Previously we considered the approach to energy efficiency [1]. In this article we review the role of energy efficiency policies.

Take note
•Enforcement of policy can lead to energy savings.
•Motors can be designed to be energy efficient at a cost.
•Careful assessment of initial costs and TCO is necessary to evaluate savings.

About the author
Constantin Danut Pitis holds an MSc in electrical engineering from the technical university of Jassy – Romania, a BSc degree in reliability of electronic components and installations, and a postgraduate diploma in rockets engineering. He is registered PrEng with ECSA and a member of the SAIEE and SAEE.
Contantin can be contacted on malali@telus.net.

Our South African manufacturing industry is in need of finding more and more ways of becoming internationally competitive. This article argues that the moving of materials and goods within a plant is an area that is very likely to provide fertile ground for efficiency improvement. We argue further that these efficiencies are to be found not only in the optimal movement of goods, but also in the technologies chosen to move those goods.

Take note:
•Roller-based conveyor systems cannot cope with steep slopes and sharp corners.
•Roller-based systems are modular, and expansion is simple – control is plug and play.
•Brushless dc motors are integrated into the roller, and autonomous motor operation allows optimal efficiency.
•Systems should be planned with the assistance of a knowledgeable organisation that can advise on how best to meet your needs.

About the author:
Wayne L Freel has gained extensive experience in materials handling and conveying principals by working for two international materials handling equipment manufacturers during the past 20 years. Wayne currently holds the position of sales director for Lilac Process Automation.
Wayne can be contacted on (011) 397 2800 or wayne@lpa.co.za.

There are many ways of measuring flow, but the calorimetric method allows very low flow rates to be detected. This also allows small changes to be detected, such as those associated with leaks.

Take note:
* The calorimetric principle compares two thermistor values.
* The energy used to balance the values is connected to a flow rate.
* Very small changes in flow are accurately detected.

About the author

Gunther Weber has his Dipl.Ing and holds the position of Chief Executive Officer of Weber Captor. Weber is locally represented by the Spero Group.
For more information locally contact snymans@spero.co.za.

Previously we emphasised the need for a rational approach to alarm management [1]. In this article we consider the prioritisation of alarms.

Take note:
• Safety integrity level determination is a risk-based assessment.
• A rational approach is to consider the maximum consequences method.
• Proper assessment requires a summation of the consequences in a rational way.

About the author:
Clive Timms has over 35 years experience in the petrochemical industry with offshore and onshore plant experience. He recently retired from Shell UK Exploration and Production where he was head of automation and control. He is now a director of Asset Integrity Management, which specialises in the application of the IEC 61508 and IEC 61511 standards, and was a founder director of the CASS scheme for conformity assessment to IEC 61508. He chaired the UKOOA working group that produced the UKOOA guidelines for instrument-based protective systems, as an offshore sector interpretation of IEC 61508. He has a BSc and MPhil in Control Engineering, is a member of the IEE and currently chairs the Institute of Measurement and Control Safety Panel.
Clive can be contacted at clive.timms@assetintegrity.co.uk.

South Africa needs its manufacturing industry to grow. Your products need to meet specific requirements. These requirements apply to medical equipment especially. Medical products must be engineered to an acceptable reliability and safety standard.

Take note:

• Medical equipment must comply with regulations and standards of safety that are amongst the strictest.
• When designing any product it is essential to be fully familiar with all relevant standards and regulations.
• When designing a product, failure modes should be considered and a risk identification process completed.
• Risk, once understood, can be effectively controlled.

About the author:
Terry Cousins is a director of Motswedi TLC Software and is responsible for product hardware development. Terry has a BSc (Electrical Engineering) from Wits and is a member of the SAIEE and the IEEE.
Terry can be contacted on terry@tlc.co.za.

This case study, like any DSM opportunity, experienced its fair share of ups and downs and frustrations despite being a well-researched, well-developed, well-motivated and ‘no risk’ fundable business case. Besides the inherent operational value of the technical opportunity the greatest impediment was in overcoming the negative human perceptions and scepticism to champion it at various levels within the client's institution. Failure to recognise this can lead to either a protracted or unsuccessful process.

Take note:

• DSM does work.
• A savings model must be developed.
• Final results should be compared to the predicted results.
• In this case, for a capital cost of R800 000,00, a saving of over R200 000,00 per year is being achieved.

About the author:
Gregory Diana is a senior lecturer at the School of Electrical and Electronic Engineering at the University of KwaZulu-Natal and leads the UKZN Measurement and Verification Team for Demand Side Management operations.
Gregory can be contacted on gdiana@ukzn.ac.za.

Temperature is a key condition indicator and is the most frequently made measurement. Temperature measurement indicates the state of ‘health’ of machinery and the human body. By periodically measuring these temperature indications we are able to set up a thermal profile which in turn allows us to predict an impending failure before it happens, thereby preventing the cost of downtime. This article looks at some older techniques of maintenance used and the benefits of predictive maintenance utilising thermography in industrial environments and the effect on revenue protection.

Take note:
•Temperature is a key condition indicator.
•Running equipment to failure is seldom a bright idea.
•Predictive maintenance is a condition driven preventive maintenance programme.
•Thermography is a non-contact technology that allows an assessment of the equipment condition.

About the author:
Brendan Campbell obtained his National Diploma in Microbiology and has been involved in the sales of Fluke industrial tools for the past eight years. Brendan has been with Comtest since the company was formed and is a qualified Level II Snell Infrared thermographer.
He can be contacted on bcampbell@comtest.co.za.

Confucius said that a thousand mile journey began with a single step and likewise a thousand mile journey eventually ends with a single step [1]. More than one birthday will have come and gone, not to mention anniversaries and other domestic rituals that have run their course, while one has slogged and slaved away on a plant’s design and construction, eventually reaching the milestone of plant start-up.

Take Note:
•Often, engineers still just lurk in the backroom.
•At the end of the day, the engineers either make or break a project.
•Let’s never forget all the other people involved.

Resume:
Bill Steenberg is a qualified industrial instrumentation mechanician and holds a National Technical Diploma in Industrial Instrumentation and Control Systems. He has 25 years experience in the chemical, petrochemical, mining and metallurgical process industries and is a freelance senior instrumentation engineer.
Bill can be contacted on 083 949 8104.