Professional Documents
Culture Documents
Wherever I drive I see adverts and billboards offering Obviously this does not happen often but it does
solutions; I get MBs of emails offering solutions happen, and sadly the nave out there find desperation
many to ominous-sounding personal conditions that I driving them to invest in systems which they can
assume the sender of the message must surely suffer neither manage nor really afford to run.
Ian Jandrell
from. Fortunately their plight withers away in my junk
mail folder And then they blame the system.
And we have many, many advertisers and authors who It is not the systems fault. The fault must surely lie
strive to share their expertise at providing solutions to somewhere between an uninformed buyer and a rather
our readers. overzealous seller I suspect.
It is, after all, a solution that we want. I need a solution Real solutions are almost by default holistic in nature; each
to my problem; I need a solution that will make my plant element of a solution affects another part of the process;
more efficient. and may indeed rely on another one. The implication of
this is that each part of your solution needs to be carefully
Then I found myself involved in a debate: buying the right considered and designed, and holistically integrated into
software package could be the solution you are looking for. a system which can support it at all levels, be these
machine, virtual or people-based. That support must be
Well, it depends. in place ready and waiting.
I have a growing suspicion that folk often assume that a As an aside, another issue that I often find myself up
particular piece of software will, just like that, provide the against is the tendency to look for technological solutions
solution they are after. Buy it, install it, and your troubles only after the wheels have fallen off. Working with
are gone. competent consultants, contractors and vendors, and
building up a good relationship will ensure that you do
Of course they are not. They have only just begun. not find yourself in this position.
The views expressed in this publication are not necessarily those of the publisher, the editor, SAAEs, SAEE, CESA or IESSA
August 11 Electricity+Control 1
Contents
Cover
FEATURES:
Control systems and automation
Drives and motors
Standby and back-up
Temperature measurement
Transformers and substations
Features
Are you EnviroFicient?
8 No need for cables: Autonomous GSM/GPRS control monitors water supply shaft
By B Fiene, Phoenix Contact
EATON Blade UPS
10 Round UP A Scalable Solution for
a Greener Data Centre
36 Round UP
Temperature measurement
40 Potential errors that can affect temperature measurement accuracy
By S Courts, Lake Shore Cytronics
44 Round UP
Publisher: Advertising Managers: Quarter 4 (October December 2010) Published monthly by:
Jenny Warwick Helen Couvaras and Heidi Jandrell Paid circulation: 104 Crown Publications cc
Free circulation: 4681 Cnr Theunis and Sovereign Sts
Editor: Circulation: Total circulation: 4806 Bedford Gardens
Wendy Izgorsek Karen Smith PO Box 140, Bedfordview 2008
Tel: (011) 622-4770; Fax: (011) 615-6108
Editorial Technical Director: Reader Enquiries: e-mail: ec@crown.co.za
Ian Jandrell Radha Naidoo admin@crown.co.za
Website: www.crown.co.za
Design & Layout: Cover Design:
Adl JvR Bothma Adl JvR Bothma Printed by: Tandym Print
August 11 Electricity+Control 3
Control systems and automation
A closer look at todays diagnostics concepts for serial fieldbuses (eg PROFIBUS), Ethernet-based fieldbuses (eg PROFINET) and industrial
Ethernet networks reveals principal differences between the systems as well as advantages and disadvantages of existing diagnostics products.
A parallel analysis of customer requirements for efficient network diagnostics shows that much is left to be desired. For this reason, the authors
company has developed a trendsetting, unified diagnostics concept that features a combination of remote monitoring and central analysis.
F
ieldbus systems such as PROFIBUS, Interbus or CAN using Industrial communication
RS485 bus physics have been analysed for more than 20 years.
Diagnostics of Ethernet-based fieldbuses and industrial Ethernet
The basic principle is identical for all protocols: A passive station
With Ethernet, the automation industry welcomes new opportunities
monitors all telegram exchange and evaluates the recorded telegrams
but also faces new challenges. At Ethernet-based fieldbuses such as
based on the respective protocol stack. This information forms the
PROFINET, field devices are connected like simple I/O devices, drives
basis for a status display of the entire network and all connected sta-
etc. This increases the number of stations and real-time capability
tions. Most tools focus on complex telegram analysis with extensive requirements as well as complexity of network topology. Unlike as
trigger and filter functions which are highly useful for experts and is the case with diagnostics of conventional fieldbuses, monitoring
service providers when troubleshooting, but are far too complex for an entire network is not realistically feasible in case of Ethernet, a
the user. Bus physics may be tested with easy-to-use wire testers; switched medium. A passive diagnostics tool in Ethernet can only
however, this has the drawbacks of plant downtime and the fact monitor communication between two stations and requires expensive
that many failures are missed because they occur only temporarily, TAPs for non-reactive measurements. Sniffer-based concepts like the
perhaps for only a few milliseconds. Taking account of the limits commonly used Wireshark are not suitable for plant-wide monitoring
of these tools, this company focused on ease of use with their first either. Other limitations are the high performance requirements and
diagnostics tool, the PROFIBUS scope. With the xEPI 2 diagnostics large data volumes which render continuous monitoring with passive,
unit (new: TH LINK), a solution for permanent, stationary monitor- telegram-based analysis rather impracticable, as they necessitate
ing of entire networks was launched for the first time ever. All key powerful measuring tools or PCs. The introduction of intelligent
diagnosis information is available via the web browser at any time; devices has changed diagnostics strategies, with managed devices
an alert function notifies of problems before they actually occur. This providing comprehensive information on communication quality or
allows instant action well in time while troubleshooting tools in such topology via standard protocols such as SNMP, LLDP, DCP. These
cases waste valuable time. can be actively read out from operational devices across the entire
network. Infrastructure and network suppliers have been providing
Formula for efficient network diagnostics
powerful IT tools for this task for several years. However, these are
Permanent network monitoring instead of reactive troubleshooting. designed for typical IT office applications or globally connected sites
Automatic alert in case of failures - the network notifies the user
in case of problems. It is crucial that any network problem can be diagnosed easily and
Use of intelligent devices - managed components such as reliably.
The most useful diagnostic systems are permanent, rather than reactive.
switches.
A diagnostic tool is available that will cover around 70% of current
Traffic light principle for diagnostics.
fieldbus systems.
Permanent documentation and inventory taking of network and
devices.
T ake note
4 Electricity+Control August 11
Control systems and automation
CAN Controller Area Network
DCP Digital Communications Protocol
FAT Factory Acceptance Test
HMI Human Machine Interface
IP Internet Protocol
IT Information Technology
LLDP - Link Layer Discovery Protocol
OLE Object Linking Execution
OPC OLE for Process Control
PC Personal Computer
SAT Site Acceptance Test
SNMP Simple Network Management Protocol
TAP Test Access Point
TPC Touch Panel Control
Abbreviations
The web-based concept enables access to diagnostics information
from all connected networks from anywhere at any time. An email
alert notifies well in time about any irregularities that might occur.
and internet traffic analysis, which makes them highly complex in Unified
a way that is neither useful nor manageable for maintenance staff. This is a unified, control and manufacturer-independent diagnostics
On top of that they do not contain any protocol-specific functions of concept for conventional and Ethernet-based fieldbuses or Industrial
the fieldbuses which are essential for troubleshooting. PROFINET in Ethernet. All key functionalities and diagnoses are comprehensively
particular comes with an efficient diagnostics model based on the displayed in parallel in the evaluation software. Only fieldbus-specific
proven PROFIBUS diagnostics concept and further enhanced for features are provided per network and in more detail. Users find infor-
PROFINET networks. The bottom line is that neither simply updat- mation that is already processed and do not have to troubleshoot at
ing diagnostics concepts from the conventional fieldbus world nor protocol, telegram or signal level. This drastically reduces complexity
adopting existing tools from the IT world will be very helpful for right from the start.
Ethernet users in the automation industry. What is needed and has
been developed is a unified, practicable concept which combines
Expansibility, scalability
the advantages of existing solutions with new ideas while always
There is expansibility and scalability with regard to protocol and
focusing on user requirements.
the number of networks. Usually, networks are installed in parallel;
plants are rebuilt or extended, changing the number of networks. A
What users really want PROFINET installation might be added to a PROFIBUS plant, then
additionally connected to Industrial Ethernet. Most users are also in
To find out what users really need, three basic questions must be
some kind of transition period between PROFIBUS and PROFINET,
asked:
taking a two-track approach. To account for this, Trebing + Himst-
What is the biggest hurdle preventing the use of diagnostics?
edt designed a modular concept which can be used for the various
Diagnostics is too demanding and too complex. Simplicity in
specifications and characteristics.
application is the top priority. Troubleshooting is often rather
obscure to electricians or maintenance staff. Apart from that,
there are too many tools for the various fieldbuses and protocols.
What is not needed in todays diagnostics concepts?
Less is more! What is needed is the clear and easy traffic light
principle instead of further specialisation and level of detail which
is of no interest to most users. The web-based concept enables
access to diagnostics information from all connected networks
from anywhere at any time. An email alert notifies well in time
about any irregularities that might occur. The diagnostics concept
consists of the web-based TH SCOPE software and the TH LINK
network access point for PROFIBUS, PROFINET and Industrial
Ethernet.
How can we get increased benefit from network diagnostics?
The network should be self-monitoring, sending alerts only as
required in case of irregularities or failures! Diagnostics informa-
tion then needs to be clearly understandable and easily acces-
sible at any time, ideally including recommended procedures for
troubleshooting.
The concept described in this article has been designed to meet these
The diagnostics concept consists of the web-based TH SCOPE software and
customer requirements with its basic features: the TH LINK network access point for PROFIBUS, PROFINET and industrial
Ethernet.
August 11 Electricity+Control 5
Control systems and automation
Permanent monitoring and alert plers such as the Siemens diagnostics repeater for PROFIBUS DP
To enable the network to be self-monitoring, permanent, network- or the Pepperl+Fuchs SK3 for PROFIBUS PA are available, providing
wide monitoring is the basic prerequisite. The concept therefore information on bus physics which is analysed by the TH LINK. For
supports an email alert function. PROFINET/Industrial Ethernet, there are numerous managed devices
such as switches.
Any number and type of TH LINK units can be combined and
Diagnostics concept for all networks
the application can be of a very large scale without encountering
The new concept consists of two parts which form a combination of any performance problems. Diagnostics information is stored his-
remote monitoring via the TH LINK network access points and central torically in a local memory of up to 4 000 messages. At the same
analysis with the TH SCOPE diagnostics software. The TH SCOPE time, all relevant real-time information is available in a browser via
provides one parallel, unified network overview of the automation integrated web server independent of TH SCOPE availability. This
networks PROFIBUS, PROFINET and Industrial Ethernet based on the is a key benefit compared to exclusively central PC-based concepts
traffic light principle. A first network map is available immediately or special network tools.
after installation, as all connected TH LINK units are automatically
identified without any need for time-consuming configuration or
engineering work. The entire range of functionalities is available Conclusion
via any web browser, enabling the use of tablets/ smart phones as The diagnostics concept was developed for a global market and in
well as remote access for remote maintenance while also facilitating close cooperation with leading competence centeres, automation sup-
cooperation with external service providers when troubleshooting. pliers and end users. It will cover 70% of relevant fieldbus networks.
Failures trigger an email alert containing initial fault information and Today the solution is available for the leading networks PROFIBUS,
specifically linking to additional information and troubleshooting rec- PROFINET and Industrial Ethernet; further networks such as Ethernet
ommendations in the TH SCOPE. The TH SCOPE displays the status IP are in progress. An accompanying field test provided essential
of all networks in one parallel overview. Critical network stations feedback with regard to robustness, performance and functional
are quickly identified via error statistics. Statistics of communication detail enhancements. Maintenance staff and contractors were par-
quality and performance, diagnostics lists, device log books and trend ticularly enthusiastic about the solutions easy handling, conclusive
analyses allow quick identification of network stations sending an and comprehensive information supply without detail overload, and
increased data volume or faulty packages. With Ethernet, the focus the hierarchically built traffic light principle. The intuitive, web-based
shifts from physical troubleshooting to more complex application operation and handling as well as instant availability of information
and configuration problems. Incorrectly connected ports and wrong almost always created a 'wow effect' when customers saw 'their'
firmware versions or configuration are typical faults. Network topol- network after no more than a few seconds. This first-time-ever trans-
ogy supplies the means to quickly check if all devices are connected to parency brought a lot of surprises which led to first maintenance
the right port. Comparisons with saved reference configurations and measures. Within a very short time, numerous customers from all
the generation of acceptance test records for commissioning or FAT/ fields of industry decided in favour of the diagnostics concept. They
SAT are additional options. With documentations of network instal- are committed to shorter commissioning times and higher plant
lations often incomprehensive in todays practice plus involving a lot availability.
of time and effort, the TH SCOPE provides a permanent inventory at
the click of a mouse, supplying a real-time overview of network and
device information (firmware version, order number, etc). This not
only saves costs for special software or external service providers but
also hotline calls and delays in case of servicing and plant downtime.
A Microsoft Office export transfers all diagnostics information to MS
Excel in a structured manner as a basis for customer-specific analyses,
evaluations and reports based on default filters. Integration into other
applications such as HMI or Asset Management systems is enabled
via OPC. The TH LINK, which processes all network information
based on the respective protocol, is the second part of the concept.
As required, it is available as a hardware part or as a pure software
solution for mobile service scenarios via notebook. In addition to
PROFINET-specific protocols, the TH LINK also uses all usual standard The TH SCOPE displays the status of all networks in one parallel overview.
protocols for PROFINET/Industrial Ethernet networks. This means that Criticial network stations are quickly identified via error statistics.
non-PROFINET devices such as printers, cameras or switches too are
detected in 'mixed' networks. The same is true for PROFINET parts Steffen Himstedt is the managing director of Trebing + Himstedt. The
that use purely TCP/IP send/receive functions. Lapp Group stocks Trebing + Himstedt products. Enquiries: Grant Joyce.
Experience has shown that using intelligent components brings Tel. 011 201 3200 or email grant.joyce@lappgroup.co.za.
substantial diagnostics benefits that more than make up for the
higher purchase costs. For PROFIBUS, intelligent repeaters/cou-
About the author
6 Electricity+Control August 11
Control systems and automation
Abbreviations
T
he Nienburg-South water company in Germany provides some
20 000 residents with drinking water originating from the Harz
and Blockhaus waterworks and combined at a remote mixing
station. The autonomous control system with an integrated GSM/
GPRS modem continuously monitors the measurements there but
it is not on the electric grid. By using a radio connection, they have
been saved the trouble of laying almost 1 500 metres of cabling.
The outlying areas of the southern district of Nienburg are sup-
plied with drinking water through a widely branched, 565 km long
pipeline. Wells from the Blockhaus waterworks as well as pipelines
from the Harz waterworks cover the demand of 1,4 million cubic me-
tres per year. The water is channelled into the main transport pipe of
the Nienburg-South water company via a valve pit, which is situated
some distance from the Blockhaus waterworks. Pressure-regulating
valves from Hawle Armaturen GmbH, which are installed in the supply Figure 1:Supply shaft with pressure-regulating valves.
shaft, reconcile the variable pressures in the Harz waterworks' pipe-
lines and in the main transportation pipeline. Furthermore, sensors
monitor the shaft for flooding and intrusion (see Figure 1). Error message via SMS
In the course of automation, all elevated tanks, pumping stations, and
GSM and SMS are no longer simply things that make your phone work waterworks are connected to the control room in Drakenburg using
and your personal life easier. components from Phoenix Contact. The systems are monitored by
Radio systems require no additional cable to be laid, thus resulting in a process flow system which shows the system states, documents
significant project savings. the inflows and outflows, and provides a statistical evaluation of the
Data transfer over GSM is a reliable means of monitoring remote sites water pumping. The pipeline pressure is monitored continuously in
and transmitter stations are readily powered by solar energy making the distributor station. If, for example, a pressure drop occurs due to
them largely stand-alone.
T ake note a pipe breakage, the supply system sends a fault message by SMS to
the on-call service. At first, transmitting the signals was problematic,
8 Electricity+Control August 11
Control systems and automation
as the valve shaft was at a remote forest location and was connected its tilt angle can be set in stages. Therefore, the solar system can be
neither to the control centre nor to the electric grid. The nearest sta- used at virtually all latitudes.
tion for forwarding signals a waterworks connected to the control
centre is about 1 500 metres away. On the basis of this automa- Figure 3: The pre-installed
switching cabinet saves time
tion solution, the company contracted to upgrade the waterworks, and minimises the time and
Brggemann Systemtechnik, discovered a modern, cost-effective, money it takes to wire up the
and reliable alternative to installing a long pipeline. solar system.
August 11 Electricity+Control 9
ROUND UP
Leaders in softstarters
A utomation specialists Rockwell Automa-
tion are the undisputed leaders in the
softstarter market thanks to the compact,
delta type starters. With its relatively small
dimensions, the SMC Flex softstarter is ideal
for retrofit, as it typically fits comfortably in
modular, high performance Allen-Bradley a third of the usual space when compared to
SMC Flex product line.This flexible, stepless, traditional electro-mechanical and star-delta
cost-effective and extremely user-friendly type starters. This space saving is achieved
softstarter suits most applications, except by eliminating the need for at least two con-
for those with constant or square torque tactors and the overload device.
control requirements, such as lifting/hoisting From a temperature and altitude perspec-
type applications. tive, the SMC Flex stands out from the crowd.
On the SMC Flex, on-board integrated by- For the most part in southern, sub-Saharan
pass circuitry that automatically closes when and South African conditions, there would
the motor reaches up-to-speed is offered be no need to derate this starter as a result
as standard. This provides cooler operating of high ambient temperatures or high alti-
temperature, lower heat dissipation require- tudes. The SMC Flex is designed to perform
ments and hence a much reduced enclosure to its full stated rating current to an ambient
size and starter cooling requirements. It temperature of 50C, up to an altitude of 2
is generally 50% smaller than traditional 000 m without derating, instead of the usual
designs with heat losses being 80% lower, 40C and 1 000 m as is the industry norm,
notwithstanding the fact that the unit is rated explains van Wyk.
to operate to an ambient temperature of 50C The SMC Flex softstarter fits perfectly
up to an altitude of 2 000 m without derating. into the Rockwell Automation Integrated
The SMC Flex is ideal for almost any Architecture environment when connected faster, more accurately and can leverage
softstarting requirement application, and to Open Networks EtherNet IP, ControlNet from the diagnostic data to call out the cor-
is especially well suited when used with or DeviceNet; and boasts massive third party rect technician to rectify the problem in a
centrifugal pumping applications. It offers a communication capabilities. It shares the much more accurate and efficient way.
unique, cost-effective approach to reducing same DPI communication module platform With the SMC Flex, all regular metering
fluid surges or hammering by utilising its with the PowerFlex 7 Class AC and Power- devices that would traditionally be required
unique patented pump control algorithm, Flex dc drives. The diagnostic feedback sets on the door of the motor control centre
bringing unrivalled closed loop starting and the SMC Flex apart from its competitors. (MCC) are onboard to be viewed on the in-
stopping performance without the use of All levels of warning and trip set points are tegrated backlit LCD screen and could easily
additional external devices. adjustable, additionally, all set points allow be extended externally to the door by way
Available across varied power ranges, for delay and inhibit per warning and trip set of an optional remote mounted full numeric
voltages from 200 V to 690 V, 50/60 Hz, for point to suit application and site variability 7-line backlit LCD keypad offered in both IP20
motor currents ranging from 5 A to 1 600 A, specific to most application requirements, or IP66 versions.This translates in space and
the SMC Flex softstarter can run connected explains van Wyk. cost savings, since these traditional meters
in line or inside the delta-loop configuration, Diagnostic and troubleshooting feedback no longer need to be fitted to the door of
making it even more attractive to utilise is enabled by the use of alpha-numerical text, the MCC.
when upgrading or retrofitting traditional instead of codes. As a result, the operator Enquiries: Adrian van Wyk. Tel. 011 654 9700 or
3- or 6-wire electro-mechanical and star- or technician is guided to identify problems email avanwyk@ra.rockwell.com.
12 Electricity+Control August 11
ROUND UP
Electricity+Control
Features September 2011
Electrical protection and safety
Energy efficiency
Plant maintenance, test and measurement
Control systems and automation
Sensors, switches and transducers
Are You EnviroFicient?
Send your all your relevant news to the editor - ec@crown.co.za
by 11 August 2011.
August 11 Electricity+Control 13
ROUND UP
Control systems and automation
16 Electricity+Control August 11
ROUND UP
August 11 Electricity+Control 17
Drives and motors
By R Billiet, NTSA
The need for Transient Switching Surge Protection (TSSP) equipment has never been more pressing read about the emerging influences
since the inception of the initial TSSP device and their implemented solutions for protection of motors, generators and transformers against
vacuum breaker switching spikes.
T
he first TSSP device was designed in South Africa by a con- UPS facilities in order to supply this shortfall. This translates again in
sultant, Rapha Pretorius (now deceased), in the early 1980s. increased switching operations. The need for PROTEC Z is evident.
It was initially conceived mainly for motors. The motor initial Non-linear loads such as capacitors, chokes, VSD, UPS and
windings were failing because of the switching transients of vacuum oversaturated transformers cores create harmonics. These in turn
circuit breakers. This device brought the solution. South Africa was can create serious problems with the following elements:
at that time under sanctions and the TSSP market was generally Transformer overheating and winding failures
limited to this country. The internationalisation of the market and Failing of capacitors
the technological and environmental trends necessitated important Failing of VSD
updates, refinements and expansions of the design. This has been Failing of UPS
achieved in the PROTEC Z HV, Compact and LV units. Failing of switched mode power supplies
Since 1980, many trends emerged with respect to: Fuses age and interrupt prematurely
Power quality Filter failures
Machine characteristics Existence of super and inter harmonics
Breaker issues Existence of standing waves
Safety considerations Switching problems
Earth fault incidences rise
A discussion follows on these trends - one by one with an explana- Breaker failures
tion of the improved characteristics that the PROTEC Z inherently Protection failures
possesses. NER/NEC failures
Power electronics failures
Rectifier failures
Power quality
Motor, generator and Dry Type Transformer winding failure
From 1980 - 1985, South Africa had a massive increase in new power
stations. The economy was booming because of the mining sector These effects also influence the older TSSP devices. The PROTEC
expansions. The electricity tariff structure was relatively simple, Z design however has increased the original THD (V) <5% limit to
the generation capacity was excellent and the networks were well 10% as standard and provision was made for situations were higher
maintained. levels are required.
Since then we are experiencing frequent load shedding, the The more intricate tariff requirements on a global scale and the
inception of green energy, more non-linear loads, maintenance increasing costs of copper and other conductor materials will increase
inadequacies and shortages of properly trained crew and engineers the need for more power factor correction. This means more capaci-
and increased lightning incidents because of global atmospheric tors and more harmonic stressing of the insulation and other equip-
influences. ment cited above. The capacitors act as amplifiers in certain cases
The effects of load shedding puts extra strain on the already and can contribute to standing waves and resonance phenomena.
heavily laden networks. It can cause brown outs and even black The added risk is that the network can become over-capacitive with
outs in severe cases. The loads are disconnected and reconnected its negative influence on breaker behaviour. This can lead to severe
and the TSSP needs to operate much more frequently to protect the switching challenges
machines. Their protective action is required increasingly more, even Copper theft leads to badly earthed networks which lead in turn
more so on the LV side. to over voltage situations and over-stressing of the networks and
Green energy helps the networks but it cannot be depended upon machinery. The possibility of alternative earthing can pose a real
at all times. The network needs to be underpinned by generators and risk to the installations. The influence of maintenance inadequacies
18 Electricity+Control August 11
Drives and motors
The need for TSSP is stronger now than ever.
South Africa has a rich heritage of TSSP development.
The PROTEC Z is the most recent development in transient protection
for motors, generators and transformers.
Take note
Safety
The initial design of the original TSSP did not rule out catastrophic
failures. PROTEC Z has been designed with a higher THD (V) level
(minimum 10%) and an ambient temperature of 55. Units with higher
THD (V) and ambient temperature limitations are designed and ob-
tainable from NTSA.
The original TSSP required checks on a regular basis on the
eventuality of bulging tanks, bushings and oil leaks. These require
maintenance and engineering skills which are often in short supply.
and shortages of properly trained crew and engineers further exac- These maintenance oversights can lead to failure to detect possible
erbates this cycle of events as the need for corrective action is often gas build up in the vessel and can lead to a rupture of it because of
not properly understood or inadequately implemented. over pressure. The risk to human life and assets can be substantial.
The PROTEC Z vessel is made from non-magnetic stainless steel.
This feature improves drastically the risk of rupturing of the vessel
Machine characteristics and potential loss of life, fire hazard and damage to the machines.
As already alluded to, increased costs of copper and steel and relent- However over and above this standard improvement, we have
less global competition from multinationals and the adoption of the designed a safety switch feature which can be offered with each PRO-
World Trade Organisation has led to smaller and higher optimised TEC Z HV and Compact unit. This feature measures on a continuous
machines. This in turn has created new technological challenges such basis the internal vessel pressure. Once a preset level is exceeded
as the use of optimised core steel, narrower gaps in the machines the switch will operate and this can be used for alarming or tripping,
and lower tolerance levels. The effects are possible capacitive cou- thus clearing the emerging fault situation.
pling phenomena, flimsier insulation and possible amplification of The use of fuses is not recommended as a fuse can fail and if not
transient switching and lightning spikes. The harmonic influences detected, the particular affected winding on that phase of the machine
and engineering deficiencies mentioned earlier are not improving the can be damaged over time.
situation. The increased levels of harmonics and lightning incidence
are likewise creating negative effects in these optimised machines.
Ultimate TSSP device
Repairs and overhauls of these become more intricate as the toler-
ances are cut to the minimum. Improvements to the PROTEC Z include:
We can conclude that PROTEC Z is justified more than ever and The stainless non-magnetic steel vessel ensures better contain-
an excellent case for the LV applications can be made. ment thus allowing for higher permissible ambient temperatures
and/or harmonic loading and higher frequency and voltage vari-
ations.
Breaker issues Special high harmonic voltage models are available.
Over the past thirty years, we have witnessed a transition from air Stainless steel in the vessel design and has a much higher cor-
and oil breakers to SF6 and even more prominent to vacuum breakers rosion resistance than the initial 3CR12 1980 units. There will be
and vacuum contactors. no rusting even in coastal areas.
Recently we witness an even bigger shift toward vacuum breaker The capacitor standards are to IEC 60871-1; VDE0560 part 410 [1];
and contactor solutions as the SF6 gas can cause cancer and appears ANSI/IEEE 18 [2]; NEMA CP-1 [3].
not to be green friendly. Temperature range: -40/+55C (-40/+F) as standard is achieved.
The emergence of the rotating arc is another improvement Manufactured under IEC and CE standards in the European Union.
to protect the breaker and the contacts. However the claims made ISO 9001 Bureau Veritas Certification [4].
by some people that this also solves the problem of the transient All of this results in a truly global competitive product.
August 11 Electricity+Control 19
Drives and motors
We will be stocking these products for our customers in South Power quality
Africa. Machine characteristics
We can develop additional voltages and frequency spectrums Safety considerations
not already covered in our standard range. Furthermore on an international scale, we fully comply with the glo-
The number of types and different models is vastly reduced bal requirements in terms of standards and BIL ratings. The number
because the units are designed for multi-ranging applications. of types is totally optimised in order to reduce any stocking costs.
Competitive pricing.
Ongoing research and improvement.
Future developments
Unique safety feature is available.
Unique LV range with Class 1 lightning protection and superbly The current research is centered on the PROTEC Z +. This is a com-
flexible and ultra-compact PROTEC Z LV units. bined PROTEC Z HV with an integrated PD monitor. This unit will both
protect the machines in the conventional TSSP applications and offer
The customer can now have complete peace of mind that the PROTEC a full PD analysis of the connected machine.
Z is state of the art in TSSP equipment. The quality and safety aspects
are optimised for all the issues discussed under: Conclusion
Over the past 30 years important developments
have taken place in the South African and global
By choosing to do business with Northern Technologies SA networks. The need for TSSP equipment has
you gain access to more than 70 years of combined never been more pressing than now to protect
experience in the lightning / surge suppression industry
the vulnerable initial machine windings from
the spikes generated by Vacuum breakers. The
PROTEC Z is uniquely designed to cover all the
challenges as outlined; the innovative safety
switch arrangement and its super-compact LV
ULTIMATE SURGE PROTECTION range offers high reliability and better protection
of motors, generators and transformers.
For Medium and Low Voltage Generators, Motors and Transformers
Bibliography
[1] Schneider Electric. Cahier technique no. 198Vac-
uum Switching by Phillipe Picot March 2000.
[2] Merlin Gerin. Behaviour of the SF6 MV circuit
breakers Flu arc for the switching of motor start-
ing currents. By Jacques Hennebert July 1992.
References
[1] IEC 60871-1: 2005; VDE0560-410: 2006. Shunt
capacitors for ac power systems having a rated
voltage above 1 000 V - Part 1: General.
[2] ANSI/IEEE Standard 18. Shunt Power Capaci-
tors. 2002.
[3] NEMA CP 1. 2008. Shunt Capacitors.
[4] ISO 9001:2008: Quality management systems
requirements.
20
NTSA ad.indd Electricity+Control
1 August 11 2011/07/27 12:13:39 PM
Drives and motors
Abbreviations
Why do we need
that VSD again?
By G Botha, Neu Bergmann Technik
Voltage source variable speed drives have made the cage rotor induction machine even more of a workhorse in industry than before. There
still seems to be quite a bit of vagueness when listing the benefits of and problems associated with the application of speed control to various
systems. Let us take a closer look at some of the popular themes.
A
rguments for adding a variable speed control drive invariably compared to the kind of savings obtainable by better controlling the
will cite efficiency. Often drive suppliers cite things like im- application in the first place - as per our example. So it is important
proved power factor, for example, but the first order question to consider the application first and score big there before paying
to be answered should be: Why would it be more efficient to control attention to secondary benefits.
the speed of the application? As with all things engineering, nothing
is ever simple
Take a pumping application for instance. The relative power Other benefits
consumption of a centrifugal pump can be expressed as P1 / P2 = (n1 In our example, turning the pump slower must result in less wear
/ n2)3(d1 / d2)3 where P is power, n is impeller speed and d is impeller on the pump but there are also consequences such as having fewer
diameter. Graphically, the pump curves are depicted as in Figure 1. elements to look after (fewer valves etc).
A little knowledge can be dangerous: For instance, phenomena
Figure 1: Centrifugal pump curves.
such as cavitation limit the range of control one is able to achieve in
practice. It is often not good enough to deploy variable speed drive
It can be seen, that both flow rate q as
solutions without a holistic approach to the problem at hand. The char-
well as header h are affected by n, the
acteristics of the complete plant need to be thoroughly understood.
speed of the impeller. Pump affinity
On the other hand, additional benefits become available this way
laws reveal that increasing flow by 10%
that would not be the case otherwise. Consider the following case,
results in the head increasing by 21%
keeping to our pump example.
and power increasing by 33% (for an ideal pump) for a given system.
If we had an application where we had to ensure a certain
amount of flow, we would have to size the pump to be bigger than Example
the maximum flow we would need by a margin large enough to
We have a pump station comprising three parallel connected pumps.
overcome normal imperfections like impeller wear etc. Then bleed
One pump is a standby, the other two run simultaneously at any point
off any excess flow by means of a bypass relief or restrict it through a
in time. The first obvious fact is that one only ever has to start one
throttling valve to limit the flow to the value required. If this excess is
pump at a time. So surely, having one drive that allows one to start a
only 10%, the pump would permanently draw 33% more power than
pump and then transfer it to the supply line will do. In this case, one
actually required to move the fluid we want! So here one can clearly
drive can be used to start any of the three pumps. Once the pump
see how speed control results in dramatically improved efficiency.
runs, it is transferred to the supply and the next pump may be started
Secondary to this fundamental factor, by a country mile, come
up using the same drive.
things like the improved power factor and improved utilisation of the
But understanding the application reveals further benefits. Hav-
electrical machine. For instance, many drives will control the voltage
ing two pumps running at the same impeller speed and pumping
level effectively applied to the motor when running at constant speed
against the same header means that the power consumed and the
to just be enough to get the job done. This translates to less energy
flow rate achieved by each pump will be a function of the efficiency
required to flux the machine etc. But these savings, as well as savings
of each pump. A single drive will enable us to choose one of the two
achieved by using high efficiency motors etc, are relatively minor
running pumps and control its speed to take more or less of the
22 Electricity+Control August 11
Drives and motors
VSDs, like induction machines, are a workhorse of industry.
A drive must be suited to the application.
Modern drives are a part of the system and process and must be
part of the industrial communications network.
Take note
shared fluid flow. In this way, the overall efficiency as well as wear Apply direct current to the motor windings and let it work as
rates etc can be better controlled. Two drives will allow for even more an electromagnetic brake: This method produces sufficient
control. The complexity and cost of various options will determine performance where braking torques of around 10% to 20%
how far one goes. or so will do. Some vendors have enhanced algorithms that
achieve a bit more but this is basically as good as it gets.
Control the motor to act as a generator: This will cause the
voltage on the drives dc link to increase. A dc-braking module
or similar sounding term can be added to the drive. This unit
will allow the dc link voltage to increase up to a pre-determined
level and then activate a chopper dumping the energy into a
braking resistor. This reduces the voltage level again. This form
of braking can produce braking torque matching whatever the
drive is able to achieve in motoring mode and converts the
energy into heat via the resistor. It is only suitable for relatively
small applications or short duration braking.
Regenerative. Also known as 4 quadrant drives. Two common
methods:
A thyristor dc drive is used to control the voltage on the dc link.
Some drives are available with such an input stage or alterna-
tively many variable speed ac drives provide a way to power
the drive directly at the dc link, bypassing the input rectifier
Figure 2: Powtran P7800 VSD with multiple pump control module. stage. This is to allow the use of several drives powered by a
common dc bus and can therefore be used in conjunction with
Some variable speed drive products are supplied with control al- a suitable dc drive to control the drive in regen mode too.
gorithms and hardware to handle applications like this (see Figure Active front end (AFE). Here a similar arrangement as the out-
2) or one may design a more elaborate system with more features put stage of a conventional variable speed ac drive is used as
consisting of multiple drives and controllers. an input stage. By suitable control, a dc link voltage in excess
of the normal rectified magnitude is produced and the output
stage work as before. This system provides lower harmonics
Which drive is suitable? and better robustness than the thyristor dc drive but can be
There are a number of marketing terms as well as engineering con- more costly.
cepts from which to choose. So often it is difficult to select the ap- Non regenerative applications include fans, pumps, normal convey-
propriate drive for an application. We shall ignore drives like current ors etc. Regenerative drives are applied to certain winches, winders,
source inverters for this discussion but for voltage source inverters lifts etc.
(the majority type for low voltage applications) there are only two Some applications, like fans etc, need not have the motor produce
major types of hardware configurations: high levels of torque at standstill whilst things like mine winders need
Non-regenerative. Also known as single quadrant drives. These to be able to produce typically twice the rated motor torque with
drives have diode rectifiers as an input stage and can therefore the motor at standstill. This is important to consider because most
not pump energy back into the supply. Why would this be needed? control algorithms that do not have rotor position feedback tend to
Some applications may require the motor to act as a brake. Drives fail at low rotor speeds. We can broadly categorise control schemes
can achieve this with one of two main strategies: in the following categories:
August 11 Electricity+Control 23
Drives and motors
August 11 Electricity+Control 25
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26 Electricity+Control August 11
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August 11 Electricity+Control 27
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Drives and motors
28 Electricity+Control August 11
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M&Cs specialised
rotational curing facility
ensures even distribution
of the resins.
August 11 Electricity+Control 29
ROUND UP
Drives and motors
30 Electricity+Control August 11
August 2011
August 11 Electricity+Control 31
Standby and back-up
It is like waiting for a bus. You wait and wait then two come at the same time. Alternatives to short lived, toxic lead acid traction batteries, with
their indifferent performance, have been sought for over 100 years. Now both lithium-ion batteries and supercapacitors are near to replacing
lead acid traction batteries in the many traction applications where they are still used.
L
ead acid traction batteries are the favourites for light com- other things. Different vehicles exhibit these problems to a different
mercial vehicles, golf cars, surface boats, material handling extent. For example, a mobility aid for the disabled can cause a seri-
vehicles such as forklifts, airport ground support equipment ous crisis if it is itself disabled by running out of electricity through
(GSE), e-bikes and mobility vehicles for the disabled. Better alterna- failure or discharge.
tives have been sought for twenty years and now, like waiting for a
bus, two come along together. They are lithium-ion batteries and
supercapacitors ie ultracapacitors.
Bikes need on-board chargers
E-bikes include bicycles converted to electric power, partially or
wholly, and e-scooters where the driver's feet are on a platform, with
Various benefits no pedals. Here something smaller than the lead acid battery frees
Actually, these vehicles do not form a coherent group when it comes up space and weight for the convenience of an onboard charger -
to their needs for traction energy storage. It is true that they are all something already taken for granted in all mobility vehicles.
tolerant of limited range. People still buy them even when their range An on-board charger reduces range anxiety because you are
is only five to 20 miles. However, the weight of the lead acid battery much more likely to be able to charge en route and on arrival if all
in a golf car, surface boat, GSE and large mobility vehicle keeps the you need is a domestic socket. On the other hand, GSE is intensively
centre of gravity low so they do not fall over: with land vehicles the used these days, being shared between airlines in many cases, and
weight can also assist grip on the road. extra power, for instance for pulling a wider range of aircraft and
extra range expressed as less frequent charging ie downtime, are of
interest. Reliability also matters more and more.
Where weight is a pain
Contrast e-bikes and small mobility vehicles that can be lifted into a
car or into the home: here the weight is literally a pain. Most e-bikes
Tolerating frequent stop start
are bought by people that live in apartments and they want to carry Then again, many commercial vehicles need to tolerate a high rate
the bike or at least the battery up to the apartment at night to charge of stopping and starting. From now on, most conventional cars and
it and avoid theft. Most e-bike designs mount the battery high on a commercial vehicles will automatically switch off the engine when
pannier or amidships where weight actually makes it top heavy. One they stop for any reason. Some of these so-called micro hybrid vehi-
bright spark at a recent British Electric Bike Association (BEBA) meet- cles are genuinely electric vehicles in that the regenerated electricity
ing in the Houses of Parliament referred to a brick on a butterfly. briefly powers the wheels not just the more onerous starter battery
function. Here the lead acid battery is often used but it struggles with
low temperatures and tough duty cycles.
Impediments of lead acid
The disparate reasons for wanting to get rid of lead acid traction bat-
teries include the nuisance of having three sets for a forklift - one in
Tolerating high currents
use, one charging and one cooling down. Then there is the handling Fast charging stations must connect to more tolerant batteries or
of acid, the short life, the lead pollutant - even though recycling the battery is damaged or destroyed by the thunderbolt. The new
is very thorough - and the poor energy and power density which energy harvesting shock absorbers being trialled in commercial
makes them big, grabbing space in the vehicle that is wanted for and military vehicles can also suddenly pump many kilowatts into
32 Electricity+Control August 11
Standby and back-up
Both lithium-ion batteries and supercapacitors are almost ready to
replace traditional lead-acid batteris in some traction applications.
Many of these evolving solutions will find themselves of value in a
BEBA - British Electric Bike Association variety of industrial applications.
GSE Ground Support Equipment
Current advances in supercapacitor technology have been remarkable.
LFP - Lithium iron phosphate
The importance of power management and back-up solutions for South African businesses cannot over emphasised. After all, even though
we have seemingly moved past the infamous load-shedding incidents of 2008 our power remains notoriously unstable, with spikes, surges and
dips in voltage that can cause damage to expensive equipment as well as frequent power failures that can cause loss or corruption of data.
U
PS solutions along with generators are prerequisites for
protecting data and equipment from the dangers of unstable A UPS solution along with a back-up generator is crucial for today's
power supply. However as the needs of businesses change businesses.
Intelligent power management solutions enable the shutdown of pe-
and the world moves towards a greener, more sustainable future,
ripheral devices while leaving mission critical equipment up and running
there is a growing requirement for greater intelligence when it comes
during a power outage.
to power management solutions.
Power management solutions are also able to automatically shut down
No longer is it simply enough to have a UPS along with a generator equipment that is not in use even when power is clean and stable.
for extended power outages and to help regulate the supply of power
to equipment.Thanks to new laws that require significant energy sav- Take note
ings from businesses as well as rising costs of utilities and increasing
pressure for greater eco-consciousness, it is also necessary to actively Power monitoring tools
reduce electricity consumption. Power monitoring tools also allow for more intelligent use of equip-
ment, as through the reporting features organisations can easily
gauge where power is being used unnecessarily and turn off non-
Intelligent power management solutions
critical equipment when it is not needed. During power outages this
This is where intelligent power management solutions come to the ensures that the generator runs at a lower capacity, using less fuel
fore. These solutions combine smart software which enables the and saving money, and can run other equipment long enough for a
shutdown of peripheral devices while leaving mission critical equip- stateful shutdown to be performed, so that data can be protected.
ment up and running during a power outage, as well as the automatic
shut down of equipment that is not in use even when power is clean
and stable. Along with power monitoring software, intelligent power Considerations
management and back-up solutions are crucial for the effective run- When looking to purchase a UPS or generator there are several con-
ning and maintenance of the data centre. Along with the ability to siderations that need to be taken into account. Firstly the generator
allow for intelligent running and management of attached equipment, needs to be powerful enough to run all of the essential equipment, and
these tools actively monitor power usage continuously, so that they should have a margin for future growth, as should the UPS. Secondly
can not only protect equipment in the event of power surges, dips the UPS needs to be able to keep all mission critical equipment running
and outages, they can also help businesses to understand exactly for long enough so that the generator can kick in or that the equipment
where they are consuming power. can safely be shut down in the case of a generator failure. Finally, with
new demands being placed on power consumption and decreasing
energy bills, it is becoming vital to choose a UPS solution with in-built
Understand power consumption
intelligence to automatically switch off non-essential equipment.
By reporting on power consumption on a regular basis, power moni-
toring software can prove invaluable as it will enable businesses to
understand their power consumption and rectify any inefficient opera- Conclusion
tions. It also enables the real time measuring and monitoring of power A UPS solution along with a back-up generator are crucial equip-
consumptions and heat emissions by individual server, server group ment for today's businesses, as together they ensure that machines
or location, so that organisations can ensure that data centres are kept never suddenly switch off, which can cause corrupted or lost data,
at a temperature optimal to the maintenance of a sound data centre. and regulate the power supply so that the effects of unclean power
The world is constantly changing and the IT space is no exception. can be minimised, once again protecting data. They also enable
As equipment becomes more sophisticated it is also necessary to continued productivity during power failures, which is crucial to the
have increasingly sophisticated solutions to protect this equipment. smooth running of any business. Intelligent solutions combine this
The move now is away from the typical, traditional UPS that with smart power management and maintenance tools. Without an
simply ran in the background 24 hours a day in case of emergency, intelligent power management and back-up solution organisations
to devices that can actively help organisations to save money. With put their data, and as a result, their business, at risk.
in-built intelligence UPS devices now have the ability, through being
constantly connected to certain equipment, to monitor their usage Robert Brandt is a UPS and infrastructure product specialist at Drive
Control Corporation. Enquiries: Tel. 011 201 892 or email: robertb@
and intelligently switch off load equipment that is not being used.
drivecon.net
This translates into electricity savings on everyday usage along with
the mandatory protection these devices deliver.
A
bout the author
34 Electricity+Control August 11
COVER STORY
FEATURES:
Control systems and automation
Drives and motors
Standby and back-up
Temperature measurement
Transformers and substations
Are you EnviroFicient?
August 11 Electricity+Control 35
ROUND UP
Standby and back-up
36 Electricity+Control August 11
120~480W Wide Input Range
Features
Single and two phase wide input
Build-in active PFC 240W Series (WDR-240) 480W Series (WDR-480)
UL508 approved Model Output Tol. R&N Efficiency Model Output Tol. R&N Efficiency
WDR-240-24 24V, 0-10A +1.0% 100mV 90% WDR-480-24 24V, 0-20A +1.0% 100mV 92%
WDR-240-48 48V, 0-5A +1.0% 120mV 90% WDR-480-48 48V, 0-10A +1.0% 150mV 93%
General specifications
Model no. WRD-120 WRD-240 WRD-480
AC input voltage range 180-550VAC (single and two phase ); 254-780VDC
DC adjustment range 12V: 12-15V, 24V: 24-29V, 48V: 48-58V 24V: 24-28V, 48V: 48-55V
100C 5C
Range 105C 5C 95C 5C
Overload protection (TSW1: detect on heatsink of power switch)
Type Shut down output voltage, recovers automatically after temperature goes down
Working temperature -25 +70C (Refer to output derating curve) -30 +70C (Refer to output derating curve)
DC OK signal Relay contact
Features
High efficiency up to 94%
(SDR-240/480) 240W Series (SDR-240) 480W Series (SDR-480)
Universal AC input/full range Model Output Tol. R&N Efficiency Model Output Tol. R&N Efficiency
Cooling by free air convention SDR-240-24 24V, 0-10A +1.0% 100mV 94% SDR-480-24 24V, 0-20A +1.2% 100mV 94%
150% peak load capability SDR-240-48 48V, 0-5A +1.0% 120mV 94% SDR-480-48 48V, 0-10A +1.0% 1520mV 94%
General specifications
Model no. SDR-120 SDR-240 SDR-480
Overload protection > 150% rated power or short circuit, constant current limiting with autp-recovery within 2 secondsand may cause to shut down if over 2 seconds
Range 14-17V for 12V model (SDR-120 only ), 29-33V model, 56-65V for 48V model
Over voltage protection
Type Shut down o/p voltage, re-power on to recover Shut down o/p voltage with auto-recovery
DIN Series
EMC standards Compliance to EN55022 Class B. EN61000-4-2,3,4,5,6,8,11, ENV50204, EN61000-6-2 (EN50082-2), EN61204-3, heavy industry level, SEMI F47, GL
General specifications
Model no. MDR-20 MDR-40 MDR-60
AC input voltage range 85-264VAC; 120-370VDC
DC adjustment range +10% rated output voltage 0 - +20% rated output voltage
Overload protection 105% - 160% constant current limiting, auto-recovery 105% - 150% constant current limiting, auto-recovery
-20 - 55oC@100%, 70oC@60% load )5V only;
Working temperature -20 - 50oC@100%, 70oC@50% load -20 - 60%oC@100%, 70oC@60% load
-20 - 45oC@100%, 70oC@50% load)
DC OK signal Open collector Relay contact
General specifications
Model no. DR-30 DR-60 DR-100
AC input voltage range 85-264VAC; 120-370VDC 88 - 264VAC; 124 - 370VDC
12V: 12 - 15V
DC adjustment range +10% +10%
15V: 15 - 18V, 24V: 24 - 29V
Overload protection 105 - 160% constant current limiting, auto-recovery 105 - 135% constant current limiting, auto recovery
Working temperature -20 - +60oC(please refer to output derating curves)
Safety standards UL60950-1, TUV EN60950-1 approved
DIN Series
Johannesburg Branch
Phone: 011 462-4253 / 4254 / 4269 / 0390 / 0448 / 1031 / 1620 / 2310 / 2425 / 2503 / 2600
45W ~ 480W Single Phase
45W Series (DR-45)
Model Output Tol. R&N Efficiency
DR-4505 5V, 0-5.0A +2% 80mV 74%
DR-4512 12V, 0-3.5A +1% 120mV 81%
DR-4515 15V, 0-2.8A +1% 120mV 82%
DR-4524 24V, 0-2.0A +1% 150mV 83%
General specifications
Model no. DR-45 DR-75 DR-120 DRP-240 DRP-480 DRP-480S
AC input voltage range 85-264VAC (DR-45/75, DRP-240); 90-132/180-264 VAC selectable by switch (DR-120, DRP-120S) 180 - 264VAC only (DRP-480)
DC adjustment range +10% 12V: 12 ~ 14V, 24V: 24~28V, 48V: 48~53V
Overload protection 105 - 150% constant current limiting, auto-recovery
Range 115% - 142% rated output voltage 30-36V for 24V model, 54-60V for 48V model
Over voltage protection
Type Shut off, AC recycle to re-start (DR-75: hiccup mode, auto recovery)
Working temperature -10 - +50oC -10 - +60oC -10 - +70oC -20 - +70oC
EMC standards EN55022 class B, EN61000-3-2,3, ENV50204, EN61000-4-2, 3, 4, 5, 6, 8, 11, EN61000-6-2 heavy industry level
General specifications
Features Model no. DRH-120 DRT-240 DRT-480 DRT-960
Input 340-550VAC, 3-phase
AC input voltage range 340-550 VAC, singe phase 340-550 VAC, 3-phase 4 wires (dual-phase operation possible)
4 wires (single phase for 120W)
DC adjustment range 24V: 24-28V, 48V: 48-55V
High efficiency and low
dissipation 105 - 125%
constant current
Protections: Short circuit/ Overload protection
105 - 160% rated output power; 105 - 150% rated output power;
limiting, delay
overload/over voltage/over Constant current limiting, auto recovery Constant current limiting, auto recovery
shut off after
temperature 3 sec.
Built-in constant current limiting 125 - 155%
Range 24V: 30-36V, 48V: 59-66V rated output
circuit Over voltage protection voltage
DIN Series
(960W only) EMC standards EN55022 class B, EN61000-3-2,3, ENV50204, EN61000-4-2,3,4,5,6,8,11, EN61204-3, EN61000-6-2 heavy industrail level
Electricity+Control
Enquiries:
Editorial
Wendy Izgorsek (ec@crown.co.za)
Advertising
Helen Couvaras (helencou@crown.co.za)
Heidi Jandrell (heidij@tiscali.co.za)
Tel. 011 622 4770
Flip though Electricity+Control ONLINE
www.crown.co.za
August 11 Electricity+Control 37
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Standby and back-up
38 Electricity+Control August 11
Temperature measurement
Abbreviations
The ability to measure the temperature of a system accurately and with the required resolution depends on a variety of factors. While the first
step in estimating the errors in a system is the sensor and instrument calibration, to really determine accuracy, it is important to look at the
quantifiable factors that affect accuracy: the uncertainty of the measurement.
U
ncertainty of the measurement is simply the estimate of all the Type B - systematic errors: These can be evaluated by other means.
errors associated with the measurement. By accounting for Design, installation, and environmental errors are systematic. For
all the uncertainties of the measurement a total uncertainty example, sensors in magnetic fields will create an offset to the
is estimated. This article explains where or how errors can occur. It measurement. This offset can be estimated from prior information
then explains the two classes of errors that exist, and details specific or directly measured by other means (isothermal measurements with
errors and a brief explanation of each. It ends with an explanation of and without field). RF noise can also cause both random errors (eg
the methodology for combining the uncertainties to determine the current noise) and systematic errors (eg self-heating).
overall accuracy.
40 Electricity+Control August 11
Temperature measurement
Measurement is inherently uncertain.
It is important that the sources of measurement uncertainty are
known.
Once the uncertainty is understood, it is possible to determine
the overall temperature uncertainty.
Take note
works is that the IR drop in the current leads is not measured, For resistive temperature sensors such as platinum or CernoxTM,
and the voltage drop in the voltage leads is extremely small due the potential temperature error, TR, is TR = R / [dR/dT] = [V/I]
to the very small current required by the voltmeter to make the / [dR/dT] since from Ohms law, V = IR.
voltage measurement. Even inherently 2-lead devices should be Self-heating: Any difference between the temperature of the
connected in a 4-lead measurement scheme. sensor and the environment the sensor is intended to measure
produces a temperature measurement error or uncertainty.
Dissipation of power in the temperature sensor will cause its
temperature to rise above that of the surrounding environment.
Power dissipation in the sensor is also necessary to perform a
tem-perature measurement. Minimisation of the temperature
measurement uncertainty thus requires balancing the uncertain-
ties due to self-heating and output signal measurement.
Self-heating is really a combination of sensor design and instru-
mentation. The primary reason for self-heating offsets at low
temperatures is the thermal boundary resistance between the ac-
tive sensor element and its surroundings. At temperatures below
Figure 1: 4-Lead connection configuration for electrical resistance 50 K the thermal boundary resistance has a very strong inverse
measurement.
cubic relationship with temperature. This forces the instrumen-
tation to be capable of sourcing a small excitation and measuring
Instrumentation: In addition to the sensor calibration, the instrumen-
a small volt-age signal. The optimum excitation power will be a
tation used to perform the temperature measurement must also be
function of sensor, resistance, and temperature.
calibrated. Most often this instrumentation consists of a current source
and a voltmeter. Like other electronic components, their calibration Environmental concerns: Environmental changes like magnetic fields,
degrades with time and manufacturers typically provide accuracy ionising radiation, or changes in the pressure, humidity, or chemistry
specifications stated for a given period such as six months or one of the environment can create a systematic bias in the temperature
year. The effect of each is discussed below. Note that in the end result measurement.
the offsets are excitation level dependent. Thermoelectric and zero offset voltages: Voltages develop in
Effect of current source accuracy: Because resistance temperature electrical conductors with temperature gradients even when no
sensors are linearly dependent upon the current source accuracy, current is allowed to flow as a result of the thermoelectric effect.
this is more important for them than for diode sensors where the Thermoelectric voltages appear when dissimilar metals are joined
response is nonlinear. For resistance sensors, an error in current and joints are held at different temperatures. Typical thermoelectric
measurement is inversely related to the resultant measurement voltages in cryogenic measurement systems are on the order of tens
error of resistance: R R = V/(I + I) (V/I)(1 I/I) = R R(I/I) of microvolts. Thermal EMFs in the sensor leads and connections
where I is the current setting, I is the variation from that setting, have a larger effect on resistance measurements as compared to
and R = RI/I. diode measurements because diode signal levels are much larger
The temperature error, T, due to current source uncertainty, I, (typically a few tenths of a volt at room temperature to several volts
is then T = R/(dR/dT). at 4,2 K). For resistance measurements, performing current reversal
Effect of voltage measurement accuracy: for diodes, the effect eliminates the effect of thermoelectric voltages.
of voltage measurement accuracy on resultant temperature Also, the instrumentation can have a zero offset (the signal value
measurement is not difficult to calculate, provided that diode measured with no input to the measuring instrument). The zero off-
sensitivity is known for the temperature of in-terest. The potential set can drift with time or temperature and is usually included in the
temperature error, TV is TV = V/[dV/dT]. instrument specifications.
August 11 Electricity+Control 41
Temperature measurement
42 Electricity+Control August 11
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Temperature measurement/instrumentation
44 Electricity+Control August 11
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Temperature measurement/instrumentation
NIR measurement and control in snacks
August 11 Electricity+Control 45
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Temperature measurement/instrumentation
46 Electricity+Control August 11
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Temperature measurement/instrumentation
Measuring wheel encoder for precise acquisition of conveyor speed
A s in many other applications, often it
is not advisable or simply technically
not feasible to install the encoder straight
at the drive train to detect the speed of a
conveyor belt.
Any slip occurring at the belt may cause
measuring errors, or equipment requires
retrofitting a speed feedback system to syn-
chronise the conveyor speed with the follow-
ing process steps.
Typical fields of application are labelling
operations in the packaging or bottling
process and observation of defined time
intervals, for example where material has
to be conveyed through a heating furnace
or oven. Measuring wheel encoders are
virtually predestined to master such tasks
and they also convince in letter and parcel
sorting facilities as well as in the textile and
printing industry.
Available from Temperature Controls, the
Baumer measuring wheel encoder MA20
provides eased, flexible and dependable
position and speed feedback straight at the
conveyor. The two-in one device unites a
high-resolution optical incremental encoder
and a precision measuring wheel with a sus-
pended arm bracket (photo). Low conveyor
speeds call for high resolutions. Thanks to
the patented Low Harmonics technology the
encoder is capable of 25,000 ppr allowing for
ultra-precise measuring results even at very
low speed. 16 predefined resolutions between
100 and 25 000 ppr can be conveniently se-
lected using the HEX switch.
Thus, the multi-purpose device covers
varied application requirements which will
keep product variety and inventory costs
at a minimum. The continuously adjustable
contact pressure ensures reliable surface
contact without slip even in alternating ap-
plication conditions.
The wear-resistant measuring wheel with
200mm circumference is available with
various rubber harnesses to ensure optimal
adhesion to the measured material.
The pivoting, height-adjustable arm
bracket allows for quick and easy installation.
The measuring wheel encoder operates on
a supply voltage between 4,75 and 30 Vdc,
e-connection is by 8-pin M12 connector. With
high-class IP64 protection in its standard
configurations and enduring ambient tem-
peratures ranging from -20C to +85C, the
measuring wheel encoder defies even harsh
operating conditions.
Enquiries: Tel. 011 791 6000 or email sales@
tempcon.co.za.
August 11 Electricity+Control 47
ROUND UP
Temperature measurement/instrumentation
48 Electricity+Control August 11
ROUND UP
Temperature measurement/instrumentation
New ScopeMeter replaces older models
With an ageing power component population, todays electrical utility industry faces a tough challenge as failures and consequent repair and
revenue loss may inflict major costs. Transformers and their bushings have become one of the most mission critical components in the electri-
cal grid. The need for reliable diagnostic methods drives the worlds leading experts to evaluate new technologies that improve reliability and
optimise the use of the power network.
T
he condition of the insulation is an essential aspect for the
operational reliability of electrical power transformers, genera-
tors, cables and other high voltage equipment. Transformers
with high moisture content can not without risk sustain higher loads.
Bushings and cables with high dissipation factor at high temperature
can explode due to thermal runaway. On the other hand it is also
very important to identify good units in the ageing population of
equipment. Adding just a few operating years to the expected end-
of-life for a transformer or bushing means substantial cost savings
for the power company.
50/60 Hz dissipation factor measurements Figure 1: Typical dissipation factor temperature corrections.
A common insulation diagnostic test is measuring capacitance and
dissipation factor at 50/60 Hz. This is the standard test performed It is obvious that the given values are approximate guidelines only.
whenever there is a need for investigating insulation properties. IEEE 62-1995 states; The power factors recorded for routine overall
Tests are typically done at any temperature using a test voltage tests on older apparatus provide information regarding the general
from about 30 V up to about 10 kV for field tests and up to nominal condition of the ground and inter-winding insulation of transform-
ers and reactors. They also provide a valuable index of dryness, and
voltage in factory measurements. There are also tests with variable
are helpful in detecting undesirable operating conditions and failure
voltage (tip-up/ step-up testing) as well as tests where tan-delta over-
hazards resulting from moisture, carbonisation of insulation, defective
temperature is measured. Analysis is based on standards, historical
bushings, contamination of oil by dissolved materials or conducting
statistics and comparing factory values. Since insulation properties
particles, improperly grounded or ungrounded cores, etc. While the
are pending temperature, temperature correction is commonly used
power factors for older transformers will also be <0,5% (20C), power
for measurements not performed at 20C, this is normally achieved
factors between 0,5% and 1,0% (20C) may be acceptable; however,
by using temperature correction table values for certain classes of
power factors >1,0% (20C) should be investigated. Moreover in IEEE
devices [1]. In IEEE 62-1995 [1] and C57.19.01 [2], typical power factor
C57.12.90-2006 [3]; Experience has shown that the variation in power
(dissipation factor/tan-delta) values for transformers and bushings
factor with temperature is substantial and erratic so that no single
are categorised.
correction curve will fit all cases.
Typical Power Factor values @ 20C
New Old Warning Dielectric frequency response measurements
-alert limit The first field instrument for DFR/FDS measurements of transformers,
Power 0,2 - 0,4% 0,3 - .5% >0,5% bushings and cables was introduced 1995 [4]. Since then numerous
transformers, evaluation of the technology has been performed and as an exam-
oil insulated ple, several international projects/reports define dielectric response
Bushings <0,5% <1% >1% measurements with insulation modelling as the preferred method
(OIP) for measuring moisture content of the cellulose insulation in power
transformers [5-8]. In DFR tests, capacitance and dissipation/power
Table 1: Typical power factor values. factor is measured. The measurement principle and setup is similar
50 Electricity+Control August 11
and
Temperature
Transformers measurement
substations
to traditional 50/60 Hz testing but with the difference that a lower Figure 4 describes parameter influence on the reference curve.
measurement voltage is often used (140 V) and instead of measuring
at line frequency 50/60 Hz, insulation properties are measured over
a frequency range, typically from 1 mHz to 1 kHz.
The results are presented as capacitance or tan delta/power fac-
tor versus frequency. Measurement set-up is shown in Figure 2 and
typical DFR results from measurement on transformers in different
conditions in Figure 3.
August 11 Electricity+Control 51
Transformers and substations
The two transformers are very different and maintenance measures and some utilities try to avoid applying temperature correction by rec-
for the two would also be different. Transformer 1 has good oil but ommending performing measurements within a narrow temperature
needs drying. Transformer 2 has low moisture but needs oil change range [11]. Examples are shown in Figures 8 and 9. Dissipation factor
or regeneration. was measured at 10 kV on four transformers and three bushings of
different age, condition and at various temperatures. Temperature
dependence is very different for the transformers and bushings and
Individual temperature correction (ITC) using standard temperature correction tables will not give correct
DFR measurements and analysis together with modelling of the insu- values for the 20C reference value.
lation system includes also temperature dependence. A new method-
ology (patent pending) is to perform DFR measurements and convert
the results to dissipation factor at 50/60 Hz as a function of temperature
[10]. This technique has major advantages in measurement simplic-
ity for bushings. Instead of time consuming heating/cooling of the
bushing and doing several measurements at various temperatures,
one DFR measurement is performed and the results are converted to
50/60 Hz tan delta values as a function of temperature. The method
is based on the fact that a certain dissipation factor measurement at
a certain frequency and temperature corresponds to a measurement
made at a different temperature at a different frequency. The conver-
sion calculations are based on Arrhenius law/equation, describing
how the insulation properties relate to temperature.
Figure 10: Dissipation factor as function of frequency for dry Kraft paper.
52 Electricity+Control August 11
Transformers and substations
C1 (UST) is a common test and typical guidelines for evaluating the
C1 dissipation factor are:
Between nameplate tan delta and up to twice
nameplate tan delta - bushing acceptable
Between twice nameplate tan delta and up to three times name-
plate tan delta - monitor bushing closely
Above three times nameplate tan delta replace bushing
Figure 11: Tan delta at 50Hz for dry Kraft paper as function of temperature. Type Tan delta @ 20C
New OK Monitor Replace
Another example, applying individual temperature corrections for
OIP <0,5% 0,5-1% 1-1,5% >1,5%
transformers of various ages is shown in Figure 12. Transformer data
bushings
is summarised in Table 2.
Table 3: Tan delta values for typical OIP bushings.
Manufacturer Year Moisture Power Status
rating Measuring the bushings over temperature and in particular at high
Pauwels 2005 0,4% 80 MVA New, at factory temperature gives further information about the condition of the insu-
lation and indication of ageing/high moisture content. See examples
Pauwels 2000 0,3% 20 MVA New, at utility
presented in Figures 13 [6] and 14 [9].
Westinghouse 1985 1,5% 40 MVA Used, spare at
utility
Yorkshire 1977 4,5% 10 MVA Used and
scrapped
Bushing diagnostics
Deterioration through ageing of high-voltage bushings is a grow-
ing problem and manufacturers as well as utilities and test system
providers are suggesting and testing various methods for detecting
bushing problems before they turn into catastrophic failures destroy-
ing a costly transformer. This includes on-line monitoring as well as
off-line diagnostic measurements [12- 16]. 50/60 Hz tan delta measure-
ments are the most common insulation diagnostic test on bushings.
August 11 Electricity+Control 53
Transformers and substations
heating which increases the losses even further and the bushing
finally explodes.
Figure 13: Dissipation factor (%) vs temperature for OIP bushings with vari-
ous moisture content, [12].
DFR measurements
DFR measurements were performed in the beginning of the program. DFR measurements at three temperatures are presented for two
The bushings were tested at various voltages (tip-up tests) and tem- bushings in Figures 18 and 19.
peratures, see Table 4. Insulation temperatures are estimates based
on using DFR data at ambient temperature to determine temperature
dependence (ITC).
Low voltage DFR results are presented in Figure 14. The differences
in dissipation factor between the bushings are much larger at low
frequencies compared to 60 Hz values.
Tip-up measurements
Figure 17: Tan delta temperature dependence (relative tan delta) for the six Two tip-up results are shown in Figures 20 and 21.
bushings (temperature on x-axis).
56 Electricity+Control August 11
Transformers and substations
Figure 20: DFR tip-up measurement on bushing Figure 21: DFR tip-up measurement on
#3 (bad). bushing #5 (good).
60 Hz tan delta values are almost independent of test voltage and not sensitive to ageing effects.
At lower frequencies there is a tip-down effect.
For the good bushing the effect is very small.
Moisture assessment
The DFR measurements can also be used for moisture assessment using the same modelling
technique as for oil-immersed power transformers. Results for the six bushings are presented
in Table 6. Measurements performed at ambient temperature.
Looking at the HV bushings results we can see that 60 Hz tan delta is low/as nameplate. Also the 1
Hz values are about the same as 60 Hz values, indicating low temperature dependence. Conclusion
is that HV bushings are in good condition. Looking at the LV bushings reveals a somewhat differ-
ent situation. 60 Hz data differs between phases but are all within the 0,5% OK limit. However
1 Hz low frequency data differs, especially for X3, indicating higher temperature dependence.
August 11 Electricity+Control 57
Transformers and substations
Transformers and their bushings have become one of the most mission
critical components in the electrical network on plant, in a distribution
network and on the national grid.
The insulation properties are a good indicator of power system com-
ponent condition and knowing the condition helps to avoid potential
catastrophic failure.
Dielectric Frequency Response measurement is a technique for general
insulation testing and diagnostics and offers many advantages over 50
Hz dissipation factor measurements.
Figure 24: Tan delta temperature dependence, 26 kV GE type T bushings.
Take note
Factory testing
A bushing manufacturer is regularly testing bushings at different
steps in the production. Figure 25 presents DFR results performed Conclusion
on a series of newly manufactured bushing insulations (without Dielectric Frequency Response (DFR/FDS) measurement is a tech-
porcelain). In this example we see that 50 Hz data for one of the bush- nique or methodology for general insulation testing and diagnostics.
ings is increased and at low frequency the difference in the dielectric In comparison with 50/60 Hz dissipation factor measurements, DFR
response is substantial. Based on the measurements, the bushing measurements provide the following advantages:
with high deviation was taken out for inspection and a manufactur- Capability of performing individual temperature correction of
ing fault was found. measured 50/60 Hz dissipation factor at various temperatures to
values at reference temperature, 20C.
Capability of estimating temperature dependence in an object
and from measured dissipation factor at a certain temperature
calculate the Capability of estimating the moisture content of
oil-immersed cellulose insulation in power transformers and
bushings.
Capability of generally investigating causes for increased dissipa-
tion factor in power components.
The insulation properties are very important for determining the con-
dition of a power system component. Knowing the condition helps
to avoid potential catastrophic failure, and identifying good units
and decide upon correct maintenance, can save significant money
due to postponed investment costs.
Figure 25: DFR measurements on a series of bushings.
58 Electricity+Control August 11
measurement
substations
DFR Dielectric Frequency Response
DGA Dissolved Gas Analysis
FDS Frequency Domain Spectroscopy
and
ITC Individual Temperature Correction
Temperature
OIP Oil Impregnated Paper
Transformers
PD Partial Discharge
UST Ungrounded Specimen Test
Abbreviations
References
[1] IEEE 62. 1995. Guide for diagnostic field testing of electric power [14] Kane C. Bushing, PD and winding distortion monitoring. Paper
apparatus; Part 1: Oil-filled power transformers, regulators, and presented at ABB seminar on Power Transformer Health Moni-
reactors. toring and Maintenance. Johannesburg 2008.
[2] .IEEE C57.19.01. 2000. Standard performance characteristics and
[15] Niemanis R, et al. Determination of moisture content in mass
dimensions for outdoor apparatus bushings.
impregnated cable insulation using low frequency dielectric
[3] IEEE C57.12.90. 2006. Standard test code for liquid-immersed
spectroscopy, IEEE Power Engineering Society Summer meeting
distribution, power, and regulating transformers,
2000, Seattle, Washington, USA.
[4] Werelius P, et al, Diagnosis of Medium Voltage XLPE cables by
[16] Braun JM, et al. Accelerated ageing and diagnostic testing
High Voltage dielectric spectroscopy. Paper presented at ICSD,
1998. of 115 kV type U bushings. Paper presented at IEEE Anaheim
[5] Gfvert U, et al, Dielectric spectroscopy in time and frequency 2000.
domain applied to diagnostics of power transformers. Sixth Inter-
national Conference on Properties and Applications of Dielectric Peter Werelius has a Master of Science in Electrical
Materials. June 21-26, 2000, Xi'an, China. Engineering (1991) and a Doctorate Electrical Engineer-
[6] Gubanski SM, et al, Dielectric response methods for diagnostics ing (2001) both from KTH (Royal Institute of Technology)
of power transformers. Electra, No. 202. June 2002, pp 23-34also in Stockholm, Sweden. He started WaBtech in 1996,
manufacturing FDS/DFR (Frequency Domain Spectroscopy/
in CIGRE Technical Brochure, No. 254, Paris 2004.
Dielectric Frequency Response) test equipment for cables
[7] Gubanski SM, et al. Reliable diagnostics of HV transformer insula-
and power transformers. He continued this work with Programma Electric
tion for safety assurance of power transmission system. REDIA- and later within GE Energy Services after GE acquired Programma in 2002.
TOOL - a European research project, paper D1-207 CIGRE. 2006. In 2005, he and others founded Pax Diagnostics. In 2008 Pax Diagnostics
[8] Gubanski SM, et al. CIGRE report 414. Dielectric response diag- was acquired by Megger. Peter is their technical specialist in transformer
noses for transformer windings. 2010. testing. Enquiries: Email peter.werelius@megger.com
[9] Frimpong GK, Perkins M, Fazlagic A, Gafvert U. Estimation of
moisture in cellulose and oil quality of transformer insulation Matz Ohlen graduated from the Royal Institute of Technol-
using dielectric response measurements, Doble Client Confer- ogy (M.Sc. EE) in Sweden in 1975. He first worked at IFM
Akustikbyran AB which specialised in signal analysis,
ence, paper 8M, 2001.
acoustics and noise and vibration control. He later worked
[10] Werelius P, Ohlen M. Dielectric frequency response measure-
in industrial automation and measurement at Karlson In-
ments on power transformers. EuroTechCon 2008, Liverpool, UK.
struments and Programma Electric. In 2000 he joined Bluetooth products
[11] Tyagi RK, Victor S, Sodha NS. Application of temperature cor- at National Semiconductor and in 2007 he joined Pax Diagnostics, spe-
rection factors for dissipation factor measurements for power cialising in test systems for SFRA (Sweep Frequency Response Analysis)
transformers a case study. Doble Client Conference, Vadodara, and FDS/DFR (Frequency Domain Spectroscopy/Dielectric Frequency
India 2006. Response Measurements) in transformers, generators and cables. In Oc-
[12] Swedish bushings plant sees growth in RIP designs. INMR tober 2008 Pax Diagnostics was acquired by Megger and Matz is director
Quarterly, Issue 68, 2005. of transformer test systems. Enquiries: Email matz.ohlen@megger.com.
[13] Brusetti R. Experience with on-line diagnostics for bushings and
current transformers. NETA Fall 2002, paper A335. About the authors
August 11 Electricity+Control 59
ROUND UP
62 Electricity+Control August 11
Are U enviro Ficient ?
Energy management
system standards:
A structured approach to
reducing energy costs
By J Ryan, Certification Europe
This article seeks to redress the common view that we need energy to run our business but rather, by explaining the concept of a holistic
energy management system, seeks to install the concept of energy as a resource in businesses.
T
he concept of energy management is not new. Graduates of at managing energy as a resource and aimed at becoming more
engineering schools worldwide emerge into the workplace energy efficient and reducing energy costs.
with many theoretical and indeed practical example of how Using a management system approach to manage energy
to run plant, equipment and processes in energy efficient or energy requires organisational change. Such change is required as all per-
conscious manners. However, in many workplace applications, or- sons in an organisation, both internal and external, can impact on
ganisational demands focus not on energy management per se but energy use. From security personnel who identify equipment in use
on energy demand management. outside of operating hours, to cleaning staff who light up the night
sky in their rounds in office buildings, to the purchasing department
personnel who continue to buy equipment without considering the
What is an energy management system?
energy costs associated with the use of that equipment, there are a
There are many forms of energy management system from those plethora of influencers. To manage all of these influencers requires
that simply tell us how a building or process is using energy to those a change and this change can only be facilitated and effected by
that allow us increase and/or decrease energy use in a controlled adopting a standardised model for an energy management system
manner. For example, a building management system (BMS) is a tool
defined within the European Standard for Energy Management EN
that typically includes a series of sensors feeding energy data directly
16001, and now enshrined within ISO 50001 [1].
into a software program for analysis allowing real-time monitoring of
user-selected alarms and maintenance of critical equipment based on
runtime hours. These systems are deployed in many industrial and
commercial setting as many types of equipment have non-uniform The Energy Barometer, devel-
usage and maintenance by actual hours of use can provide a better oped by Energy Cybernetics,
policy for equipment care than frequency based maintenance. Thus, allows you to:
while energy use data is captured, the focus is on plant maintenance Save energy and money.
and not energy management. Assess your energy
Even the more developed intelligent building management sys- consumption.
tems that supply tools for users to view and control subsystems, ac- Know your energy
cess and analyse data, manage equipment maintenance, see Intranet consumption status.
and Internet pages and generate graphs, charts and reports all from Showcase your results.
a desktop, do not address the basic principles of managing energy Optimise your energy
as a resource. Other monitoring systems, such as ICA (Instrument
consumption.
Control and Automation) and SCADA (Supervisory Control and Data
See your bottom-line grow.
Acquisition) also allow facility managers see what is happening in
terms of energy use and demand. However, when we talk about an Enquiries: Gustav Radloff. Tel.
energy management system in this article we are not talking about 083 441 1094 or email gustav@
a technical tool such as a BMS/ICA or SCADA but a set of interlinked energycybernetics.com.
processes, practices and procedures driven by a clear policy, aimed
64 Electricity+Control August 11
Are U enviro Ficient
Abbreviations
Many organisational demands focus not on energy management per
se but on energy demand management. Apart from these published formal standards what have other
The development and deployment of an international management countries done? The Netherlands has an energy management sys-
system standard (ISO 50001) will provide industry with an agreed set tem that was developed in 1998. This is not a standard per se but
of requirements by which they can manage their energy usage.
is linked to an industry long term agreement programme aimed at
ISO 50001 was published in June 2011, is based on EN 16001 and is
reducing energy use. The Chinese also joined the energy standards
considered to represent international best practice.
community and aimed to develop a series of national standards us-
Take note ing the American National Standards Institute (ANSI)/Georgia Tech
standard as a format. Research conducted in 2007 [2] identified that
the aforementioned countries and Brazil, Korea and Spain had all
initiated work on an energy management standard, while commu-
Standards for energy management systems
nication with Sustainable Energy Ireland in 2008 [3] confirmed that
The idea of a standard for energy management is not new. A number South Africa was also joining the area and more recently, UNIDO
of standards have been published across the globe on the subject. (as part of capacity building) have been promoting the adoption of
These include, but may not be limited to the standard outlined in the ISO standard [4].
Table 1:
August 11 Electricity+Control 65
Are U enviro Ficient ?
References
The critical first step an initial review [1] ISO 50001:2011. Energy management systems requirements
During the first step it is critical to gain a fundamental understating of with guidance for use.
your organisations energy profile where do you use energy; why [2] McKane A, Williams R, Perry W. Setting the standard for industrial
do you use so much; who controls how energy is used; how much energy efficiency. Paper 070, Topic No. 9, Industrial Management
are you paying/losing; where could you improve? These fundamen- Issues, UNIDO, 2007.
tal and common sense questions are posed through the process of [3] Ryan J. personal communication, May 2008.
conducting an initial energy review. Applying this process approach, [4] Sustainable Energy Ireland, LIEN Annual Report, 2008.
customised to a site or an organisations needs, provides the starting [5] McKane A. Status of ISO 50001 - Energy Management; Industrial
point for an effective management system. But rather than verbalise Energy Efficiency Improvement Project Presentation, UNIDO,
the theory, let us look at some examples of where the standard ISO Johannesburg, South Africa, September 2009.
50001 has been deployed with great success. In providing the follow- [6] http://www.carbonindependent.org/sources_home_energy.htm#h.
ing examples the author is cognisant that the organisations referred [7] Danish DS 2403:2001, Energy Management-Specification.
to are large businesses and that smaller entities may regard their
achievement as unattainable (in terms of energy savings). However,
these organisations operate complex business processes constrained Dr Ryan was in South Africa earlier this year as a guest of DQS and Energy
by specific energy and environmental boundaries and require signifi- Cybernetics to run the first courses in Implementing and Auditing ISO
cant preparation and top management support to effect change. The 50001 training in South Africa. The training, which is run under licence
lesson is, if a complex process can achieve significant savings, a small from Certification Europe, will see the ISO 50001 being rolled out later this
to medium enterprise (SME) can too! Indeed, operational experience year by Energy Cybernetics in various centres in South Africa.
in relation to energy management standards across various compa- Enquiries: Email asdic@mweb.co.za.
nies, from local SMEs to multinational corporations, confirms that in
all cases, both energy and cost savings are achievable.
About the author
66 Electricity+Control August 11
Are U enviro Ficient
Increased competence in energy efficiency
E ndress+Hauser is well placed to offer customers even better support in issues relating to
energy efficiency. The Endress+Hauser Group now has a majority share of the German
consultancy company Systemplan. Systemplan will bring a wealth of experience in measuring,
Calendars support Endangered Wildlife
You can track the passage of time with just
charting, analysing and sustainable optimising energy flow in both plants and offices. any old calendar or you can do it in the com-
For the majority of companies, energy efficiency is on top of the agenda. Hardly any pany of South Africas most beautiful and
other investment pays off so quickly, states Michael Ziesemer, chief operating officer of the endangered wildlife. Endress+Hauser chose
Endress+Hauser Group. As a consequence of the debate on renewable energies and preventing the latter and in the process made a valuable
climate change, the topic has also gained a political dimension. Energy efficiency is not only the contribution to the Endangered Wildlife Trust.
most effective but also the most economical way of meeting the internationally agreed objectives Why dont you do the same?
for carbon dioxide reduction, reports Michael Ziesemer. Enquiries: www.ewt.org.za.
Endress+Hauser is already supporting its customers in this field. With our energy monitor-
ing solutions, we help to record and monitor energy flow, explains Michael Ziesemer. And of
Solar-powered replacement geyser
course we have extensive knowledge of our customers applications. Systemplan rounds off this
insurance
range of services: Our strength is in giving advice that takes full cost optimisation into account,
Nedbank Groups insurance division, Nedgroup
says company founder, Michael Hager. We help in the analysis of energy flows, identifying the
Insurance, has launched a pilot project that
measures required to effectively reduce energy consumption.
offers a seamless facility for its home owner
Endress+Hauser will initially own 60%, while the remaining shares to be transferred at a later
clients to install solar geysers as replacements
date. Michael Hager will continue to head the company as Managing Director and will report to
when their existing geysers burst or malfunc-
the management of the Endress+Hauser Group in Reinach, Switzerland.
tion. Furthermore, a portion of home insurance
Enquiries: Hennie Blignaut. Tel. 011 262 8000 or email info@za.endress.com.
revenue generated will be channelled to the
Green Trust, which champions sustainability
Mandela School of Science and Technology issues and projects. Nedgroup Insurance be-
lieves this project will aid its clients in reducing
Eastern Cape their electricity consumption and thereby their
household running costs, while also assisting
August 11 Electricity+Control 67
Light
&Current & Product News
Biggest lamps order
SO 9001:2008 accreditation
W ade Walker has achieved ISO 9001:2008 accreditation, also
obtaining a four-star IRCA rating on its quality systems.
It has been neither an onerous, nor a particularly lengthy process,
able to complete the entire process within nine months, being ac-
credited by international body, DQS.
As a result of unreserved buy-in driven from executive manage-
Larry Davin, marketing manager at Wade Walker, says. Our quality ment, staff at Wade Walker were quick to embrace the modified
standards were already well above the norm, so relatively few adjust- procedures and systems, with each department head accountable for
ments needed to be implemented. We took existing procedures and adoption and compliance in his/her area ensuring that all were kept
refined them to comply with ISO requirements, rather than working updated with developments.
through the standard mechanistically to ensure compliance. We were Enquiries: Tel. Tel. 011 466 0377. Visit www.wadewalker.co.za.
68 Electricity+Control August 11
Light
&Current & Product News
Donation to refurbish schools science lab Bizz Buzz
O din Primary School in Ennerdale recently unveiled its brand new fully equipped science
laboratory funded by a R250 000 donation from Zest Electric Motors. The event was
broadcast in April 2011 as an M-Net Cares insert on national television.
Health and safety
awards
Honeywells UK Process Solutions and Build-
The donation funded the rehabilitation of what was effectively an empty classroom and
ing Solutions business units have been recog-
provision of all equipment for 750 learners of different grades. The laboratory now boasts
nised for their commitment to the health and
state-of-the-art science equipment, including an overhead projector, screen, laptop and printer
safety of their global workforce by the British
as well as a full range of science kits for Grades 4 to 7 and 18 months worth of chemicals for
Safety Council, which has given the company
science experiments.
two prestigious International Safety Awards.
Along with basins and specialised gas/water cabinets for experiments needing Bunsen
The awards acknowledge the commitment to
burners, the lab is also equipped with a fume cupboard where chemical experiments can be
improving corporate health and safety and
safely carried out without harming the children. A well-stocked library of educational science
achieving high safety standards. This year
videos has also been supplied, ensuring that the learners will receive a quality education in
there were more than 600 applications from
science from now on.
across the world. The International Safety
Esm van der Merwe, group human resources manager at the Zest Group, says Zest aims
Awards are open to all industries and sec-
to remain involved in the provision of science laboratories into other areas of the country in
tors across the globe and are independently
which the business operates.
adjudicated.
When we were approached by NGO Touch Africa to make this donation to the Odin Primary
Enquiries: Email philip.powell@britsafe.org or
School, we felt it was an ideal opportunity to invest in learners who could well enter our field hsa@honeywell.com.
of work electrical engineering in the future.
Zest is therefore committed to embarking on similar projects that will serve as catalysts to
the progress of young science learners. Local is lekker - even in
Enquiries: Jamie Wilson. Tel. 011 723 6000. the USA
The locally developed Ni9htwatcher security
light has impressed safety savvy Americans.
The light, jointly owned and distributed by
Eurolux, has been recognised by several well
known trade magazines and TV shows in the
USA as a 'Favourite New Product for 2011'.
The light is not only activated by motion,
but it continues tracking the motion within
the 10 metre plus radius, whilst recording
everything. It features a day/night sensor, is
able to turn 220 degrees and will keep fol-
lowing the motion until no further motion
is detected. This leaves intruders with the
impression that they are being followed and
monitored and they are!
A visit to Odin Primary School in Ennerdale are Zests Esm van der Merwe, Helene Marsh, and James Enquiries: Shaun Bouchier. 021 528 8400 or
Blakemore (chairman of the Zest Group). email shaun.bouchier@eurolux.co.za.
Fully integrated ERP allows full control FNB KZN Top Business
Award - Trade
Magnet is the winner of the FNB KZN Top
B ooyco Engineering, specialist in the design and development of custom-made air handling
systems for special applications, is currently undergoing a re-engineering exercise to ac-
commodate present and anticipated future growth. Included in this company-wide enhancement
Business Portfolio Awards 2011 in the trade
category. This prestigious award is a great
honour for Magnet, says Brian Howarth,
exercise is a significant investment into replacing the companys previous ERP software with the
Magnets managing director. The company,
latest SYSPRO manufacturing and MRP system. Booyco Engineering financial director, Richard
which originally supplied magnet wire and
Smith, who is project managing the installation of the software, says the existing system had
insulation materials to the local armature
become cumbersome and was not geared sufficiently to support the companys current and
winding industry, has expanded its operation
future manufacturing activities. We have invested in SYSPROs latest release, version 6.1, which
to become a major supplier nationally of a
is one of the most comprehensive, single-source ERP solutions on the market, with many valu-
wide range of electrical components. Finalists
able features and functions, Smith says. The beauty of the system, from our point of view,
in the trade category were Magnet, Mr Price
is that it is fully integrated and allows us full control of company operations, eliminating the
Group and Spar.
manual and labour intensive factor we were dealing with on our previous system".
Enquiries: Brian Howarth. Tel. 031 274 1096 or
Enquiries: Pieter de Koning. Tel. 011 974 8640. Visit www.booyco.co.za. email brianh@magnetgroup.co.za.
August 11 Electricity+Control 69
Light
&Current & Product News
Protec Tongaat educating students for 20 years
B MG, which supports Protec - a national non-profit technological career development programme
for senior school students celebrated Protec Tongaats 20 anniversary in Maidstone recently.
BMG is very proud to support this education programme that focuses on science, engineering
and technology, to help learners enter the workplace with confidence and credibility, says Veronique
Bezuidenhout, marketing manager for BMG Bearing Man Group.
The companys social responsibility programme encompasses an ongoing commitment to investing
in education in order to promote the growth of technically skilled South Africans, especially those from
previously disadvantaged communities.
Enquiries: Veronique Bezuidenhout. Tel. 031 576 6221 or email veroniqueb@bmgworld.net.
70 Electricity+Control August 11
Light
&Current & Product News
Power Transmission and Distribution Technology Innovations Day
Rodney Swartz, Xolani Hlongwane and Bohani Christian Gassner (Siemens) next to the Gas- Back: Vineet Singh, Jayesh Ranchod, Anton
Shingange (Siemens). Guard 8. Budricks (Siemens) Sphiwe Nkosi (Eskom).Front:
Keneuwe Maithufi and Petunia Mahopo (Eskom).
August 11 Electricity+Control 71
Social Engineers
While lightning events are often seen as the primary motivation for providing surge protective devices for facility protection, there is a need
for a full facility system approach to surge protection design and application. The installation of a Lightning Protection System that includes
effective surge protective devices goes a long way in mitigating the effects of lightning events in both the high stress and medium stress envi-
ronments. In fact protection to the structure itself is the primary focus of the Lightning Protection System Industry. Andi Haa.
A successful conference, held over three days, included experts in the field of earthing, lightning and surge protection from various parts of
the world including USA, Germany, Ghana, Kenya and of course, South Africa.
Andi Haa (Surge Suppression Inc, Vice Chair and Secretary for IEEE Surge Marius Grobbelaar and Gary van den Heever (Energy Control Systems).
Protection Device Committee Working Groups); Jeff Edwards (Energy
Control Systems, USA).
Mario Kuisis and John Kotze (Martec). Trevor Manas (Pontins), Olof Bekker (Fluor SA).
72 Electricity+Control August 11
Social Engineers
Mandi du Preez and Willem van Schalkwyk (Eskom). Selorm Amoaku and George Eduful (Electricity Company of Ghana).
Ali Yarrow and Enock Bosire (Kenya Power & Lighting Company). Nhlakanipho Chili, Mduduzeni Ngema and Nsizwa Mhlongo (Total Facilities
Management Company).
Ratanang Nuku, Neo Mahuma and Keorapetse Phora (Eskom Distribution). Holger Heckler and Tony Rayner (Phoenix Contact).
August 11 Electricity+Control 73
Social Engineers
Grant Joyce and Mark Dilchert (Lapp Group Southern Africa). Winner: Cape Peninsula University of Technology.
74 Electricity+Control August 11
The HellermannTyton
Mindbender
Winner
Congratulations to Douglas North of Goodyear Tyre, Uitenhage.
Competition rules
Please answer the question online.
Visit http://www.crown.co.za/electricity_control.htm.
Answers to reach the editor by 1 September 2011.
August 11 Electricity+Control 75
CLIPBOARD
Appointments
Endress+Hauser
Yogesh Devichund Xola Tyukana Mayson Reddy Jacques Fouche Dirk Steyn Preston Reddy
Internal Sales, Internal Sales, Internal Sales: Projects Acquisition Field Service Field Service
Gauteng Gauteng Gauteng Manager Technician, Cape and Technician, Gauteng
Southern Namibia
Rudi Swanepoel Lisa Willemse Byron Griffiths Guy Harris, independ- Anton Hugo Giel Pretorius
Project/Applications PA to GM Sales/ Branch Manager, ent non-executive Production Manager, Technician, head
Engineer, Johan- Engineering and GM Cape Town director, to Board of head office office
nesburg. Operations Directors
INDEX TO ADVERTISERS
Musts for your diary
ABB..........................................................2
The regulation of international trade in The inaugural POWER-GEN Africa conference ACDC Dynamics..................................OBC
energy and exhibition, to be held in Johannesburg, Re- Ampcontrol.............................................55
16 August 2022: 17:30 for 18:00: Sasol Audito- public of South Africa on 6 - 8 November 2012, Becker Mining Systems.........................14
rium, Rosebank, Johannesburg. has announced the Call for Papers now open, Beckhoff.................................................11
CBI electric.............................................13
Hosted by the South African National Energy with a deadline for abstract submittal of 3 Feb-
Comtest..................................................49
Association (SANEA), this presentation by Lam- ruary 2012. The POWER-GEN Africa Advisory
Countapulse Controls.............................47
bert Botha (international trade practitioner) will Board has announced that the 2012 conference Cummins South Africa...........................37
provide an overview of the more topical issues will consist of three tracks running simultane- Current Automation..........................Insert
currently being discussed within the context of ously. Under the theme of Global Technology Danfoss..................................................26
WTO regulation of cross border trade in energy for Local Solutions, the three-track conference Delba Electrical......................................28
and natural resources in general. will work under the broad headings of Strategy, Endress+Hauser.....................................15
Hansen Industrial Gearboxes.................30
Enquiries: Tel. 031 368 8000 or email sanea@ Technology and Renewable Energy, each with
HellermannTyton....................................75
turnergroup.co.za. sub-topics to ensure broad coverage of the
Mecosa..................................................46
industry within Sub-Saharan Africa. Megger...................................................53
Enquiries: Lee Catania.Email leec@pennwell. Meissner............................................. OFC
com. Visit www.powergenafrica.com. Neu Bergmann Technik..........................24
4th SA Innovation Summit NTSA......................................................20
30 August 1 September 2011 Powertech..............................................60
Predictive Maintenance Conference.....39
IDC Conference Centre, Sandton
Reinhausen South Africa.......................63
Lets co-innovate with Eskom! Eskom has SAEEC2011 - Energy Efficiency@Work
Reliable Transformers............................54
launched four challenges on their Open Innova- in 2011 RJ Programmable..............................Insert
tion Platform and you are invited to participate. 16/ 17 November 2011 Emperors Palace, Rockwell Automation.............................21
See details on www.openinnovation.eskom. Gauteng Rubicon................................................ IBC
co.za. Submissions take place via website. This two day convention and exhibition will Schneider Electric....................................7
Enquiries: Email innovation@eskom.co.za. bring together stakeholders in the energy Siemens................................................IFC
Southern Power Maintenance...............61
efficiency sector, including equipment sup-
Temperature Controls.............................43
pliers, consulting engineers, energy service
Thermocouple Products.........................44
companies, end-users of energy, utilities and Three-D Agencies..................................62
POWER-GEN Africa announce Call for researchers. Trans Electron Transformers..................29
Papers Now Open Enquiries: Erika Kruger. Tel. 018 290 5130 or WIKA......................................................45
6-8 November 2012, Sandton Convention Cen- email convention@saee.org.za. Winder Controls.....................................27
tre, Johannesburg Woodbeam.............................................57
Yokogawa...............................................10
Zest........................................................25
76 Electricity+Control August 11