African Petrochemicals May/June Edition 15.3 {2018}

IN THIS EDITION 

CHOOSE THE CORRECT EQUIPMENT FOR THE TYPE OF RISK YOU FACE 

Edition 15.3 

THE HIGH VALUE INDUSTRIAL SAFETY OFFERING May / June 2018 

VEGAFLEX series 80: 

Simple, reliable and versatile

Proudly hosted by 

The African Petrochemical Roadshow offers a diagonal slice of 

the industry, showcasing and highlighting multiple products, 

services and expertise available to the Petrochemical Industry, 

General Engineering, Mining and Power Generation sectors. 

SECUNDA 

28 JUNE 2018 

Sasol Recreation Club 

Book your stand 

or pre-register to 

visit online. 

Upcoming 2018 

Roadshows 

Secunda Petrochemical 

Roadshow 

28 June 2018 


The Engineering, Procuremant 

& Construction Expo Gauteng 

30 August 2018 

Leeuwkop Golf Club, Kyalami 

Mosselbay Petrochemical 

Roadshow 

October 2018 

Mosselbay Civic Centre 

Germiston Independent Power 

Providers 4.0 Africa 

Roadshow 

25 October 2018 

Victoria Lake Club 

Durban Petrochemical 

Roadshow 

1 November 2018 

Amanzimtoti Civic Centre 

Dates are subject to change 

30 August 2018 

THE ENGINEERING, 

PROCUREMENT & 

CONSTRUCTION EXPO 

The Engineering, Procurement and Construction Expo 

This is the only expo hosted specifically for the Engineering Procurement and Construction (EPC) Industries in 

Gauteng. The show is an ideal business to business networking opportunity. 

Please contact us for further information 

011 083 5125 • sales@africanpetrochemicals.co.za • www.africanpetrochemicals.co.za

IN THIS EDITION 

CHOOSE THE CORRECT EQUIPMENT FOR THE TYPE OF RISK YOU FACE Edition 15.3 

THE HIGH VALUE INDUSTRIAL SAFETY OFFERING May / June 2018 

African Petrochemicals is published bi-monthly by Direct Publications cc 

Edition 15.3 May / June 2018 

VEGAFLEX series 80: 

Simple, reliable and versatile 

Direct Publications 

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richard@africanpetrochemicals.co.za 

Accounts and Admin 

Ashni Padiachie 

accounts@africanpetrochemicals.co.za 

Sales 

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production@africanpetrochemicals.co.za 

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CONTENTS 

Emerson expands its Pressure Gauge 

Portfolio to help plants improve reliability 4 

Front Cover Story: Measurement unfazed 

by harsh reality 5 

Instrumentation and measurement 

solutions for the South African water 

industry 6 

Alert, Aware, Alive - Atlas Copco 

Industrial South Africa emphasizes 

safety in the workplace 8 

New HMI software features improve 

operator efficiency 10 

Linear Encoders for future-proof 

position measurement in Hydraulic 

Cylinders 11 

HiQ: The high value Industrial Safety 

Offering 12 

MSA Africa offers latest safety 

technology for hazardous environments 14 

Rope access, drone combo for Tsumeb 

Namibia maintenance project 16 

New Wireless Pressure Gauge App 

increases convenience and safety 17 

Choose the correct equipment for the 

type of risk you face 18 

New Controllers can simplify machines, 

improve safety performance 20 

Latest PlantPAx DCS Release Empowers a 

Converged Workforce through a Smarter, 

More Intuitive Experience 21 

thyssenkrupp secures EP contract for 

first Skid-mounted Chlorine Plant 

in Sub-Saharan Africa 22 

Twice as easy - On the safe side with 

differential pressure measurement 23 

BMG extends Eaton range of Winner hose 

to include 4S 6S spiral hose and hose 

fittings 23 

Understanding the effects of pulsations 

on gas flow 24 

Rapid Allweiler Pumps lands ANSI 

Heavy Duty Process Pump contracts 26 

New Micro PLC can reduce complexity 

of large standalone machines 28 

FLUKE’S battery analyzer increases 

accuracy, safety - reduces test time 28 

Valve company celebrates 20 years 

supply of Butterfly Valves in South Africa 30 

Monitran’s compact hand-held Vibration 

Meter 31 

Capitalising on big data and analytics for 

improved operations 33 

Dual-Range Pressure Calibrator for 

gas custody transfer measurements in 

intrinsically safe environments 34 

VISIT AFRICAN PETROCHEMICALS ONLINE: 

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3

EMERSON EXPANDS ITS PRESSURE GAUGE PORTFOLIO 

TO HELP PLANTS IMPROVE RELIABILITY 

The Rosemount Smart 

Pressure Gauge delivers 

safer and more reliable 

readings, enabling better 

visibility of field changes 

where an effective local 

display is necessary 

Emerson expands its pressure gauge 

portfolio to help plants improve reliability. 

4 

Emerson has introduced the Rosemount 

Smart Pressure Gauge to help users gain 

better visibility of field changes. 

The Smart Pressure Gauge utilises 

industry-proven Rosemount pressure 

sensor technology to deliver reliable 

pressure readings. With the flexibility to 

accommodate changing process conditions, 

the Smart Pressure Gauge gives up to 150X 

overpressure protection and provides a safer 

field environment. By utilising two layers 

of process isolation, the Smart Pressure 

Gauge can help prevent process failures 

from becoming dangerous by preventing 

employee contact with process fluid by 

keeping it safely inside the pipe. 

The gauge’s Rosemount pressure sensor 

technology replaces 100-year-old bourdon 

tube gauge technology, eliminating weak 

points common to mechanical gauges. 

Mechanical gauges are plagued with 

quality and reliability issues associated with 

overpressure, vibration, corrosion, extreme 

temperatures and accidental damage, 

and can contribute to numerous reliability 

and safety issues in plant environments. 

Additionally, mechanical gauges are unable 

to communicate device status. 

With up to a 10-year life, which reduces 

maintenance cost and time, and increased 

visibility from a large 4.5-inch face with status 

indicator light, the gauge provides easy field 

visibility. 

The new Rosemount Smart Pressure Gauge 

expands the Emerson gauge portfolio. 

“The industry response to the Rosemount 

Wireless Pressure Gauge has been positive, 

and now with the addition of the Smart 

Pressure Gauge, our customers have 

even more options for upgrading their 

problematic gauges,” said Sven Hendrickson, 

product manager for pressure gauges. 

To learn more about Emerson’s pressure 

gauges visit: www.Emerson.com/ 

RosemountPressureGauge 

About Emerson 

Emerson (NYSE: EMR), headquartered 

in St. Louis, Missouri (USA), is a global 

technology and engineering company 

providing innovative solutions for customers 

in industrial, commercial, and residential 

markets. Our Emerson Automation Solutions 

business helps process, hybrid, and discrete 

manufacturers maximize production, protect 

personnel and the environment while 

optimizing their energy and operating costs. 

Our Emerson Commercial and Residential 

Solutions business helps ensure human 

comfort and health, protect food quality 

and safety, advance energy efficiency, and 

create sustainable infrastructure. For more 

information visit: Emerson.com. 

Further information is available from: 

Rob Smith, Sales Manager, 

South & East Africa Emerson Automation 

Solutions 

Tel: 011 451 3700 

Email: Rob.Smith@emerson.com 

Web: www.Emerson.com

MEASUREMENT UNFAZED BY HARSH REALITY 

FRONT COVER STORY 

VEGAFLEX guided radar sensors allow a choice between level and 

interface measurement in industrial processes 

More flexible, more efficient processes paired 

with completely reliable status monitoring? 

Yes, VEGAFLEX 81 guided radar sensors can 

provide that, and also give the user a choice. 

They combine level measurement and 

optional interface detection in one single 

innovative device. In addition to efficiency, 

they ensure an optimal price-performance 

ratio in many processes. 

“Two in one” is the motto of the skilful 

combination of two measurement 

applications built into VEGAFLEX 81. These 

multi-talent instruments are suitable for all 

types of liquids, whether in storage tanks, 

standpipes, dosing containers or large tank 

farms. The range of media they can measure 

with great precision ranges from bitumen to 

liquefied gases. Thanks to the special design, 

even ammonia can be measured without 

difficulty. Your advantage in terms of cost 

and safety: VEGAFLEX 81 needs only one 

mounting hole in order to measure the level 

and the layer interface continuously at the 

same time, particularly in pressure vessels. 

In addition to VEGAFLEX 81, which has 

been optimized for use in liquids, there 

are three more instrument versions in the 

guided radar series 80 – each designed for a 

special area of application. VEGAFLEX 82, for 

example, is ideal for measuring bulk solids 

under extremely harsh conditions. When 

foodstuffs or aggressive media have to be 

measured, VEGAFLEX 83 is the best choice. 

With its resistant materials and suitably 

finished surfaces, the instrument meets the 

high requirements of hygiene and durability. 

VEGAFLEX 86 measures practically any fluid, and that maintenance free under extreme pressure 

and temperature conditions, even in applications with heavy build-up, foam or condensate. 

And then there’s VEGAFLEX 86, which is predestined for applications with extreme 

temperatures and high pressures, for example in distillation columns. 

VEGAFLEX series 80 guided radar sensors are maintenance free and ensure, not least thanks to 

their intelligent electronics, reliable measured values and safety for the entire processing facility. 

More information at www.vega.com 

KEEP UP TO DATE WITH THE LATEST PETROCHEMICAL INDUSTRY NEWS, 

SPECIAL REPORTS, TECHNOLOGICAL ADVANCES AND MUCH MORE 

Connect with us on 

www.africanpetrochemicals.co.za 011 083 5125 sales@africanpetrochemicals.co.za 

5

INSTRUMENTATION AND MEASUREMENT SOLUTIONS 

FOR THE SOUTH AFRICAN WATER INDUSTRY 

6 

KROHNE has been active in water markets for over 60 years. In fact, the Duisburg, 

German-based company was the first to introduce an electromagnetic flowmeter 

(magmeter) for water, wastewater, additives and sludge in 1961. Since then, 

KROHNE has not only developed a complete portfolio for flow measurement, 

including partially filled pipes, but also level, pressure, temperature as well as 

process analytics to equip waterworks, sewage treatment plants and all networks 

in between. 

Since magmeters remain the standard in water measurement, 

KROHNE has widened its OPTIFLUX portfolio over the years with many 

different liners for applications from clean water to sludge with high 

solid content. However, the development of standalone, batterypowered 

electromagnetic water meters has mostly taken place in 

the last 10 years. Although it was demanded by customers as an 

alternative to mechanical meters at points where no mains power is 

available, the development of these meters depended on a special 

design of the measuring tube. Introduced in 2009, the WATERFLUX 

battery-powered water meter (certified to MID MI001 and OIML 

R49) has been a very successful product in the drinking / clean 

water market. It features a unique rectangular measuring tube 

design. Because inlet or outlet sections are not required, the 

sensor allows for a compact installation and a small overall 

installation footprint. Even better, there is no need for 

grounding rings because, as standard, the flow sensor has 

a reference electrode for grounding and a special coating 

allows for subsoil (IP 68) installation. To leave out grounding 

rings is also available as an option for the OPTIFLUX series 

(virtual reference option). 

As water meters are often installed in remote locations, 

reducing the frequency of visits to the sites, the time spent on 

set-up and maintenance is crucial. 

This relies on aspects such as a 

simplified installation, integrated 

diagnostics, a long battery lifetime, 

remote communication options 

and low overall maintenance 

requirements of the meters. The 

features and options of WATERFLUX 

contribute to these targets 

and the device is continuously 

updated to keep up with modern 

requirements. 

In terms of installation, the 

polycarbonate converter housing 

with protection class IP68 rating is 

now standard for both the compact 

and the remote version, that is, for 

temporarily flooded measuring 

WATERFLUX 3070 C battery-powered electromagnetic 

water meter. 

pits. It features IP68 Mil connectors that do not require wiring on site, 

and a small installation footprint to fit into electrical cabinets. For 

locations where mains power is available, WATERFLUX is now available 

with an external FlexPower unit to connect the meter to a power 

source on site, e.g. electrical grid, solar panel or a small windmill. 

The integrated pressure and temperature sensor allows the use of 

WATERFLUX for various tasks in drinking water networks: Flow and 

pressure measurement data are an important input for pressure 

monitoring, maintaining the water balance, district zoning (DMA), 

and for leak detection in drinking water networks when comparison 

of pressure and flow values are used as methods. Eliminating the 

installation and wiring of external pressure sensors, the integrated 

pressure sensor can provide an alarm when a programmed upper 

Battery-powered IP68 water metering point 

with GSM/GPRS communication. 

or lower limit is reached. The same applies for the 

integrated temperature sensor that can serve for 

quality monitoring of potable water, also without 

the need to open the line a second time. Alarms can 

be generated via the status output or via Modbus 

when critical limits for pressure and or temperature 

are exceeded. 

Current communication options meet water companies’ increasing 

demand for more measurement and status data. The Modbus RTU 

output offers an alternative to the two-pulse and two-status outputs. 

Transferred data includes measurement data (sum, forward and 

reverse counters, flow rate), status data (battery lifetime, meter status), 

actual values for pressure and temperature, and alarms. In addition, 

remote data communication solutions are also available off-the-shelf. 

Contact: 

Deon Rampathi 

Tel: 011 314 1391 

Email: d.rampathi@krohne.com 

Web: www.za.krohne.com

Conveyor Belt 

Fire Protection 

Conveyor Belt fires 

poses a Risk to Life, Safety, 

Production and Asset Losses 

Our philosophy is based on Preventative Thermal 

and Fire Detection with Early Warning Maintenance 

Alarms and Belt Stoppage. 

Extinguishing is automatic once a fire is detected. 

All our solutions are based on NFPA Standards 

or Rational Engineering Designs. 

We Engineer, Procure, Construct and 

Maintain Full Turnkey Solutions. 

The Ultimate Conveyor Fire Detection and Suppression 

Solution for Underground and Surface Applications 

FIRE DETECTION 

• Bearing Temperature Sensing 

• IR Temperature Scanners 

• IR 3 Flame Detectors 

• Linear Heat Detection 

• Fibre Optic Distributed 

• CO, SO 2 

and Smoke Detection 

FIRE SUPPRESSION 

• Water – NFPA 15 

• Foam – NFPA 16 

• Water Sprinklers – NFPA 13 

FIRE CONTROL PANEL 

• Unique Modular Design 

• Auto / Manual Function 

• Fault Notification 

• Maintenance Notification 

• Fire Alarm 

• Fire Suppression Failure Alarm 

• Belt Stop Function 

• Auto Solenoid Activation 

Do not hesitate to contact us 

for additional product information and re-seller opportunities. 

www.spero.co.za • info@spero.co.za • +27 12 665 0317 

7

All Atlas Copco participants armed with the knowledge and 

confidence required to deal with emergency situations. 

ALERT, AWARE, ALIVE - ATLAS COPCO INDUSTRIAL SOUTH AFRICA 

EMPHASIZES SAFETY IN THE WORKPLACE 

On 25 April 2018, Atlas Copco Industrial South Africa and Reality Wellness Group joined forces to host 

workshops for all Atlas Copco and Rand Air employees at Atlas Copco House, in Jet Park, Boksburg, with 

the objective of promoting a safe and healthy work environment. 

World Safety and Health Awareness day was 

globally celebrated on 28 April 2018 and 

companies around the world held initiatives 

to encourage the prevention of occupational 

accidents and diseases and to reduce the 

number of work-related injuries and fatalities. 

Atlas Copco is employee-centric and 

considers the health and safety of all its 

employees as top priority. The safety day 

initiative presented the perfect platform to 

ensure that employees are fully versed with 

all safety procedures. Enthusiastic employees 

participated in four workshops which 

focused on identifying potential hazardous 

and procedures for handling emergency 

situations such as accidents, fire, loss of 

limbs, etc. in the office, warehouse as well as 

in the yard area. 

8 

Reality Wellness Group’s Annie Dean 

(Occupational Health Practitioner), Elarda 

Botha (Health and Safety Consultant), 

and Chris Fourie (Registered Counsellor), 

sketched two typical accident scenarios 

which can occur in the office and warehouse 

environment. The practical side of the 

workshops was certainly not for the faint 

hearted with graphic demonstrations of 

severe injuries including a severed finger. 

Reality Wellness Group not only shared 

vital information but also encouraged the 

employees to be interactive and hands-on; 

employees had to assist the injured to see 

how they would react during emergency 

situations. 

In another interactive demonstration, 

employees donned special goggles which 

gave them a feeling of intoxication so that 

they could experience what it feels like to 

Atlas Copco participants walked away with a brand new First Aid Kit. 

work under the influence of narcotics or 

alcohol. These vivid demonstrations were 

an eye opener for employees who became 

aware of how quickly accidents can occur 

and the importance of sobriety in the 

workplace. 

The safety day initiative also included HIV/ 

Aids, cholesterol, sugar, body mass and blood 

pressure screening and testing for employees 

to encourage healthy lifestyles. 

Established in 2002, Reality Wellness Group 

offers comprehensive wellness interventions 

and activities to companies with the aim of 

assisting employees to become aware of 

safety regulations and to take responsibility 

for health and wellness in the workplace. 

The company provides services across five 

wellness dimensions including screening 

and testing, disease management, lifestyle 

coaching and education, physio-social 

counselling and support, as well as workforce 

wellness reporting. “One of our primary 

messages is that safety is not an individual 

responsibility but everyone’s responsibility,” 

states Annie.

Atlas Copco employees were impressed by 

the efforts put in by Reality Wellness Group 

and described the day as an unforgettable 

experience. “The demonstrations were 

relevant not only to our day-to-day duties 

in the workplace but can also be applied to 

life outside the office,” says Wendy Buffa- 

Pace, Atlas Copco Group Human Resources 

Manager. 

The successful safety day concluded with 

all participants armed with not only the 

knowledge and confidence required to deal 

with an emergency, but also with a brand 

new First Aid Kit! 

Atlas Copco is a world-leading provider 

of sustainable productivity solutions. The 

Group serves customers with innovative 

compressors, vacuum solutions and air 

treatment systems, construction and mining 

equipment, power tools and assembly 

systems. Atlas Copco develops products and 

services focused on productivity, energy 

efficiency, safety and ergonomics. The 

company was founded in 1873, is based in 

Stockholm, Sweden, and has a global reach 

spanning more than 180 countries. In 2016, 

Atlas Copco had revenues of BSEK 101 (BEUR 

11) and about 45 000 employees. 

Learn more at www.atlascopco.co.za. 

Atlas Copco employees were hands-on by assisting with the different emergency scenarios presented 

during the workshop. 

For further information please contact: 

Wendy Buffa-Pace, Atlas Copco Group Human Resources Manager 

Tel: +27 (0)11 821 9000 

Email: wendyb@za.atlascopco.com 

Petrochemical_Ad_AWC.indd 1 2018/01/27 13:42 

9

NEW HMI SOFTWARE FEATURES IMPROVE OPERATOR EFFICIENCY 

FactoryTalk View 

software updates 

offer better 

information access, 

mobile support and 

software integration 

FactoryTalk View software version 10.0. New features include greater access to information, new mobile device support and 

better cross-software integration to improve productivity. 

10 

Rockwell Automation has updated its HMI 

software to equip industrial workers with 

better information to run and maintain their 

systems. New features in the FactoryTalk View 

software version 10.0 include greater access 

to information, new mobile device support 

and better cross-software integration to 

improve productivity. 

Operators can now use the TrendPro tool in 

FactoryTalk View Site Edition (SE) software 

to overlay alarm information on trend data. 

This feature can help them connect alarm 

occurrences with data-point values to speed 

up troubleshooting. They can also use the 

tool to save and share ad hoc trends with 

other workers. 

“This version also adds support in the HMI 

for flexible alarming with the Allen-Bradley 

Logix line of controllers,” said Christo Buys, 

Business Manager – Control Systems Rockwell 

Automation Sub-Saharan Africa. “Previously, 

users had to manually create alarm conditions 

in both the controller and the HMI. With tagbased 

alarming, operators can now create the 

alarm configuration in Logix and the HMI will 

process it automatically, which saves time by 

reducing the need for programming.” 

FactoryTalk View SE v10.0 also integrates 

the ThinManager software login into the 

FactoryTalk View platform. In the past, users 

had to separately log in to both systems. 

Now, they can bypass the second security 

point with an automatic login pass-through 

for easier and faster operations. 

For process industries, the FactoryTalk 

View SE software introduces an abnormal 

situation management (ASM) multi-monitor 

framework. This feature allows operators to 

see different levels of data across multiple 

screens in accordance with standards-based 

ASM guidelines. It can also provide operators 

with more viewable information, helping 

them more efficiently run and maintain their 

systems. 

The updated FactoryTalk ViewPoint software, 

which extends the FactoryTalk View SE 

software to mobile devices, now supports 

recipe management. This update allows 

workers to view and download recipes on 

the device of their choice. And now, with 

ViewPoint v10.0 software, FactoryTalk Alarms 

and Events alarm history is also available on 

their mobile devices. 

The FactoryTalk View Machine Edition 

(ME) software v10.0 adds design-time and 

run-time enhancements to improve user 

efficiency and productivity. The HMI software 

now better supports restoring and upgrading 

legacy projects and improves usability when 

editing displays. 

“Prior to this release, operator actions could 

be logged to an audit trail, but there was no 

guarantee that the system would capture 

them,” said Buys. “Now with onboard audit 

trails, this information is captured locally on 

the terminal, and audit data is securely stored 

there until it can be backed up. For highly 

regulated industries, like pharma production, 

this supports requirements such as US 21CFR 

Part 11 or EU Annex 11.” 

About Rockwell Automation 

Rockwell Automation Inc. (NYSE: ROK), 

the world’s largest company dedicated to 

industrial automation and information, 

makes its customers more productive and 

the world more sustainable. Headquartered 

in Milwaukee, Wis., Rockwell Automation 

employs approximately 22,000 people 

serving customers in more than 80 countries. 

Enquiries: 

Christo Buys 

Business Manager – Control Systems 

Rockwell Automation Sub-Saharan Africa 

Tel: +27 (0) 11 654 9700 

Email: cbuys@ra.rockwell.com 

Web: https://www.rockwellautomation.com/ 

en_ZA/overview.page

LINEAR ENCODERS FOR FUTURE-PROOF POSITION 

MEASUREMENT IN HYDRAULIC CYLINDERS 

There is an increase in the demand for linear sensors 

for mobile automation in general and, even more so, 

for hydraulically driven machines. But the quantitative 

aspect is just one side of the story. This, according to 

Alexander Hurt, Head of Linear Encoders Business Unit, 

SICK AG, Germany. 

The MAX linear encoder, which has been developed 

specially for mobile automation applications, 

can take complete, integrated, and non-contact 

absolute position measurements in hydraulic 

cylinders. It is primarily used in the extreme 

environmental and operating conditions that are 

typical for mobile machines. 

When digging, the option to control the depth of 

excavator shovels using position measurement 

avoids damage being caused to cables, pipes, 

and foundations. 

More and more vehicle manufacturers, 

integrators, and operations managers 

are setting their sights on top-quality 

innovations. Everyone wants the added value 

that came to be standard within industrial 

automation long ago: the encoder needs to 

gather status and process information. 

In future, precise, high-performance 

position measurement is set to come with 

the added option of performing detailed 

analyses on the basis of sensor information. 

This will make it possible, for example, to 

provide support for assistance systems, 

avoid sudden machines failures, optimise 

maintenance routines, and improve machine 

availability on the whole. Within the field 

of hydraulic measurement technology for 

mobile automation, the linear encoders in 

SICK’s MAX product family are currently the 

only devices of their kind to offer this added 

value. They operate in line with the robust 

operating principle of magnetostriction, 

provide extensive diagnostic functions (the 

first sensors of their kind), and offer added 

value for mobile machines that will continue 

to be relevant as we head into the future. 

Innovation with magnetostriction 

One key feature of the new SICK linear 

encoders is their full mechanical compatibility 

with existing cylinder constructions that 

are already prepared for integration into a 

path measurement system. Integration into 

Alexander Hirt, Business Unit 

Head: Linear Encoders. Hirt 

has been in charge of the 

linear encoders business 

unit since 2016 and he, and 

his team, established the 

magnetostriction technology 

in the SICK portfolio. 

hydraulic cylinders is therefore guaranteed to 

be a quick and easy process. 

Inside these linear encoders, there are 

various technologies and innovations when 

compared to the market standard. On the 

basis of more than 25 years of experience 

in linear path measurement technology for 

mobile machines, SICK STEGMANN began 

by studying the market requirements and 

then went on to develop a radical new sensor 

concept. The main features include the use 

of magnetostriction, the optimisation of the 

power density by minimising measurement 

dead zones, and the integration of diagnostic 

and prognostic functionalities that can be 

used to avoid machine downtimes and 

improve operational plans and maintenance 

routines for entire fleets. 

Magnetostriction technology offers a 

number of benefits when linear encoders 

are used in hydraulic machines. Position 

measurement is absolute – the precise piston 

position is detected as soon as on-board 

voltage is supplied when the machine is 

started up. There is no need for a reference 

run, as is the case with incremental sensors. 

During operation, magnetostriction is 

exceptionally reliable, wear-free, and even 

robust, proving particularly resistant to 

mechanical stress and extreme electrical 

influences, such as those caused by radiated 

or coupled faults in the on-board power 

supply of a vehicle. The high level of 

operational safety of the MAX linear encoder 

as a device within vehicles that requires 

approval is certified by the E1 approval 

mark issued by the German Federal Motor 

Transport Authority. 

Excavators can be fully automated and operated 

with extreme precision when removing highway 

embankments. 

The MAX linear encoders make it possible to 

automate and monitor work processes performed 

by mobile machines. 

11

HIQ: THE HIGH VALUE INDUSTRIAL 

SAFETY OFFERING 

Precision matters in everything we do, says 

Hans Strydom, technical services manager for 

special products and chemicals at Afrox. Here 

he talks about Afrox’s HiQ range of innovative 

solutions, tailor made to suit customers’ specific 

speciality gas and equipment requirements. 

12 

At Afrox and all other Linde companies 

around the world, HiQ is the global brand for a 

specific range of made-for-purpose gases, gas 

mixtures and associated products that comply 

with very high purity and quality standards. 

Afrox HiQ speciality gases include pure 

‘scientific’ gases; made-to-order scientific 

carrier gases and mixtures; calibration 

mixtures for certifying the accuracy of 

instruments; as well as a host of specialpurpose 

mixtures for safety, research and 

development in the petrochemical, energy 

and mining industries, scientific laboratories 

and at health facilities. 

At the starting point of the HiQ product range 

are Afrox’s high purity atmospheric gases: 

argon, carbon dioxide, helium, nitrogen and 

oxygen. For use in HiQ gas formulations, each 

of the source gases must be of exceptionally 

high purity. “We talk about gas purity levels in 

terms of a number of nines: a five nines (N5) 

purity, for example is 99.999% pure, which 

means it has an impurity level of less than 

0.001% or 10 parts per million (ppm),” Strydom 

explains. 

For modern HiQ gases, Afrox now offers six 

nines (N6) purity levels, which contain less 

than 1.0 ppm of contamination. This is the 

basis for the HiQ® 60 range, according to 

Strydom. These gas mixtures are designed 

to have a shelf life of up to 60 months, as 

opposed to the previous generation mixtures 

that could only be guaranteed for 36 months. 

When it comes to the calibration of safetycritical 

measuring equipment, the purity level 

of the calibration mix represents true value. 

Emissions analysis of smoke stacks at refineries, 

power stations and processing plants is a 

legal requirement and, in some cases, the 

emission monitors used are required to detect 

contaminant levels below 100 ppbillion. 

To calibrate these instruments, the calibration 

gas used must accurately mimic the polluting 

gas that the instrument needs to monitor – 

getting the measurement wrong can be costly, 

with potential fines. Low ppm HiQ calibration 

gas mixes, many of which are manufactured 

at Afrox’s state-of-the-art Gas Operations 

Centre (GOC) facility in Germiston, offer local 

customers legislative compliance, consistency, 

accuracy and cost savings, says Strydom. 

Citing Afrox HiQ methane and carbon 

monoxide mixes, he says that these are used 

to calibrate the monitors for ship engine 

rooms, and for the explosive and toxic meters 

used in underground goldmines. These gases 

pose fire and explosion dangers, so reliably 

monitoring their presence is essential for the 

safety of people working in engine rooms or 

underground. 

In addition to the calibration gases for 

environmental and safety monitors, Afrox 

HiQ gases are widely used as carrier gases 

for gas chromatography-mass spectrometry 

(GC-MS) instruments, which are used in 

laboratories and testing facilities all over the 

world to determine the exact constituents and 

contamination levels of substances. 

Applications include drug detection, 

environmental analysis, fire and explosion 

investigations, and the identification of 

unknown substance samples. GC-MS is 

widely used for forensic identification of 

substances found at crime scenes because 

specific samples can be traced to the criminal 

with 100% certainty. Blood samples are often 

tested if someone has been poisoned, for 

example, to identify the exact poison and its 

source, notes Strydom. 

For GC-MS instruments, Afrox offers HiQ 

helium. The purity of the carrier gas is 

obviously very important to the accuracy of 

the result, but the instruments themselves are 

also very sensitive to oxygen, moisture and 

any hydrocarbon contaminants. 

In the petrochemical industry, for example, 

samples of a fraction from the distillation 

of crude oil, such as diesel, petrol or natural 

gas, are analysed. The chosen fraction 

gets vapourised and separated on a 

chromatography column. It then goes into 

the mass spectrometer, which produces a 

chromatogram from which every constituent 

element of the sample, including all of the 

impurities, can be identified and quantified. 

The result is automatically compared to a 

library of substances in a database, so all 

the constituents and their percentages are 

immediately identified. And if the instrument 

is calibrated for a particular substance mix 

– Afrox is currently working on a very toxic 

benzene/toluene/xylene calibration gas – 

then tiny quantities of the contaminant of 

interest can be found. 

For the petrochemical industry, Strydom says 

that Afrox develops a vast range of calibration 

gases, which mimic the potentially harmful 

pollutants that need to be kept out of the 

fuels that are used by the industry. 

HiQ gases are also widely used by water 

utilities which use GC-MS to pick up any 

dangerous pollutants such as volatile organics 

and other carcinogens in their water. Samples 

are taken of the river water coming in, the 

water being processed as well as the treated 

drinking water being delivered to consumers 

to ensure safety levels are being met. 

“We thrive in situations where researchers 

are looking for local solutions that are tailor 

made for African conditions, for dealing with 

mosquitoes and malaria, for example, as 

well as for a host of biochemical and health 

applications, such as IVF treatment,” Strydom 

reveals, while assuring he will unravel some of 

these successful applications in a future article.

13

MSA AFRICA OFFERS LATEST 

SAFETY TECHNOLOGY FOR 

HAZARDOUS ENVIRONMENTS 

From hearing protection to integrated harness 

systems, MSA Africa offers industries such 

as petrochemicals and oil-and-gas the latest 

technology to guarantee worker health and 

safety in hazardous environments. 

The Latchways PRD range from MSA Africa includes a Workman 

Premier and Workman Utility full-body harness. 

For example, the Latchways Personal Rescue 

Device (PRD) integrated harness system from 

MSA Africa is a lightweight, unobtrusive rescue 

device contained in a small backpack, attached 

to a full-body harness. It has been designed to 

be used in conjunction with a fall protection 

system or anchor point. 

The patented components of the Latchways PRD 

fit neatly into the backpack, allowing workers to 

carry out their daily tasks unhindered. Indeed, 

the backpack becomes part of the daily Personal 

Protective Equipment (PPE) required for those 

working at height. 

In the event of a fall, the MSA Latchways PRD 

suspends the worker, who is then lowered to 

the ground gently in a controlled descent. The 

device features a 20 m spool of Aramid rope, 

released at a controlled rate via an integral 

braking mechanism. The innovative design 

uses quality components and a limited number 

of moving parts so as to guarantee 100% 

mechanical integrity. 

Unlike competitor rescue kits, the MSA 

Latchways PRD requires no specialist training, 

as it is simply worn in conjunction with a 

standard fully-body harness, and is activated 

by simply pulling the release cord. Its userfriendliness 

is enhanced by the fact that preuse 

checks are minimal. 

The Latchways PRD range from MSA Africa 

includes a Workman Premier and Workman 

Utility full-body harness. A rescue pole is also 

available, which can be used by a third party 

to activate the Latchways PRD in the event of 

a worker at height being incapacitated. The 

rescue pole is 800 mm when retracted, and 3 

400 mm when extended. 

MSA Africa’s harness-system offering has 

been enhanced further with the addition of 

its Latchways 3 m Personal Fall Limiter (PFL), 

designed specifically for environments where 

close anchorage is available. The lanyard 

uses multiple-spring radial energy-absorbing 

technology, believed to be a world-first. 

14 

The MSA Latchways PFL is supplied with a choice of steel or aluminium 

top carabiner with a range of connectors to select from.

The new design eliminates the need for an 

external energy absorber outside of the 

housing, resulting in this being the most 

compact PFL available on the market today. 

Suitable for a range of applications, the 

MSA Latchways PFL not only requires zero 

recalibration or adjustment, but a fullyrotating 

attachment point allows for total 

flexibility, including 180° and 360°. Precision 

engineering has resulted in a structurallyreinforced 

pawl mechanism. 

The Self-Retracting Lifeline (SRL) is housed 

in a highly-durable polycarbonate casing 

that is transparent to allow for easy visual 

inspection of critical internal components. All 

components have been manufactured from 

high-grade stainless steel and engineered 

plastics. 

The MSA Latchways PFL is supplied with a 

choice of steel or aluminium top carabiner, 

with a range of connectors to select from. 

These include a forged steel snaphook, an 

aluminium or steel scaffold hook, or a forged 

steel swivel snaphook. 

It can withstand a temperature range from 

–40°C to +54°C. The high-performing, highstrength 

webbing has been manufactured 

to the most rigorous international standards, 

including EN360: 2002, ANSI Z359.14 – 

2012, OSHA 1910.66, OSHA 1926.502, CSA 

Z259.2.2-98. 

In terms of hearing protection, which is often 

under-considered when taking into account 

other forms of protection such as respiratory 

and head-and-face protection, MSA Africa’s 

innovations include its Left/Right WW (Wireless 

World) communication solutions. The solution 

is available in two product versions, both with 

a Bluetooth-enabled headset. 

The ‘cut-off’ surrounding sound function 

on the MSA Left/Right WW Dual version 

means that surrounding sounds such as 

voices and signals are reproduced inside 

the ear muff, with an adjustable sound gain. 

This means end users are fully aware of 

their surroundings at all times, while being 

protected by passive attenuation. It also 

allows workers to communicate in noisy areas 

while keeping their hearing protection on, 

which improves safety and efficiency. 

MSA’s Left/Right WW communications 

solutions feature ergonomically-shaped ear 

muffs that provide a better match for any 

head shape, as well as following the ears. 

This means that the left and right cups are 

different, with up, down, and tilt adjustment 

for a perfect fit for all head profiles. There 

are also two configurations with different 

headbands and helmets, with three adapters 

to fit various helmet models. 

About MSA 

MSA Africa has been the world’s leading 

manufacturer of high-quality safety products 

since 1914. MSA products may be simple 

to use and maintain, they are also highlysophisticated 

devices and protective gear 

– the result of countless R&D hours, relentless 

testing, and an unwavering commitment 

to quality that saves lives and protects 

thousands of men and women each and 

every day. Many of MSA’s most popular 

products integrate multiple combinations 

of electronics, mechanical systems, and 

advanced materials to ensure that users 

around the world remain protected in even 

the most hazardous of situations. MSA’s 

dedication to safety has been the key to its 

impressive year-over-year growth. In eight of 

the past ten years, MSA has achieved record 

growth numbers, with annual revenues of 

more than US$1 billion. 

Online 

epaper.africanpetrochemicals.co.za 

VIEW THE BACK EDITIONS ONLINE 

(No opt in or log in details required) 

15

16

Rope access was used in conjunction with 

remotely piloted air system RPAS drones. 

Skyriders has inspected two 

smokestacks and a cooling tower for 

client Dundee Precious Metals at the 

Tsumeb Namibia mining operation. 

ROPE ACCESS, DRONE COMBO FOR TSUMEB NAMIBIA MAINTENANCE PROJECT 

Skyriders has carried out routine 

inspections of two smokestacks and 

one cooling tower using a highly 

successfully combination of rope access 

and Remotely-Piloted Air System (RPAS) 

drones for client Dundee Precious Metals 

at the Tsumeb Namibia mining operation. 

The drones completed a general internal 

visual inspection, followed by detailed 

visual inspection and core sampling 

by a six-person rope-access team. “The 

deliverable was a comprehensive report, 

with recommendations signed off by our 

consulting engineers,” Skyriders Marketing 

Manager Mike Zinn explains. 

The deployment of drones makes for rapid 

and safe visual inspections. “This allows 

decision makers such as engineers and 

plant owners to formulate a more focused 

inspection plan, honing in on the areas 

of concern picked up during the drone 

inspection,” Zinn elaborates. 

Introduced by Skyriders in 2015, the use of 

drones has become an integral element of 

the company’s turnkey service offering. This 

comprises visual inspection using drones, 

detailed inspection by means of rope access, 

repairs undertaken by rope access, and then 

using drones as a quality-control measure to 

inspect and verify the final repairs. 

This is the maiden project that Skyriders has 

undertaken for Dundee Precious Metals, 

with Tsumeb Namibia being an important 

showcase for its project and service offering. 

With commodity prices remaining under 

strain across the board, Skyriders’ turnkey 

rope-access solutions extends its clients’ 

inspection and maintenance budgets, saving 

both time and money. 

Skyriders offers a full suite of inspection 

services, from NDT to rope access. Its 

in-house expertise includes concrete 

repair, confined spaces, painting, bolting, 

rigging and welding, and work-at-height. 

Its technicians are not only qualified and 

highly skilled in rope access, but also 

have expertise in critical inspection 

methodologies such as NDT and drone 

operations. 

Connect with Skyriders on Social Media 

to receive the company’s latest news 

Facebook: www.facebook.com/ 

SkyridersIndustrialRopeAccess 

Twitter: twitter.com/SkyridersZA 

About Skyriders 

Skyriders (Pty) Ltd, established in 1998, is 

a leader in the South African rope access 

industry, providing cost- and time-saving 

solutions to clients in the power generation 

and petrochemical industries who require 

rope access aided inspection, NDT and 

maintenance work to be done in difficult to 

reach, high-up locations. 

Skyriders Contact 

Mike Zinn 

Skyriders Marketing Manager 

Tel: (011) 312 1418 

Email: mike@ropeaccess.co.za 

Web: www.ropeaccess.co.za 

The deployment of drones makes for 

rapid and safe visual inspections. 

16

NEW WIRELESS PRESSURE GAUGE APP INCREASES CONVENIENCE AND SAFETY 

New wireless pressure gauge app increases convenience safety. 

Emerson’s Plantweb Insight application 

provides streamlined view of networked 

Rosemount wireless pressure gauges, 

helping maintenance personnel stay 

informed and safe 

Emerson announces a new Plantweb 

Insight application for wireless pressure 

gauges that displays data in an easy-tounderstand 

dashboard for maintenance 

leads and instrumentation and electrical (I&E) 

personnel. An entire suite of Plantweb Insight 

applications collectively helps users quickly 

make sense of plant data and drive overall 

enterprise profitability. 

This Industrial Internet of Things (IIoT) 

application delivers field data from a fleet 

of wireless pressure gauges as frequently 

as once per minute. By keeping operators 

updated on changing conditions remotely, 

the app allows personnel to make fewer 

manual rounds and minimize their exposure 

to hazardous areas. 

The gauge itself, the industry’s first 

WirelessHART® pressure gauge, utilizes 

industry-proven Rosemount pressure sensor 

technology to deliver reliable pressure 

readings. It provides up to 150x overpressure 

protection compared to traditional gauges 

using bourdon tube technology, and two 

layers of process isolation for a safer field 

environment. The gauge, which has a 10- 

year life, also reduces maintenance costs by 

eliminating common weak points found in 

mechanical gauges. 

The new application is the latest addition to 

Emerson’s Plantweb digital ecosystem, a 

scalable portfolio of technologies, software, 

and services that take advantage of IIoT 

innovations to extend the benefits of 

automation beyond process control to the 

entire enterprise, improving operations, 

strengthening decision-making, and 

institutionalizing best-practices. 

Easily integrated with a variety of 

WirelessHART gauges and remote field 

sensors, Plantweb Insight applications 

combine continuous, real-time data provided 

by Emerson’s Pervasive Sensing strategies 

with predictive analytics to give maintenance 

and operations personnel actionable, upto-date 

process information in any location, 

improving reliability, safety, production, and 

energy management. 

Learn more at www.Emerson.com/Plantweb- 

Insight 

About Emerson 

Emerson (NYSE: EMR), headquartered 

in St. Louis, Missouri (USA), is a global 

technology and engineering company 

providing innovative solutions for customers 

in industrial, commercial, and residential 

markets. Our Emerson Automation Solutions 

business helps process, hybrid, and discrete 

manufacturers maximize production, protect 

personnel and the environment while 

optimizing their energy and operating costs. 

Our Emerson Commercial and Residential 

Solutions business helps ensure human 

comfort and health, protect food quality and 

safety, advance energy efficiency, and create 

sustainable infrastructure. 

For more information visit: Emerson.com. 

Further information is available from: 

Rob Smith, Sales Manager, South & East 

Africa Emerson Automation Solutions 

Tel: 011 451 3700 

Email: Rob.Smith@emerson.com 

Web: www.Emerson.com 

17

CHOOSE THE CORRECT EQUIPMENT FOR THE TYPE OF RISK YOU FACE 

to sense heat on each 1m section to 1°C 

accuracy. The system is easy to install and 

report a change in temperature or ‘hot 

spots’ according to pre-set perimeters. 

Early warning by the system can prevent 

loss and damage or the system can be 

used as a detection method to activate fire 

suppression systems. 

Some other early detection tools available 

include Infra-Red temperature scanners and 

conveyor bearing temperature sensors. 

Plumber block temperature sensors 

(analogue or digital 68˚C) and IR Temperature 

scanners allow for temperatures to be 

monitored on surface by any SCADA system. 

18 

Moab CAF Conveyor Belt System. 

Sperosens offers a complete range of 

products and services including, as a first 

phase, a Risk Analysis to determine what fire 

prevention solutions are best suited to the 

type of fire risk faced by each customer. 

Sperosens provides the design, manufacturing, 

installation, management and maintenance of 

safety solutions which enable our clients to focus 

on their core business. 

Cutting-edge detection and suppression 

technologies are applied to ensure safe working 

and operational conditions even in in harsh 

environments. This is achieved by installing 

monitoring and controlling remote detection 

devices. Our solutions prevent operational 

stoppages, delays and damage through early 

detection and appropriate suppression in 

identified risk areas. 

Risk assessments provide the information 

required to determine the correct system despite 

the various tools found on the market today. 

In addition to risk analysis, it is important that 

fire prevention becomes part of an integrated 

strategy. Any fire can have catastrophic 

consequences and therefore preventing fire from 

breaking out is preferable rather than providing 

a reactive cure when a fire breaks out. 

The strategy should include critical parameter 

measurements as well as carrying out 

preventative maintenance in order to prevent 

fires from breaking out resulting in lost 

production time and lives. 

Early detection plays a pivotal role in the 

elimination or reduction of fires occurring. 

There are multiple early detection systems in the 

market. 

AP Sensing Distributed Temperature Sensing 

(DTS) use Fibre Optic Cable up to 10km long 

Fire suppression methods use various 

technologies such as deluge systems, water 

and foam mist, sprinkler systems and clean 

gas agents. All these products are non-toxic 

and environmentally friendly. 

Water and Foam mist systems works well 

in high risk areas where the cooling off 

and oxygen displacement combination 

instantly assists in extinguishing fires in local 

applications. 

The system design must address critical 

parameters such as the belt coverage, flow 

rate, nozzle selection, pipe diameter as well 

as the duration and capacity requirements 

of the fire protection system chosen, for 

example, in terms of duration and capacity 

requirements, the NPFA 15 requires the 

system to spray for 30 minutes as well as an 

additional 30 minutes for backup. 

Sperosens designed dedicated controllers to 

immediately transmit any malfunction alarms 

or hazardous conditions to a control room. 

24/7 real time management and measuring 

the health of the system in use is critical. Fire 

System Readiness and Reporting is achieved 

by the Sperosens Verifi System. The system 

can report that each component was in 

working order and armed at the time when 

an incident occurred. 

All Sperosens Solutions comply with the 

relevant local and/or international standards 

eg. NFPA and SANS. 

Sperosens is a leading supplier to the mining 

industry and has many certifications and 

accreditations such as: SAQCC, ASIB, FDIA, 

FPASA, ECSA Professional Registration, 

FEASA, ISO 9001, SANS 1475 and CIDB. 

Sperosens insure product innovation & 

service excellence with each fire prevention 

solution supplied. 

For more information please visit: 

www.spero.co.za

SONIC V 

APR TUBE INSPECTION 

We are the experts in the use of APR (Acoustic Pulse Reflectometry) 

> Speed of Inspection : APR is fast and can inspect 20m tube in 

15 seconds 

> Defects Detects : Leaks, porosity, pitting, loss of wall 

thickness & blockage 

> Systems Inspected : Economisers, Condensers, Boilers, Heat 

Exchangers & any Engineering System 

which uses multiple tubes 

> Applicable Industry : Oil & Gas Refineries, Power Generations 

Utilities, Petrochemical & Chemical 

Industry Food & Beverage Industry, Air 

Condition (HVAC), Pulp & Industry, Tube 

Cleaning Quality Assurance. 

CONTACTS: 

502, 20 Albert Street, Marshaltown, Johannesburg 

Phone: +27 (0) 11 492 3735 

Cell: +27 (0) 73 930 5827 

Email: mphom@temoroti.co.za 

Web.: www.temoroti.co.za 

19

NEW CONTROLLERS CAN SIMPLIFY 

MACHINES, IMPROVE SAFETY 

PERFORMANCE 

Rockwell Automation controllers scale to 

specific machine safety requirements and 

support faster reaction times 

Engineers can simplify their machine safety 

systems and improve safety performance 

using new controllers from Rockwell 

Automation. 

The Allen-Bradley GuardLogix 5580 and 

Compact GuardLogix 5380 controllers can be 

scaled from safety system levels SIL 2/PLd to 

SIL 3/PLe. This scalability can help engineers 

optimise a safety system design and 

potentially reduce its costs, while adhering 

to the latest machine safety regulations. 

The high-performance controllers also use 

increased processing power to achieve faster 

reaction times and shorter safe distances. 

This can help create smaller machines, save 

valuable floor space and increase operator 

efficiencies. 

“Many engineers build safety systems to 

a higher safety level than an application 

requires,” said Christo Buys, Business Manager 

– Control Systems, Rockwell Automation 

Sub-Saharan Africa. “Such systems end up 

having more components than they need, 

leading to increased complexity and costing 

more than they should. Our new controllers 

allow engineers to right-size a safety system 

and its cost to meet appropriate safety levels, 

without excess.” 

20 

The new high-performing controllers can 

also help engineers consolidate the number 

of controllers they use in complex machines. 

Having a single high-performance controller 

for both standard and safety control can help 

improve productivity and reduce the system’s 

cost, complexity and cabinet size. 

Other benefits of the new controllers 

include: 

Greater Communications Capacity: 

Embedded gigabit Ethernet on the 

GuardLogix 5580 and Compact GuardLogix 

5380 controllers provides greater 

communications capacity to support the 

growing number of smart devices. This 

can help engineers meet data-intensive 

smart-manufacturing goals without adding 

extra hardware. It also can help future proof 

machines for end users that may someday 

need to collect and share more data. 

More Productive Machines: The controllers, 

when used with the Studio 5000 integrated 

development environment and Kinetix 

5700 servo drive, support new safe-stop, 

safe-speed, safe-position and other safemonitoring 

functions. These safety functions 

can create more flexibility in safety system 

operations, for example, slowing down a 

machine instead of stopping it when a worker 

approaches. This can improve machine 

productivity while still achieving a desired 

level of safety. These new functions are 

implemented using built-in safety instructions 

available in the Studio 5000 software. 

Engineers can also use the safety functions to 

support applications like collaborative robots. 

If a human comes too close to the robot, the 

system can detect their presence and either 

slow down or stop the robot’s motion. 

The GuardLogix 5580 and Compact 

GuardLogix 5380 controllers are TÜV certified 

for functional safety. 

The Allen-Bradley GuardLogix 5580 and Compact GuardLogix 5380 

controllers can be scaled from safety system levels SIL 2/PLd to SIL 3/PLe. 










Enquiries: 

Christo Buys 



Tel: 011 654 9700 


Web: https://www.rockwellautomation.com

LATEST PLANTPAX DCS RELEASE 

EMPOWERS A CONVERGED 

WORKFORCE THROUGH A SMARTER, 

MORE INTUITIVE EXPERIENCE 

New capabilities in Rockwell 

Automation modern DCS help digitally 

transform process control operations 

for increased plant-wide value 

The latest PlantPAx DCS contains features based on input from process users. It 

aligns with industry standards to deliver a smarter, more intuitive and protected 

system to a broad range of process industries. 

With the latest release of the PlantPAx distributed control system 

(DCS) from Rockwell Automation, industrial producers can create 

smarter, more productive and protected operations. The new system 

capabilities include a more intuitive design and the ability to see 

contextualised information from plant assets. These improvements 

help digitally transform process control operations – helping to 

enable a Connected Enterprise with reduced time-to-market and a 

lower total cost of ownership. 

“The PlantPAx DCS has long helped make connectivity possible 

through its alignment with scalable, plant-wide automation 

technology and use of open communication standards,” said Christo 

Buys, Business Manager – Control Systems, Rockwell Automation Sub- 

Saharan Africa. “Now, Rockwell Automation is releasing capabilities 

that help process-control operations capture more value across the 

entire process plant.” 

Smarter – This system release leverages enabling technologies to 

eliminate a complexity barrier for small to mid-sized operations 

seeking to implement a DCS. By consolidating servers into a single 

machine, applications can implement the full functionality of a 

modern DCS. This simplification, which can be used on virtual or 

physical machines, reduces engineering time, licenses and system 

footprint by up to 75%. 

The modern DCS also features an expanded library that supports 

electrical protection devices, leveraging both EtherNet/IP and IEC-61850 

standards. Connecting electrical functions with control extends plantwide 

integration, resulting in better plant control. Also, new standard 

control panel offerings ease implementation for a lower risk startup. 

Process Business, Rockwell Automation. “These innovations help 

companies leverage a modern DCS to more easily increase profits 

from plant-wide integration in a Connected Enterprise.” 


Rockwell Automation Inc. (NYSE: ROK), the world’s largest company 

dedicated to industrial automation and information, makes its customers 

more productive and the world more sustainable. Headquartered in 

Milwaukee, Wis., Rockwell Automation employs approximately 22,000 

people serving customers in more than 80 countries. 

Enquiries: 

Christo Buys, Business Manager – Control Systems 


Tel: +27 (0) 11 654 9700 


Website: https://www.rockwellautomation.com/en_ZA/overview.page 

Honeywell latest ControlEdge PLC product 

Honeywell’s new PLC is part of the ControlEdge family, a next 

generation family of controllers providing unprecedented connectivity 

through all levels of process and business operations. The result 

is optimized operations and maintenance efficiencies that release 

personnel from manual processes. ControlEdge PLC is one of the 

first controllers supporting Honeywell’s IIoT-ready initiative. The 

ControlEdge PLC, when combined with Experion, dramatically reduces 

integration costs for balance of plant operations, minimizes downtime 

through unified support, decreases risk with embedded cyber security, 

and lowers total cost of ownership through Experion-level extended 

system lifecycle. 

More Productive – The system features an expanded library of 

process objects that improve human interactions with the process, 

including the handling of alarms and abnormal situations. Simplified 

faceplate design provides a more intuitive user experience that is 

easier for training and support. The library also features historian 

templates to optimise the display of event information with real-time 

and historical data. 

Protected – With the PlantPAx DCS, users can now define access 

rights both by role and area, providing a new level of security through 

authentication and access privileges. The system release also expands 

network availability for I/O communications and extends the value of 

converged plant-wide architectures. 

“The latest system release of our PlantPAx DCS contains features 

based on valuable input from process users and aligns with industry 

standards to deliver a smarter, more intuitive and protected system to 

a broad range of process industries,” said Jim Winter, director, Global 

For more information, please contact Debi de Villiers 

Cell: 072 702 1148 Email: debi.devilliers@honeywell.com 

21

THYSSENKRUPP SECURES EP CONTRACT FOR FIRST SKID-MOUNTED CHLORINE 

PLANT IN SUB-SAHARAN AFRICA 

The Process Industries business of 

thyssenkrupp Industrial Solutions 

South Africa was successful in securing 

the engineering and procurement 

contract for a 45 tonne modular skidmounted 

chlorine plant in Tanzania, the 

first of its kind to be installed in Sub- 

Saharan Africa. 

Process Industries’ General Manager, 

Neville Eve, and Senior Manager for Special 

Projects Bruce Bassett, are spearheading 

the project and were instrumental in 

winning the contract. The duo are working 

in close collaboration with thyssenkrupp 

Uhde Chlorine Engineers based in Milan, 

Italy, who are responsible for the design, 

development and manufacture of this new 

lean method of project delivery for these 

standardised projects. 

thyssenkrupp Industrial Solutions’ modular 

skid mounted 15 and 45 ton capacity 

chlorine plants are particularly suited to the 

African market as they offer a cost-effective 

and practical solution to industries on 

the continent who require small chlorine 

alkali plants for applications such as water 

treatment and mineral processing. Many 

African countries import chlorine and 

caustic but the quantities are not large 

enough to sustain chlorine alkali plants. 

Small quantity requirements coupled 

with the vastness of the continent makes 

importation expensive and economically 

unviable. An on-site chlorine production 

solution thus presents a better alternative 

to import. 

In the modular solution, electrolysis is 

built on multiple skids that fit into 40 

foot containers that can be easily, quickly 

and cost-effectively transported to site. 

Construction and assembly is also fast and 

easy and requires only a small team, leaving 

only the non-modular plant sections to be 

stick built. Rapid project implementation 

and plant start up time result in substantial 

savings in terms of construction time and 

costs. 

“thyssenkrupp has installed of over 600 

chlorine alkali plants around the world 

but the Tanzania project is our first 

involvement,” comments thyssenkrupp 

Industrial Solutions South Africa CEO, 

Sub-Saharan Africa, Philipp Nellessen. “We 

are extremely excited about this project 

because it will help us to gain experience 

in one of thyssenkrupp’s flagship 

technologies.” 

“This project also demonstrates the 

strategic importance of thyssenkrupp’s 

presence in Africa through its South African 

subsidiary,” continues Nellessen. “The 

skid-mounted chlorine plant will boast the 

most up-to-date technology and emissions 

according to World Class Standards. 

We, as part of the global thyssenkrupp 

network, have the necessary capabilities 

and competencies to deliver a world-class 

technology in the form of the skid-mounted 

chlorine plant to Africa. This chlor-alkali 

project serves as a prime example of the 

successful combination of thyssenkrupp’s 

global technology and our local knowledge 

to offer a complete turnkey solution!” 

Alongside the development and delivery 

of products and technologies to boost 

the profitability of mines and plants in 

Africa, thyssenkrupp also embraces the 

growing trend of business-community 

collaboration. Any successful business, 

irrespective of industry, is able to develop 

the local community through employment 

and upskilling its people which ultimately 

helps to stimulate the economy of the 

country where the business is operating. 

The chlorine plant will be a significant step 

forward for Tanzania’s industrialisation 

efforts. The chlorine that will be produced 

by the plant will be used for disinfection 

and water treatment and is the basis for 

many industrial processes. With the help 

of this plant Tanzania will evolve from an 

importing to a self-sufficient exporting 

nation for these chemicals. “It is clear 

that there is enormous potential for the 

development of similar plants in Africa,” 

notes Nellessen. 

Oil and gas services company Serba 

Dinamik Holdings Bhd in a joint venture 

agreement with Junaco (T) Ltd. is 

responsible for the set up and running 

of the chlor-alkali plant. Janaco (T) Ltd. is 

part of the Junaco Group of Companies, 

a Tanzanian dynamic group with interest 

in varied businesses including water 

treatment, agriculture, technological 

solutions and logistical services. Junaco 

Group of Companies work in alliances 

and partnership with several world class 

manufacturers and service providers. 

Serba DInamik Holdings Bhd is taking up 

a 25% stake in a joint-venture company 

in Tanzania, Sufini Holding Ltd, a special 

purpose vehicle to hold 100% of equity in 

Msufini (T) Ltd, which in turn will own the 

plant directly and also provide assistance 

and support to Msufini. 

The ground-breaking ceremony took place 

in the Msufini area in Tanzania on Tuesday 

24th April 2018. 

About thyssenkrupp Industrial 

Solutions 

The Industrial Solutions business area at 

thyssenkrupp is a leading partner for the 

engineering, construction and service 

of industrial plants and systems. Based 

on more than 200 years of experience 

we supply tailored, turnkey plants 

and components for customers in the 

chemical, fertilizer, cement, mining and 

steel industries. As a system partner to the 

automotive, aerospace and naval sectors 

we develop highly specialized solutions to 

meet the individual requirements of our 

customers. More than 21,000 employees 

at over 70 locations form a global network 

with a technology portfolio that guarantees 

maximum productivity and cost-efficiency. 

For more information visit: 

www.thyssenkrupp-industrial-solutions.co.za 

Contact: 

thyssenkrupp Industrial Solutions 

(South Africa) 

Kgothatso Ntsie 

Marketing & Communications 

Tel: +27 11 236-1000 

Fax: +27 11 236-1125 

Email: kgothatso.ntsie@thyssenkrupp.com 

Company blog: https://engineered. 

thyssenkrupp.com 

22

TWICE AS EASY 

On the safe side with differential pressure measurement 

Pressure vessels and process tanks have to 

meet high safety requirements. Continuous 

monitoring of the differential pressure plays 

a major role in minimizing the risks from 

hazards such as excess pressure, leaks or 

dust-explosive substances. VEGABAR series 

80 pressure transmitters have proven to be 

The process pressure 

transmitter VEGABAR 82 

with oil-free, ceramiccapacitive 

CERTEC® 

measuring cell. Its most 

outstanding features 

are high abrasion and 

overload resistance as 

well as self-monitoring 

of the measuring cell. 

very effective for this task. And the method is 

simple: just put two of them together. 

Thanks to innovative technology, two 

of these pressure gauges can be quickly 

transformed into a perfect electronic 

differential pressure system. Two sensors 

of the VEGABAR series 80 determine the 

process pressure with the help of two 

measured values: the tank pressure and the 

total pressure resulting from the pressure 

of the medium and the overpressure. The 

user can simply take a pressure transmitter 

from stock, order another identical sensor 

with electronics version “slave” and have an 

electronic differential pressure system up 

and running in a jiffy. 

As opposed to conventional differential 

pressure systems, electronic differential 

pressure measurement with VEGABAR 

series 80 is not affected by the ambient 

temperature or strong vibration. And it has 

another impressive feature: in the version 

with oil-free ceramic CERTEC® measuring 

cell, the pressure transmitter is completely 

resistant to temperature shocks. In fact, this 

extremely high overload resistance factor 

of 200 can be found nowhere else on the 

market. Its simple operation based on the 

proven instrument platform plics® and 

optional “second line of defense” make it 

the ideal solution for differential pressure 

measurement. 

More information at www.vega.com 

BMG EXTENDS EATON RANGE OF WINNER HOSE TO 

INCLUDE 4S 6S SPIRAL HOSE AND HOSE FITTINGS 

BMG has extended its range of Eaton 

Winner hose and fittings to include 

Eaton’s latest generation of 4S/6S spiral 

hose and hose fittings, designed for use 

in high pressure hydraulic systems used 

in mobile machinery and equipment. 

“This new series of spiral hose fittings 

incorporates major technological 

advancements in fitting design, that provides 

a high-performing spiral hose assembly for 

the most demanding applications,” explains 

David Dyce, business unit manager, Fluid 

Technology, BMG. “Three outstanding features 

of this recently-launched range include the 

elimination of cool-down leakage, advanced 

metal fitting corrosion protection and a simple, 

user-friendly hose fitting assembly process. 

“Extreme care must be taken in the correct 

selection, assembly, installation and 

maintenance of hose and hose fittings. It 

can be highly dangerous if hose assemblies 

are misapplied and if inadequate attention 

is given to the maintenance of the hose and 

related equipment.” 

These new Eaton 4S/6S hose assemblies - 

which refer to the 4-spiral and 6-spiral wire 

reinforcement of the hose approved with 

respective 4S and 6S series fittings - exceeds 

stringent industry specifications. 

Eaton’s DURA-SEAL technology eliminates 

hose assembly cool-down leakage, thus 

reducing equipment downtime and 

extending life of the hose assembly. DURA- 

KOTE plating technology offers over 1 000 

hours of corrosion protection on carbon steel 

fittings, which is three times the corrosion 

protection of competitive hose fittings. 

The MatchMate hose/fitting identification 

system helps the assembler of spiral hose 

and hose fittings to quickly and easily 

identify the correct hose and hose fitting to 

be crimped together. 

This system not only enhances reliability 

and safety of the product, but also reduces 

wastage from assembling the wrong hose 

and fitting. 

Eaton 4S/6S hose is designed for applications 

that include high pressure hydraulic systems, 

petroleum and water-based fluids, as well 

as construction and agriculture equipment. 

This range consists of a synthetic rubber 

tube and cover with 4 and 6-spiral wire 

reinforcement. An ink transfer layline in this 

series is standard. Matching hose and hose 

ends reduce the chance of assembly error. 

Other products available from BMG’s 

fluid technology division include valves, 

accumulators, cylinders, heat exchangers, 

hydraulic motors and hydraulic plumbing, 

pumps and reservoir accessories. 

The company’s fluid technology services 

encompass project engineering and 

consulting, cylinder design and manufacture, 

hydraulic training, repair and testing and 

onsite container services. 

For further information: 

David Dyce, Business Unit Manager, Fluid 

Technology, BMG 

Tel: +27 11 620 1530 

Email: daviddy@bmgworld.net 

JP Steyn, Product Manager, Hoses and 

Fittings, BMG 

Tel: +27 11 620 7538 

Email: jps@bmgworld.net 

Web: www.bmgworld.net 

23

Pty (Ltd) 

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DESIGN & FABRICATION OF PIPING, COMPENSATORS & VALVES 

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(THE ONLY MANUFACTURER IN SA TO FULLY COMPLY WITH THE MSS SP 58 & 69 CODE) 

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24 

With dedication, attention to the fine details and a true focus on our customer’s needs. You are reassured that 

doing business with us will be a true breath of fresh air. With over 70 years of industry experience, both in 

light to medium fabrication & heavy engineering, come an understanding of what it take to get the job done 

right the first time. 

Join the wave of companies that believe in what we do & how we go about our business dealings. Taking 

advantage of highly skilled labour, expert technical know-how, Machining, NDT services & our ability to 

contribute to our customer solutions, makes us at K5Mzansi, the best in all our industries to get the job done. 

Mzansi Fabrication & Welding Pty (Ltd) 

2 Murray Road 011 825 0254 

Wadeville, Germiston 

info@mzansifw.co.za 

K5 Mzansi Pty (Ltd) 

Johannesburg 1422 

www.mzansifw.co.za 

Tel: 087 160 0262/082 807 4261 Email: sales@k5mzansi.co.za Web: www.k5mzansi.co.za

UNDERSTANDING THE EFFECTS OF PULSATIONS ON GAS FLOW 

A measurement problem that is mostly undetected with serious consequences for the user is that 

caused by pulsation flow. It is, therefore, important to grasp the effects of pulsations on gas flow 

meters to be able to formulate control techniques to effectively mitigate pulsation effects. 

24 

To clearly explain the 

effects of pulsations 

on gas flow metering, 

Hendrik van Huyssteen, 

Managing Director of 

Energas Technologies, 

a leading supplier of 

high-end and specialised 

equipment to the oil 

and gas industries in 

Southern Africa, cites a 

closer-to-home instance. 

He says that natural gas 

from Mozambique, for 

instance, is supplied in 

Gauteng, South Africa, 

through a network 

of distribution and 

reticulation pipework. 

He notes that the American Gas Association 

gives recommendations for installation 

of flow meters to minimise the negative 

effect of line conditions that could result in 

metering errors such as non-uniform flow 

and swirl along the distribution pipework. 

However, the installation requirements 

cannot compensate for the effect of 

pulsations in the line. Pulsations can be 

caused by piston compressors, often used 

to increase the pressure of the gas as in 

Compressed Natural Gas (CNG) applications. 

“Custody certified meters used here must 

have errors not more than +/- 1% when 

compared to a certified master meter,” notes 

Van Huyssteen. “Such meters are equipped 

with volume correctors which calculate 

totalised gas flow corrected to standard 

pressure (101.325 kPA) and temperature (15 

°C) and compensate for the compressibility 

of gas.” 

The types of meters used and ranges at 

typical operating pressures used in the 

industry are: 

• Diaphragm meters for small flow rates less 

than 16 Sm3/h at 50 kPa 

• Positive displacement meters up to about 

1500 Sm3/h at 100 kPa 

• Turbine meters up to 200 000 Sm3/h at 

3000 kPa 

• Ultrasonic meters in excess of 500 000 

Sm3/h at 3000 kPa 

Diaphragm meters for small flow rates. 

Pulsating gas flow 

In turbine meters, for example, pulsating 

gas flow causes a cyclical slowing and 

speeding of the main rotor. This can result 

in considerable over-reading of the meter, 

resulting in the client being billed for much 

more than the gas used. 

“Most meter types are adversely affected 

by pulsations. A pulsation is a periodic 

fluctuation in local pressure and velocity 

that occurs throughout a piping system or 

network. Pulsations typically move through 

a piping system as travelling waves. The 

travelling waves can be effected by closed 

and open ends of a piping network,” explains 

Van Huyssteen, adding that pulsating gas 

flow can cause severe damage to pressure 

components and supports in the pipework 

and should, therefore, be minimised. 

Pulsation dampeners 

To reduce the effect of pulsations, pulsation 

dampeners could be installed at inlet and 

outlet of reciprocating compressors. A 

well designed pulsation dampener would 

consider the frequency of pulsations, 

design pressure, gas properties and the 

pipe network lay-out. The pulse frequency 

is determined by the number of pistons and 

the rotating speed of the compressor. 

“The pulsation dampener is a pressure vessel 

with a series of carefully positioned baffle 

plates. The pulsation dampener must be 

designed for the line 

pressure and temperature 

and comply with the PER 

requirements,” says Van 

Huyssteen. “Normally, it 

is recommend to put the 

dampener as close to the 

compressor as possible, 

to avoid resonances in 

the pipeline. In a case 

where you have two 

compressors, it would be 

safer to put a dampener 

on each compressor.” 

Using one dampener 

with two compressors 

will work from a 

mathematical standpoint, 

but you have to connect 

it further from the pulsation source, which 

risks having a harmonic length of pipe in the 

line before the dampener. 

The pulsation dampener reduces the 

amplitude of the pulsation as it travels 

through the vessel. The reduction is 

dependent on the frequency and can be 

reduced by as much as 97%. 

Auto-Adjust Turbine meters 

The AGA report No. 7 notes that pulsations 

cause a positive error in turbine meter output 

that is dependent on pulsation velocity 

amplitude at the meter, flow rate, gas density 

and meter and pulsation properties. This 

error can be as large as 50%. 

According to Van Huyssteen, the Auto-Adjust 

Turbine (AAT) meter supplied by Sensus is 

the only one of its nature that can detect 

and compensate for pulsating flow. Energas 

Technologies is the sole representative of 

Sensus Meters in South Africa. Energas has 

supplied AAT meters to the local natural gas 

industry since 2001. 

“The AAT meter has two rotors, a main 

rotor and a second sensing rotor, typically 

running at 10% of the speed of the main 

rotor,” he explains. “The speed of the rotors 

is monitored by a special volume corrector 

using complex algorithms. Any deviations of 

accuracy relative to the originally calibrated 

accuracy are detected and displayed.”

Inaccuracies at the meter could be due to 

various conditions such as bearing failure, 

dirt build up in the meter, swirl of the gas 

after bends, pulsations or non-uniform flow. 

The meter can compensate 100% for these 

deviations up to deviations of 5% of the 

correct flow rate. 

“Even small deviations in accuracy of as little 

as 0,2% could result in losses of millions 

of Rands for large meters over a 12 month 

period. A new meter must be supplied with 

a factory calibration certificate, showing the 

meter is accurate to 99% or better over the 

meter’s operating range. To achieve higher 

accuracies, meters in high pressure gas 

applications are often tested at the specified 

operating pressure,” says Van Huyssteen. 

With a normal single rotor turbine meter, 

pipeline disturbances, bearing drag or dirt 

is not detected once the meter is in the line. 

As meters are recalibrated typically once 

in two years or longer, meter problems are 

not detected and meter inaccuracies goes 

undetected for up to a period of two years. 

“The AAT meter solves this problem by 

showing a delta A, a deviation relative to the 

original calibration from the moment it is 

first operated. Deviations can be investigated 

immediately. As long as the delta A stays 

below 5%, the meter technically does not 

need to be recalibrated,” concludes Van 

Huyssteen. 

Energas Technologies contact: 

Laetitia Botha 

Tel: +27 (0)11 397 6809 

Email: laetitia@energas.co.za 

Web: www.energas.co.za 

The African Petrochemical Roadshow offers a diagonal slice of the industry, 

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Generation sectors. This show includes Instrumentation and Control, Health and 

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25

2 x Rapid Allweiler ANSI 495 1.5x3 13 pumps. 

RAPID ALLWEILER PUMPS LANDS 

ANSI HEAVY DUTY PROCESS PUMP 

CONTRACTS 

In January and September 2017, due to our short 

quotation and delivery times, first-class technical 

team, product quality and excellent aftersales services, 

Rapid Allweiler Pumps were awarded the contract for 

the supply of ANSI pumps for both phases of a new 

fertiliser production plant in Gauteng. Rapid Allweiler’s 

technical team was responsible for the correct pump 

selections for the various applications and our in-house 

foundry and manufacturing factory for the complete 

manufacture of the pumps and bases and the assembly 

and supply of the full pump sets. 

For the 1st phase of the project, due to all the 

chemical pumping applications operating 

at ambient temperature, the selected pump 

material was 316 stainless steel. From the 

duties supplied by the client, Rapid Allweiler 

selected and supplied the following full 

pump sets: 

• 2 x ANSI 495 1x2/10 

• 4 x ANSI 495 1.5x3/13 

Following installation and commissioning, 

no problems with any of the pumps were 

encountered and after more than one year 

of operation, the Rapid Allweiler ANSI pumps 

are still operating at design duties. 

26 

Because of the service and success of the 1st 

phase of the project, Rapid Allweiler Pumps 

was selected, during the second half of 2017, 

as the supplier of choice for the ANSI pumps 

for the 2nd phase of the project. For this 

phase the chemical pumping applications 

were all to be operated at temperatures 

exceeding 100˚C and for this reason Rapid 

Allweiler’s technical team selected CD4 

Rapid Allweiler ANSI 495 1.5x3 13 pump.

MCU (duplex stainless steel) as the material 

of manufacture, due to its good corrosion 

resistance at high temperatures. From the 

client supplied duties the Rapid Allweiler 

team selected and supplied 4 x ANSI 495 

2x3/13 full pump sets. 

Following installation and commissioning of 

the pumps, the client noticed that two of the 

pumps were leaking through the mechanical 

seal. The Rapid Allweiler technical team 

identified the following problems: 

• The pump suction pipelines had been 

installed incorrectly causing cavitation and 

water hammer; and 

• The auxiliary flushing pump (not Rapid 

Allweiler selected or supplied), used for 

continual flushing of the primary pump 

seals to prevent crystallisation of the 

chemicals being pumped, had been 

incorrectly specified and was not causing a 

positive pressure differential on the seal. 

After the suction pipelines had been 

correctly installed and a new auxiliary 

flushing pump (this time specified by Rapid) 

was installed, these problems were rectified. 

Rapid Allweiler supplied and installed 

replacement mechanical seals and no 

further problems were encountered. After 

more than 6 months of operation, these 

pumps continue to operate problem free at 

design duties. 

Once again proving that for the past 85 years, 

Rapid Allweiler Pumps has been and is your 

pump solution provider of choice. 

For more information on Rapid Allweiler 

Pumps, including our in-house stainless steel 

and SG iron foundry, our manufacturing 

factory, our pump repair centre, our pump 

test bay and the various services offered 

Rapid Allweiler ANSI 495 2x3 13 pump. 

by our technical teams and field-service 

installation, alignment and maintenance 

teams, please contact us or visit our website. 

Contact: 

Tel: 08600 RAPID 

Email: solutions@rapidallweiler.co.za 

Web: www.rapidallweiler.co.za 

CHEMICAL PROCESS PUMPS 

ANSI 

• Semi open impeller 

• Handle solids up to 25mm 

• Back pull out feature 

• Horizontal suction and Vertical discharge 

• Suitable for standard & heavy duty 

applications 

ANSI 

CLT 

CLB 

RA PUMP 

RANGE 

MINIMUM 

FLOW (m 3 /h) 

MAXIMUM 

FLOW (m 3 /h) 

MINIMUM 

HEAD (m) 

MAXIMUM 

HEAD (m) 

MAXIMUM 

TEMPERATURE 

ANSI 2 900 3 140 260˚C 

CLT 2 1050 3 140 180˚C 

CLB 2 450 3 140 180˚C 

CLT & CLB 

• High interchangeability of parts 

• Suitable for clean liquids & highly aggressive 

chemicals 

• Excellent hydraulic performance with low N.P.S.H 

required values 

Est. 1932 

• Horizontal suction and Vertical discharge 

• Standard flanges conform to DIN 2543 PN16 

• The wet end components made out of high grade 

Cast Stainless Steel 

• The entire range offers a high interchangeability, 

thus reducing spares stock holding 

08600 RAPID 

www.rapidallweiler.co.za 

27

NEW MICRO PLC CAN REDUCE COMPLEXITY OF LARGE STANDALONE MACHINES 

Allen-Bradley Micro870 PLC, new 

flagship of Micro800 family, can be used 

in place of multiple micro PLCs 

Machine designers can use a new micro 

programmable logic controller (PLC) to help 

optimise the control architecture in large 

standalone machines or systems. The new 

Allen-Bradley Micro870 PLC can support 

smart micro applications that require up to 

304 I/O points, 280 KB of memory and 20 000 

program instructions. 

“Designers today use several PLC sizes for 

their automation projects” said Christo 

Buys, Business Manager – Control Systems, 

Rockwell Automation Sub-Saharan 

Africa. “This approach requires inventory 

management of the different PLC sizes and 

maintenance of different programs. Now 

designers can use the Micro870 PLC to scale 

their controller to their application needs. 

This helps simplify inventory management, 

especially for those designing multiple 

machine types.” 

The Micro870 PLC uses a flexible design 

concept that provides designers up to 

three plug-ins and eight expansion I/O 

modules. This capability allows them to easily 

customise or expand the controller to meet 

each machine type’s unique requirements. 

The controller’s 280 KB memory capacity 

supports modular programming and the 

use of user-defined function blocks to help 

reduce design time. Additionally, machine 

builders can use this memory capacity to 

maintain a single program for all machine 

models that use the Micro870 PLC. 

The controller communicates via EtherNet/ 

IP and includes multiple embedded 

communications options, including a USB 

programming port, a non-isolated serial port 

and an Ethernet port. It can also support up 

to two axes of motion. 

drives, Kinetix component servo drives, 

electronic overload relays, light curtains and 

configurable safety relays. This feature can 

save engineers time and costs compared with 

using another programming tool for each 

device in a system. 

A new conversion tool in version 11 makes it 

easier for MicroLogix customers to upgrade 

to the Micro800 controller family. In addition, 

version 11 allows Encompass members of 

the PartnerNetwork program to help ease 

configuration of complementary third-party 

products via graphical configuration profiles. 

These profiles support the Micro800 plug-ins 

as well as expansion I/O to help make the 

configuration process faster and more accurate. 

About the Rockwell Automation 

PartnerNetwork Program 

The Rockwell Automation PartnerNetwork 

program offers global manufacturers 

access to a collaborative network of 

companies mutually focused on developing, 

implementing and supporting best-in-breed 

solutions to achieve plant-wide optimisation, 

improve machine performance and meet 

sustainability objectives. 










Enquiries: 

Christo Buys 



Tel: 011 654 9700 


Web: https://www.rockwellautomation.com 

28 

The new Connected Components Workbench 

software version 11 provides a single 

design environment for programming the 

Micro870 PLC. The software can also be 

used to configure Allen-Bradley PanelView 

800 graphic terminals, PowerFlex AC 

The new Allen-Bradley Micro870 PLC can support smart micro applications that require up to 304 I/O 

points, 280 KB of memory and 20 000 program instructions.

FLUKE’S BATTERY ANALYZER INCREASES ACCURACY, SAFETY - REDUCES TEST TIME 

To help ensure reliability, stationary batteries need to 

be maintained and tested regularly. Even “maintenance 

free” batteries require regular testing because they can 

deteriorate over time. All it takes is one battery in the 

string to fail to take the entire string off-line. One bad 

battery will affect the usable life of adjacent batteries 

by raising their charge voltage. Worse still, a battery 

or interconnect with a high impedance could overheat, 

ignite, or explode during a discharge. In addition 

to providing backup power, stationary batteries are 

increasingly used to store renewable energy, such as 

solar and wind. Those batteries are subject to the same 

potential degradation and need to be tested regularly. 

FLUKE 500 Series Battery Analyzer comes with shoulder strap, and 

magnetic hanger for hands-free operation. 

While battery testers have been around for 

quite a while, recently Fluke noticed a gap 

between what was available and what was 

needed to effectively test stationary battery 

systems. Most of the battery testers on the 

market had either no CAT rating or a low 

CAT rating, and so Fluke developed a battery 

analyzer that is not only more efficient but 

also has a CAT III safety rating. 

Fluke had the advantage of being able to 

develop their battery analyzers from the 

ground up to address the requirements 

of the IEEE Standard 1188, which was 

established in 2005 after most other battery 

analyzers on the market had been developed. 

This standard governs maintenance, test 

schedules, and testing procedures for 

optimizing the life and performance of 

stationary batteries. Fluke started with the 

IEEE standard and then made those tests 

safer, resulting in the development of Fluke® 

500 Series Battery Analyzers. 

The Fluke 500 Series is intuitive and 

specifically designed for measuring all kinds 

of stationary batteries, including GEL, AGM 

(absorbed glass MAT), lithium-ion, and wetcell 

lead-acid. The 500 Series analyzers offer 

improved impedance test performance even 

in high-ripple environments. The intuitive 

user interface and intelligent test probes 

simplify the testing process by guiding 

technicians quickly through setups. The 

result is reduced measurement complexity 

and cost, and increased accuracy, safety, and 

operational efficiency. 

Multiple tests at the same time 

All three Fluke 500 Series Battery Analyzers— 

the BT 510/520/521—offer a broad 

range of battery test functions including 

simultaneously measuring DC voltage while 

testing internal resistance, and full condition 

testing using automated string function 

testing. 

The Fluke BT520 and BT521 include an 

Intelligent Test Probe with an integrated 

LCD display that shows measurements 

right on the probe. Measurements can be 

captured automatically in sequence mode 

or manually by pressing the save button on 

the probe. The LCD display indicates that the 

measurement has been taken and saved and 

uses audible voice cues to indicate which 

measurements in the sequence have been 

made. The voice count battery ID identifies 

which battery is being testing to help keep 

track of progress, especially handy when 

testing a long string of batteries. 

The BTL21 Intelligent Probe on the BT521 

analyzer adds an infrared temperature sensor 

to measure temperature and up to two other 

data points simultaneously—1000VDC, 

600VAC, and ripple— to provide a more 

complete view of battery health. 

All models also include: 

• Ergonomic two-prong test lead probes 

with a kelvin connection to ensure 

resistance measurement accuracy 

• Replaceable tips to extend test lead life and 

further reduce the cost of ownership 

• Long reach test probe extenders for 

testing double stacked battery cells 

Easy analysis and reporting 

When testing is finished testing, the 

battery analyzer can be plugged 

into a PC via the USB port and 

measurements are exported using 

Fluke Battery Management Software, 

so that users can easily compare results, 

analyze trends, and generate battery analysis 

reports. 

In addition to simplifying testing, the Fluke 

Series 500 analyzers offer several ergonomic 

features for easy handling: 

• compact design and rugged construction 

• smart lithium-ion battery delivers more 

than eight hours of continuous operation. 

View the battery charge status via built-in 

LEDs. 

• shoulder strap, belt strap, and magnetic 

hanger to provide hands-free operation. 

Applications for the Fluke 500 battery analyser 

are for maintenance, troubleshooting, or 

performance testing on individual stationary 

batteries or battery banks. 

For more information: 

on Fluke 500 Series Battery Analyzers, or 

information about seminars, demos or to 

locate the nearest dealer, 

please contact Comtest 

Tel: 010 595 1821 

Email: sales@comtest.co.za 

FLUKE BT521 test probes include an 

integrated temperature sensor. 

29 

29

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30

VALVE COMPANY 

CELEBRATES 20 

YEARS SUPPLY OF 

BUTTERFLY VALVES 

IN SOUTH AFRICA. 

Valve group, TTV Fluval, founded by Frank Olsen in 1998 is celebrating 20 

successful years of business in South Africa. The company was originally 

established with only one valve manufacturing brand, TTV butterfly valves 

of Spain. Today TTV Fluval offer a wide range of valves and valve actuation 

products. These include Fluval valves Spain, Pekos ball valves Spain, TTV 

pneumatic actuators, Ontrac electric actuators, china, Power Genex positioners, 

korea, Fritz Barthel Marine Valves & samplers Germany. 

30 

Over the years TTV butterfly valves have continuously shown 

improvements in R&D, quality and support for this sought after 

mechanical product. Butterfly valves are versatile, group CEO Olsen 

explains. They are used for isolating or regulating flow. The valve body 

is full bore to the pipe diameter with the closing mechanism in the form 

of a disc. Even in the open position the valve disc is always present in 

the flow. TTV’s design on the elastomer valves, has a shaft with a spline 

drive to the disc, this ensures that the flow media is only in contact with 

the valve liner, elastomer and the valve disc, substantially reducing 

corrosion as the media is never in contact with the valve shaft or body. 

The sealing arrangement coming from the disc seating resiliently into 

the rubber elastomer. The disc is actuated via the shaft from a hand 

lever, gear operator or actuator. TTV manufacture a cast body in a wide 

variety of material from cast iron to alloys. The cast iron and ductile iron 

body comes in a coating of epoxy or Rilsan nylon for protection of the 

surrounding elements. The technology of the elastomer seating has 

been the most noticeable improvement over the past 50 years. New 

materials driven by industry demands, to handle severe services such 

as abrasion and corrosion resistance, higher temperatures and pressure 

of the process and mining applications. Butterfly valves are used in all 

industries today including, mining, oil & gas, petrochemical process, 

power generation, solar, water and desalination, food & beverage, 

marine, naval and shipbuilding industries, 

We offer the full range of TTV butterfly valves, from concentric 

design, (zero off-set), elastomer lined wafer type low pressure general 

industrial valves, mining hi- abrasion resistant polyurethane lined 

and PTFE for high chemical resistance. These are light weight valves, 

economical to install and service. The concentric design named 

from the assembly arrangement of the valve shaft and disc all being 

centralised in the valve body and bore. The valve liners are replaceable 

and interchangeable. All butterfly valves are quarter-turn from shutoff 

to fully open making automation simple and cost effective. The most 

popular basic butterfly valve supplied in South Africa is a wafer body 

design in pressure rating pn10 and pn16 the simplistic design is the 

success of this valve. 

TTV also supply a double eccentric design butterfly valve for higher 

pressures, this design incorporates 2 offsets giving these valves their 

name. One offset between the shaft and the valve body, the second 

offset between the valve shaft and disc to the valve bore. This design 

reduces the resistance between the valve seating, prolonging valve 

life. We manufacture these butterfly valves in various materials, 

ductile iron, carbon steel, stainless steel, bronze and alloys. TTV’s 

latest design double eccentric valve branded “Colossus” has an 

interchangeable metal seat ring in 316 stainless steel and a PTFE seat 

ring. This giving the customer an option of metal seated or soft seated 

double eccentric valve with a short delivery time. 

TTV Fluvals’ High- performance valve for severe service, (harshest 

conditions of critical process) and sealing requirements, is a triple 

eccentric butterfly valve. This design incorporates a third offset, the 

axis of the seat cone angle is offset from the valve centreline bore. 

This provides an uninterrupted valve sealing surface, improves cycle 

life and 100% tight sealing in both directions. The break torque off 

the valve seat is vastly reduced, making the actuation size smaller 

thereby reducing cost of automation. These valves can handle high 

temperatures and pressures with low fugitive emission design. The 

metal seat ring is easily replaced making servicing inexpensive on 

these valves. They use both laminated metal seat and solid seat design. 

Olsen explains that the success over the years of butterfly valves can 

be summarised to these facts: they are compact, easily installed with 

less pipe support required. They have bi-directional sealing, zero 

leakage, quarter turn design making automation simple, cost savings, 

versatile design to include fire safe, elastomer and metal seated. The 

valve body design offers compact wafer, lugged & flanged type for 

end of line service.

MONITRAN’S COMPACT HAND-HELD 

VIBRATION METER 

m3⁄h 

l/h 

fact 

m/s 

Liquid flow measurement 

up to 600 °C or 490 bar 

OPTISONIC 4400 – 

technology driven by KROHNE 

Instrotech is offering the Monitran’s MTN/VM220, a 

compact, handheld meter for measuring vibration levels. 

It is a rechargeable, portable instrument designed to 

operate with a constant current accelerometer to provide 

accurate vibration measurements. Conforming to 

ISO10816-3, the MTN/VM220 is engineered to detecting 

the early signs of component wear or failure in pumps, 

motors, gearboxes and other mechanical assemblies. 

Measuring only 130 x 78 x 28mm, the MTN/VM220 has an 

easy-grip, rubberised case and a long-life rechargeable battery 

and had the ability to store up to 100 time-stamped readings, 

including; RMS, peak, peak-peak, crest factor and bearing 

conditions, all on an easy-to-read, colour LCD display. 

• Ultrasonic flowmeter for 

high temperature and high pressure 

liquids, e. g. in vacuum distillation, 

visbreaking or coker unit 

• HT version: 45…+600 °C, 

DN25…1000 

• HP version: ≤490 bar, DN25…200 

• Flow range 0,5…20 m/s, 

bi-directional 

• Communication options 

with NAMUR NE 107 diagnostics 

The unit is shipped in a foam-lined, durable carry case and 

includes the MTN/2200, a general purpose sensor probe with 

a default sensitivity of 100mV/g, as well as a magnetic base 

and spike (for use with the probe), a coiled cable with a 4-pin 

Lumberg connector at each end, and a universal battery 

charger. 

Monitran is a world leader in the design, development 

and manufacture of sensors and systems for vibration and 

displacement measurement. 

For more information: 

on Monitran’s MTN/VM220 vibration meter, contact the 

Instrotech team 

Tel: 010 595 1831 

Email: sales@instrotech.co.za. 

KROHNE South Africa 

8 Bushbuck Close, Corporate Park South 

Randjiespark, Midrand, Tel.: +27 113141391 

Fax: +27 113141681, Deon Rampathi, 

d.rampathi@krohne.com, www.za.krohne.com 

31

MARITIME WEEK AFRICA 

9-13 JULY 2018 • ACCRA, GHANA 

THE LEADING EMEA FOCUSED BUNKER CONFERENCE, 

CELEBRATING ITS 10 TH YEAR! 

This hugely successful event, taking place at the 

Labadi Beach Hotel, benefits from consistent 

attendance from 196 bunker industry firms from 

the Far East, Europe, the Middle East and all 

across the African continent. 

All who attend will enjoy a first-class Oil and 

Shipping Conference, training programmes 

(where desired) and numerous networking events 

to cement existing relationships and discover new 

business contacts and opportunities. 

In addition to the one and a half day Oil & 

Shipping Conference, Petrospot Limited will 

also be conducting our new Bunker Trading & 

Operations Course from Wednesday 11th to 

Thursday 12th of July 2018. 

SPONSORED BY 

With the programme almost finalised, we are 

excited to share with you our key topics: 

• EMEA shipping and bunkering overview 

• EMEA bunker availability and quality 

• West Africa session 

• How will 2020 impact on suppliers and 

traders? 

• How are fuel buyers in the region preparing 

for the global sulphur cap? 

• Legal and regulatory bunker market 

overview 

PLATINUM GOLD ASSOCIATED ENDORSED BY 

MEDIA PARTNERS 

32 

For more information contact our sales team on +44 1295 814455 or sales@petrospot.com 

www.maritimeweekafrica.com

CAPITALISING ON BIG DATA AND ANALYTICS FOR IMPROVED OPERATIONS 

Enhancing shareholder value, changing the way businesses 

operate and compete, and obtaining real-time insight into 

consumers, risks, profit, performance, and productivity 

management are all core elements of ‘big data’ and analytics, 

a digital enterprise capability from Advisian, WorleyParsons’ 

global advisory business. 

Mohamed Madhi, Managing Director of Advisian SSA, says that 

the company’s big data and analytics capability provides more 

certainty to clients than ever before by tapping into every possible 

source of data available. 

A relatively new concept to southern Africa, big data and analytics 

can be applied to both new and existing operations in many 

sectors of industry. Madhi says that it will prove highly beneficial 

particularly to the power generation sector where data such as 

billing and usage information, and digital technology such as 

smart meters, allows better understanding of load patterns to 

optimise operations. 

Big data and analytics relies on tapping into as much raw data as 

possible, comprehensively analysing the data and then capitalising 

on it, thus allowing commercial enterprises to optimise their 

operations and become more cost effective. Digital technology is 

used to generate, store and process data while digitalisation then 

uses this information to create value for the organisation. 

By processing big data, digitisation and advanced analytics can 

be used to create virtual plants, access real-time market data to 

manage operational schedules, and plan and optimise production 

while simultaneously improving monitoring and control. 

Big data solutions include real-time monitoring to help identify 

abnormal conditions as they arise; providing real-time status 

updates to stakeholders; looking at alternate ways of organising, 

distributing and transacting units of value through a block chain 

approach; and smart optimisations such as smart grid power 

utilities that can predict demand by location and segment their 

customers accordingly using smart meters and analytical solutions. 

“Before the benefits of big data analysis can be realised, 

comprehensive and effective data mapping is required. Advisian 

assists companies in understanding how to tap into and use the 

big data concept by developing a comprehensive map of all data 

flows available,” explains Madhi. “The next step identifies data 

gaps throughout all operations before sensing, monitoring and 

recording all data flows. The final stage is capitalising on data 

analytics to improve operations.” 

He adds that detailed data mapping and identifying data gaps 

assists in optimally matching operational supply with customer 

demand, while the ability to sense, monitor and record data 

flows has recently become more readily attainable through 

advancements in technology and digitalisation. 

“The latest sensor technology makes previously unobtainable 

information readily available as sensors can now be placed 

in hostile and volatile environments such as those with high 

temperatures or high pressures for example, while fast-paced 

innovation in connectivity and social platforms allows marketrelated 

data such as user habits and usage demands to be 

relatively easily obtained.” 

“As smart and connected equipment becomes the norm and new 

sensor-based features become available, adapting technology 

infrastructure becomes critical for success, and this is where 

big data and the associated analytics are key to providing a 

competitive advantage,” says Madhi. 

Drawing on WorleyParsons’ global capabilities and resources, the 

big data and analytics capability was developed by Advisian’s 

global digital enterprise business line and offers large-scale data 

analysis to optimise future projects, and allows WorleyParsons to 

deliver and execute projects in a highly efficient way. 

Madhi says that while there are companies in the country offering 

statistical data analysis, Advisian is in the unique position of 

being able to offer a digital enterprise capability combined with 

engineering skills grounded in years of experience. 

Advisian provides consulting services focused on asset intensive 

business operating within the hydrocarbons, minerals and 

metals, chemicals, power and infrastructure sectors. The company 

focuses on harnessing the significant experience of their locally 

based teams with their strong global capabilities to provide their 

customers with access to world class capability across a wide 

range of industries and asset portfolios. 

33

DUAL-RANGE PRESSURE CALIBRATOR 

FOR GAS CUSTODY TRANSFER MEASUREMENTS 

IN INTRINSICALLY SAFE ENVIRONMENTS 

Comtest is offering Fluke ‘Ex’ Dual Range Pressure Calibrator for use in 

classified environments, offering ranges, accuracies and capabilities ideal 

for gas custody transfer measurements. 

The Fluke 721Ex, with IECEx and Atex Ex ia IIB T3 Gb (Zone 1) ratings, is available 

in 14 models and can be used with a Fluke 720RTD probe for temperature 

measurement. Fluke has also introduced 700 series pressure test hose and 

pump kits which minimise the difficulty and leaks when connecting a pressure 

calibrator or pump to a device under test. The quick installation, without the 

use of tools, increases efficiency, and saves time. These pressure accessories 

are a best-in-class set of premium hose and No Tools Required (NTR) pressure 

connection accessories. 

The rugged Fluke 721Ex Dual Range Pressure Calibrator, featuring two 

isolated, stainless steel, pressure sensors with accuracies to ±0.025% Full Scale, 

provides measurement of static pressure, difference in pressure and (optional) 

temperature of gas flow. The Fluke 721Ex is configured by choosing either a 

1.1bar or 2.48bar low-pressure sensor, together with one from seven highpressure 

ranges, including 6.9, 20, 24.5, 69, 103.4, 200, or 345 bar. The large 

backlit display will show two pressure readings and a temperature reading 

simultaneously. Up to five frequently used setups can be stored. 

The Fluke 721 Ex Precision Pressure Calibrator. 

Fluke 700 Pressure Calibration Test Kits introduce a family 

of pressure connection accessories to make the difficult 

task of making pneumatic and hydraulic pressure test 

connections easy and leak free. This family of accessories 

includes two special transmitter test hoses, the TTH5K and 

the TTH10K, providing No Tools Required connections 

between hand pumps or pressure transmitter to the 

standard IEC ¼” female input on most pressure transmitters 

worldwide. The 700MTH test hose is similar to the 700TTH 

but has a ¼” male metric hose termination rather than the 

¼” NPT male connection. The 700M20TH is intended for 

connection to female Chinese M20 process connections. 

The 700PTPK2 Pneumatic Test Pressure Kit and 700HTPK2 

Hydraulic Test Pressure Kit are premium versions of the 

standard 700PTPK and 700HTPK and add premium test 

hoses and a NTR connection to easily attach and remove 

700G test gauges or other devices with ¼” NPT male 

terminations. 

The Fluke 721Ex is supplied with a soft case offering 

storage for an RTD probe. 

For more information contact: 

The Comtest Team 

Tel: 010 595 1821 

E-mail: sales@comtest.co.za 

Subscription Services 

For address changes, subscriptions or missed editions, please email 

accounts@africanpetrochemicals.co.za 

or call 011 083 5125 

34

Please come register as a member for: 

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35

We build quality tanks 

Forgeweld manufactures and supplies a range of competitively 

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Tel no: +27 12 719 9052 | Email: info@forgeweld.com | Web: www.forgeweld.com 

36

African Petrochemicals May/June Edition 15.3 {2018}

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