Endress+Hauser magazine
8 In the molecular realmThe youngest member of the Endress+Hauser Group brings plenty of specialist knowledge into the fold.
10 Curtain up! The new Liquiline System CA8O analyser platform combines top precision with easy operation.
4 Main Feature
wazzupwww.za.endress.com Edition 1/2015
Analytics in red and blue
Contents
10 Curtain Up! 16 Universal Training Rig4 Main Feature
The new Liquiline System CA8O analyser platform combines top precision with easy operation and maintenance. The first of many: the CA80AM ammonium analyser.
Africa Automation Fair at the Coca Cola Dome in May features the brand new 1.8 million ZAR Universal Training Rig (UTR).
Analysis in red and blue4
Endress+Hauser is strengthening its analytics business on a broad scale.
Curtain Up!
A crystal masterpiece
Maintenance made easy
Talking water with Hennie
Analysis in simple terms
Temperature Training
E-business
Universal Training Rig
Prepared for everything
Quadruple knowledge of analytics
The Power of Light
In the moleculer realm
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To produce a medicine, a customer needs to process an active ingredient into the right molecular arrangement.
How is maintenance actually supposed to be performed on Liquiline System CA80 and what parts are used for this?
Spectroscopy technology simplifies materials analysis while creating totally new ways to control and monitor processes.
Kaiser Optical Systems is a world market leader in Raman spectroscopy.
The new sample preparations of the Liquiline System product family enable optimised sampling for CA80 analysers - and they do so under a wide variety of process conditions.
A modular system that can be used to easily optimise the different processes in a wastewater treatment plant.
In this issue: Colorimetric measuring principle and optical turbidity measurement.
Understanding of temperature measurement principles and sensor selection.
A not to be missed feature being introduced on the Endress + Hauser stand on the Africa Automation Fair at the Coca Cola Dome in May is the brand new 1.8 million ZAR Universal Training Rig (UTR).
Africa Automation Fair
Endress+Hauser›s exclusive E-direct product range positions itself as a cost effective solution to the process environment.
The new Liquiline System CA8O analyser platform combines top precision with easy operation and maintenance. The first of many: the CA80AM ammonium analyser. • Endress+Hauser Conducta
• SpectraSensors • Kaiser Optical Systems • AnalytikJena
On the one hand advanced analytical technologies enter the process industry and on the other the Group has opened up the market for laboratory analysis.
2
3MD’s Column
Welcome to the first Wazzup newsletter of 2015.
It has been quite a tumultuous start to 2015. The Oil Price has hit record lows reflecting a general decline in resources. The electricity crisis continues in South Africa and this is one of the major influences on a GDP growth which refuses to turn around. This will certainly be a time of reflection for the manufacturing and process industries in South Africa, balancing reducing capital expenditure with the need to increase efficiencies while at the same time managing the risk of increasing maintenance costs with aging plant and equipment.
For Endress+Hauser at a time like this we question again how can we help with these challenges? How does one reduce the cost of maintenance while at the same time increasing plant availability? How can one increase process efficiencies and reduce energy consumption.
The Mission statement of Endress+Hauser includes the statement that “we help our customers to design their processes to be reliable, safe, environmentally compatible and efficient”. We would like you to put us to that test. Our range of products, services and solutions is particularly designed to help. From instrument application training and web-enabled asset management to instruments with advanced diagnostics. From design of standard operating procedures for plant commissioning to the supply of full plant maintenance contracts.
At the Africa Automation Fair in May, which you will read more about in this newsletter, we will be presenting many of these products, services and solutions, as well as new technologies for gas analysis. This promises to be the premier of automation exhibitions in Africa, we look forward to seeing you there.
I wish you the best of success in 2015.
With kind regards
How can we help?
4 Analytics in red and blue
Operators of process control systems need to maintain a comprehensive picture of what is happening in the process at any time. They want information not only on ‘process conditions, but also on material characteristics - without time lag and without impacting production. It may be a pipe dream, but it’s one that could soon become reality in many applications thanks to advanced analysis.
“Advanced analysis satisfies the needs of our customers who want to control product quality during operation,” says Matthias Altendorf, CEO of the Endress+ Hauser Group. Advances in the field of spectroscopy are playing an especially important role in creating diverse opportunities for fast, non-destructive material inspections. “Our strategy is to make these technologies better and easier to use for the world of process control.”
SpectraSensors became part of the Endress+Hauser Group in 2012 . The company is a global leader in laser-based gas analysis with absorption spectroscopy. Using this technology, even the smallest concentrations of individual substances can be precisely determined. In 2013 Endress+ Hauser acquired Kaiser Optical Systems, a pioneer in the field of Raman spectroscopy. These
instruments provide online information about process stream composition and material properties.
Both companies will continue to operate as independent competence centers. “We naturally want to exploit any synergies that result from common expertise,” explains George Balogh, Managing Director of SpectraSensors. Even common technology platforms for future products are conceivable. Know-how in laser technology and optics needs to be shared and proliferated together. Tim Harrison, Managing Director of Kaiser Optical Systems, has no doubt about the strategy’s success. “Raman technology has the potential to herald a paradigm change.” More importantly, advanced analysis opens up new fields of application for which there have simply been no solutions thus far.
From lab to production Advanced analysis technologies are fast, reliable and highly precise. And because they require no expendable materials and no special environmental conditions, they are cost-effective and low-maintenance, driving down operational expenditure. SpectraSensors’ gas analysers are
Analytics in red and blue Endress+Hauser is strengthening its analytics business on a broad scale. On the one hand advanced analytical technologies enter the process industry and on the other the Group has opened up the market for laboratory analysis.
5Endress+Hauser magazine
designed for process control and monitoring applications. The Raman instruments from Kaiser Optical Systems are used in production as well as in the lab.
The second thrust of Endress+ Hauser’s analytics strategy is therefore aimed at the laboratory analysis market. ‘We are encountering the same customers in both the process control and lab analysis sectors,” explains Matthias Altendorf. “Our aim is to support these customers in all phases of their operation, from R&D to product and process development right through to manufacturing.”
A stake in AnalytikJena, a specialist in analytical instrumentation and bioanalytic systems, is opening the door to the world of laboratory analysis. Endress+Hauser currently holds more than 50 percent of the company’s stock, with the option to increase its share to around 80 percent. The long-term goal is to assume full ownership of the publicly-traded company.
Red and blue structures Klaus Berka, co-founder and CEO of AnalytikJena, believes this relationship will secure the success of his life’s work. He expects Endress+Hauser will be the catalyst for further growth. “We benefit from a structural framework that provides us with a wide range of new business opportunities. I’m convinced that AnalytikJena as a member of the Endress+Hauser Group will be playing in a totally new league.” The new Group companies are bolstering the established analytic business. Even Endress+Hauser Conducta, the center of competence for liquids analysis, long ago made inroads into advanced
analysis with sensors and devices that extend beyond conventional pH or conductivity measurements. This category includes ion-selective electrodes for determining ammonia and nitrate concentrations in wastewater treatment plants as well as multi-parameter systems with sensors that work in the ultraviolet and visible range of the spectrum.
“The red world of laboratory analysis and the blue world of process analysis are very different,” says Matthias Altendorf, referring to the red in the AnalytikJena trademark and the blue in the Endress+Hauser logo. Because the laboratory business has special requirements, sales will be driven independently under the well-established AnalytikJena brand. The plan is to expand the worldwide presence of this laboratory sales organization that will also introduce Kaiser Optical Systems products to markets not yet served.
The blue side of the analysis will nonetheless be strengthened as well. “Our modern analysers and samplers require comprehensive understanding of the application, as well as the chemical processes,” explains Dr Manfred Jagiella, Managing Director of Endress+Hauser Conducta. Endress+Hauser plans to set up a specialised sales and service fo rce to support the analytics-based process control business. These specialists will bring their expertise to customers around the world whenever complex analytical products from SpectraSensors, Kaiser Optical Systems and Endress+Hauser are deployed in process engineering applications. “This allows us to help our customers gain a competitive edge by employing advanced analysis.”
Analytik Jena
Sales channel
Company
Application area
analytikjena
Endress+Hauser Conducta
SpectraSensors
Kaiser Optical Systems
Laboratory
• Research• Product development• Quality control
Pilot plant
• Process development• Quality control
Process plant
• Production• Environmental technology• Quality control
New structures for the analytics business of the Endress+Hauser Group
6 Quadruple knowledge of analytics
Endress+Hauser Conducta
Headquarters in Gerlingen, Germany; production facilities in Waldheim and Groβ-Umstadt, Germany; Anaheim, California/United States; and Suzhou, China; approximately 730 employees.
History Founded in 1970 under the name Conducta, the company has been part of the Endress+Hauser Group since 1977.
Profile Endress+Hauser Conducta is a leading provider of measurement devices and systems for liquid analysis. The company›s products are used to analyse a variety of parameters in, liquids including pH value, conductivity, oxygen and chlorine content, turbidity and suspended solids as well as ammonia, nitrate and phosphate concentrations. The customers are active in the chemical & petrochemical, life sciences, food & beverage, water & wastewater, pulp & paper and power & energy industries. The services range from sensors and assemblies to transmitters and complete sampling systems.
Highlight With its Memosens technology, Endress+Hauser Conducta is moving the conventional pH glass electrode - the prevalent technology in liquid analysis - into the future. Memosens incorporates digital intelligence into the sensor and uses contact-free induction technology to transfer data and supply power, thus preventing disruptions caused by issues such as moisture.
Quadruple knowledge of analytics
SpectraSensors
Headquarters in Houston, Texas/United States; production center in Rancho Cucamonga, California; more than 100 employees.
History SpectraSensors was formed in 1999 as a spin-off of the renowned Caltech Jet Propulsion Laboratory, where it was tasked with developing a form of laser spectroscopy on behalf of NASA. The company has been part of the Endress+Hauser Group since 2012.
Profile SpectraSensors is a leading global provider of laser-based online analysers. The technology relies on tunable diode lasers that operate at a very specific wavelength, thus achieving optimal results with every task. Very small concentrations of various substances can be measured, including carbon dioxide, hydrogen sulfide, oxygen, ammonia and a range of other parameters. The analysers are used for process control and monitoring applications in natural gas production, transport, storage and procuring, refineries and petrochemical plants, as well as for atmospheric weather measurements.
Highlight Contactless laser absorption spectroscopy offers several major advantages over conventional electrochemical or capacitive sensors. The analysers are precise, immune to contaminants and low maintenance. Laser spectroscopy represents a breakthrough technology in many applications where reliable measurements have not been available, such as natural gas pipelines, which are prone to internal corrosion due to traces of moisture and hydrogen sulfide.
Kaiser Optical Systems
Headquarters in Ann Arbor, Michigan/ United States; European sales office in Lyon, France; more than 80 employees.
History Kaiser Optical Systems was formed in 1979 as part of Kaiser Aerospace & Electronics Corporation. The company has been active in the field of spectroscopy since 1990. Endress+Hauser acquired Kaiser Optical Systems from its parent company Rockwell Collins in 2013.
Profile Kaiser Optical Systems is a world leader in Raman spectrographic instrumentation and applied holographic technology. Principal products include Raman sensors and instrumentation and advanced holographic components for spectroscopy, telecommunications, astronomy and ultra-fast sciences. The products are deployed in research laboratories as well as in the process industry, including life sciences, chemical & petrochemical and power & energy industries. Raman spectroscopy can be applied to solids, liquids and gases in order to analyse the composition and material properties of particles as tiny as a human hair or as large as an entire planet.
Highlight A holographic notch pass filter developed by Kaiser Optical Systems was a breakthrough technology for Raman spectroscopy. The filter removes unwanted light at the excitation wavelength that would otherwise swamp the frequency shifts that are characteristic of the substance being examined at the detector.
7The power of light
AnalytikJena
Headquarters in Jena, Germany; additional locations, subsidiaries, share holdings and representatives in Germany and overseas; approximately 1,080 employees, including more than 760 in Germany.
History Klaus Berka and Jens Adomat founded AnalytikJena in 1990 as a trading company for analytical instruments. At the end of 1995 the company acquired Carl Zeiss Jena’s lab analysis engineering; in 2000 Analytik Jena went public. Endress+Hauser acquired a controlling interest in September 2013.
Profile The core business is high-end analytical instruments designed for industrial and science applications in the environmental, food processing, pharmaceutical, medicine and agriculture industries, as well as turnkey bioanalytical systems and solutions for the fields of biotechnology, pharmaceuticals and molecular diagnostics. Under the Docter brand, AnalytikJena also has a third business area that markets high-quality optical products such as binoculars, telescopic sights and miniature sight systems.
Highlight AnalytikJena revolutionised the field of atomic absorption spectroscopy with its contrAA series. These instruments rely on a single xenon lamp as a continuum radiation source to measure the entire relevant wavelength area, whereas conventional systems utilise a separate radiation source for each element to be measured.
Whether it’s Analytik]ena, SpectraSensors or Kaiser Optical Systems, the new Endress+Hauser Group companies all have one thing in common: core expertise in the field of spectroscopy, a technology that relies on light radiation to analyse various substances and materials. The extent to which the light is absorbed or scattered provides information - in the form of patterns or intensity levels - as to the composition and properties of the substance being analysed.
Kaiser Optical Systems utilises Raman spectroscopy, a technology that analyses how a laser light source interacts with the material. Individual laser photons transfer energy to molecules, whereupon these molecules emit new photons. The difference in energy between the incoming and emitted photon causes a shift in frequency from the excitation wavelength that can be detected. This form of light scattering creates a fingerprint for each substance. In contrast to infrared spectroscopy, for example, Raman spectroscopy can also be easily used to analyse aqueous systems or living organisms.
The AnalytikJena and SpectraSensors analysers mainly rely on various forms of absorption spectroscopy. This technology measures how a material absorbs light radiation across various frequencies, from ultraviolet and visible to the infrared range. The absorbed or non-reflected part of the spectrum offers clues regarding the composition and properties of the material.
Complex technology, simple application All of these methods have advantages and disadvantages and corresponding application potential and restrictions. What they have in common is that they are fast, reliable and highly precise. They are also easy to use and require little or no maintenance. Across various industries there is a growing reliance on advanced spectroscopy for in-situ analysis. This approach has far-reaching potential given that the time-consuming and complex task of extracting samples and analysing them in the laboratory is eliminated. The result is that customers have continuous control of quality and the ability to constantly optimise their processes.
The power of lightSpectroscopy technology simplifies materials analysis while creating totally new ways to control and monitor processes.
8 In the molecular realm
“Our products allow us to size up things as big as planets, or smaller than a human hair”, says Tim Harrison, Managing Director of Kaiser Optical Systems. In fact, the range of potential uses for Raman spectroscopy is almost as large as the actual spectrum of light which is broken down into its components with this high-tech method: It reaches from the chemistry lab to telecommunications, from forensic investigations to nanotechnology, from deep sea research to outer space
Kaiser Optical Systems was established In 1980 as an off-shoot from the University of Michigan to develop optical systems for the avionics market. Ten years later, the team’s Holographic Notch Filter caused a technological revolution: the option of blocking a narrow band of light around a specific wavelength led to a crucial simplification of the Raman measuring method. The company has since continually consolidated its market position and, step-by-step, developed new
In the molecular realmKaiser Optical Systems is a world market leader in Raman spectroscopy. The youngest member of the Endress+Hauser Group brings plenty of specialist knowledge into the fold.
applications with Innovative samplers and analysers. Laboratory probes were soon followed by in situ-liquid sample probes (1997), probes for solids analysis in the life science industry (2006), and others for gas-phase measurements in the petrochemical industry (2008).
Broad spectrum Put in simple terms, Raman sensors work along the principle that a fraction of light changes its wavelength characteristically according to the matter (molecules) it hits. “This allows us to determine the composition and properties of solids, fluids and gases in great detail,” explains Ian R Lewis, Head of Marketing. Initially designed for
laboratory analysis, in situ methods are becoming ever-more Important; “Thanks to continuous in-process measurements, we can detect and record material changes in real time.” The focus is on biotechnology, energy and the oil and gas industry, with a number of special instruments also developed for (academic) research laboratories. Tracking scattered light: an employee optimises a spectrograph, the heart of many Raman analysers.
Kaiser Optical Systems has been a part of the Endress+Hauser Group since 2013, after the Group recognised the immense potential of this technology. Located at the crossing of laboratory and process measurement technology, Raman spectroscopy perfectly complements the existing product portfolio. “It enlarges our offering in our key industries and is highly important in many future fields,” stresses Matthias Altendorf, CEO of the Endress+Hauser Group. Even today, many of Kaiser Optical Systems’ customers are also customers of Endress+Hauser, albeit often discretely: “Our technology is a competitive factor, that’s why many customers play their cards close to their chest,” says Tim Harrison, who is quite forthcoming when talking about the future of Kaiser Optical Systems: “As part of Endress+Hauser, we are in a position to make the best possible use of our potential, worldwide: he says. “We are proud to be part of this corporate culture.”
“Raman technology has the potential to be a paradigm shifter in the laboratory and process world.”Tim Harrison, Managing Director of Kaiser Optical Systems
9A crystal masterpiece
Whether a tablet, a powder or a spray, the active ingredient of a medicine is, in most cases, a chemical substance in crystalline form; what does this mean? Many compounds can occur in several different manifestations, for instance by crystallisation. We then talk of polymorphism. Polymorphic forms are chemically identical, yet have differing physical and biological properties. Take diamonds and graphite, for example: both are made of pure carbon. But this is where the similarity ends. A graphite drill would be a tunnel digger’s nightmare, while diamonds in pencils would never catch on among draftsmen and writers ... not only due to the high price.
If the customer doesn’t want to produce a placebo, he must make sure that the substance maintains the correct polymorphic form. Why is the first choice a Raman analyser? Raman analysers operate using the principle of the Raman Effect, discovered in 1926 by the Indian physicist and Nobel Prize winner C. V. Raman (1668-1970). Using Information generated in situ on the chemical composition, in-process optimisation of the reactive mechanism allows the customer to achieve the maximum yield in the correct form and to monitor the process in real time. This guarantees that the correct polymorphous form is processed.
How has Kaiser Optical Systems made use of the Raman technology? A laser beam is focused on the sample using a lens and captured by a detector. This ‘light’ is composed of reflected laser light, elastically scattered light (at the same wavelength as the incident laser light), and a tiny percentage (1 in 1,000,000) of inelastic scatter, known as the Raman Scatter. As the light in the sensor’s wavelength would ‘blind’ the detector, it is filtered out by the Holographic Notch Filter, allowing the weak Raman scatter light to be detected. Determining the nature of the scatter now allows a ‘fingerprint’ of the material or substance to be generated and its concentration to be established.
A crystal masterpieceTo produce a medicine, a customer needs to process an active ingredient into the right molecular arrangement.
Which are the advantages of Raman versus other analysis methods? Relying on the Raman analysers, it offers non-contact, non-destructive measurements for many chemical substances (gases, solids, fluids). The only moving part is a shutter that allows the sensor data to be read at the detector. A Raman measurement is so sensitive that even a fraction of one percent can be identified reliably. It can be used in situ, without the need to disrupt the process by extracting or diluting a sample.
4,000 meters below sea level Kaiser’s Raman systems are not only used in laboratories and in the process Industry. The Monterey Bay Aquarium Research Institute (MBARI), a globally leading marine and ocean research institute was Kaiser’s first customer to place a Raman a analyser on the ocean floor. The research scientist’s gained new insights into the ocean chemistry - for instance on the binding effect of carbons - and used the technology for on-site analysis of methane hydrates which are seen as potential fuel and power sources. Almost 5 kilometres below the ocean surface, the instruments have demonstrated their resilience and reliability.
A Raman spectrometer analysing a methane hydrate outcrop on the sea bed.
10 Curtain Up!
For the development team, the Liquiline System CA80 was without question a challenging project. The scope alone for developing and working out a completely new platform for Endress+Hauser’s future analysers was enormous. But as recently discovered, at the launch of Liquiline System CA80AM in South Africa, the colorimetric analysis system for ammonium was well worth the challenge!
Endress+Hauser’s new analysers are special in that they provide measurements as precise as in a laboratory - and they do this right at the critical checkpoints for water and wastewater treatment. You could also say that they are a laboratory in a compact cabinet, which can then be set up at exactly the place you need it. Consequently, the online analyser returns the measured values faster compared to laboratory measurements by means of cuvette tests. Then the operating personnel can promptly respond to varying ammonium levels and optimally control the blowers in the aeration basin. In the outlet, the precise system provides support in achieving ammonium values that comply with legislation and preparing the required documentation for the water authorities.
Curtain up! The new Liquiline System CA8O analyser platform combines top precision with easy operation and maintenance. The first of many: the CA80AM ammonium analyser.
Familiar operation thanks to Liquiline technology As a member of the Liquiline family, the Liquiline
System CA80 has the same user-friendly operation as our measuring points for other analytical parameters. This means that plant personnel can perform commissioning, operation and maintenance as usual - retraining is virtually unnecessary.
Low consumption and easy maintenance reduce costs Quite critical for a colorimetric analysis system: The
precise syringe pumps for dosing the reagents with Liquiline System reduce the consumption of the reagents. In addition, an intelligent cooling system extends the lifetime of reagents up to three months. Automatic cleaning and calibration functions as well as extended maintenance functions increase the reliability of the processes and minimise maintenance effort.
Colorimetric analyser for monitoring water and wastewater
• Quick commissioning and plug-and-play thanks to Memosens technology and the Liquiline operation concept • Fast expansion to a complete measuring station is possible, since Memosens sensors are easy to connect • Extended diagnostics options and extensive process documentation via remote access • Cuts costs due to low consumption of reagents and maintenance without tools • Measurements using the standard indophenol blue method in accordance with ISO 7150-1, DIN 38406-5 and
GB 7481-87 that are guaranteed to be re liable and comply with legislation
11Prepared for everything
In the inlet and outlet, in the biological treatment and in pressure pipelines, basins and channels - the Liquiline System CAT810, CAT820 and CAT860 sample preparation systems are prepared for everything. They are an integral part of our Liquiline platform. The entire measuring point is controlled and synchronised via the CA80 analyser using Memosens technology. Forward-looking diagnostic functions and operating hour counters provide support for predictive maintenance and reliable operation.
Liquiline System CAT810 The optimum solution for sampling in pressure pipelines! A self-cleaning cross-flow filter minimises blockages; in addition, this can be equipped with an automatic backwash function.
Liquiline System CAT820 Ideal for sampling in the outlet and aeration basin of wastewater treatment plants, as well as in industrial processes! Liquiline System CAT820 can be conveniently adapted to various installation situations using an optional air-backwash function and various hose lengths. Compatibility with our modular Flexdip CYH112 holder provides support for this.
Prepared for everythingThe new sample preparations of the Liquiline System product family enable optimised sampling for CA80 analysers - and they do so under a wide variety of process conditions.
Liquiline System CAT860 This sample preparation system is a unique product for applications in the inlet. This is provided for by a ceramic filter with a pore size of 0.1 µm, a backwash function for cleaning solutions and communication by means of Memosens technology: Liquiline System CAT860 is automatically detected and the measuring point configuration is checked as early as the commissioning stage. Numerous diagnostic functions help the measuring point function reliably during operation.
Liquiline System CA80AM Endress+Hauser has developed all sample preparation systems so that they make it easier to commission the measuring point as well as to operate and maintain the system. As a product family, the Liquiline platform is still one-of-a-kind on the market.
12 Maintenance made easy
Wet-chemical analysers require a certain amount of attention from customers over the course of their service life: Chemicals and wear parts have to be replaced regularly. Therefore we are sure to have sustainable business here.
Maintenance and service-friendly analyser designSince analysers have a basic need for service, our experienced service department was integrated into the development process of Liquiline System CA80AM from the beginning. The result is a maintenance- and service-friendly analyser that had a sophisticated service portfolio. For example, simple, illustrated instructions for commissioning and maintenance as well as a continuously updated on our web page, which quickly
Maintenance made easyHow is maintenance actually supposed to be performed on Liquiline System CA80 and what parts are used for this?
clarifies frequently asked questions. These tools are of inestimable value precisely in the beginning period, when it is still too early for the local customers to have much experience.
Various service kits for easy maintenance The all-inclusive CAV800 maintenance kit, for example, contains all parts needed for maintenance over one, two or three years. And should anything ever get broken, the CA80 has already been equipped with numerous spare part kits for all contingencies. The kits are to be found on our website: www.za.endress.com (search CA80AM) which contains the order codes, detailed installation guides and drawing numbers (also readily found in the Operating Instructions), which can be used to find the parts you need quite easily.
Enquiries: Glenn SmithAdded Value Services Development [email protected]
Illustrated instructions make maintenance of Liquiline Systems CA80 quite easy
13Analysis in simple terms
If you do not have a background in technical studies, use this section in each issue to explain in more detail a different “piece of the puzzle” of our huge area of expertise. In this issue: Colorimetric measuring principle and optical turbidity measurement.
The name colorimetry gives away the most important aspect of this measuring principle: it must have something to do with colour. Measuring with the help of a colour is in fact the critical difference with other optical measuring principles. That is because in the colorimetric method, special reagents are added that make the invisible contents of liquids visible. This little “magic trick” works because a colour reaction takes place with the particles contained. The more particles there are in a medium, in other words, the more that there are available for the reaction, the more intensely the sample changes colour. Then the colour intensity is measured photometrically. To do so, light is irradiated and receivers analyse the level of absorption - that is, how much light is “sucked up” by the coloured particles. The concentration of the content being searched for is determined using a stored calibration curve.
Analysis in simple terms
Colorimetry - laboratory in a box
Turbidity is the term used to refer to liquids that are not clear. This state results when solids, oils, or gas bubbles are in the liquids. Turbidity is normally measured using a scattered light method. For this purpose, a focused beam of light is shone through the liquid. When the beam hits the un-dissolved substances, it is broken up into many smaller beams and scattered into different directions. Receivers measure how much light is diverted, so to speak, by the particles, and how much light passes through the liquid unchanged. Depending on the degree of turbidity - the number and size of the contained particles - the receivers are installed at different angles to the emitted beam of light to obtain accurate results. Low levels of turbidity i.e. dispersed particles that are invisible to the naked eye, are best measured with receivers at a 90° angle to the emitted beam of light. This is how sideways scatter is measured. The ideal way to measure high levels of turbidity is to analyse the light that is scattered back. Therefore, the receivers are installed at an angle of 135° to the emitted light.
Optical turbidity measurement - keeping a clear view in muddy waters
Which topic have you always wanted to haveexplained? Or do you have any suggestions?
14 Talking water
There are various reasons for why plant operators want to optimise the control of their wastewater treatment plant. The objectives are almost always the same: an easy and cost-effective automation solution and guaranteed effluent quality. This is intended to optimise the energy needs for plant operation and provide for maximum reliability in the processes. The ideal solution for this is Endress+Hauser’s Liquiline Control. The latest generation of the automation system replaces our previous Liquiline Control. By simply turning it on and mapping your I/O, you are ready to optimise the wastewater treatment plant with Liquiline Control. This is mainly thanks to the convenient hardware architecture and seamless integration in the process control system by means of fieldbus technology. Long, unnerving commissioning processes and complex operation concepts are now a thing of the past. The operator can focus on what is most important: increasing efficiency and process reliability.
Liquiline Control is a modular tool that provides proven and intelligent new control concepts for the various requirements of municipal and Industrial wastewater treatment plants. Plant managers have the following software modules available to them: blower control (intermittent, continuous), phosphate control (disturbance variable control, pilot control) and the control of internal reticulation pumps. The core of the system consists of a Programmable Logic Controller (PLC), supplemented by a touch display with menu guidance in line with the Endress+Hauser product standard. Also available is an optional modem for remote service purposes. This manageable hardware concept ensures that a plant can be quickly re-commissioned after a hardware failure. To do so, you simply have to replace
The next generation of Liquiline Control
the CPU. Thus the plant can be made operational again within five minutes with little effort - an essential aspect for maintaining operational reliability. A standardised licensing concept, as with the Liquiline CM44 transmitter, enables additional software modules to be subsequently activated with ease. Thus a blower control can be easily expanded to phosphate control. Doing so requires no mechanical or electrical effort. Successful field tests have demonstrated simplicity and efficiency. A wastewater treatment plant near Dusseldorf used our intermittent blower control in direct comparison with the competition. To do so, the operators of the plant performed a test with two biological stages working in parallel. Within two weeks, they found clear differences in energy consumption and improvements in effluent quality, compared to the ORP·based solution of the competition. And the bonus is that it took less than one hour to integrate the Liquiline Control system into the existing process control system of the plant.
The utilisation of the Liquiline Control can, in summary, reduce energy consumption, reduce chemicals dosed for Phosphate removal as well as maintaining effluent quality within stringent limits. This is a clear winning product to achieve or maintain Green Drop status.
Enquiries: Hennie PretoriusIndustry manager: Water and waste water [email protected]
A modular system that can be used to easily optimise the different processes in a wastewater treatment plant.
Liquiline Control: one piece of hardware for five key functions:• Intermittent blower control• Continuous blower control• Phosphate removal control with
feed forward control• Phosphate control with pilot control• Control of inorganic nitrogen
The next generation of Automation
i
15E-business
What is E-direct? Endress+Hauser’s exclusive E-direct product range positions itself as a cost effective solution to the process environment. The E-direct product range consists of switches, sensors, components, displays and recorders. Equipping a simple measuring point should not be complicated, and requires minimal application assistance. E-direct products are quality products offered at economical prices.
When did E-direct start? E-direct has changed over time. It all started in 1996, with one simple product – Liquiphant FTL260 – and in an attempt to market it in a cost effective way. It was so successful that it quickly evolved over time. Nineteen years later, with many more products and in a fast changing world, the reality of E-direct has evolved to a broader product portfolio encompassing a combination of dimensions and products with specific characteristics. The whole concept of E-direct is its 4 key characteristics, ie, high quality, cost effective prices, easy to select and quicker manufacturing time.
Why you should buy E-direct products? It is quite simple, though. E-direct products will save you money. As an example, let’s take a closer look at the price of a Digital Indicator RIA45. Customer A buys 1 RIA45 every month for a year. The price of a RIA45 is R4130. Customer A will pay around ZAR49560. Customer B on the other hand, buys the same unit in bulk, i.e., 12 units in 1 order and pays ZAR46092. That is a saving of ZAR3500.
E-direct – Endress+Hauser’s Basic Product Line A closer look at E-direct!
Let us help you save. For more information on E-direct, please contact Deshini Govender E-business Specialist [email protected]
So in essence, the more you buy the less the unit price is. Buy in bulk and save. This ensures you receive the best value for your money. The E-direct scaling prices works in relation to the quantity purchased. The higher the quantity, the lower the unit price is. E-direct products are very easy to select – You can easily pick out the appropriate version from a wide range of variants. All E-direct products meet the well-known Endress+Hauser quality standards and the cost-effective prices will ensure you get the best value for your money. E-direct products have shorter manufacturing times.
Where & how can you access the E-direct products?Whether you want to fit your application with a level, pressure, flow or temperature instrument, simply log into our website www.za.endress.com/e-direct to view detailed information of our full E-direct portfolio. E-direct vision is simply to serve our customers worldwide with simple high quality products in a fast, cost effective and sustainable way.
16 Universal Training Rig
Purpose built for Endress + Hauser South Africa at the company’s Application Training Centre (ATC) in Reinach Switzerland, the UTR utilises 20 devices from the company’s extensive range of flow, level, pressure and pH measuring instruments in a variety of flow and control loop configurations.
The integrated oil, water, acid and alkaline reservoir tanks combined with mixing and separation chambers allow a huge range of flow, level and pH conditions to be created through the utilisation of different control loop strategies based on pressure, temperature, level, density and pump speed primary values.
Whilst not emulating a production process of any specific industry, the UTR presents the application frame conditions in a way to offer a variety of training possibilities. An agitator (level disturbance), heater element (temperature changes) and injected compressed air (entrained gas) allow the process conditions to be interrupted in a controlled manner giving the trainee a practical perspective of the sensitivities of each instrumentation type operating under varying field conditions
All operational parameters including instrument selection are controlled via the integrated Programmable Logic Controller and touch screen display.
A not to be missed feature being introduced on the Endress + Hauser stand on the Africa Automation Fair at the Coca Cola Dome in May is the brand new 1.8 million ZAR Universal Training Rig (UTR).
Universal Training Rig
17Universal Training Rig
For further enquiries about the UTR training program
or the planned open day, please contact:Chris GimsonTraining [email protected]
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From June this year, Endress + Hauser will be offering two new intensive 5 day training courses targeted at technical plant personnel from Technician and Engineer grades right through to Maintenance, Engineering and Project Management. The two courses cover all of the major process measurements classes including level, flow, pressure, temperature and analytical starting from the principles of operation through to application topics such as meter selection, set up, installation and application issues, and trouble shooting. The trainee is introduced at a practical level to the standard Endress + Hauser instrument selection and sizing software tool “Applicator” plus hands on instrument configuration
Training Manager
and troubleshooting using the device keyboard and display as well as the service software tool “FieldCare”.
As well as “real life” instrument and control operation, the UTR also allows different field communication strategies to be presented via its use of Wireless HART, Profibus as well as standard 4-20 mA connections. Supplementary topics such as reading and understanding P&ID diagrams and Plant Asset Management are also included.
The courses are interactive with all theory accompanied by extensive practical assignments on the UTR itself followed by written assessments thus maximising the learning experience. MerSETA approval for the training package is currently in progress.
On request, a training brochure is available outlining the UTR and training course modules in more detail including pricing and schedules. An open day is under planning for later in the year where you will be able to have an in-depth look at the UTR and the training program and discuss what it has to offer your company.
Chris Gimson is a Chartered Engineer holding a Batchelor of Science degree in Electrical Engineering and Masters Degree in Thermodynamics.He has worked for Endress+Hauser for 32 years, initially in Manchester, England as Head of R&D developing instrumentation for the oil industry.As Technical Director, he undertook the introduction of thermal mass gas flow metering into the company product portfolio and was responsible for the development, marketing and ultimately production of successive models of the thermal gas flow metering range including the design and commissioning of two production gas flow rigs.Whilst in the UK, Gimson introduced the concept of hands on gas flow workshops using the in-house flow rigs allowing the user for the first time to see and “feel” the issues uniquely associated with gas flow measurement (as opposed to liquid flow). The feedback from customers was incredible and these customer workshops have now been regularly repeated around the world using portable flow rigs.In 2002 it was decided to move the product technology to the groups
Flow headquarters in Reinach, Switzerland to benefit from the latter’s State of the Art Development and Production facilities. As Project Manager, Gimson was responsible for the transfer of know how to the Swiss Development and Marketing organisations leading to the successful introduction of the next generations of thermal flow meter launched worldwide in 2006. Having moved to Switzerland, he continued to support the on-going development and marketing of the new Gas Flow group with particular emphasis on the educational aspects of Gas Flow measurement and Energy Management including the construction of a new purpose built gas calibration flow rig featuring variable pressure and temperature control and mixed gas capabilities with an investment level of 11 million Rand.In 2011, Gimson relocated yet again to South Africa to head up the Group’s Temperature Sensor Manufacturing Facility, Endress+Hauser Pyrotemp in Benoni, Gauteng. His primary responsibility was the modernisation of the business including the introduction
of modern production processes including SAP and an up-to-date machine workshop.After retiring in December 2014, Gimson was attracted back by the prospect of returning to one of his “professional passions” of further education. As Training Manager of Endress+Hauser Sandton, he is responsible for external customer training and his first task is the introduction of a brand new training program based around the Universal Training Rig (UTR) that is described further in this article.
Chris Gimson BSc Mphil MIET C.Eng
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Temperature TrainingUnderstanding of temperature measurement principles and sensor selection
With unprecedented experience and extensive manufacturing facilities the world over, Endress+Hauser is recognised as a specialist in temperature measurement technology.
We specialise in the design and manufacture of industrial temperature sensors and engineered solutions tailored to our customers’ needs across all industries. Drawing on considerable international experience and with accredited calibration laboratories (DKD, SIT and SANAS), our global network of production facilities and logistics partners supports our customers in 86 countries. Our production centres manufacture around 6,500 temperature assemblies and transmitters every week, to supply Endress+Hauser customers around the globe.
Our Production Centre in Benoni, Johannesburg houses our local Centre of Competence for Engineered Temperature Solutions as well as a wide range of standard products.
With extensive temperature manufacturing and testing facilities, we handle single piece work through to large volume projects, offering expertise in the manufacture of tailormade solutions for our customers. Key production and technical personnel with over 40 years’ experience are familiar with all aspects of temperature sensor design and manufacturing techniques to provide an accredited quality service across sub-equatorial Africa.
Scope and ObjectivesBy attending this course you will learn the basic principles of operation of RTD’s and thermocouples, leading to an increased understanding ofapplication suitability.
You will increase your knowledge of sensor construction, including selecting of correct lengths
Temperature Training at Pyrotemp
Course Outline
• Introduction to basic temperature measurement
• RTD’s• Thermocouples
• Introduction to temperature transmitters
• Products• Technologies• Benefits of transmitters
• Process discussions• Understanding product• make up• Materials of construction• Process connections• Specifications and• measurements of a• thermowell• Sizing of thermowell
• Understanding calibrations and accuracy requirements
• Build your own sensor and gain an understanding of the manufacturing processes
• Receive a Certificate of Competence
Course Schedule• 14-15 April 2015• 24-25 June 2015• 18-19 August 2015• 17-18 November 2015See website for agenda details
Venue DetailsEndress+Hauser Pyrotemp,Cnr. Rotterdam Rd and MilanPlace, Apex extension 3, Benoni
Booking DetailsContact: Cezanne GonsiorE-mail: [email protected]: +27 11 262 8097
Course feesR900.00 (excl. VAT) per person,includes refreshments andlunch, temperature sensor takeaway and training material
and dimensions for inserts and thermowells, diameters of sensors, process connections, housings, terminations and many other attributes of a temperature sensor.
Gain insight into how the sensor signal is transformed into an analogue or digital signal for retransmission.Also increase your knowledge of temperature transmitters and when to use which type. Finally, gain insight into the accuracy of sensor and transmitter, an understanding of sensor-transmitter matching and also understand the necessity for calibration.
Build your own Sensor As part of the course assessment you will be required to “build your own sensor” by putting theory into practise. This will reinforce what you have learnt during the two days, and provide you with the opportunity to build your very own sensor which you can take away with you.
19Africa Automation Fair
Endress+Hauser at Africa Automation Fair 2015
AFRICA AUTOMATION FAIR 2015, incorporating Process Expo Africa, will be staged from 5 - 7 May 2015 at the Dome in North Riding, Johannesburg, and ultimately aims to be the largest, most comprehensive showcase of Industrial Control Technologies of its kind in the Southern Hemisphere.
Held at the Coca Cola Dome, one of South Africa’s most prominent land marks, AFRICA AUTOMATION FAIR 2015 will proudly open its doors to the world for international trade and communication within the industrial arena. With a strong world-wide focus on Africa and its economic growth within the industrial sector, AFRICA AUTOMATION FAIR 2015 will be the number one meeting place for smart people and smart, innovative process control, automation, instrumentation and information technologies. Visitors to the expo will represent organisations across the Southern Hemisphere from their respective Manufacturing & Processing Industries, Machine & Plant Engineering facilities, Planning & Engineering Service Providers, Retailers & Wholesalers, Energy Supply Businesses, Research Facilities & Institutes and Educational & Training Facilities.
AFRICA AUTOMATION FAIR promises the delivery of a focused, industry-specific, state of the art technology event where companies will have the opportunity to display their latest cutting edge products and services to thousands of potential buyers over 3 days. The event also offers a number of workshops and presentations by world leaders from the industrial automation industry, affording our visitors an all-round educational, informative and enjoyable experience.
Endress+Hauser products, systems and solutions capabilities will be showcased at Africa Automation Fair 2015, stand D33-D38, to be held at the Coca Cola Dome in Randburg. Here, the latest innovative technology developments will be demonstrated, including the new Liquiline System CA80, the new range of level sensors, locally produced temperature sensors and Memosens digital technology for analytic sensors to name just a few. We will also be launching the Endress+Hauser customer process automation training possibilities along with the Universal Training Rig.
Furthermore our competence as a solutions provider will also be highlighted in gas analysis. We will be launching the recently acquired
Endress+Hauser group of companies SpectraSensors and Kaiser Optical Systems and by visiting us at stands E32-E33, we will be show casing the latest technology in laser-based gas analysis with absorption spectroscopy and the latest developments in Raman technology.
Our technical staff will also be available to discuss our ‘services by your side’ capabilities including local calibration facilities. A calibration simulator will be on view to demonstrate the process of an onsite flow calibration. In addition, it is able to show our documentation and calibration management concepts such as the Web Enabled Management (W@M) and CompuCal.
For more information and to register as a visitor, see the
website details as below:http://www.africaautomationfair.com
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Contact
Endress+Hauser (Pty) LtdS Commerce, Crescent WestEastgate, Ext 13, Sandton
Tel: +27 (0) 11 262 8000Fax +27 (0) 11 262 [email protected]
