force of eight sticks of dynamite. As personnel perform regular maintenance on electrical equipment, it is crucial that they are aware of arc flash dangers, know how to avoid them and use equip-ment designed to minimise arc flash risks. In recent years, research and development has yielded many advances in electrical safety and much of that research has focused on preventing arc flash events. Arc flash dangers are a critical issue for companies around the world. Oil and gas, water and wastewater, mining, and utility operations are expected to run continuously, and the systems that power them must also run 24 hours a day, seven days a week. Arc flash events can endanger employees and the equipment that powers these industries.

Low voltage motor control centres

Low voltage motor control centres (MCCs) are routinely accessed during maintenance and are designed to help protect personnel and equipment from the danger of arc flash. These MCCs lower the probability of electrical shock and reduce incident arc flash energy during maintenance. There are guidelines for arc flash prevention and equipment that are intended to help prevent injury and to pro-tect equipment. However, there is room for interpretation, and the applicable standards and guidelines can be confusing.

Applicable codes and standards

The National Fire Protection Agency (NFPA) Article 70E [1] identifies safe practices for personnel to follow while working on energised electrical equipment. The purpose of NFPA 70E [1] is to provide guidelines to limit injury. Both the National Electrical CodeT (NECT) and the Occupational Safety & Health Administration (OSHA) refer-

ence the NFPA 70E standard in their arc flash documentation. A safe and sound electrical safety programme is key to enhancing safety. NFPA 70 Article 340.7 [1] states that an employer is responsible for providing training and supervision by qualified personnel to:• Explain the nature of the hazard• Develop strategies to minimise hazards• Provide methods to avoid and protect against hazards• Convey the necessity of reporting any hazardous incidents

Additionally, the Institute of Electrical and Electronics Engineers (IEEET) 1584 [2] provides guidelines on how to calculate incident arc flash energy to develop boundaries and to establish personal protec-tive equipment (PPE) requirements. Incident energy is the amount of energy impressed on a surface a certain distance from the source. Its unit of measure is in calories per square centimetre (Cal/ cm2). The flash protection boundary is specified as the point where incident energies drop to 1,2 Cal/ cm2 - the amount of energy that begins to form second-degree burns.

Low and medium voltage switchgear is used to protect, control and monitor distribution systems and to protect operating and main-tenance personnel from arcing faults. Arc flash hazards in switchgear are addressed through the American National Standards Institute (ANSI) C37.20.7 [3] specification that lists testing guidelines for arc-resistant switchgear. Switchgear that is built to meet arc-resistant standards redirects or channels the arc energy and pressure through a plenum, out the top of the switchgear, regardless of where the arc originated. The guideline looks at internal arcing faults on metal-enclosed switchgear rated up to 38 kV. Equipment tested to this standard protects against the effect of abnormal internal pressure or arc flash as long as all doors and access areas are properly secured.

By DB Durocher, Eaton

Low voltage motor control centres (MCCs) are routinely accessed during maintenance and are designed to help protect personnel and equipment

from the danger of arc flash.

Take note

Arc-preventative MCCs Safety and protection for personnel

and equipment

• increasingly, the risk of arc flash injury is being incorporated into designs and procedures.

• arc flash can be associated with an lV mCC.• arc-preventative mCCs are designed to protect personnel and equip-

ment from the danger of arc flash.


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The danger of arc flash is not limited to switchgear. However, the application of ANSI C37.20.7 [3] to MCCs has limitations. At this time, there is no MCC arc flash guideline. Arc-resistant gear or arc-redirection gear does provide higher levels of safety for personnel in the vicinity of the equipment, but does not address a common cause of electrical accidents - mistakes. The overwhelming number of arc flash accidents occur during maintenance or troubleshooting.

Arc resistant vs arc preventative

A common misconception in the industry is that the use of arc-resistant switchgear in MCCs adds significant safety margins for any electrical worker in the area. The major flaw in this assumption centres on how electrical workers perform equipment maintenance. Most MCC compartment doors need to remain closed to meet the thrust of arc-resistant guidelines. But much electrical maintenance requires working with the doors open; eventually, personnel need to access the interior components and connections. That may be more dangerous with arc-resistant gear than with non–arc-resistant gear. Opening the door may form conditions where the path of least resistance for the pressure wave is no longer the safe path of the plenum at the top of the gear, but out through the open door to maintenance personnel. That is not to say that arc-resistant gear should be avoided. The key is applying guidelines to the equipment that they were designed to address. Improving operator and electrical worker safety from arc flash incidents is necessary. It is crucial to find arc-resistant gear that lets electrical workers perform maintenance with little risk of arc flash exposure.

At this time, the arc-resistant designation applies only to switch-gear tested to meet ANSI C37.20.7 [3]. MCCs need to be accessed for maintenance, so closed-door operation requirements fall short, given normal operating procedures. MCCs are routinely accessed for a variety of reasons - connecting or disconnecting starters or feed-ers, adjusting trip settings, replacing fuses, adding motor loads and general troubleshooting. To make adjustments, access to the interior of the unit buckets is necessary. Yet, this means that the MCC does not provide the highest level of personnel protection. In MCCs, the predominant cause of arc flash incidents is due to the operator plug-ging in or removing a unit from a live bus with the unit door open.

Maintaining a deadfront barrier, like connecting and disconnect-ing MCC starter or feeder units while the unit is closed and provid-ing insulated components or connections, significantly reduces the possibility of an arc flash incident. Arc flash preventative designs are relevant to MCCs. Closed door operation, in combination with safety interlocks, addresses this arc flash safety need.

What makes for arc flash preventative MCCs?

The strategy: prevention and protection. Key strategies are used to help safeguard employees against injuries from electric shock, arc flash burns and arc blasts:• Multiple insulation and isolation features enable arc flash preven-

tion.• Unlike conventional MCCs, arc-preventative MCC design enables

units to be disconnected and reconnected to the vertical bus with the door closed; maintaining a closed door during these opera-tions increases operator safety.

• A series of safety interlocks ensures that doors cannot be opened and that units cannot be removed from the structure while the stabs are connected to the vertical bus.

• Each unit contains visual indicators that report the position of the isolation shutters and the stabs, providing maintenance person-nel with additional assurance that dangerous voltages are not present inside the unit when service is required.

Testing by IEEE 1584P [3] can be conducted to verify that closed door operation provides considerably lower risk category than the risk Category 3 assigned by the NFPA 70E Table 130.7 (c) (9) (a) [1] for insertion and removal of MCC units. Beyond thermal hazards, a closed door provides better protection from shrapnel, noise, gases and blinding light. Remote operated racking devices are available so that an operator may advance and retract the stabs from upwards of 15 feet (4,572 m), which places the operator outside the arc flash boundary.

Arc-preventative MCCs - application example

When motors are geographically dispersed throughout a facility, the motor starters are aggregated in an MCC. The motor starters are segregated into individual units or buckets within the MCC for ease of isolation and maintenance. Each bucket is connected to the MCC power bus through rear-mounted stabs. Insertion or removal of the buckets is done manually with the MCC door open. Accepted practice allows electrical personnel to physically push the bucket onto the main bus by hand. While the MCC should be de-energised during this action, plant operation usually demands that the MCC maintains power, creating arc flash and electrocution hazards.

For example, the periodic testing and troubleshooting of motor starters requires the main power to remain on, in order to perform any meaningful tests or troubleshooting. Because the equipment is powered, electrical personnel are exposed to dangerous arc flash

Abbreviations

ansi - american national standards instituteiEEE – institute of Electrical and Electronics EngineersmCC – motor Control CentrenEC – national Electrical CodeosHa – occupational safety & Health administrationPlC – Programmable logic ControllerPPE – Personal Protective Equipment


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conditions. The main power stabs in conventional MCC circuits feed a control-power transformer via a short-circuit protective device such as a circuit breaker or a fuse. The control-power transformer reduces the 480 Vac incoming voltage to 120 Vac for the control circuits. Con-trol circuits powered by the transformer include pushbutton stations, timers, relays and programmable logic controllers (PLCs).

A means to connect and disconnect individual unit starters with the door closed keeps the arc flash boundary secure, while remote operating stations assure that operators remain outside the arc flash boundary. Additional safety features to prevent injury from electric shock, arc flash burn and arc-blast impact include: isolation and insulation of the current-carrying bus and components, finger-safe covers and components, mechanical interlocks to prevent inadvertent energisation and access to live components, and control circuits that use voltages below electrocution hazard levels.

Arc-preventative MCCs specified

Despite a gap in the arc flash guidelines, there are MCCs designed to enhance personnel safety and to protect equipment from arc flash hazards. Arc-preventative MCC design focuses on:

• Enhancing safety through training, labelling, analysis and solu-tions that reduce exposure to dangerous situations

• Avoiding extra costs by reducing or eliminating unplanned downtime and equipment damage, and enhancing safety through improved safety practices

• Mitigating risk by meeting or exceeding the standards from NFPA 70E and IEEE 1584 [3]

Arc-preventative MCC design addresses prevention through insula-tion and isolation. The horizontal bus is insulated; an arc-free insulated bus and barrier system reduces the possibility of arcing phase-to-phase and phase-to-ground short circuits. Active interlocks provide positive mechanical disconnect and prevent insertion or withdrawal of the MCC bucket while the stabs are engaged or extended. Independent shutter mechanisms automatically isolate both the vertical bus and the unit power stabs when the motor control unit is withdrawn. The shutter position indicator provides further verification of the bucket’s safety status - indicating whether the internal isolation shutters are open or closed.

A critical component of arc-preventative MCCs is a retractable stab mechanism. This component enables the stabs to be discon-nected or reconnected to the vertical bus with the unit’s door closed.

Also, an optional remote racking system extends the operator’s safety zone to a maximum of 15 feet (4,572 m) while disconnecting or reconnecting the unit power stabs to the vertical bus during main-tenance or bucket replacement.

The movable assembly of the retractable stab mechanism free wheels in both directions at the end of travel to prevent over torque-ing and damaging the housing and movable components. Visual indicators should provide quick, positive verification of stab position. Additionally, for maintenance personnel, the cabinet itself is the main defence against arc exposure.

Substantial steel panels with doors can be securely latched to suppress dangerous effects of an arc flash and provide a barrier between the flash and the operator. Through-the-door controls and indicators help plant personnel perform routine operations without having to open the enclosure. Even when maintenance personnel do need to open MCC doors, visual indicators help personnel to verify the bucket position from outside the enclosure.

Arc-preventative MCCs specified

• Arc-free insulated bus and barrier system reduces possibility of arcing phase-to-phase and phase-to-ground short circuits

• Active interlocks prevent insertion or withdrawal of the MCC bucket while the stabs are engaged or extended

• Independent shutter mechanisms automatically isolate both the vertical bus and the unit power stabs when the motor control unit is withdrawn

• Through-the-door voltage present indicator• Remote connect and disconnect racking motor accessory• Automatic insulation tester to monitor insulation integrity


About the author

• Load-side stabs up to 180 A to safely remove the unit without removing the motor leads

• Padlock accessory locks the unit door closed and is engineered to allow access by qualified personnel

• Substantial steel panels with doors that can be securely latched

Arc-preventative MCC designs can also be used in conjunction with an Arcflash Reduction Maintenance System to reduce the amount of energy available to produce an arc flash. Less energy means less danger and less damage should an arc event occur.

Flash Reduction System

Arcflash Reduction Maintenance System Mitigation

An Arcflash Reduction Maintenance System is an optional plug-in module that can be applied to the main breaker and permits the operator to add an instantaneous trip setting to temporarily reduce the breaker’s normal trip threshold during mainte-nance. If the breaker is in this setting, it will open much quicker when an arc fault occurs. Clearing the fault faster and limiting its impact on downstream circuits means the Arcflash Reduction Maintenance System can greatly reduce the level of energy avail-able during an arc flash event.

Conclusion

A strategic approach to arc flash safety involves education, a robust safety programme and state-of-the-art equipment engineered to help prevent personal injury and property damage. Solutions engineered to address arc flash dangers are help-ing to solve critical safety issues, while reducing downtime and increasing building efficiency.

There are MCCs engineered to protect equip-ment and personnel from the danger of an arc flash. Minimising the impact and the exposure to higher PPE levels in industrial environments means increased uptime and enhanced personnel safety. These MCCs lower the probability of creating a short-circuit phase-to-phase or phase-to-ground fault, while also lowering the probability of electri-cal shock and reducing incident arc flash energy during maintenance.

References

[1] NFPA 70 E. 2012. Electrical safety in the work-place.

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[2] IEEE 1584. 2002. Guide for performing arc-flash hazard calcula-tions.

[3] ANSI C37.20.7. 2007. IEEE Guide for testing metal-enclosed switchgear rated up to 38 kV for internal arcing faults.

About the author

david B durocher is the global segment manager for Eaton Electrical sector in Wilsonville in the usa. david has been with Eaton since 1978.Enquiries: mark strydom. tel: 011 824 7400 or email [email protected].

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The Thomson hydro plant, located at the Thomson dam site (on the Thomson river), comprises an 11 kV induction generator. It is connected to an SP AusNet 22 kV distribution feeder, via a

22/ 11 kV, 7,8 MVA transformer. When the Melbourne Water Coopera-tion’s (MWC) network agreement expired, the plant’s impact on the SP AusNet distribution network (based on the Victorian Electricity Distribution Code [1]) had to be reviewed.

Figure 1: Thomson hydro plant connection to SP AusNet Network.

The SP AusNet Distribution Code (version 4) [2] stipulates:• Voltage variations: The level should be maintained at ±6% for a

period of less than one minute under normal operation.• Power Factor (PF): Maintain the PF at 0,9 for 50% load.• Additional compliance: Other factors concerning reverse power

flow, thermal elements of the plant and fault level limitations, were also outlined to MWC.

Study recommends solution

The study, conducted by Entura (Australian energy and water consult-ants) evaluated the effect of Thomson’s 7,45 MW power generation on the SP AusNet network. It went on to recommend the use of a combined power quality solution, made up of the world’s fastest dynamic compensation systems, enabling MWC to comply with the distribution code. Full simulations included various possible scenarios during the plant’s operation, simultaneously evaluating the system’s performance in comparison with other capacitor banks. Load flow analysis was performed for the expected maximum (7,45 MW), 50% of rated (3,15 MW) and 25% of rated (1,57%) of the Thomson hydro plant in order to identify voltage or reactive power control issues:• Voltage variations: Different reactive support sizes were evaluated

in order to find the optimum solution.• Voltage drop during generator start-up: The current make-up of

the site, its location and adopted solutions were analysed in full. Analysis was also based on the effects of generator start-up on different points over the entire network. MWC was particularly interested to reduce the expected voltage drop of 8,11% as a result of generator start-up tripping.

• Other elements: Due to the nature of the plant’s location with the network, and its operation, Thomson was able to meet the additional compliance as set out by SP AusNet.

Best operational outcome

The results of the EQ’s performance were compared with other sys-tems under various circumstances:• Steady state voltage variation: When the EQ system was con-

nected to the 11 kV Thomson generator during steady state, the maximum voltage variation of the connection point would range between 0,98 pu and 1,044 pu - proving to be the best perfor-mance and well within the voltage limits given by the Victorian Electricity Distribution Code [1] of ±6%. When other generators down the line, such as the Blue Rock, were in service, the voltage rose approximately 1,3% in this area and 1,1% in the Thomson area – falling once again well within the code [1] guideline range.

• PF: Even without the use of the EQ-ST during generator start-up, the EQ’s PF of 0,89 would fall within the code [1] limits of 0,90. Although this is just slightly below the Code’s limitation, Entura felt that the EQ would still prove to give the best operational outcome to the SP AusNet distribution network.

Dual combination combating voltage drop during generator start-up

The start-up procedure of the Thomson hydro generator consists of running the generator to slightly above synchronous speed (~1,02 pu) and closing the generator circuit breaker. During the starting period, the generator is connected to the 11 kV transformer LV terminal through a 14,5 Ohm series reactor. This proposed solution was adopted in order to limit the voltage drop down the line. Two seconds after starting, the series reactor is bypassed and the generator is con-nected directly to the 11 kV terminal of the transformer.

By Y Harary, Elspec

The installation of Equalizer (EQ) and Equalizer-ST (EQ-ST) systems at the Thomson Reservoir hydro plant in Melbourne, Australia, achieved the

necessary reactive support and code compliance.

Take note

When power meets quality

• Coupling a hydro system into a network requires careful engineering.• Voltage fluctuations and general quality of supply issues must be

understood and accounted for in such a system.• modern state-of-the-art systems introduce optimal compensation based

on the network needs of any given time.


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Parameter Network CodeCompliance

With Elspec Solution

Power Factor –Use of EQ only

0,90 0,89

Voltage variations –

use of EQ only

±6% 1,044 pu

Parameter Without Elspec Solution With Elspec Solution

Voltage dropDuring start-up

8,11% 2,37%

Table 1: Initial Entura study results – Thomson Hydro Plant.

The simulations run by Entura proved this solution to be unacceptable, as at least 5 – 6 MVAr reactive support will minimise the starting volt-age drop to an acceptable limit – from 8,11% to 4,77%. Furthermore, the proposed generator start-up reactive support must be equipped with a fast switching control system in order to automatically switch off when the requirement of the generator drops off. Failure to do so within 20 msec could force 22 kV (voltage) to reach unacceptably high voltages, which would ultimately harm the network or customer’s equipment down the line.

Conclusion

Taking all of these factors into consideration, WTC adopted Entura’s recommendation and installed a combined solution. The combina-tion consists of Elspec’s 1,1 MVAr EQ-ST system for the steady-state that will also compensate for any residuum reactive energy – and a 5,4 MVAr EQ-ST system for the start-up of the plant’s generator. The response time of both units is typically one cycle. Both systems are operated based on reactive set point. If the generator reactive require-ment is beyond reactive set point, then the unit starts compensating until reactive demand drops below 90% of the set point.

Therefore, the actual voltage response proved to be smoother and faster when compared to the initial results shown in the study (see Table 1). As the systems are equipped with detuned reactors, they provide protection on any harmonic oscillations, and therefore any harmonic resonances due to its use are unlikely.

References

[1] Electricity Distribution Code. May 2012. Version 7.[2] SP AusNet Distribution Code. February 2010. Version 4. About the author

yoram Harary is founder and chief executive officer of Elspec Engineering. the company specialises in developing and installing systems for stabilis-ing electricity networks at industrial plants. Enquiries: Wayne Bromfield. impact Energy. Email [email protected].

Thomson Hydro Plant.

Figure 2: Electrical diagram EQ-ST and EQ installation.

Figure 3: Generator starting voltage drop without Elspec solution.

Figure 4: Generator starting voltage drop with Espec solution.


Round uP

In large industrial and chemical plants, which often contain large numbers of mo-

tors to provide the necessary motion, any unplanned or sudden motor stops can lead to faults in the process sequence, which can be very cost-intensive. For this reason, reli-able management and protection of these motors is of vital importance for ensuring a controlled production sequence.

Some current motor feeders are built up discretely, using for example, thermal motor protection based on a bimetal relay. In such a system implementing protection and control functionality is cumbersome and complex; motor control and interlocking functions must be programmed in the process con-troller, and control and feedback signals are exchanged via input and output modules that must be designed and wired.

Additional protective functions such as motor winding temperature monitoring via

a thermistor require additional devices and wiring. These and many other functions are integrated in a single device, the intelligent universal motor controller UMC100. Some-times referred to as an ‘intelligent motor management module’, the UMC100 offers motor control, motor protection, fieldbus communication with the control system and diagnostic functions. Compared to con-ventional motor feeders, motor controllers offer many advantages throughout the entire lifecycle of an industrial plant.

Changing global markets is one reason many companies are being forced to reduce their operating and production costs while increasing output and quality. Energy effi-ciency is another factor that manufacturers in particular are interested in improving. In fact, there is now an increasing demand for more modular, flexible and integrated solutions. This in turn is causing many providers to look

at their portfolios and find ways of enhancing their product offerings in response to this demand. Integrated solutions are fast be-coming more commonplace, in part because technology advances are making integration easier, additionally these solutions function more effectively as a whole, rather than the sum of their individual elements.

Enquiries: Hendrik Spies. Tel. 010 202 5000 or email [email protected].

NewElec’s K Series, including the KA, KB and KC relays, provide a single

unit solution in pumping applications that traditionally would have used a combina-tion of thermal overload, undercurrent and restart timers. The units provide overload, underload, single phasing, unbalanced cur-rent, over/under voltage and phase rotation protection.

The K Series electronic motor protection and control relays are housed in a small foot-print, DIN rail mount enclosure. Fixed ther-mal curves (Class 15 cold - Class 5 Hot) with

thermal pre-loading, match the hot and cold stall times of the motor during operation.

The KA relay is mains powered auto-selecting a 400 V or 525 V supply, while the KB and KC relays require either a 110 V or 220 Vac auxiliary supply. Utilising microproces-sor technology, the relays with their compact design, require minimal cubicle space.

They are available in the range from 0,5 A to 50 A directly through the current transformer module block and in the range from 50 A to 200 A using external current transformers in a xxx:5 ratio. Manufactured

to ISO 9001:2000 requirements, protection is also provided for locked rotor, jam, phase loss and current unbalance protection.

Enquiries: Luc Dutrieux. Tel. 012 327 1729 or email [email protected].

MEAN WELL has introduced the new SDR-75 series (75 W) to complete the high efficiency slim DIN rail power product line.

The diverse wattages of 75 W, 120 W, 240 W, 480 W and 960 W are now available. The slim design of 32 mm in width helps save space on the rail and also makes it 41% smaller in size compared with its predecessor model DR-75. The SDR-75 is 9 - 12,5% more efficient than corresponding models and the working temperature, from -30°C - +70°C is superior to the range of -10 - +60°C of the DR-75, in keeping with green power and energy saving. With an up-to-date high performance circuit de-sign, the SDR-75 series has full range ac input (88 - 264 Vac) and can be cooled through free air convection from -30°C to +55°C or +60°C ambient temperature under full load, and even up to +70°C with a suit-able derating. SDR-75 has 150% peak load capability and is equipped with overload protection of constant current limiting and delay shut down, which is perfect for all kinds of critical loading, such as inductive

and capacity loads. Other standard functions include front panel LED indicator, front panel dc voltage adjustment, as well as protection for short-circuit, overload (constant current mode), over voltage, and over temperature. In addition, the new series complies with UL, CUL, CB, TUV, and CE certificates and also meets EMC requirements of heavy industrial immunity levels (EN61000-6-2). Suitable applications include industrial control systems, semi-conductor fabrication equipment, fac-tory automation, electro-mechanical applications, and any installation with fanless or low noise requirements.

Enquiries: Email ettienne@rectifier.

co.za.

Intelligent motor control evolves to the next level

Pump application protection

New series - DIN rail power

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Round uP

Hot on the heels of the 2012 PneuDrive Challenge winning team’s recent trip to

SEW Eurodrive’s headquarters in Germany, SEW Eurodrive general manager (communi-cations), Rene Rose, spoke to the Tshwane University of Technology (TUT) students about their winning design and their overall involvement and experience in the contest.

The winning team, comprising Mias Swanepoel, Byron Nielson, JP Joubert and Gerrit Botha, said that upon entering the contest they were confident that they were going to develop a winning design that would highlight the reality of hunger in the world, thereby tying into the contest’s theme of engineering a solution that could improve the lives of South African disadvantaged communities.

The team’s initial research into the area of plant yields revealed that significant improvements could be made in the area of seed propagation and planting. The team recognised that many disadvantaged communities have insufficient land to grow crops and have limited income to purchase enough food to meet their daily requirements. As a result, the team aimed to develop a concept that would essentially increase the effectiveness of the seeding propagation and planting process, and thereby decrease the cost of seeding and crop production, which would offer op-portunities to supply cheaper agricultural products to end-consumers.

After months of in-depth research and consultation with professors, lecturers, industry professionals and fellow students, the team developed the concept of a high-speed, automated seeding machine that brings together new research in ‘arbori-culture hydrogels’ and mass production in order to improve the process of preparing seeds for planting. The team points out that research indicates that by reducing the costs associated with seeding and improv-ing the productivity and planting efficiency of greenhouse farms, food production can be increased at a lower cost.

The Gel Seed Printer makes use of hy-drogels with mechanised seed planting. One of the most important characteristics of the hydrogel is its ability to hold large amounts of water far exceeding its own weight. The team stresses that this charac-teristic is important in a farming environ-ment because hydrogels can store water and nutrients in capsules allowing for slow release in areas that are characterised as

being arid. Instead of releasing the water all at once, the hydrogel consumes moisture and locks it in, keeping the ground moist.

A sproutling that has been fed and vac-cinated against disease and pests results in a seed that is more likely to take root and grow, when compared to a seed that has to germinate naturally. By designing a high-speed machine that has the ability to prepare seedlings inserted in pre-prepared hydrogels, the result is a unique approach to seed propagation and greenhouse farm-ing. Overall, the judging panel awarded first place to the TUT team for a well-researched and innovative design which essentially could mechanise, simplify and improve the efficiency in the way farmers raise their crops.

Enquiries: Rene Rose. Tel. 011 248 7000 or email [email protected]. Eugene van der Lith.

Tel. 011 573 0902 or email [email protected].

TUT students engineer solutions to tackle world hunger

The successful TUT team: Mias Swanepoel, Byron Nielson, JP Joubert and Gerrit Botha and Lecturer

Johan Benade.

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Until fairly recently, the return on investment for power factor correction equipment, in commercial and industrial applica-tions, was unacceptably long for most companies.

Avoidance of wasteful electricity demand and consumption was not given the attention it deserves and energy efficiency has only very recently become a strategic objective. The significant electricity tariff increases introduced in recent years, have made investments in power factor correction very attractive for most commercial and industrial consumers.

What is power factor?

Power factor (also referred to as cosine phi) is the ratio between the active load power (kW) and the apparent load power (kVA) drawn by an electrical installation. It is a measure of how effectively the cur-rent drawn by the load is being converted into useful work output.

Figure 1: Power triangle

All current will cause losses in supply and distribution systems. A load with a power factor of 1,0 results in the most efficient loading of the supply and a load with a power factor of 0,5 will result in much higher losses in the supply system. A poor power factor can be the result of a significant phase difference between the voltage and cur-rent at the load terminals.

Figure 2: Phase angle.

Poor load current phase angle is generally the result of an inductive load such as an induction motor, power transformer, lighting ballasts, welder or induction furnace.

A poor power factor due to an inductive load can be improved with the addition of power factor correction. A poor power factor can also be caused by a high harmonic content or distorted/discontinuous current waveform. A distorted current waveform can be the result of a rectifier, variable speed drive, switched mode power supply, discharge lighting or other electronic load. The power factor of a load with a distorted current waveform requires a change in equipment design or expensive harmonic filters to gain an appreciable improvement.

Power factor correction of inductive loads

An inductive load, such as a motor, draws current from the supply, which is made up of resistive components and inductive components. The resistive components are:• Loss current (small)• Load currentThe inductive components are:• Leakage reactance current (small)• Magnetising current

Figure 3: Current vectors.

The current due to the leakage reactance is dependent on the total current drawn by the motor, but the magnetising current is independ-ent of the load on the motor. The magnetising current will typically be between 20% and 60% of the rated full load current of the motor.

The magnetising current is the current that establishes the flux in the iron and is very necessary if the motor is going to operate. The magnetising current does not actually contribute to the actual work output of the motor.

It is the catalyst that allows the motor to work properly. The magnetising current and the leakage reactance can be considered passenger components of current that will not affect the power drawn

Reduce electricity costs and free up capacityBy E Solot, Alpha Power Solutions

Power factor correction – how it can benefit industrial and commercial businesses in terms of savings in electrical energy costs as well as the

freeing up of electricity supply capacity.

MagnetisingCurrent

Motor Current

Work Current

kvarkVA

kVA= PFcosθ =

kW

kW


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by the motor, but will contribute to the power dissipated in the supply and distribution system. In the interest of reducing the losses in the distribution system, power factor correction is added to neutralise a portion of the magnetising current of the motor. Typically, the cor-rected power factor will be above 0,95. Some municipalities penalise consumers with a poor power factor by charging them for excessive kvarh consumed (> 30% of kWh consumed during the same period) and by doing so encourage them to reduce wasted energy by apply-ing power factor correction.

Power factor correction is achieved by the addition of capacitors in parallel with the connected motor circuits and can be applied at the motor (static power factor correction), or applied at the distribution panel (bulk power factor correction). The resulting capacitive current is a leading current and is used to cancel the lagging inductive current flowing from the supply to the inductive load.

Figure 4: Power factor correction current vectors.

Bulk power factor correction

When bulk power factor correction is applied, the power factor of the total current supplied to the distribution board is monitored by a controller which then automatically switches capacitor banks in a fashion to maintain a power factor better than a preset limit (typically between 0,95 and 0,98).

Figure 5: Bulk power factor correction.

Ideally, the power factor should be as close to unity as possible. There is no problem with general correction operating at unity (even though this is usually not the most cost effective target power factor), but correction should not be applied to an unloaded or lightly loaded transformer. If correction is applied to an unloaded transformer, you create a high Q resonant circuit between the leakage reactance of the transformer and the capacitors and destructive high voltages can result.

Static power factor correction

As a large proportion of the inductive or lagging current on the supply is due to the magnetising current of induction motors, it is easy to correct each individual motor by connecting the correction capacitors to the motor starters.

Figure 6: Static power factor correction.

With static correction, it is important that the capacitive current is less than the inductive magnetising current of the induction motor. In many installations employing static power factor correction, the correction capacitors are connected directly in parallel with the motor windings. When the motor is off line, the capacitors are also off line.

When the motor is connected to the supply, the capacitors are also connected providing correction at all times that the motor is con-nected to the supply. This removes the requirement for any expensive power factor monitoring and control equipment.

Power factor correction and harmonics

Harmonics are caused by many non linear loads, the most common in the industrial market today, are the variable speed controllers and switch-mode power supplies.

Harmonics cause a higher current to flow in the capacitors of a power factor correction installation because the impedance of the

MagnetisingCurrent

Work Current

Contactor Overload

Capacitors

Motor

Line Current

Capacitor Current

Capacitor Banks

Motor Current


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capacitors goes down as the frequency goes up. This increase in current flow through the capacitor will result in additional heating of the capacitor and reduce its life. Harmonic voltages can be reduced by the use of a harmonic compensator, which is essentially a large inverter that cancels out the harmonics and is an expensive option. Passive harmonic filters comprising resistors, inductors and capaci-tors can also be used to reduce harmonic voltages but this is also an expensive exercise.

In order to reduce the damage caused to the capacitors by the harmonic currents, it is becoming common today to install detuning reactors in series with the power factor correction capacitors. These reactors are designed to make the correction circuit inductive to the higher frequency harmonics. Typically, a reactor would be designed to create a resonant circuit with the capacitors above the third harmonic. Adding the inductance in series with the capacitors will reduce their effective impedance at the supply frequency. Reducing the resonant or tuned frequency will reduce the effective impedance further. The object is to make the circuit look as inductive as possible at the 5th harmonic and higher, but as capacitive as possible at the fundamental frequency.

Examples of power factor correction

Assume an active load of 100 kW and an associated apparent power of 142 kVA, resulting in a power factor of 0,70.

Figure 7: Apparent power before and after adding capacitors.

By reducing the reactive power to 33 kvar (by means of a 67 kvar power factor correction panel), the power factor improves to 0,95 and the apparent power decreases to 105 kVA. The reduction of apparent power (37 kVA) not only results in financial benefits to the consumer (reduction in maximum demand and associated costs) but also a reduction in heat losses of the system

Benefits of power factor correction

Reduced electricity costs

Eskom provides working (kW) and reactive power (kvar) in the form of apparent power (kVA). While reactive power (kvar) does not reg-

ister on kW demand or kW hour meters, Eskom’s transmission and distribution system must be large enough to provide the total power. Eskom and the municipalities have various ways of passing along the expense of larger generators, transformers, cables, switches, etc to the consumer. A reduction in apparent power results in a reduction in electricity costs.

Reduced losses

Losses caused by poor power factor are due to reactive current flowing in the system. These are watt-related charges and can be eliminated through power factor correction. Power loss (watts) in a distribution system is calculated by squaring the current and multiplying it by the circuit resistance (I2R).

Increased system capacity

Power factor correction capacitors increase system current-carrying capacity. Raising the power factor on a kW load reduces kVA. There-fore, by adding capacitors, additional kW load can be added to a system without altering the kVA.

Figure 8: Power factor correction increases transformer output.

Improved voltage conditions

Low voltage, resulting from excessive current draw, causes motors to be sluggish and overheated. As power factor decreases, total line current increases, causing further voltage drop. By adding capacitors to an installation and improving the system voltage, motor efficiency, life and performance is improved.

Industries benefiting most from power factor correction

Low power factor results when inactive motors are operated at less than full load. This often occurs in cycle processes - such as those


Meanwell Summary

APV-12/16 APC-12/16 APV-25/35 APC-25/35 - NEW

AC Input 90-264VAC; 127-370VDC

Overload Protection Hiccup up mode, auto recovery

Dimension (L x Wx H) mm 77 x 40 x 29 84 x 57 x 29.5

AP series - 12-35W Single Output LED Power Supply

LPL-18 LPH-18 LPV-20 LPV-35 LPV-60 LPV-100

AC Input 90-132VAC 180-264VAC 90-264VAC

Overload Protection Hiccup up mode, auto recovery

Dimension (L x Wx H) mm 140 x 30 x 22 118 x 35 x 26

148 x 40 x 30

162.5 x 42.5 x 32

190 x 52 x 37

LP series - 18-100W Single Output LED Power Supply

LPLC-18 LPHC-18

AC Input 90-132VAC 180-264VAC

Overload Protection 105%-135% rated output voltage

Dimension (L x Wx H) mm 140 x 30 x 22

LP series - 18-60W Single Output LED Power Supply

ELN-30 ELN-60


Overload Protection 110%-150% rated output voltage

Dimension (L x Wx H) mm 145 x 47 x 30 181 X 61.5 X 35

ELN series - 30-60W Single Output LED Power Supply

PCD-16/25 PCD-40/60

AC Input 115VAC (90-135VAC) or 230VAC (180-295VAC)

Withstand Voltage I/P - O/P: 3.75kVAC

Dimension (L x Wx H) mm 84 x 57 x 29.5 128 X 60 X 31.5

PCD series - 16-60W Single Output LED Power Supply with AC Dimmable Power Unit

PLD-16 PLD-25 PLD-40-NEW PLD-60-NEW

AC Input115VAC (90-

135VAC) or 230VAC (180-295VAC)

90-295VAC 230VAC (180-295VAC)


Dimension (L x Wx H) mm 84 x 57 x 29.5 128 X 60 X 31.5

PLD series - 16-60W Single Output LED Power Supply with PFC

PLM-12-NEW PLM-25-NEW PLM-40-NEW

AC Input 90-295VAC; or 127-417VAC


Dimension (L x Wx H) mm 145 x 38 x 22 175 X 42 X 24

PLM series - 12-40W Single Output LED Power Supply with PFC

LPF-16(D)/25(D)-NEW LPF-40(D)/60(D) LPF-90(D)



Dimension (L x Wx H) mm 145 x 40 x 32 162.5 x 43 x 32 161 X 61 X 36

LPF series - 16-90W Single Output LED Power Supply with PFC

PLC-30 PLC-45 PLC-60 PLC-100

AC Input 90-264VAC; or 127-370VAC Cold start, 40A at 230VAC

Connection (Inout/Output) 2+2P screw terminal block 3+2P screw terminal block

Dimension (L x Wx H) mm 160 x 46 x 30 181.5x 62 x 35 200.5 X 69.5 X 35

PLC series - 30-96W Single Output LED Power Supply with PFC

IP30

IP67

IP67

IP64

IP30

IP30

IP30

IP67

Meanwell Summary

PLN-20 PLN-30 PLN-45/60 PLN-100

AC Input 90-277VAC; 127-392VDC 90-295VAC; 127-417DC

Withstand Voltage I/P-O/P: 3.75kVAC

Dimension (L x Wx H) mm 148.5 x 38.5 x 28 145 X 47 X 30 181 X 61.5 X 35 200 X 70.5 X 35

PLN series - 20-96W Single Output with PFC

HLN-40H HLN-60H HLN80H


Withstand Voltage I/P - O/P: 3.75kVAC I/P - FG: 2kVAC O/P - FG: 0.5kVAC

Dimension (L x Wx H) mm 161 x 61.5 x 35 181 X 61.5 X 35

HLN series - 40-80W Single Output LED Power Supply with PFC

LCM-40(DA)/60(DA)

AC Input 180-295VAC; or 254-417VDC


Dimension (L x Wx H) mm 123.5x 81.5 x 23

LCM series - 40-60W Multi-Stage Output Current LED Power Supply

PLP-20 PLP-30 PLP-45/60

AC Input 90-277VAC; or 127-392VAC 90-264VAC; or 127-370VAC

Withstand Voltage I/P - O/P: 3.75kVAC I/P - FG: 2kVAC O/P - FG: 0.5kVAC


PLP series - 20-60W Single Output LED Power Supply with PFC

HLP-40H HLP-60H HLP-80H

AC Input 90-305VAC; or 127-431VDC

AC inrush current (max.) Cold start 50A at 230VAC Cold start 55A at 230VAC


HLP series - 40-80W Single Output LED Power Supply with PFC

CEN-60/75 CEN-100


Current Adjustment range -+75% - 100% 65%-100%

Dimension (L x Wx H) mm 185 x 62.5 x 40.5 195 X 62.5 X 40.5

CEN series - 60-96W Single Output LED Power Supply with PFC

CLG series - 60-150W Single Output LED Power Supply with PFCCLG-60 CLG-100 CLG-150


AC inrush current (max.) Cold start, 35A at 230VAC Cold start, 40A at 230VAC Cold start, 65A at 230VAC

Dimension (L x Wx H) mm 195.6 x 61.5 x 38.8 222.2 X 68 X 38.8

HLG series - 40-320W Single Output LED Power Supply with PFCHLG-40H HLG-60H HLG-80H HLG-100H HLG-120H


Current Adjustment range 60%-100% 50%-100%

Dimension (L x Wx H) mm 171 X 61.5 X 36.8 220 X 68 X 38.8

⇒ LDD /DC-DC Current Driver

IP64

IP64

IP67

IP67

IP20

Series Dimension (L x W x H) C.C or C.VCEN-60/75 185 x 62.5 x 40.5 mm c.v + c.cCEN-100 195 x 62.5 x 40.5 mm c.v + c.cSeries Dimension (L x W x H) C.C or C.VCLG-60 195.6 x 61.5 x 38.8 mm c.v + c.cCLG-100 222.2 x 68 x 38.8 mm c.v + c.cCLG-150 229 x 68 x 38.8 mm c.v + c.cSeries Dimension (L x W x H) C.C or C.VHLG-40H/60H/60H-C 171 x 61.5 x 36.8 mm c.v + c.cHLG-80H/80H-C 195.6 x 61.5 x 38.8 mm c.v + c.cHLG-100H/120H/120H-C 220 x 68 x 38.8 mm c.v + c.cHLG-150H/185H/185H-C 228 x 68 x 38.8 mm c.v + c.cHLG-240H 251 x 68 x 38.8 mm c.v + c.cHLG-320H 252 x 90 x 43.8 mm c.v + c.cSeries Dimension (L x W x H) C.C or C.VHVG(C)-100 236 x 68 x 38.8 mm c.v + c.cHVG(C)-150 245 x 68 x 38.8 mm c.v + c.cSeries Dimension (L x W x H) C.C or C.VHSG-70 127.2 x 90 x 38.8 mm c.v + c.cSeries Dimension (D x H) C.C or C.VHBG-100 130 x 66.5 c.v + c.cHBG-160 151.68 x 66.5 c.v + c.cHBG-240 191.5 x 69 c.v + c.c

Series Dimension (L x W x H) C.C or C.VLPF-16(D)/25(D) 148 x 40 x 32 mm c.v + c.cLPF-40(D)/60(D) 162.5 x 34 x 32 mm c.v + c.cLPF-90(D) 161 x 61 x 36 mm c.v + c.c

Series Dimension (L x W x H) C.C or C.VPLC-30 160 x 46 x 30 mm c.v + c.cPLC-45/60 181.5 x 62 x 35 mm c.v + c.cPLC-100 200.5 x 69.5 x 35 mm c.v + c.cSeries Dimension (L x W x H) C.C or C.VPLN-20 148.5 x 38.5 x 28 mm c.v + c.cPLN-30 145 x 47 x 30 mm c.v + c.cPLN-45/60 181 x 61.5 x 35 mm c.v + c.cPLN-100 200 x 70.5 x 35 mm c.v + c.cSeries Dimension (L x W x H) C.C or C.VHLN-40H/60H 161 x 61.5 x 35 mm c.v + c.cHLN-80H 181 x 61.5 x 35 mm c.v + c.c

Series Dimension (L x W x H) C.C or C.VPLP-20 140 x 32 x 22 mmPLP-30 101.6 x 50.8 x 26.6 mmPLP-45/60 101.6 x 50.8 x 29.6 mmSeries Dimension (L x W x H) C.C or C.VHLP-40H/60H 147 x 53 x 27 mm c.v + c.cHLP-80H 167 x 53 x 29.5 mm c.v + c.c

Series Dimension (L x W x H) C.C or C.VAPC-12/16 77 x 40 x 29 mm c.v + c.cAPC-25/35 84 x 57 x 29.5 mm c.v + c.cSeries Dimension (L x W x H) C.C or C.VLPLC-18, LPHC-18 140 x 30 x 22 mm c.v + c.cLPC-20 118 x 35 x 26 mm c.v + c.cLPC-35 148 x 40 x 30 mm c.v + c.cLPC-60 162.5 x 42.5 x 32 mm c.v + c.cSeries Dimension (L x W x H) C.C or C.VELN-30 145 x 47 x 30 mm c.v + c.cELN-60 181 x 61.5 x 35 mm c.v + c.c

Series Dimension (L x W x H) C.C or C.VPCD-16/25 84 x 57 x 29.5 mm c.cPCD-40/60 128 x 60 x 31.5 mm c.cPLD-16/25 84 x 57 x 29.5 mm c.cPLD-40/60 128 x 60 x 31.5 mm c.cSeries Dimension (L x W x H) C.C or C.VPLM-12/25 145 x 38 x 22 mm c.cPLM-40 175 x 42 x 24 mm c.cSeries Dimension (L x W x H) C.C or C.VLCM-40(DA)/60(DA) 123.5 x 81.5 x 23 mm c.c

Series Dimension (L x W x H) C.C or C.V

ULP-150 215 x 67.4 x 33 mm c.v

Series Dimension (L x W x H) C.C or C.VAPV-12/16 77 x 40 x 29 mm c.vAPV-25/35 84 x 57 x 29.5 mm c.v

Series Dimension (L x W x H) C.C or C.VLPL-18, LPH-18 140 x 30 x 22 mm c.vLPV-20 118 x 35 x 26 mm c.vLPV-35 148 x 40 x 30 mm c.vLPV-60 162.5 x 42.5 x 32 mm c.vLPV-100 190x 52 x 37 mm c.v

Note

At the moment of power on, the LED power supply will work in C.V mode and can provide a peak output current; after the LED turns on, the LED power supply will go into C.C mode (patent pending).

→

→

→

→

Metal Case

Plastic Case

PCB Case

Plastic Case

PFC

Non-PFC

Constant Voltage

+

Constant Current (C.V+C.C)note

→

→

→

Plastic Case

U-bracket Metal Case

Plastic Case

PFC

NON-PFC

NON-PFC

Constant Current (C.C)

Constant Voltage (C.V)

Quick Selection Map

JHB:Tel: 010 591-1713 Fax: 011 462-0420

Bloemfontein: Tel: 051 011-0158 Fax: 086 657-9836

KZN: Tel: 031 569-2854 Fax: 031 569-2864

CapeTown: Tel: 021-200-5754 Fax: 021-300-1728

www.rect i f ier .co.za / www.power-solut ions.co.za

NEW

NEW

NEW

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Meanwell Summary

using circular saws, ball mills, conveyors, compressors, grinders, punch presses, etc - where motors are sized for the heaviest load.

Examples of situations where low power factor (from 30% to 50%) occur include a surface grinder performing a light cut, an unloaded air compressor and a circular saw spinning without cutting.

The following industries typically exhibit low power factors:

Industry Uncorrectedpower factor

Saw Mills 45 – 60%

Plastic (especially extruders) 55 – 70%

Machine tools, stamping 60 – 70%

Plating, textiles, chemicals, breweries 65 – 75%

Hospitals, granaries, foundries 70 – 80% Table 1: Typical industries with low power factor.

Factors influencing investment payback periods for power factor correction equipment

Each electrical installation is unique and the required investment in power factor correction equipment as well as the associated payback period is influenced by the following factors:• Uncorrected power factor: The worse the uncorrected PF, the

shorter the payback period of the investment in PFC equipment• Requested target power factor: If the end-user insists on achieving

a PF of 1 under peak load conditions (rather than 0,96 – 0,98), this will have a significant impact on the total investment required as well as the associated payback period

• Current and voltage harmonics present in the installation: If the harmonic levels are excessive, blocking reactors will have to be fitted in the PFC panel, which increases the investment costs, without there being a direct saving in maximum demand

• Load changes: Pulse loads (for example large spot welding ma-chines required for the manufacturing steel meshing) require thyristor controlled PFC equipment, which has a negative impact on the total investment required

• Unbalanced loads: Large single phase loads in a 3-phase instal-lation - such as large single phase welding machines - require single phase thyristor controlled PFC, which has cost implications

• Installation constraints: Installation costs can represent a signifi-cant portion of the total investment in PFC equipment, especially for smaller installations of less than 150 kvar. Factors influencing the total installation costs are:

o Labour (manhours and travel time) o Cabling (size and length)

o Electrical consumables required for the installation of the PFC equipment

o Protection equipment such as (fused) isolators and circuit breakers

o Required IP rating of the PFC panel to prevent dust and water ingress

o Elevated ambient temperatures necessitating the fitment of air conditioning systems to the PFC equipment

• Actual maximum demand rate being charged: Ranges from R15/kVA to R138/kVA! This has obviously a significant impact on the payback period

Examples of savings and investment payback periods for PFC equipment

Example 1:

Load profile (under peak load conditions) of an installation with a very poor power factor and a customer being charged fairly costly maximum demand rates:

Current (A) 645,0

Voltage (V) 393,4

Power Factor 0,50

Active Power (kW) 219,5

Apparent Power (kVA) 439,0

Reactive Power (kvar) 380,2

Target Power Factor 0,97

Required pf correction (kvar) 325,2 Table 2: Load profile of customer 1.

This customer required making an investment of R88 000 in power factor correction equipment (on a turnkey basis) in order to elevate the power factor of the installation to 0,97 under peak load conditions.

The investment resulted in an associated reduction in maximum demand of 213 kVA, which represents a monthly saving in electrical costs of R24 990 at the current maximum demand rate being charged, being R117 49/kVA.

Active power (kW) 219,5

Uncorrected power factor 0,50

Uncorrected apparent power (kVA) 439,0

Corrected power factor 0,97

Corrected apparent power (kVA) 226,3

Savings (kVA)/month 212,7

Cost per kVA (maximum demand) R 117 49

Saving (R/month) R 24 990 Table 3: Monthly savings customer 1.

The savings achieved in the first year of installation resulted in an investment payback period of 3,5 months!Power factor correction equipment has a life expectancy of at least

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10 years with minimal maintenance. Estimated total savings over ten years, taking into consideration tariff increases of 25% in 2011 and 2012, and further annual tariff increases of 10% thereafter are approximately R6 000 000.

Figure 9: Total savings customer 1.

Example 2:

Load profile (under peak load conditions) of an installation with a reasonable power factor and a customer being charged fairly cheap maximum demand rates:

Current (A) 1407,5

Voltage (V) 392,0

Power Factor 0,80

Active Power (kW) 763,6

Apparent Power (kVA) 954,5

Reactive Power (kvar) 572,7

Target Power Factor 1,00

Required pf correction (kvar) 572,7 Table 4: Load profile of customer 2.

This customer required making an investment of R202 000 in power factor correction equipment (on a turnkey basis) in order to elevate the power factor of the installation to unity, under peak load conditions.

The investment resulted in an associated reduction in maximum demand of 190 kVA, but due to the very low maximum demand rated being charged to this particular customer, the associated monthly saving in electrical costs was only approximately R3 000!

Active power (kW) 763,6

Uncorrected power factor 0,80

Uncorrected apparent power (kVA)

954,5

Corrected power factor 1,00

Corrected apparent power (kVA) 763,6

Savings (kVA)/month 190,9

Cost per kVA (maximum de-mand)

R15,60

Saving (R/month) R2 978 Table 5: Monthly savings customer 2.

The savings achieved will result in an investment payback period of 48,8 months!

Estimated total savings over ten years, taking into consideration tariff increases of 25% in 2011 and 2012, and further annual tariff increases of 10% thereafter are estimated at R500 000.

Figure 10: total savings customer 2.

Even though the return on investment was very poor, this customer decided to purchase the power factor correction equipment in order to be able to install additional machinery in the factory without over-loading his 1 000 kVA supply transformer.

PFC equipment

Capacitors are the key component in any power factor correction equipment and they determine their life expectancy.

The life expectancy of the capacitors is mostly determined by the following factors:• Quality of the polypropylene carrier film• Heat dissipation properties of the housing (aluminium vs plastic)• Average and maximum operating temperature• Network pollution: Harmonics and voltage surges • Rated voltageCapacitors need to be well ventilated and easily replaceable.

Good quality PFC controllers keep track of the number of cycles each step has been subjected to as well as the total duration each Take note

• Power factor correction has always been around – but do we really understand its value?

• Payback time for power factor correction equipment is quite short.• if you do not have power factor equipment in your system, now is the

time to seriously consider it.

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About the author

step has been in operation. The controller uses this information to determine which step to add or remove when a load change occurs and this results in the even wear of complete power factor correc-tion installation.

It is also possible to manually add or remove a step from the controller front panel keypad. The controller will not allow the manual addition of a particular step before a preset internal timer has lapsed, ensure that the capacitors are sufficiently discharged before being re-energised. This feature increases the life expectancy of the capacitors

Conclusion

Industrial and commercial organisations can no longer ignore the benefits of power factor correction and harmonic filtration. Failure to do so will not only result in significant and unnecessary costs being incurred by these organisations but will also affect their opportunities for growth. Indeed, Eskom and municipalities have started to cap the maximum apparent power organisations can draw from the power distribution network. In order to add additional electrical equipment

on their premises, organisations are now forced to improve their power factor and use more energy efficient electrical equipment.

Bibliography

[1] Wayne S. Power Factor Correction: A Guide for the Plant Engineer. Eaton Corporation, June 2006.

[2] Lex Electrix, www.lexelectrix.com.[3] Wakileh GJ. Power system harmonics. Springer-Verlag, Berlin,

2001.

Eric solot holds a master of applied Engineering (Electrotechnology) from the university College in Ghent (Belgium). at present he is the managing director of alpha Power solutions, which specialises in power factor correction and harmonic filtration. Enquiries: Email [email protected].

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ifm electronic’s switched mode power supplies of-fer both value and performance, and come in two

designs: BasicLine in a compact plastic housing and ClassicLine in a robust metal housing. Both designs only require a little space on the DIN rail, due to their slim housing. After power-on, the power supplies start, even without minimum load, and are short circuit proof and overload protected. Two LEDs and a DCok output signal the operating states. With their wide input voltage range and cULus approval they can be used worldwide. Besides the long mains buff-ering time of up to 400 ms, another special feature

of the ClassicLine is the intelligent power reserve: at a 1,5-fold nominal load the power supplies can provide extra current for 5 s, and for a longer time in case of lower overload. This additional power allows even difficult loads to start such as motors and dc/dc converters. The input voltage range is from 100 to 240 Vac ± 10 %, and the output voltage of the 24 Vdc power supplies can be set from 24 to 28 V. Additional types are designed for the AS-Interface fieldbus system. They have, in addition, an integrated data decoupling and a constant current characteristic

Enquiries: Chris Cronjé. Tel. 012 450 0370. Visit www.ifm.com/za.

In response to the high reliability of power supply demands nec-essary for the medical industry, Meanwell has introduced the

GSM40/60 series - 40 W and 60 W ac-dc desktop-type medical adaptor featuring high efficiency and low power consumption. Both series comply with the international medical safety regulation - *MOPP. With an extremely low leakage current (≦100 µA), 91% high efficiency, and low no load power consumption (<0,1 W), they are excellent power solutions for ‘patient contact’ medical applications. The entire GSM40/60 series complies with the latest energy-saving regulations

(level V), such as ErP step 2 of European Union and EISA 2007 (Energy Independence and Security Act of 2007) of USA.

The GSM40/60 series has a similar PCB design and the same enclo-sure dimension. With 80 - 264 Vac full range input and 5 – 48 V different output voltage options to for different types of medical equipment, they have Class I power with an earth ground pin and are enclosed by UL 94V-0 rated plastic case, which can effectively prevent users from receiving an electrical shock. Enquiries: Ettienne Van Der Westhuyzen. Email [email protected].

Switched mode power supplies – great value and performance

Reliable power for medical applications


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A high power modular and scalable 200 kW to 1 200 kW UPS solution for business critical conti-

nuity applications is now available in South Africa from Master Power Technologies, the Randburg-based special-ist in secure power back-up solutions.

The Trinergy UPS, developed and manufactured by Emerson/ Chloride, offers flexible, secure power supply solutions for critical applications such as data centres and business IT networks. It incorporates three standard configurations – maximum power control (VFI), maxi-mum energy saving (VFD) and high efficiency and power conditioning (VI) in one high power UPS.

This unique combination of technologies allows the UPS to monitor the environment and operating condi-tions of the mains network, and intelligently selects the function mode that best suits the line conditions. This enables the system to work at maximum efficiency and at the same time ensuring maximum security to the load at all times.

The result is that the Trinergy is able to achieve ex-traordinary energy savings while maintaining first class performance and maximum power protection, with a high level of flexibilty, energy efficiency and adaptability in line with the EU code of conduct on best practices.

Apart from data centre and IT network applications, the Trinergy will also support critical air-conditioning loads, process control systems, factory lighting systems and stadium floodlights, among other applications.

Enquiries: Tel. 011 792 7230. Visit www.kva.co.za.

Test Instruments Africa (TIA) has launched the SA 30i, a leakage current meter from SCOPE. It is a ‘state-of-the-art’, online test system for residual life as-

sessment of surge arresters. The instrument measures and directly displays the values of resistive and total leakage current. The SA 30i can be pre-loaded with the identity (asset number, make, year, serial number etc) and tests conducted on the same ID of the arresters are saved under its own folder. Trend analysis software, Sadata, picks up this data and files it in a similar fashion on a PC. This analysis software enables the user to take a decision to repair or replace the arresters, while considering safety limits. The SA 30i is designed to work under the hostile electrostatic noise found in live EHV switch yards. A special low-noise clamp-on CT is used to read leakage current in the earthing conductor of the arrester. The field probe is a non-contact, remote sensing device employed to take the reference signal from the HV line to the arrester, for measurement of phase and system harmonics. The SA 30i measures 3rd harmonic resistive and total leakage current by compensating the harmonics present in the system as per IEC 60099-5 B2 or without system harmonic compensation as per IEC 60099-5 B1.

Range Total leakage current 100 mA to 10 mA, Resistive leakage current 1 mA to 10 mAField Probe current 10 mA to 1 mA

Resolution 1 mA for both resistive and total currents

Accuracy ± 5% for both currents

Inputs External clamp-on CT, field probe, external PT-optional(110 Vac)

Outputs Self-calibration output

Display 4 line X 20 character large backlit LCD

Keyboard 5 keys

Measurement Total current, resistive current

Compensation Automatic, for noise, system harmonics and remperature

Temperature In-built silicon thermometer for compensation

Enquiries: Justin Clarkson. TIA. Tel. 0116088541 or visit www.testinstrumentsafrica.com.

New UPS solution in RSA Assessment of surge arresters

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IR measurement devices, such as that described, make it safe to take surface temperature readings of items like rotating, hard-to-reach, electrically live, or dangerously hot targets. For preventative

maintenance tasks, they cut measurement time to almost zero with the ability to take a surface temperature reading in less than one second.

IR thermometers can be used to conduct thousands of different types of measurements, including:• Electrical: IR thermometers can be used to troubleshoot problems

with electrical connections and verify uninterruptible power sup-plies by locating hot spots in the output filters or dc battery con-nections. They can also be used to check components in battery banks, power panel terminations, ballasts, switch gears, circuit breaker and fuse connections that could be draining energy due to the heat created by loose connections or corrosion buildup.

• Preventive maintenance: Using IR thermometers for preventive maintenance measurements of hard-to-reach equipment such as HVAC supply diffusers or dangerous equipment like motors, generators, and bearings helps identify potential problems.

• HVAC: It’s estimated up to 30percent of air conditioning leaks are due to faulty ducting, which can be quickly and easily detected with an IR thermometer.

• Steam: IR thermometers are particularly useful in taking surface temperature measurements of uninsulated steam lines, steam valves, fittings, receiver tanks, and condensate return lines, which pose a large safety hazard due to the potential presence of live steam.

• Food processing: IR temperature measurement is the fastest, most efficient, and FDA-recommended method of monitoring food safety along the critical control points in Control Point (HACCP) standards. IR thermometers provide a fast and easy method of monitoring temperature on the surface of food where bacteria begin to grow, ensuring that food is safe at every step of food processing and preparation.

• Fast test of multiple targets: IR thermometers are excellent for checking multiple points easily from one location, saving time and money.

Proper use of IR technology

Although IR temperature measurement is not as accurate as a cali-brated contact temperature device, a typical reading will be within 1°C

of the actual temperature when the instrument is properly applied. For scanning applications, like those mentioned that do not require precise measurement, this level of accuracy is more than adequate.

Putting IR technology to use is easy, but there are two critical parameters that must be understood to ensure proper and consist-ent temperature measurements with infrared type devices. They are:• Optical resolution• Emissivity

Optical resolution

Optical resolution refers to the sample area the IR meter is measur-ing at a given distance. Optical resolution is also referred to as the 'distance-to-spot-size ratio' or 'field-of-view'. Know your application! A device with a 4:1 optical resolution cannot effectively be used to measure the temperature of an object 1,5 m away – even if the laser beam sight projects that far.

Try to determine how you are going to apply the IR thermometer before purchasing, and then buy a tool that provides the appropriate optical resolution forth application. Many erroneous readings are taken because the technician unknowingly samples a larger area than the object that’s being measured.

Emissivity

Emissivity indicates the ability of an object to emit infrared energy. Emissivity is determined by the material from which the object is

Non-contact temperature measurement using IR thermometersBy B Campbell, Comtest

Infrared (IR) thermometers allow non-contact measurement of surface temperatures by analysing the invisible, infrared spectrum emitted from

an object.


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constructed and its surface finish. Values can range from less than 0,1 for a highly reflective body like polished metal, to 1,0 for an ideal black body.

In simple terms, emissivity can be likened to the reflectivity - or shininess - of an object. Items such as soft-drawn copper are very smooth and shiny even under a microscope, while other objects such as lacquer paint appear quite porous under the microscope. The porous object will have a relatively high emissivity (typically 0,7 to 0,98), while new soft-drawn copper (shiny, not oxidised) will have a low emissivity (typically below 0,2). Shiny objects reflect IR energy from objects sur-rounding them, which dilutes the IR energy from the measured object. A porous body tends to absorb surrounding IR energy, thus emitting its IR energy without dilution (like a black body).

Low-cost IR measurement instruments are typically fixed at 0,95 emissivity. To get an effective actual temperature reading, the surface being measured must have an emissivity close to 0,95. In other words, measuring a surface that is not highly reflective will provide an accurate reading. For shiny surfaces, use a coat of black paint, electrical tape, or magic marker to reduce reflection. If a 0,95 fixed emissivity IR instrument is used to measure an object that is not close to 0,95, the reading will be incorrect as follows:• If the measured object is warmer than ambient temperature, the reading will

be erroneously lower than the actual temperature;• If the measured object is colder than ambient temperature, then the reading

will be erroneously higher than the actual temperature.

Abbreviations

Take note

• non-contact infrared (iR) thermometers are useful tools for technicians to carry about with them.

• Even the smartest instrument must be used properly – and understood – if it is to render useful results.

• When properly used, iR thermometers provide accurate results – even in difficult ap-plications.

Fda – Food and drug administration (usa)HaCCP – Hazard analysis Critical Control PointsHVaC – Heating, Ventilation and air-conditioningiR – infrared

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Effect of incorrect application

Understanding the optical resolution and emissivity ratings of your IR thermometer and the target you plan to measure will help you avoid inaccurate measurements. The example below illustrates how an incorrect application can lead to inaccurate results.

The task

A technician needs to take a temperature measurement on a new, shiny copper refrigerant line located between the evaporator and the compressor to help determine the superheat in the system. The technician has just purchased his first IR thermometer and is anxious to put it to use. He decides to compare it against his digital contact thermometer. Here are the facts:• IR thermometer: Fixed at 0,95: Optical resolution of 4:1• Target size: 34,9 mm diameter copper pipe (this pipe will provide

a little over a 25,4 mm diameter sample area from the side.)• Ambient temperature: 25ºC• Refrigeration line temperature as measured with the calibrated

‘contact’ thermometer: 13ºC (t his is the correct temperature)

Attempt 1:

The technician already knows the proper line temperature is around 13ºC. He holds the IR thermometer 12 inches away from the line and reads a temperature of 22ºC. He moves the thermometer to within 7 cm of the target and the measurement on the IR thermometer lowers to 20ºC. A slight improvement, but still not close to the expected value.

In this first attempt, the technician has adjusted his distance from the target to fall within the instrument’s optical resolution, but has not accounted for emissivity differences between the instrument rating and the material.

Attempt 2:

Ten minutes later, the technician returns to the refrigeration unit with his IR instruction sheet and some black electrical tape in hand. He applies a few pieces of the electrical tape to cover the shiny copper refrigerant line. Upon re-measuring at a distance of 7 cm with the IR thermometer targeted at the electrical tape, the thermometer registers 14ºC, which is within the accuracy specifications for the instrument.

The technician leaves the jobsite with a better understanding of IR technology and the constraints of optical resolution and fixed emissivity.

Conclusion

Fluke VT02 Visual IR Thermometer is a troubleshooting camera with an infrared heat map. Until now, electricians and industrial, HVAC, and automotive technicians have had to choose between single-point infrared thermometers and high-resolution thermal imagers (infrared or ‘IR’ cameras). Fluke VT02 Visual IR Thermometer fills the gap when a single-spot temperature reading is not enough and a high-resolution thermal image is more than most users need. This one tool combines the visual insight of a thermal imager, the visual images of a digital camera, and the point-and-shoot convenience of an IR (infrared) thermometer.

Brendan Campbell has a national diploma in microbiology and has been involved in the sales of Fluke industrial tools for the past 14 years. Brendan has been with Comtest since the company was formed and is a qualified level iii snell infrared thermographer. Enquiries: tel: +27 11 608 8520 or

email [email protected].

About the author

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With major benefits to the mining, sewage treatment, power genera-

tion, paper, oil, food and beverage and fracking industries, OMSA has launched The DM3 non-nuclear, in-line, continuous density meter, which calculates density by measuring direct mass over a known volume within a flow tube. By directly calculating density rather than inferring or estimation, this technology improves the accuracy, value for money and environmental viability of sensor and mass flow systems.

Developed by SCIAM Worldwide, of the USA, the DM3 was originally designed to replace obsolete technologies for the mining and dredging industries, and has

proven to be safer and more cost effective than hazardous nuclear techniques or inef-ficient auto-sampling. OMSA has responded to customer requirements by offering this advanced technology to the local industry.

The DM3 offers a non-nuclear way to the measurement of mining and dredging slurries, and avoids the administrative and technical problems associated with nuclear devices. These include: compliance with Department of Health regulations; use of special safety equipment (Occupational Safety & Health Act); administering and analysing radiation badges; being part of National Nuclear Regulator and DMR sur-veys; employment of costly radiation offic-

ers; mitigation of health hazards as well as costly transportation, storage and disposal issues. The DM3 is insensitive to plant vibra-tions, noise, vacuum and temperature.

Enquiries: Jan Grobler. Tel. 011 793 7421 or email [email protected].

Non-nuclear inline continuous density meter


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Berthold Technologies has introduced a new densitometer, based on the non-contacting gamma transmission technology.

The SmartSeries LB 414 detector measures density, concentration and solids content online and on all kind of slurries and liquids. Beside the high level of accuracy and repeatability, the easy way of detector handling is a major advantage of SmartSeries. The local user interface with display and the software - focusing on the main functions make calibration and operation of the HART device very easy. An infrared remote control can also be used to parameterise the detector. SmartSeries detectors are characterised by a high mechanical robustness, verified by the Fraunhofer Institute. They are cost-efficient and can be used for many years without the need for maintenance and re-calibrations. Mecosa is the sole representative for Berthold Technologies in South Africa.Enquiries: Mecosa. Tel. 011 257 6100 or email [email protected].

There is no place for water in hydraulic liquids and lubricants. Water in hydraulics or in lubricants can damage a machine

or even destroy it. ifm has introduced a means to measure water concentration. The combined oil humidity and temperature sensor LDH100 measures the relative humidity of mineral oils, synthetic esters and bio oils and simultaneously the temperature. The sensor determines the relative humidity in the oil in the range of 0 - 100% by means of a capacitive measuring element. At 0% the oil is abso-lutely without any water content. At 100%, however, the medium is completely saturated. No more water is dissolved and is then present as free water. The measured values of the temperature and the relative humidity are provided via two 4 - 20 mA analogue outputs. The sensor is designed for a medium temperature of -20 to 100°C, and short-term up to 120°C.

Enquiries: Chris Cronjé. Tel. 012 450 0370 or email [email protected].

Simply smart - new radiometric densitometer

Ensure oil remains dry


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M&W Asketeknik’s RCA MI 2200 Residual Carbon Analyser provides plant per-

sonnel with vital real time information on the combustion efficiency through continuous monitoring of the unburnt carbon content in the fly-ash.

The RCA MI 2200 assists coal fired power plants by improving their operation in com-bustion efficiency, coal mill performance and quality of fly-ash for sale.

The RCA MI 2200 is a reliable low main-tenance online monitoring instrument which reduces the need for labour intensive labora-tory analysis.

The ash sampler is a low maintenance device with no moveable parts. Pumping power is provided by utilising the pressure

difference between the ambient air and inside of the duct. This pressure difference drives an adjustable ejector. This design also means that extraction velocity automatically adapts to changes in the flow rate in the duct.

The control unit undertakes the process-ing of the transducer signals and controls all functions of the individual RCA components. The operator’s control panel displays menu selection and error messages as well as the real time carbon in ash content.

As the RCA MI 2200 monitors the amount of residual carbon in the fly-ash and it also monitors the effective utilisation of the fuel. A suitable low amount of residual carbon indicates good fuel utilisation and good fuel economy. High values of residual carbon in

the fly-ash can often be traced to coal mill performance.

Enquiries: Mike Andrews. Tel. 011 675 4447 or email [email protected].

Due to the vast range of thermal imaging applications in industry,

it is essential to take into considera-tion the various features of thermal imaging equipment available in order to meet one’s needs satisfactorily. Some applications only require basic features, others require highly sophis-ticated functions. The key is to select an imager which meets current needs as well as provides room to grow with future requirements. Comfort, battery life, lens selection and thermal sensi-tivity all have equal considerations when selecting an imager: Sensitivity: NETD or 80 mK or less, this will allow the detection of thermal variances associated with anomalies.Resolution: A personal choice in imagers. The lower the resolution the more ‘blobs’ will be seen. Blobs are areas of thermal change but cannot be discerned because of low resolu-tion. You can tell the area of interest is either hot or cold but not ex-actly where or why. A resolution of 160 x 120 would be considered a minimum. The higher the resolution the bet-ter the image quality will be.Lens: In most of these applications you will not be close to the sec-

tion being inspected. This will require a fairly wide angle lens as standard equipment. A 32° lens is standard on most testo imagers and will work very well. For close up or high detail inspections with a wide angle lens such as a 42° lens included on the testo 890 imagers is ideal for these applications..Ease of use: When searching for the source of the intrusion, comfort and battery life are key factors. Large view screen eases eye strain. One hand operation and long life batteries can simplify use. Nobody likes to have to climb down from a roof because of a battery failure.High temperature range: High tem-perature range is important because overheating is a common problem but overheating does not always cause failure right away. Several testo

imagers have extended thermal range options when ordering. The 882 series up to 550°C while the 885 and 890 series can provide effective accurate readings up to 1 200°C. unitemp offers a range of testo cameras from entry level to pro-fessional.

Enquiries: Peter Stone. Tel. 011 966 9800 or email

[email protected].

A new integrated application solution detects accel-erated fouling and identifies best cleaning time to

optimise facility’s energy usage, capacity, maintenance cost, carbon footprint, and safety

Emerson Process Management has introduced an integrated heat exchanger monitoring solution. The solution is part of Emerson’s new suite of Essential As-set Monitoring applications. The pre-engineered heat exchanger solution embeds process and exchanger best practices into software using existing wired and new wireless instrument applications for cost-effective, automated 24/7 monitoring, enabling operations im-provements and reduced energy costs.

The solution allows maintenance personnel to schedule optimal time to clean to sustain optimal heat transfer. As a result, facilities can reduce energy and capacity loss due to fouling by up to 10%. For a 250 000-barrel-per-day refinery, that could mean savings of several millions annually, across all process units.

The environmental footprint is lessened by avoiding additional emissions from heater operation because of improved heat recovery in the process. And safety is improved as wireless data transfer reduces hazard-ous information-gathering trips to the field amongst exchangers that can be difficult to access, stacked, and filled with hot flammable fluids.

Typical world-class process facilities use hundreds of heat exchangers which foul over time resulting in missed operating targets," commented Pete Sharpe, Emerson’s director of Applications Development. "Fouling typically occurs slowly but can be acceler-ated by inlet stream impurities or incompatible crude blends."Enquiries: Mark Tapson. Tel. 011 451 3700 or email mark.

[email protected].

Online monitoring of combustion efficiency

One manufacturer, many applications Pre-engineered heat exchanger


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The FP series pneumatic level switch is ideal for point level switching of liquids that are highly viscous, corrosive or contain

solids in suspension. This compact level switch can be easily integrated into original

equipment for new and replacement purposes. The FP Pneumatic level switch consists of a sensing head with a diaphragm and micro-switch housed in either a plastic (FP-3), die-cast aluminium (FP-1A) or SS (FP-1S) body, and is used in conjunction with a guide tube compatible with the medium being measured. As the level of the medium rises so the column of air is pushed up the guide tube into a chamber which in turn pushes the diaphragm to activate the micro-switch.

Main features:• Insensitive to highly viscous and corrosive liquids – the me-

dium to be measured is only in contact with the guide tube and not directly with the sensor, the guide tube can be selected to be compatible with the medium. For the highly viscous mediums a guide tube with a large diameter can be selected.

• The movement of the diaphragm is restricted to 2 mm maxi-mum thus minimising wear and tear on the diaphragm itself

• A high quality micro-switch is used and it incorporates a dead-band between set and reset points, this minimises ‘bouncing’ in the case of turbulence of the measured medium and ensures stable operation.

• Easy installation by just connecting the sensing head to the guide tube once fitted to the application.

Enquiries: Temperature Controls. Tel. 011 791 6000 or visit www.tempcon.co.za.

Pneumatic level switch for viscous and corrosive liquids

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Vortex meters are often used to measure steam. As vortex meters only measure volume flow, and steam flows are mostly bal-

anced in mass units, they are often combined with a pressure or temperature sensor as well as the respective calculator unit. In case of superheated steam, you may then also calculate the steam mass. For various applications where the mass flow of saturated steam has to be determined, there is now, in addition to the above solution, an alternative offering a cost/benefit ratio: Vortex meter PROline Prowirl 73, is equipped with a temperature sensor that is directly integrated into the sensor paddle. In addition to the volume flow, this flowmeter

also determines the temperature. As there is a defined relationship in the case of saturated steam between temperature and pressure, the electronics of the flowmeter can calculate the steam mass based on these measured values. In practical applications, this offers several advantages: you do not need an additional pressure or temperature sensor and an external steam computer. Thus, investment costs and expenditure can be significantly reduced. Except for the application in the saturated-steam field, this is also suitable to measure liquids such as thermo-oils or even gases at a constant pressure.

Enquiries: Frans van den Berg. Tel. 011 262 8000 or email [email protected].

The Siemens Industry Automation Divi-sion has extended its range of tem-

perature sensors to include the SITRANS TS product family. The new resistance ther-mometers and thermocouples are designed for universal use. The device line has a modular design, and offers a large range of sizes, materials, sensors and transmitters. It not only supports the central communication standards HART, PROFIBS PA and Foundation Fieldbus, but is also certified under ATEX and IECEx, which enables the devices to be used worldwide. SITRANS TS is therefore suitable for both basic and highly demanding applica-tions throughout the entire process industry.

The modular SITRANS TS product family consists of the three product lines SITRANS TS100, TS200 and TS500. They are suitable for a wide range of applications in the process industry, such as in the fields of chemicals, oil, gas and power. The product portfolio is

clearly structured. Certain designs are certi-fied under ATEX and IECEx as being flame-proof for gas and dust, intrinsically safe, and Ex n. This has advantages for globally active users, especially in the fields of logistics, inventory management and documentation.

The SITRANS TS100 and TS200 product series are available as cable and compact thermometers. This makes them especially suitable for universal use, such as detecting the temperatures of machine bearings. The compact insertion thermometers can also be used in confined spaces, and their mineral insulated design makes them not only flex-ible but also resistant to vibrations and high temperatures up to +1,100°C. The SITRANS TS500 product line is designed for applica-tions with low to high process stresses. A selection of protective tubes made of solid or welded pipe material is available for this purpose. The user can use a wide range of

process connections, connection heads, sensor types, transmitters and displays to configure individual solutions for a process. The optional 4 to 20 mA transmitters, HART, PROFIBUS PA and Foundation Fieldbus en-able devices to be easily integrated into the operating tools of process control systems, such as SIMATIC PDM.

Enquiries: Visit www.siemens.com.

KROHNE has introduced the new TIDAL-FLUX 2300 F for flow measurement in

partially filled pipes. The electromagnetic flowmeter features an integrated, non-con-tact capacitive level measurement and an approval for ATEX zone 1 for use in hazard-ous environments, especially for the German waste water market.

KROHNE has large experience in flow measurement in partially filled pipes. TIDAL-FLUX 2300 F continues the line of TIDALFLUX flowmeters which have been in the market for more than 16 years. The new TIDALFLUX 2300 F is designed to provide reliable flow measurement for flow streams between 10…100% of the pipe diameter. The accuracy in partially filled pipes is <1% of full scale, and the accuracy in full pipes is <1% of the

measured value. TIDALFLUX 2300 F does not require on-site calibration as it is wet-calibrated at factory in a direct comparison of volumes.

Due to the presence of H2S in many waste-water applications, the new TIDALFLUX 2300 F features an ATEX zone 1 approval. Here, the in-line flowmeter is a closed measure-ment solution for a safe and clean working environment, replacing open channel meas-urements. In addition to creating a toxic and explosive atmosphere, H2S presents another problem especially for partially filled elec-tromagnetic flowmeters - their electrodes may have only a very short life span when in contact with the strongly corrosive H2S. The electrodes of the TIDALFLUX 2300 F are mounted at a height of 10% from the pipe

bottom, ensuring that they are always wet-ted to avoid corrosion. The capacitive level sensors are integrated in the liner and have no contact with the medium. Therefore they are unaffected by H2S and any residues that may be floating on the water surface (fat, oil, etc) or particles in the water.

Enquiries: Ilana Thushini. Tel. 011 314 1391 or email [email protected].

Flowmeter with integrated temperature sensor

Modular design opens up a wide range of applications

Flow measurement solution for partially filled pipes


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Transformers are essential for the transmission, distribution and utilisation of electrical energy. They are used in virtually every commercial and industrial building, from the service

transformer that reduces distribution voltage, to a more usable volt-age for buildings and step-down transformers that serve individual floors, and to small transformers for individual equipment. Transform-ers can typically be expected to operate for 20 to 30 years or more.

Over such a long lifespan, the operating cost of a transformer can greatly exceed its initial price, so the selection of the right transformer for economic performance involves examining the unit’s capacity (size) and efficiency. In this context, efficiency means looking at both the core steel and the winding material.

Transformer losses

In the simplest terms, transformer losses comprise two components: core losses (also called no-load losses) and coil losses (called load losses).

The core losses originate in the steel core of the transformer, caused by the magnetising current needed to energise the core. They are constant, irrespective of the load on the transformer, hence the name ‘no-load’. They continue to waste energy as long as the transformer is energised. No-load losses do, however, vary with the size (kVA) of the transformer and the core steel selected; hence the emphasis on proper sizing. The coil losses, or load losses, originate in the primary and secondary coils of the transformer, and are a result of the resistance of the winding material. This is where the selection of copper windings can make a difference.

Proper sizing

Transformers are sometimes installed in advance of occupancy, so the engineer does not necessarily know the load that will be placed on the unit. As the installer is often not the party paying the electric-ity bill, there can be a tendency to oversize the transformer capacity relative to the load it will actually see. Since the no-load loss is a function of the kVA capacity of the transformer, the careful selection of transformer capacity, appropriate to its intended task, will ensure the lowest core loss.

Energy Star (TP-1) transformers may not be efficient enough

Energy Star is an international standard for energy efficient consumer products originated in the United States of America. It was created in 1992 by the Environmental Protection Agency and the Department of Energy. Since then, Australia, Canada, Japan, New Zealand, Taiwan and the European Union have adopted the programme. Devices carrying the Energy Star service mark generally use 20 to 30% less energy than required by federal standards.

The Energy Star label is applied to transformers that meet a certain minimal standard for efficiency known as NEMA TP-1 (NEMA stands for the National Electrical Manufacturers Association). This standard is intended to promote the manufacture and use of energy efficient transformers by establishing minimum efficiency standards, albeit with certain assumptions built-in.

It contains a simplified method for evaluating the initial cost of transformers along with the costs of core and load losses. It also presents tables of minimum transformer efficiencies based on kVA size, voltages and liquid or dry-type.

Unfortunately, there is nothing particularly efficient, nor cutting-edge, about transformers that meet TP-1. Yes, they are an improve-ment over so-called 'standard' transformers, which are still made and sold widely. However, many transformers are available from various manufacturers that exceed the efficiency levels of TP-1, and may provide a faster payback of their purchase price.

The efficiency standards in NEMA TP-1 are based on certain assumptions that may result in the selection of less-than-optimally efficient transformers.

One key assumption is that low voltage (600 V class) dry-type (typical commercial or industrial) transformers are loaded at 35% of their nameplate rating. For medium voltage and liquid-filled transformers, the assumed loading is 50% of the nameplate rating. Another underlying part of the economic rationale for the standard is an assumed electricity cost of six cents (US) per kWh (which is the equivalent of 62 cents per kWh in South Africa).

Both these assumptions may be inaccurate for industrial and commercial users, who often can more accurately predict their load requirements, and who may be paying more or less than six cents per kWh, particularly at peak times. In fact, recommended loading for

Proper transformer sizing and copper windingsBy E Swanepoel, Copper Development Association Africa (CDAA)

As the electrification of this continent continues, choosing the right component is critical if the result is to be both cost effective and efficient.


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1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

StdAl

TP-1Al

TP-1Cu

PremCu

StdAl

TP-1Al

TP-1Cu

PremCu

StdAl

TP-1Al

TP-1Cu

PremCu

StdAl

TP-1Al

TP-1Cu

PremCu

% of name plate load

100 100 100 100 75 75 75 75 50 50 50 50 35 35 35

Core Loss (w)

375 350 320 190 375 350 320 190 375 350 320 190 375 350 320 190

Conduc-tor loss

2829 1874 1670 993 1591 1054 940 559 707 469 418 248 1591 176 157 113

Total Loss (w)

3204 2224 1990 1183 1966 1404 1260 749 1082 819 738 438 1966 526 477 303

Efficien-cy Loss (%)

95,9 97,12 97,42 98,45 96,62 97,56 97,81 98,69 97,19 97,86 98,07 98,84 96,62 98,04 98,04 98,86

Trans-former Cost ($)

1 366(R13463)

1 979(R19505)

2 064(R20343)

3 214(R31678)

1 336(R13463)

1 979(R19505)

2 064(R20343)

3 214(R31678)

1 336(R13463)

1 979(R19505)

2 064(R20343)

3 214(R31678)

1 336(R13463)

1 979(R19505)

2 064(R20343)

3 214(R31678)

Compar-ison:Addi-tionalcost/ standardunit ($)

643(R6337)

728(R7 175)

1 878(R18510)

643(R6337)

728(R7175)

1 878(R18510)

643(R6337)

728(R7175)

1 878(R18510)

643(R6337)

728(R7175)

1 878(R18510)

Energy cost/year ($)

1964.69(R1936 4)

1363.76(R13441)

1220.27(R12030)

725.42(R7149)

1205.55(R11882)

860.93(R8485)

772.63(R7615)

459.29(R4526)

663.48(R6539)

502.21(R4949)

452.54(R4460)

268.58(R264721)

1205.55(R11882)

322.54(R3179)

292.50(R2882)

185.80(R1831)

Annual energy cost saving com-pared with standard unit ($)

600.94(R5923)

744.42(R7337)

1239.28(R12214)

344.62(R3396)

432.92(R4267)

746.26(R7355)

161.27(R1589)

210.94(R2079)

394.90(R3448)

69.90(R688)

99.95(R985)

206.65(R2036)

Payback period (years)

1,07 0,98 1,52 1,87 1,68 2,52 3,99 3,45 4,76 9,20 7,29 9,09

Table 1: Payback time comparison for 75 kVA dry-type transformers

economic sizing of a transformer is typically around 75% of nameplate;

a 35% load, if constant, means the transformer is oversized and wast-

ing core loss as well as having a higher purchase price.

Copper windings

Table 1, provided by Olsun Electrics, compares a ‘standard efficiency’

75 kVA transformer to an aluminium-wound TP-1 model, a copper-

wound TP-1 model and a ‘premium efficiency' copper-wound unit, at

various loading levels. As shown, choosing a more efficient, copper-

wound transformer that exceeds the minimal efficiencies of TP-1 (and

Energy Star) can pay back its price premium in as little as one year.

Table 1 Courtesy: Olsun Electrics, Richmond, IL.• Al (Aluminium)• Cu (Copper)• Prem (Premium)Notes:• Standard and Aluminium TP-1 units are 150C Rise, Copper TP

1 unit is 115C Rise, Premium unit is 80°C Rise.• Loss values at 100%, 75% and 50% nameplate load are at

reference temperature• Loss values at 35% nameplate load are at 75°C in accordance

with TP-1• Energy cost assumed to be $0,07/kWh

• Conversions from US$ to ZAR - 18 July 2013


About the author

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Copper Development Association Africa

The Copper Development Association Africa (CDAA) has represented

the local copper industry in southern Africa since 1962 and now

promotes copper usage throughout Africa. The CDAA’s head office is

based in Johannesburg and, on behalf of its members, the organisation

is committed to promoting and expanding the use of copper and

copper alloys throughout Africa.

Visit www.copperalliance.org.za

Noteworthy is the fact that the TP-1 (Energy Star) efficiency, copper-wound unit, loaded at 75% of its nameplate capacity (column 7), saves over US $88 (ZAR 867) per year compared to an aluminium-wound TP-1 model (column 6), but costs only US $85 (ZAR 837) more initially. At only 50% loading, the copper TP-1 unit (column 11) saves about US $50 (ZAR 492) per year compared to the same aluminium unit (column 10). No-load loss is reduced from 350 to 320 watts because the greater conductivity of copper windings allows a smaller core to be used, so energy continues to be saved even at light loading levels. For even greater savings, the premium effi-ciency, copper-wound unit saves over US $401 (ZAR 3 952) per year at 75% loading (column 8), compared to the aluminium TP-1 model (column 6), and only costs an additional US $1 235 (ZAR 12 172).

Minimising owning cost

Whenever possible, always compare competing transformer models by asking for the load and no-load losses in watts and look at the total cost of ownership. Given their life span, buying a unit based only on its initial cost is uneconomical and foolish.

Transformer lifecycle cost takes into account not only the initial transformer cost but also the cost to operate and maintain the trans-former over its life. This requires that the total owning cost (TOC) be calculated over the life span of the transformer. With this method, it is possible to calculate the real economic choice between compet-ing models. A basic version of the TOC formula would look like this:

TOC = initial cost of transformer + cost of the no-load losses + cost of the load losses

Remember that no-load losses are constant whenever the transformer is energised. Specifying copper windings can minimise both the load loss and the no-load loss, by allowing for a smaller core. If the load is known or can be predicted, choose a transformer that will be loaded to about 75% of its nameplate rating. Oversizing the unit increases the no-load losses, as well as the purchase price, unnecessarily.

If the actual losses in watts are not available, and you are seeking the transformer with the lowest losses, choose a transformer with 80°C rise, with M 6 steel grade core or better, and copper windings. Evert swanepoel is centre director for the Copper develop-

ment association africa (Cdaa) - responsible for promoting and expanding the use of copper in africa. His vast experi-ence in managing large businesses has provided him with the skill and knowledge to promote both current and new

copper projects that are positioned to increase the demand and utilisa-tion of this ductile metal throughout africa. He aims to expand the Cdaa membership in south africa and the rest of africa to include the complete spectrum of the copper industry, from primary through to downstream companies and service organisations. Enquiries: tel. 011 824 3916 or email [email protected]. Visit www.copper.co.za.

Take note

• Where there is a transformer, there are losses.• the long term cost of the losses is now a real consideration.• Copper, use appropriately, remains the conductor of choice.

Conclusion

Transformers remain a fundamental part of electrical distribution systems, and their correct sizing, for the load they are expected to carry and the material used in their internal windings, can dramatically impact these two aims. It is worth reiterating that the recommended loading for economic sizing of a transformer is typically around 75% of nameplate; whilst a premium efficiency, copper-wound unit, will also result in significant savings in the long run.


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ABB has been selected by Fastned to supply chargers to more than 200

electric vehicle fast-charging stations in the Netherlands, bringing an EV fast charger within 50 km of all of the country’s 16,5 mil-lion inhabitants. Each of the more than 200 Fastned stations along Dutch highways will be equipped with several multi-standards fast chargers, such as the 50 kW Terra 52 and Terra 53 models, capable of charging electric vehicles in 15-30 minutes. The first ABB Terra fast chargers are due to be de-livered in September 2013. Construction of the Fastned stations, which will have solar canopies, is expected to be completed by 2015. To date, the Netherlands is the most populous country to roll out a nationwide

fast-charging network. Fast-chargers will be located a maximum of 50 km apart along all highways, and because of ABB’s multi-standard design, the network will be capable of serving EVs offered by all major car brands from Europe, Asia and the USA. ABB’s open standards-based cloud connectivity solu-tion allows Fastned to create a user-friendly payment and access service for all drivers.

“Fastned chose ABB for its proven ex-pertise in deploying and managing nation-wide EV charging networks,” said Ulrich Spiesshofer, executive committee member responsible for Discrete Automation and Motion. “ABB provides the chargers and industry-leading software solutions for remote servicing as well as connectivity to

subscriber management and payment sys-tems.” Each web-connected ABB fast charger has a wide range of connectivity features, including remote assistance, management and servicing and smart software upgrades. ABB’s multi-standard design supports all fast-charging standards and protocols such as CCS and CHAdeMO. This is critical to maintain compatibility between rapidly evolving cars and chargers in the years to come, and will allow Fastned to maintain a reliable service and to upgrade its network as the technology evolves.

Enquiries: Natasha Mathebula. Tel. 010 202 6156 or email [email protected].

com.

EV fast-charging stations in the Netherlands

Powertech Batteries is on a winning streak of note. With four awards collected at two events recently the Port Elizabeth-based

operation has much to crow about. "I am proud of the spectrum of achievements for which we have received recognition," says Glenn Geldenhuis, chief executive officer of Powertech Batteries (PTB). "From our contribution to the country's economic growth, to innovation, environmental protection and putting together an exhibition stand that makes an impact, it was all there."

PTB's biggest accolade came from the SA Premier Business Awards where it scooped the Manufacturer Award. The company was also a finalist in the Green Awards category. Organised by the Department of Trade and Industry, Proudly South African and Brand SA, the SA Premier Business Awards recognise business excellence in South Africa. They honour enterprises that invest in both human techni-cal resources, produce quality products and services, and remain domestically and internationally competitive. The awards were held for the first time this year with a total of 13 categories. PTB shared the Manufacturer Awards with Bell Equipment Company.

Manufacturer Award

Glenn explains that the Manufacturer Award criteria cover all aspects of running a successful factory. "Our submission included information on products development and innovation, number of employees, the local content levels in our products, customer satisfaction and skills development programmes."

Green Award

MTN scooped the Green Award, but PTB's unique environmental approach earned it finalist status. "Powertech Batteries was the first battery company in South Africa to have ISO 14001, 18001 and 9001 accreditation," explains Glenn. "We also have complete cradle to grave control of our product, including the necessary value chains for collecting spent product. In fact, we collect more than 90% of used product and we recycle more than 99% of the components of our used products."

Enquiries: Regula Niehus. Tel. 011 706 7184.

ACTOM Power Systems, ACTOM’s sub-station construction wing, has been

awarded the electrical balance of plant sub-contract for the 80 MW Kouga Wind Farm at Oyster Bay in the Eastern Cape.

The R150 M contract, awarded in April this year by Nordex Energy SA, the engineer-ing, procurement and construction (EPC) contractor for the project, encompasses the design and turnkey provision of the electrical installation from the base of the wind turbine generators (WTGs) up to the Eskom point of connection for the power generated by the Kouga Wind Farm’s 32 x 2,5 MW WTGs.

The Kouga Wind Farm is one of eight wind energy facilities approved under the first round of government’s Independent Power Producers Renewable Energy Programme launched in November last year and com-prising a total of 28 wind and solar projects earmarked to increment the highly stressed national grid with 1 400 MW of power gen-eration capacity.

All the substation equipment required for the contract, which is scheduled for completion in November 2014, is being manufactured and/or supplied from within the ACTOM group.

CBI Electric, which is not an ACTOM com-pany, is subcontracted to supply the MV cable for the collector network.

Enquiries: John McClure. Tel. 011 430 8700 or email [email protected].

Batteries take a bow

Kouga Wind Farm - electrical balance of plant sub-contract

Glenn Geldenhuis, chief executive of-ficer of Powertech Batteries.


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ABB SACE has created a new benchmark for air circuit breakers. ABB SACE uses a patented algorithm to determine the average

absorbed power over a period of time, which thereafter controls a load list to maintain the maximum power limit specified by the user. The elimination of instantaneous based measurements and the ability to synchronise with utility measurement devices creates an efficient environment that saves on electricity bills without the need for ad-ditional monitoring systems.

The Ekip Link system and Ekip Control Panel enable local moni-toring of circuit breakers and switchgear functions in an individual switchboard. They require no programming and are available for even the most basic Emax 2 trip unit, providing an economicalmethod for a small plant to increase monitoring capabilities, or a large plant to simplify both local supervision and maintenance.

A network analyser feature provided on the Emax 2 enables analy-sis of power quality in real time, extremely accurately in accordance with EN 50160 and IEC 6100-4 30. As a result, it is possible to identify the causes of an increase of power lost or a reduction of the working life of cables and capacitors without having to install costly, external instrumentation. With Emax 2’s Network Analyzer, malfunctions can be prevented and installation efficiency and the working life of ap-pliances can be extended.

The Ekip Synchrocheck module enables the control of the synchronism condition for placing two lines in parallel before enabling circuit breaker closing. The ability of the Emax 2 to provide this feature as a module eliminates the need for the purchase and installation of independent monitoring systems.

Connectivity

Across the range, Emax 2 can be equipped with multiple cartridge-type communication modules at any time. The modules allow the circuit break-ers to be directly integrated into automation and energy management systems through the seven most popular global protocols; including IEC 61850 for the creation of Smart Grid Networks. All functions can be accessed via the internet, in complete safety, using the Ekip Link switchgear monitoring system.

The rear terminals of Emax 2be field-rotated from horizontal to vertical, however they have been spe-cifically designed to fit the most common bus con-figurations. Each terminal has been manufactured to the standard width of bus bar for that amperage and is equipped with one, two or three terminal stabs for easy connection of one to four bus runs. The ter-minal technology provides the opportunity for easy

connection and installation with fewer variants of bus bar required.The Ekip Supply Module can be connected to any voltage in AC or

DC to internally supply auxiliary power for the trip units and terminal box modules consecutively. The need for any external power supply converter elsewhere in the cabinet is eliminated, saving both space and cost. The neutral position on Emax 2 can be modified from left to right to provide ultimate flexibility.

Performance

Emax 2 uses four frame sizes, each only as wide as the amperage need requires, so that designers can optimize their space and material. The breaker design and quality materials allow for a small size while maintaining the high performances required by the most

Emax 2 incorporates new generation Rogowski sensors that provide market leading measurement. The tolerance to 1% of the actual value of current, 0.5% of voltage and 2% of power and energy guarantee precision and enable the circuit-breaker to act as a measurement device in switchgear. Measurements can be read directly on the wide trip unit display, enabling the elimination of additional devices.

The Ekip Fan Module continuously monitors the internal tempera-ture at the fixed part and activates cooling fans if required. This allows for the ability of increased current-carrying capacity in switchgear.

Enquiries: Derek Sleep. Tel. 010 202 5000 or email [email protected].

Next generation air circuit breaker

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Powertech Transformers, a subsidiary of Powertech and the JSE listed Altron Group recently completed manufacture of two 315

MVA 400 kV power transformers for City of Tshwane which are the largest for this municipality. These transformers are for the new Wildebees Infeed-Station which is situated on the eastern side of the City. This is the first 400 kV substation for City of Tshwane. The largest transformers that the company has manufactured for City of Tshwane previously were 300 MVA 275 kV transformers.

The above 315 MVA 400 kV transformers were designed, reviewed (by PTT’s technology department), manufactured and successfully tested in PTT’s test department in their Pretoria West factory with only local engineers involved.

These transformers will be transported by Rotran’s (part of ESKOM) specialised vehicle which is able to transport large transformers. Ro-tran operate a large flotilla of vehicles unique to South Africa which deal with specialised loads. This specialised equipment is supplied by Nicolas Industries, who have built all the new equipment purchased by Rotran since 2005.

The two 315 MVA transformers are of strategic importance to the City of Tshwane as they are part of the first phase of the new

Wildebees 400/132 kV Infeed-Station which is required to supply electricity to the Tshwane bulk electricity network because of the rising demand due to the increasing growth of the city. Kungwini was also recently incorporated into the City of Tshwane’s municipal area which has resulted in a further increase in electricity demand that the City has to cater for. The Wildebees Infeed-Station will form part of the major Infeed-Stations Kwagga, Njala and Rietvlei where electricity is supplied directly from Eskom. A further interesting fact is that the Wildebees Infeed-Station is the first 400 kV supply voltage that Eskom will distribute to City of Tshwane (CoT) where the existing voltages are 275 kV and 132 kV.

Bernard Meyer, chief executive officer, Powertech Transformers says: "Apart from Eskom there is only a small number of customers buying transformers at this voltage range in Africa. PTT has been a supplier to City of Tshwane for many years supplying transformers to all their major substations within their municipal boundaries. The on-time and high quality supply of the two units backed up by local after sales service will ensure total piece of mind to City of Tshwane”.

Enquiries: Jacqui Burn. Tel. 012 318-9802 or email [email protected].

Energy efficiency has a significant impact on energy savings and, according to Schneider Electric, technologies designed to lower

energy costs could cause unexpected power quality issues. “A capital investment in power factor correction and harmonic

filtering equipment can result in a healthy return of investment – depending on the utility’s demand rate structure, production quality cost due to harmonics, and voltage fluctuations in the distribution system,” says Shaun Wilson, professional services director, at Sch-neider Electric South Africa.

Power factor correction devices improve overall electrical efficiency upstream of their point of connection in the electrical network and can be used to minimise utility kVA demand charges.

Wilson explains that power electronic devices that have rapid and frequent load variations have become abundant today due to their many process control related and energy saving benefits. “However, they also bring a few major drawbacks to electrical distribution systems, such as harmonics and rapid change of reactive power requirements. Harmonics may disrupt the normal operation of other devices and increase operating costs.

Symptoms of problematic harmonic levels include overheating of transformers, motors and cables, thermal tripping of protective devices, logic faults of digital devices and drives. Harmonics can also cause vibrations and noise in electrical machines: Motors, transform-ers, and reactors,” he adds.

The lifespan of many devices can be reduced by elevated operating temperature. Plus, rapid reactive power changes demand timely reac-tive power (VAR) compensation. “Lack of appropriate and adequate VAR compensation can lead to voltage fluctuations in the electrical distribution system, impacting equipment operation, as well as product quality,” says Wilson.

An active harmonic filter (AHF) provides an effective means to mitigate harmonics, reduce process-related voltage fluctuations and

improve equipment operating life and system capacity. It can be part of a power factor correction and harmonic filtering system. Many industrial facilities place poor power quality at the top of the list of inefficiency factors responsible for losses due to reduced productiv-ity and lower quality of products. Large industrial, commercial and institutional power users can benefit from centralised medium voltage reactive power compensation systems that typically require lower initial capital expenditures (ZAR/kVAR) than low voltage solutions while still addressing the most common power quality problems.

“Medium voltage metal-enclosed compensation systems provide a centralised solution approach with attractive installation options supporting the scale and scope of large electrical services. Many large commercial and institutional customers with medium voltage distribution network can also take advantage of medium voltage reactive compensation systems,” says Wilson.

Enquiries: Belinda Aslett. Tel. 011 254 6400 or email:[email protected].

Power transformers for City of Tshwane

PFC and harmonic filtering are part of energy efficiency


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Global truck manufacturer Navistar International exclu-sively powers a number of its latest model ranges

with engines manufactured by Cummins. According to In-ternational SA sales and marketing general manager, Sally Rutter, the company has been fitting Cummins engines to its range of vehicles since the early 1970s. "International was amongst the first companies to fit Cummins engines in the USA, and the relationship has continued and flour-ished across the globe since that time," she explains.

The International product line includes the 9800 series 6 x 4 truck tractors, the WorkStar 6 x 4 truck tractor and the TranStar 6 x 4 truck tractor. Rutter points out that all International vehicles consist of the well proven and durable North American Driveline, consisting of the Cum-mins engine, Eaton- Fuller 18 speed auto shift transmis-sion, Meritor drive axles and Hendrickson HAS 460 air suspension. The 9800 series has two models, namely the 9800i and the 9800e. Both vehicles are powered by the Cummins ISX 15 l big bore engine, rated at 450 Hp and 400 Hp respectively.Enquiries: Janean Davies. Tel.

011 321 8700 or email [email protected].

Zest WEG Group’s Genset Division is supplying a custom engineered genset solution to the Silo 1 building project in Cape Town. The hybrid modern-

meets-historical building comprises nine storeys, three of which are basement levels. In what is set to become a Cape Town landmark when completed, the Silo 1 structure will provide 18 500 m2 of office space, 300 m2 of retail space and 3 500 m2 of residential space divided into 31 apartments. A six storey central atrium completes the picture. The contract was awarded to Zest WEG Group’s Genset Division based on the company’s submission of a commercial and technical solution. The company is responsible for the design, assembly, installation and commissioning of the gensets. The engines are Tier 3 emission-compliant, which is currently the highest level for production engines. “Because it was necessary to provide sound attenuation to a residential level, the design and engineering required the inclusion of special inlet and outlet air attenua-tor splitter assemblies. The exhaust systems are designed and manufactured in-house to ensure that the exhaust breakout noise is within the limitations of the local bylaws,” says Bruce McCracken, from Zest WEG Group’s Genset Division’s Cape Town offices. The contract was awarded in June 2012 and the gensets arrived on site in the second week of May 2013.

Enquiries: Jamie Wilson. Tel. 011 723 6000 or email [email protected].

Powerful truck engines Powering up – Cape Town’s Silo 1

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The properties of polyurethane, its chemical composition and its suitability to applications, are often misunderstood, and polyurethane is often wrongly perceived as a plastic, which it

is not. It is an organic polymer containing the urethane group that is core to the chemical structure and is grouped with rubbers, due to the fact that both are elastomers and made from reacting a polyol with a diisocyanate.

Chain extenders are then added to increase the molecular weight of the pre-polymer in order to form a usable elastic polymer. Polyure-thane wear solutions are among the most effective of these, helping to not only meet the plant’s projected time to break even, but also substantially reducing the expenditure required to operate the plant.

Abrasion resistance

The polymer backbone chemistry influences these properties and it is the expertise and responsibility of the urethane supplier to select the most appropriate one for the customer. For example, polytetrameth-ylene glycol polyol backbone has superior physical and mechanical properties over a polypropylene glycol polyol, delivering superior performance in applications that require high wear resistance.

Polyester based polyurethanes, on the other hand, result in strong, tough oil resistant materials, but lack hydrolysis resistance when compared with polyether. The main isocyanides, namely diphenylmethane and 1,5 naphthalene diisocyanate, form the rigid phase of the polyurethane. Different isocyanates result in materials with differing properties with regard to hydrolysis, temperature and abrasion resistance.

The variations of polyurethane composition make it suitable as an abrasion resistant and load bearing material for the mining industry and, due to its chemical resistance, as a versatile material for the chemical industry too. The major advantages of polyurethane include tensile and tear strength elongation, in addition to rebound, chemical and solvent resistance. When production chemistry is scientifically matched to the application, polyurethane can play a key role in as-sisting plant managers and maintenance engineers in protecting the plant from downtime due to either erosive or abrasive wear.

Pipeline protection

With process plants today being designed for higher throughput, the life expectancy of modern mining plants has ultimately shortened. Equipment is being designed for a certain life expectancy and no more. For this reason, engineers are moving away from traditional rubber lined steel pipes, and towards more cost effective lining alternatives.

It is, however, important to realise that rubber lined steel pipes still have a place in plant sectors that have a short life expectancy of less than five years, and where energy consumption is not an issue.

Polyurethane has been proven to be cost effective in terms of proofing the pipe against abrasion, and is also energy efficient, due to its low coefficient of friction, which is up to five times better than rubber. Through better engineering design, one can ensure that the pipeline achieves the required durability that correlates with the projected life of plant. The most cost effective lining material on the market today is polyurethane, but for the lining to meet expectation, its composition and the actual lining of the pipe must be undertaken by a competent company.

High density polyethylene (HDPE) is the major competing material against polyurethane in the local market. When applied correctly, a polyurethane lined pipe can outperform its competitors by a factor of three when conveying mine tailings and other process media. A test conducted at a phosphate plant in South America with 16 mm ore pumped at 3 ms, revealed that polyurethane lined pipes in this application outlasted HDPE by factor of 24.

If a steel polyurethane lined pipe commands a 41% premium over its closest rival, HDPE, the total lifecycle cost over a given period would work out to approximately 47% to that of HDPE. This assumes that polyurethane is a minimum of three times more wear resistant and does not take into account polyurethane’s superior performance with regards to high velocity, large particle sizes and bends. UMP's branded Redline polyurethane in particular allows for a thinner lining and a range of thicknesses to suit either the internal pipe diameter or the specific wear protection required. What's more, it delivers benefits that include shatter proofing and immunity to thermal and external shocks.

Advantages of polyurethane in industrial applicationsBy T Carolin, UMP

Local industries can substantially reduce the unpredictable downtime periods and delays on overall return-on-investment caused by premature

plant abrasion, by better understanding the benefits that polyurethane wear protection products provide.


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Electrical applications

Here, polyurethane serves as an excellent insulator. There are various prototypes and test work on making polyurethane insulators, which help to resolve conflict with regards to broken insulators, which often occurs as a result of vandalism.

General protection

Polyurethane wear protection also plays a fundamental role in chutes and other steel channels with rectangular or multi angular sections. Wear protection for these shapes is achieved by making use of UMP's range of Armadillo protective chute linings, which delivers a lifecycle cost advantage of more than 30%. Armadillo can be installed as a chute liner at the UMP factory and onsite, or it can be fabricated as a drop-in liner for ease of replacement. The major benefits of Arma-dillo include; resistance to impact and abrasion, excellent tear and cut properties and a low coefficient of friction in chutes and bins.

Despite the distinct advantages of polyurethane as a wear re-sistant material, it is of the utmost importance for plant managers to deal with an experienced wear protection company that acts as a consultant, rather than just a seller. Users should remain alert to the fact that polyurethane is a chemical with numerous variants, and that the incorrect grade of material will have disastrous consequences. They should also work to narrow down the choice set of possible polyurethanes, and then undertake field tests to determine which one will deliver optimum results.

Conclusion

If not selected correctly, polyurethane will not perform to the stand-ard promised. In the recent past, inexperienced vendors lacking an understanding of the complex nature, chemistry and production methods of this product have made unrealistic promises that have not been fulfilled. However, reputable vendors in the market are well documented and well known. In applications not suited to polyure-thane, all of them are usually able to recommend and supply suitable alternative products. The customer can benefit substantially by ap-plying the best solution for its particular application.

About the authorTake note

The properties of polyurethane,

its chemical composition and

its suitability to applications

are often misunderstood.

trevor Carolin holds a Higher national diploma in mechani-cal Engineering, as well as a management advancement Programme qualification from Wits Business school. He boasts more than 20 years of experience as a mechani-cal engineer, after beginning his career at JCi mining in

1990. in 1993 Carolin joined inter Pack Buildings as a training manager in the plastics division. three years later, he left the company as general manager to join Blister Pack, before finally buying in to umP in 1997, where he has remained a director. Enquiries: tel. 011 452 1000 or email [email protected].

• Polyurethane is an organic polymer.• Polyurethane comes in a variety of variants and the appropriate one

must be selected.• Polyurethane offers many solutions to real industrial challenges


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Siemens Metals Technologies and Lan-zaTech have signed a ten-year coop-

eration agreement to develop and market integrated environmental solutions for the steel industry worldwide. The collaboration will utilise the ground-breaking fermenta-tion technology developed by LanzaTech transforming carbon-rich off-gases gener-ated by the steel industry into low carbon bioethanol and other platform chemicals.

Off-gases from the production of iron and steel contain significant amounts of carbon monoxide (CO) and carbon dioxide (CO2). Globally, the iron and steel industry contributes 6,7% to the worldwide CO2 emissions. To produce one metric ton of steel, an average of 1,8 metric tons of car-bon dioxide (CO2) is emitted. Up to now, these gases have been flared or used to create process heat and electrical energy within the plant.

LanzaTech’s innovative technology, in-stead, re-uses the off-gases from converter, coking plant or blast furnace processes as nutrients and a source of energy. The patented biological fermentation process allows steel plant operators to make use of the chemical energy contained in off-gases in the form of CO, CO2 and H2 (hydrogen) for the eco-friendly production of bioetha-nol or other basic chemicals such as acetic acid, acetone, isopropanol, n-butanol or 2,3-butanediol.

The global market for ethanol alone is estimated to amount to an annual volume of over 80 million metric tons, of which 75 million are used as biofuel. Unlike the bioethanol produced through agriculture, this fermentation process does not com-pete with food production.

Enquiries: Email [email protected].

Siemens has been awarded a contract to supply power plant components, includ-

ing six F-class gas turbines, for the Ras Djinet and Ain Arnat combined cycle power plants (CCPP) in Algeria. The clients are Daewoo and Hyundai Engineering Ltd, Korean companies that are building the two power plants for So-ciéte Algérienne de Production de l’Electricité (SPE), the state-run energy provider in Alge-ria. Together, the two power plants will have an installed electrical capacity of more than 2 000 MW and will supply power to over five million households on Algeria’s Medi-terranean coast. The Ras Djinet power plant location is approximately 100 kilometres east

of the Algerian capital Algiers. Ain Arnat is located approximately 260 kilometres east of Algiers. The scope of delivery from Sie-mens includes a total of six SGT5-4000F gas turbines, six SST5-3000 steam turbines, and six SGen5-2000H generators. In addition, Siemens will provide technical support and services for the construction and commis-sioning of the six power trains. A framework agreement was additionally concluded for the delivery of spare parts for the plant in Ras Djinet for a ten-year period. Algeria is one of the wealthiest countries in Africa in terms of raw materials, with extensive crude oil and natural gas deposits. Due to economic

development, Algeria plans to expand its power generation capacity from the current level of 11 GW to approximately 26 GW by the year 2022.

Enquiries: Hulisani Nemaxwi. Email [email protected].

Process uses energy contained in steel plant off-gases

Components for CCPPs in Algeria

For four years Energy Cybernetics has been making its Energy Barometer tool

available to building owners to participate in the National Energy Barometer Survey (NEBS). Participants will receive their rank-ing result that indicates where they are in comparison with others in their respective industry.

This year’s participation carries no costs. Participate in the NEBS 2012 Utility Year by following these steps:

Logon to www.energybarometer.com.

Register as a participant. Enter the required details for your building(s) category. Enter the energy use from your utility account for December to January 2012. You will receive: • An emailed NEBS certificate of your

results for you to display if you so wish• The top three in each category receives

press exposure if permission is granted by you and a framed certificate of the achievement

• Total confidentiality and privacy of your results

Building envelope categories available: • Shopping centres• Corporate headquarters• General office buildings• Banks• Hotels• Hospitals

Enquiries: Visit www.energybarometer.com.

4th National Energy Barometer Survey (NEBS) now open


• Control systems and automation• Electrical protection and safety• Plant maintenance, test and measurement

• Sensors, switches and transducers• Health, safety environment and quality• Energy and enviroFiciency

**Editorial contributions are welcome! Please contact the editor, Wendy IzgorsekEmail [email protected]

For advertising, contact:Helen Couvaras: Email [email protected] Jandrell: Email [email protected]

Electricity+Control Features – September 2013

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International consultancy, engineering and project management service provider Royal HaskoningDHV has produced a master plan

to develop the Senegal River delta and is designing eight polders as a pilot project in the area. The delta is plagued by Typha, an aquatic plant that grows abundantly in the area. The plant’s proliferation limits water access for the population, reduces the potential for agriculture and increases the occurrence of diseases like bilharzia (also known as schistosomiasis) and malaria. The polders will allow intensive usability of the land in the near future and deny the Typha further space for growth.

The client for the project is OMVS, Organisation pour la Mise en Valeur du fleuve Sénégal. OMVS is a governmental organisation of Guinea, Mali, Mauritania and Senegal set-up to manage the Senegal River and its drainage basin. It aims to promote self-sufficiency in food, to improve the income of the local populations and to preserve the natural ecosystems.

With a length of 1 800 kilometres, the Senegal River is West Africa’s longest river. Its delta, which lies between the Sahel and the Sahara, is pivotal to the local population’s socio economic conditions. Many people live in villages along the banks of the river. In the 1970s, OMVS built two dams to organise the area’s water supply, improve navigation and generate energy. Fawzi Bedredine, project manager at OMVS, said: “Construction of the dams created a large freshwater lake, while flood plains are permanently under water and there has been a sharp reduction in the penetration of salt in the river. In the fresher river delta, the Typha, which flourishes in a freshwater environment, has proliferated massively on the flood plains of the river”. The aquatic plant now plagues a total area of 100 000 hectares.

George Peters, project manager at Royal HaskoningDHV, said: “The huge proliferation of the Typha has major consequences for the local people. These aquatic plants prevent them from having access to the

river, the flood plains are unavailable as agricultural land and drain-age canals become blocked. What's more, the plants attract birds that eat the crops in the nearby agricultural areas. On top of all this, 90% of the population have contracted bilharzia, a disease that can cause organ failure and is spread via worms and larvae in the river water.”

The Royal HaskoningDHV plan is designed to improve the situation of the local population by creating agricultural land and improving access to the water. Eight polders, 63 kilometres of dikes and 60 kilometres of drainage canals will be constructed in the river delta in an area covering between 3 000 and 4 000 hectares. According to Peters: “Creating the polders will make it possible to use the area for agriculture, thus preventing the Typha from growing and spreading. The local people will again get access to the river and thus to fresh water for irrigation and trade.”

Enquiries: Hillary Erasmus. Tel. 011 798 6511 or email [email protected].

On 15 and 16 October 2013, Viridis Africa hosts its third Clean Technology conference at Killarney Country Club, Johannesburg,

South Africa. The event is dedicated to the introduction of clean tech-nologies as well as associated business and investment opportunities.

The intention of Viridis Africa is to bring together investors such as Inspired Evolution, Sterling Waterford Securities, Lerako Metier, the IDC, Curatio Capital, Vantage Capital and the Technology Innovation

Agency and entrepreneurs from Africa and the rest of the world, to jointly explore commercial initiatives in green technologies.

The programme includes the presentation of 20 projects of business initiatives, ranging in size and scope and encompasses priority areas such as bioenergy, hydro, wind power, green chemistry, recycling, water treatment, desalination, amongst others.

Enquiries: Visit www.viridisafrica.com.

Polder plan protects people in Senegal

Cleantech projects to be highlighted at Viridis Africa


&CurrentLight& Product News

ART Solar’s investment in a new cross-connector machine ensures consistently high quality standards during manufacture at the photovoltaic (PV) module manufacturing

plant in KwaZulu-Natal. “This highly developed machine – the most modern of its kind in the world – requires two people to operate the system, which means there have been no job losses at the plant,” says Dr Ronald Lange, chief operating officer, ART Solar.

Enquiries: (031) 705 7162 or email [email protected].

Energy Engineered Products (EEP) and Multi Alloys’ sustainable internship programme provides engineering students with the necessary experiential training to complement

their theoretical studies, so that they can successfully complete their education and find employment in their careers of choice. EEP is a leading stockist and distributor of indus-trial stainless steel, corrosion resisting alloys and valves for over two decades and Multi Alloys is one of South Africa’s specialist suppliers of nickel alloys, duplex and high alloy stainless steel, titanium and other niche products. “As two related companies, the interns have the unique opportunity to gain experience within both businesses,” says Ken Perel, Multi Alloys owner/member.

“Although tertiary education is expensive, it is an investment if students graduate and succeeds in finding a suitable career,” continues Ken. “Both theory and practical training must be completed successfully before students can pass and this is where we believe the value of internships lies. By providing the necessary experiential training required by students, these programmes make a positive contribution to the country’s economy.” Ken also notes that as part of their programme, in-terns attend specific training courses such as SASSDA’s basic training programme on stainless steel.

Enquiries: Ken Perel. Email [email protected].

Putting theory into practice

After an illustrious career spanning some 17 years at the helm of Consulting Engineers

South Africa (CESA), Graham Pirie retired at the end of June 2013. He has overseen many initiatives which have benefited the industry tremendously, including the transformation strategy for the consulting engineering sec-tor culminating in the establishment of the Construction Industry Transformation Charter. The best Practice Guideline for Procurement of Consulting Engineering Services in the Public Sector was produced under his watch as was the Quality Management initiative culminating in ISO 9001:2008 accreditation for the CESA Directive and became a prerequisite for CESA membership. Adherence to the CESA Business Integrity Management System for members became another requirement for membership thus assuring clients that members provide a quality assured service with integrity taken as a given. He made it a priority for CESA and its members to participate actively in the International Federation of Consulting Engi-neers (FIDIC) as well as its regional grouping, the Group of African Consulting Engineers (GAMA). CESA past President Felix Fongoqa says Pirie has worked tirelessly to ensure that the sector works in a fair and reasonable envi-ronment, in which the industry can continue to grow, be profitable and sustainable.

Pirie said that it has been a privilege for him to have served such an inspiring organisation like CESA that is apolitical and does what is right and with integrity.

Enquiries: Tel. 011 463 2022 or email: [email protected]

CESA CEO changes gears

Machine operators Cynthia Mkhize (front) and Zama Mkhize ( back).

New cross-connector machine for PV plant

Erratum

The headline of the Endress+Hauser article (by S Milford) on page 16 of Electricity+Control,

July 2013, should have read as follows: Value of modern 2-wire technology for MRO.

My apology. Editor


&CurrentLight& Product News

Bizz Buzz

“With an electric Siemens motor, you can always achieve the highest ef-ficiency level. Our motor systems cover the entire range of synchronous

and asynchronous technology”, says Raymond Padayachee, vice president, Siemens Industry, Africa and Middle East.

A market study was conducted by Siemens with the aim of directly addressing the needs of the customer. Availability, flexibility, service and accessibility were identified as key elements which have now become the cornerstones in develop-ing this strategy. In consultation with Siemens distributors it was identified that price and stock availability had become a challenge for Siemens which needed to be urgently addressed. Three projects were commissioned with various Siemens Distributors in order to test the acceptance of discount structures, consignment stock and stock profiles by the market. The projects, which ran for three months, produced better than expected results. The increase in volume sales, on a month on month basis, was significant surpassing all project goals proving that the initial market study and strategies provided the correct approach.

This lead directly to the birth of Simotors. With the addition of Simotors as a key distributor, Siemens aims to improve its pricing model and delivery time to the market. The standard Low Voltage Motor 1LE0 range will be sold via Simotors and its distribution network. Apart from being a value added partner in the distri-bution of Siemens Electric Motors, Simotors will carry a full range of spares and are fully equipped to handle repairs, breakdowns and modifications. Simotors will carry the 525 V 2, 4 and 6 pole, Flange and foot mounted with other voltages and mountings available on request.

Enquiries: Keshin Govender. Email [email protected].

Becker Mining South Africa has a locally designed and manufactured Wi-Fi sys-tem which ensures reliable, safe and efficient communication underground. This

system does not limit usage to a single technology, but encompasses migration and integration of many technologies.

The Becker WRAP (Wireless Router Access Point) provides a high speed back-bone for wireless VoIP, seamless roaming of devices, advanced vehicular dispatch systems, process automation, as well as any device which can utilise a wireless, serial or fibre backbone.

WRAP has a versatile design, which means a combination of communications backbones can be used to optimise the system. For example, fibre can be used for high data throughput. In working sections of a coal mine, where there is frenetic activity, a wireless mesh topology is recommended.

“Becker Electronics has made a substantial investment in researching and test-ing underground Wi-Fi systems to overcome the problems with conventional Wi-Fi systems in underground conditions,” says Johann Smit, Becker Mining South Africa. “A critical feature of this advanced system is its intrinsically safe design, which enables safe use in hazardous and harsh mining conditions underground. What’s important about Becker’s systems – each of which can be customised to exact requirements - is that each product can be installed as a single stand-alone system, or can be deployed using a phased approach to minimise a huge initial capital outlay.”


Simotors – new to local motor industry

Safe underground communication

Namibia set to boomNamibian industry is set to boom on a number of fronts, particularly in light of its major port expansions, new min-ing potential and ambitious agro-processing goals. This emerged at the Namibian Investment Seminar staged for potential investors at Gallagher Estate in Johannesburg on 2 July 2013. Namibia’s Deputy Minister of Trade and Industry, Tweya Tjekero, and High Commissioner Marten N Kapewesha, headed a panel of sector authorities to outline the multiple investment opportunities available to investors. The Deputy Minister said: “Namibia is the gateway to the SADC region. Namibia’s policies are aimed at growing an industrial economy and in line with this, the country has attractive incentives to support partners aiming to invest in mining, infrastructure and manufactur-ing in particular.”

Enquiries: Email [email protected] or [email protected].

Microsoft’s CityNext initiative Schneider Electric will be working with Microsoft on CityNext, an initiative designed to help governments, businesses and citizens reimagine what is next for their cities. For the first time in history, more than 50% of the world’s population lives in urban areas and nearly 70% will live in cities by 2050. This ongoing migration cre-ates unprecedented opportunities, but also intensifies problems such as ageing infrastructure, hazards to public health and safety, pollution, crime and traffic. Through the CityNext initiative, the companies will help leaders to do ‘new with less’ - by combining the power of technology with innovative ideas to connect governments, businesses and citizens with city services that increase efficiencies, reduce costs and foster a more sustainable environment.

Enquiries: Visit www.schneider-electric.com.

Honeywell to automate Russian refineryHoneywell has signed an agreement with NK Rosneft, a leading Russia-based oil and gas producer, as the main automation contractor for the construction of its new refinery at Tuapsinskiy NPZ, Southern Russia. Honeywell will deliver a comprehensive set of services to equip the Tuapse refinery with a single integrated production control system – Experion Process Knowledge System (PKS) to improve both the efficiency and profitability of its production process. Honeywell will also provide assistance during the design and commissioning stages of the project. In addition, Honeywell will equip the site with systems to help improve the safety, efficiency and reliability of the production process.

Enquiries: Boni Magudulela. Email [email protected].


Social Engineers

The new Adroit Technologies Demonstration Centre at Adroit’s head office in Fourways,

Gauteng, was opened on 8 July 2013. The integrated interactive Demo Centre allows

customers such as system integrators and other partners, to really get a hands-on feel

for the range and capability of both Adroit and Mitsubishi Electric’s Factory Automation

products in a relaxed environment. In addition, various partners including Rittal, Moxa

and FAG, have all contributed to adding a real-world solution element to the system.

Adroit Technologies’ managing director, Dave Wibberley, says: “Having a hands-on

demonstration capability allows us to not only talk-the-talk but to walk-the-walk”. Hartmut

Pütz, president of Mitsubishi Electric’s Factory Automation Europe Business Group, was

present at the opening.

Enquiries: Tessa Lithgow. Tel. 011-658-8100 or email [email protected].

Air Products South Africa’s latest project on its corporate social in-

vestment agenda focuses on the development of pre-school children

and toddlers in disadvantaged communities. Initiated by Cotlands,

a non-profit children’s organisation, the programme is aimed at

providing a solid and nurturing developmental foundation through

access to educational toys, materials and play therapy. Cotlands

has joined forces with the Touch Community Network, a non-profit

public benefit organisation devoted to helping women and children

in crisis. The first Touch Toy Library was opened in Rustenburg on

6 June 2013, proudly supported by Air Products South Africa. “We

are excited to be able to support an initiative such as the toy library.

It is widely acknowledged by educationalists that ‘play’ is crucial to

a child’s social, emotional, physical and cognitive growth. Investing

in children in their formative years will have a significant impact on

their later development,” comments Neale Quilliam, general man-

ager, human resources at Air Products South Africa.

DM Agencies in Cape Town has won a gold level prize in Legrand’s ‘Club Legrand’

competition - a campaign initiated earlier this year to increase awareness of the

company’s name. “This competition, with the ultimate prize of a trip to Paris, has

created a buzz at Legrand’s distributor outlets throughout the country,” says Luk

Ivens, general manager, Legrand Southern Africa.

Enquiries: Telephone (011) 444 7971 or email legrand.south-africa@

legrand.co.za.

‘Touch to Create Toy’ Library

Gold level prize

Adroit’s Dave Wibberley and John Crain with Mitsubishi’s Hartmut Pütz (centre).

Opening of automation demo centre

Ilse van Tonder (Air Products), Marie van Schalkwyk and Rosalie du Plessis (Touch Community Network), Jackie Schoeman (Cotlands), Neale Quilliam and

Josua le Roux (Air Products).

Brandon Bosch, DM Agencies, Brett Stigant, Legrand, Joleen Klink and John Adams, DM Agencies.


Social Engineers

On Friday, 19 July 2013, Master Power Technologies hosted a workshop

at The Castle in Kyalami. Professor Ian Bitterlin, chief technology of-

ficer, Emerson Network Power Systems EMEA, began the presentations

with a thought provoking look into the future of data centres. Gert-Jan

Dorenbos, business development manager, Hitec Electric, then gave an

interesting presentation on the development and design of rotary UPS

and the implementation of rotary UPS solutions. Dave Warren, sales

manager (power generation) Master Power Technologies, gave an in-

depth overview of the best practices in genset design. Georg Herz, MTU

Onsite Energy, suggested that gas driven generators are Africa’s untapped

power source of the future. Wouter Vermeulen, new business develop-

ment (Containerised Solutions) described innovative pre-manufactured

modular data and energy centres.

Enquiries: Neil Schreiber. Tel. 011 792 7230.

On 9 July 2013, Roland Bonath, product manager Nucleonic from VEGA Germany,

gave an interesting presentation on nucleonic measurement (also known as ra-

diometric measurement) at Vega Instruments SA in Honeydew. After covering the

basics of this non-contact measurement technique, Roland went on to explain the

advantages of VEGA’s ProTrac radiometric instrumentation. These instruments

are smaller and lighter making them easier to install and are made to be robust to

withstand vibrations and are designed according to IEC 61508 and qualified up to

SIL2. Roland demonstrated how VEGA radiometric instruments are used for point

level detection, continuous level measurement, density measurement in pipes, mass

flow measurement of solids and interface measurement as well as a number of other

interesting applications.

Enquiries: Chantal Groom. Email [email protected].

Master Power Technologies Workshop

Nucleonic level and density measurement with VEGA

Professor Ian Bitterlin, chief technology officer (Emerson Network Power Systems EMEA).

Presenters: Gert-Jan Dorenbos (Hitec Electric) and Dave Warren (Master Power Technologies).

Among those attending: Adolph Shirinda (Hambisa Engineering); Sibusisu Mathebula (Makhadabi Consulting) and Edgar Shingange

(Hambisa Engineering).

Roland Bonath (product manager: Nucleonic, VEGA Germany)


CliPBoaRd

aPPointmEnts

musts FoR youR diaRyindEX to adVERtisERs

aCdC dynamics ............................. oFC, 2

Becker mining systems ........................53

Cummins Power Generation .................33

Current automation..........................insert

Eaton .....................................................59

Endress+Hauser ....................................45

Engen.....................................................11

ePlan: Blm software & service ...........9

Hansen ..................................................24

impact Energy.....................................oBC

marthinusen & Coutts...........................25

mecosa..................................................39

Phoenix Contact ....................................21

Powertech transformers .......................51

REt automation Controls ..................... iFC

Rittal ......................................................16

RJ Connect .......................................insert

Royal HaskoningdHV ............................17

sam .................................................... iBC

schneider Electric ...................................7

siemens.................................................15

solar indaba 2013 .................................56

southern Power maintenance ..............13

surgetek ................................................29

temperature Controls ............................43

trans Electron ........................................19

Wacker neuson .....................................37

WiKa .....................................................41

Zest WEG Group....................................49

Sixth Annual Innovation Summit27 - 29 August 2013. Industrial Development Corporation (IDC), JohannesburgSouth Africa’s premier platform in showcasing leading innovation and driving dialogue – this year’s theme is ‘Innovation goes viral, catch it for growth’Enquiries: Tel. 012 844 0674 or visit http://innovationsummit.co.za

3rd Annual Solar Indaba2 – 5 September 2013, Mount Nelson Hotel, Cape TownExecutive-level and multi-track summit target-ing the CSP, utility scale PV and commercial PV sectorsEnquiries: Email [email protected]

High Voltage Conference 201318 – 19 September 2013, Midrand, South AfricaUpdate your knowledge on best practice and find practical solutions to your HV design and installation issues.Enquiries: Nicole Dredge. Email [email protected]

DistribuTECH Africa 2013: Equipping Utilities for the Future30 October – 1 November 2013, Sandton Con-vention Centre, JohannesburgEnquiries: Visit www.distributechafrica.com

8th Southern African Energy Efficiency Convention (2013SAEEC)13 & 14 November 2013, Emperors Palace, GautengThis two-day convention will feature over 70 speakers, 50 exhibitors and 500 delegates and annually brings together stakeholders in the energy efficiency sector including equipment suppliers, consulting engineers, energy service companies, end-users of energy, utilities and researchers. Topics to be covered range from mining and industrial energy optimisation, tax rebates, carbon incentives, business case studies, technical case studies, energy management in buildings, alternative energies to standards and government requirements. Enquiries: Erika Kruger. Tel. (018) 290 5130 or email [email protected]

WearCheck Booyco Engineering

Aurecon

Magnet

Samesh Pillay, remote laboratories technician

Phil Hendricks, office manager (Gauteng)

Ferdi Nell, office manager (Cape Town)

Richard Smith, board of directors

Kyle Alexander, graphic designer


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