Endress+Hauser magazine / Edition 2/ 2019

Water & Wastewater: Water Management in Mines Food & Beverage: Growing Appetite for IO-Link

wazzup

Primaries & Metal

It’s dry…but you can measure it

Contents2

Index Edition 2/20198 The complexity of water

management in mines The key steps in the implementation of Water Conservation and Water Demand Management (WC/WDM) are based on resource protection and waste management

12 Endress+Hauser Apps

15 The Endress+Hauser IO-Link Portfolio

16 The people for process automation Mpumalanga Sales Team

17 Everest Base Camp Trek The ups and downs of getting to “the top of the world”

18 Innovation with a vision Endress+Hauser continuously develops its range of products, solutions and services together with its customers. This makes everyday life in the process industry easier, safer and more efficient while creating new opportunities

21 Moisture Measurement Patented technology from IMKO

22 Upcoming customer events

23 Competition I Love Endress+Hauser

10 Satisfying the growing appetite for IO-link in manufacturingMuch excitement has been created by IO-Link technology due to its advanced features

4 It’s dry but you can measure itFrom the limestone quarry through to the final product, we have the right measuring technology for the cement industry

20 Master your medium with the new Endress+Hauser Liquiphant

3Management Column

#empowerthefield

“The manufacturing of cement is a complex

process that requires modern measurement

technologies to operate and produce in a more

efficient, environmentally friendly and safe

manner.”Glen Cook

Dear Customers and Colleagues, Endress+Hauser globally grew significantly and reached a new high. We created hundreds of new jobs and have made record investments and further improved our solid position with respect to sustainability. These results will not have been achievable without the continued support of our customers – Thank you!

The South African economic and political climate has certainly had an impact on business over the past few months, and looking forward our business environment remains uncertain. With the National Elections completed and President Cyril Ramaphosa’s cabinet focusing on our economy, we remain positive and optimistic for a stronger economic environment.

This edition of wazzup is focused on cement in the Primaries & Metals Industry. The manufacturing of cement is a complex process that requires modern measurement technologies to operate and produce in a more efficient, environmentally friendly and safe manner. Endress+Hauser provides robust and reliable measurement instruments that are low maintenance, easy to clean, and deliver reliable information despite these harsh operating conditions.

Interest in Industry 4.0 or IIoT applications is growing, recognising that consistent process and device data forms the basis for productivity improvements and cost reductions. Using IIoT concepts like Endress+Hauser’s Netilion, we can #empowerthefield to support digital services using the most modern and secure Internet technologies. We combine them with the technologies of industrial production facilities to create smart factories. All our services are easy, seamless and straightforward to put into operation.

More information on Endress+Hauser’s digital services is available at www.netilion.endress.com

I hope you enjoy the read.

Yours in Process Automation…

Glen Cook

4 Primaries & Metal

It’s dry but you can measure itFrom the limestone quarry through to the final product, we have the right measuring technology for the cement industry

Portland cement is the basic ingredient of concrete. Concrete is formed when Portland cement creates a paste with water that binds with sand and rock to harden. Cement is manufactured through a closely controlled chemical combination of calcium, silicon, aluminium, iron and other ingredients. Common materials used to manufacture cement include limestone, shells and chalk or marl combined with shale, clay, slate, blast furnace slag, silica sand and iron ore. These ingredients, when heated at high temperatures, form a rock-like substance that is crushed into the fine powder that we commonly know as cement.

The most common way to manufacture Portland cement is through a dry method. The first step is to quarry the principal raw materials, mainly limestone, clay and other materials. Holding the right amounts of all the key ingredients for the production process is important and storage vessels come in many shapes and sizes including concrete bunkers and steel blending silos. Each vessel is fitted with mechanical or pneumatic discharge and filling points, and an effective level measurement must be easy to install and simple to maintain. A Solicap M capacitance point level rope probe is used to prevent overflow of bunkers and a robust rod probe to indicate low levels in

blending silos. Ropes and probes are protected with an active build up compensation, for bulk solids with a caking tendency and a two-stage overvoltage protection against static discharges from metal silos.

After quarrying the rock is crushed. This involves several stages. The first crushing reduces the rock to a maximum size of about 15cm. The rock then goes to secondary crushers or hammer mills for reduction to about 8cm or smaller. A crusher is an expensive piece of equipment and to avoid damage to the liner and optimise energy consumption, a certain level must always be maintained. You can rely on the Prosonic S ultrasonic level measurement solution to monitor your crushers. Ten sensors can be linked into the Prosonic S transmitter saving you cost and set-up time in the field. Vertical mill process optimisation and grind effectiveness is a balance of air flow, optimum pressure and temperature control. Mill product load is measured with a Deltabar S differential pressure transmitter. Deltabar S offers extensive diagnostic messaging so that troubleshooting any problem is easy. Air quantity measurement with a Deltabar S differential pressure transmitter optimises the drying process. Water metering is used to cool the mill components with Promag W electromagnetic flow meters. Oil is used on mills for

Cement grinding and storage

Raw material processing Raw meal processing

Clinker processing

Primary fuel handling

Plant overview cement

5Endress+Hauser magazine

6 Primaries & Metal

lubrication to prevent damage to bearings and shafts. Various measurements are needed to ensure the correct and trouble-free operation of the mill. A Liquiphant vibration level switch is used to measure the oil level in the reservoir. This switch is not affected by any contaminants, such as metal filings, in the oil. A Ceraphant T pressure switch is used to ensure that the system pressure is maintained, and should the pressure drop, the crusher can be stopped before any damage is caused.

The crushed rock is combined with other ingredients such as iron ore or fly ash and ground, mixed and fed to a cement kiln. The cement kiln heats all the ingredients to about 1500°C in huge cylindrical steel rotary kilns lined with special firebrick. Kilns are frequently as much as six metres in diameter – large enough to accommodate an automobile and longer in many instances than the height of a 40-storey building. The large kilns are mounted with the axis inclined slightly from the horizontal. The finely ground raw material or the slurry is fed into the higher end. At the lower end is a roaring blast of flame, produced by precisely controlled burning of powdered coal, oil, alternative fuels, or gas under forced draft. As the material moves through the kiln, certain elements are driven off in the form of gases. The remaining elements unite to form a new substance called clinker. Clinker comes out of the kiln as grey balls, about the size of 3mm to 25mm-sized marbles. The basic cement kiln system comprises a preheater in which feed material is prepared by heat exchange with hot exhaust gases from the rotary kiln. The challenge in installing a robust temperature measurement system includes the selection of cost-effective sensors and transmitters requiring minimum maintenance over the plant lifetime. For temperature measurement in the upper cyclones of the preheater, where sensor erosion is a major maintenance challenge, an Omnigrad TAF11 with an advanced ceramic thermowell made of silicon nitride is recommended. This material has been successfully tested with up to five times longer lifespan compared to AlSl310. For the bottom cyclones, we recommend Omnigrad TAF16 thermometers with a bar stock thermowell made from a nickel cobalt which offers unparalleled resistance against aggressive gases, stress cracking and high tensile strength against material impact.

The crushed rock is combined with other ingredients such as iron ore or fly ash and ground, mixed and fed to a cement kiln.

Pyroprocessing is generally regarded as the heart of the cement-making process. It is the stage in which most of the operating costs of cement manufacture appear and is also therefore the area where most of the opportunities for process improvement exist. Significant maintenance time can be saved by automating air cleaning cycles in the preheater cyclones. Clogging in the cyclones happens due to chemistry of the raw meal and the hot exhaust gases. Monitoring is important to avoid downtime and hazardous situations. Gammapilot FMG60 offers non-invasive point level or continuous measurement to monitor build up before complete blockage occurs. Trigger points can be easily configured to proactively schedule maintenance. Pressure can be monitored and blockages in the cyclone are detected using a combination of Ermeto piping and Cerabar S pressure sensors with high-purity ceramic (99.9% Al2O3) measurement cells, which are overload-resistant. Accurately control the blending of raw meal as it passes through each cyclone and ensure instrument accuracy is not affected by plant vibration by selecting a remote sensor and housing combination. Carefully monitor the adverse effects of alternative fuels on the clinker process chemical reactions and process conditions in the cyclones with a combination of Gammapilot FMG60 scintillators and high-accuracy Cerabar S gauges. In addition, Cerabar S sensors offer integrated overvoltage protection of electronics against lightning strike and power surges.

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Clinker is discharged red-hot from the lower end of the kiln and generally is brought down to handling temperature in various types of coolers. The heated air from the coolers is returned to the kilns, a process that saves fuel and increases burning efficiency. After the clinker is cooled, cement plants grind it and mix it with small amounts of gypsum and limestone. Cement is so fine that 500 grams of cement contains 150 billion grains. The cement is now ready to be transported to ready-mix concrete companies to be used in a variety of construction projects. The rate of cooling can be critical to the clinker quality and performance of cement.

A clinker cooler package includes:• Differential pressure flow sensors for metering and

monitoring cooling air consumption.• Soliwave non-intrusive microwave blockage barriers

to detect material back up in silos under the clinker cooler grate.

• Non-invasive Gammapilot radiometric scale for mass flow on clinker screw conveyors or belt feeders (indicates clinker density and infers free lime levels).

• Omnigrad TAF11 and TAF16 temperature sensors and transmitters, which last on average 10 times longer than regular stainless steel thermocouples.

• The Solicap S high temperature point level switch for fine-grained and coarse solids (designed with a sword probe which prevents build up and associated alarm conditions). The robust sensor Solicap S design is unique in the market as it permits a maximum lateral loading of up to 800Nm.

Clinker is stored in large storage silos, domes and buildings and the total capacity should amount to at least 14 days’ kiln production to ensure a continuous cement supply. Endress+Hauser level solutions can assist you maintain supply to the mills and prevent overspills of clinker dust which may be hazardous to air quality. Continuous level measurement in clinker silos can be done with a non-contact Micropilot M radar measuring device

(max. 400°C/752°F at antenna); for greater distances, use the version with parabolic antenna. Point level detection can be done with capacitance high-temperature rope probe (max. 400°C/752°F). Level measurement in cement silos is challenging and a continuous sensor health check is key in improving reliability and availability of measurements. Micropilot FMR57 is the radar level sensor best suited for measurements in high silos. The parabolic antenna facilitates very small emitting angles and is used for narrow multi-chamber silos. Dust, filling noises, temperature layers and gas layers do not affect the measurement. Use the Micropilot FMR57 health check diagnostics to monitor for deteriorations in measurement integrity caused by cement build up, steep angles of repose and rat holing. The dual output module with HART digital communications can automate radar cleaning cycles, activate silo air fluidisation and make reliable stock level measurements. The HistoROM data management chip records measurement and set-up data in each radar. Plug in touch screen displays copy and transfer set-up data to new or replacement radars. You can reach the highest reliability even in the presence of obstructions in the silos due to Multi-Echo Tracking evaluation algorithms.

Micropilot FMR5x radar family is used for continuous, non-contact level measurement in powdery to granular bulk solids. Dust, filling noises, temperature layers and gas layers do not affect the measurement.

8 Water & Wastewater

The complexity of water management in minesWater in South Africa is a very important, albeit a very scarce resource. In addition to human consumption, all industries are somehow dependent on the use of water in various forms and quality. This makes it very important for all consumers, and especially industries, to manage and monitor the water they consume and release back into the environment. Industries across the globe are encouraged to reuse water as much as possible, and therefore a “zero liquid discharge” policy has already been implemented by various companies in different sectors.

The Department of Human Settlements, Water and Sanitation

(DHWS) has updated and refined legislative frameworks with the focus on Integrated Water Resource Management (IWRM) to ensure environmental sustainability, socio-economic equity and efficiency in water use. The department developed policies and regulations that gave effect to Water Conservation and Water Demand Management (WC/WDM). Sectoral WC/WDM guidelines were developed for the Agricultural, Industrial, Power, Mining and the Water services sectors.

Water is a critical resource for the mining industry, either in the mining processes, as a feed to the beneficiation of minerals process, or

Endress+Hauser has been a valuable partner in the water and wastewater industry globally for more than 65 years and in Africa for 35 years. Based on our industry expertise, here are some examples where our products, solutions and services can be utilised in the implementation of the DHWS Best Practise Guidelines (BPG) for water management in the mining industry.

BPG H3: Water reuse and reclamationThe reuse and reclamation of contaminated water is important for any mining operation as it indicates that they optimise their water utilisation. All new and existing mines are required to prove this optimisation of water reuse and reclamation by having a Water Reuse and Reclamation plan. This

plan must consider the water and salt balance over the lifetime of the mine. Accurate measurement and storage of water abstraction, use and release data will assist in maintaining a historical record of long-term water balance. The Endress+Hauser Proline Promag family of electromagnetic flow meters can be utilised for accurate measurement of all water

The key steps in the implementation of Water Conservation and Water Demand Management (WC/WDM) are based on resource protection and waste management and entail the following:• Prevent pollution and avoid water use by implementing waterless processes.• Reduce water use by using optimised technology.• Reuse and recycle water as far as possible in accordance with applicable regulations.• Disposal of water or treated wastewater that is not reused, in a responsible manner as to not pollute the

receiving environment.• Always strive for greater efficiency in the use of water through the process of continual improvement using

feedback and adaptive management.

for potable use. With the growing demand and increased scarcity of usable water, it is very important for mines to prove that they utilise water optimally, by suitable reuse and reclamation of contaminated water. Water demand management and conservation forms an important part of mining operations, irrespective of whether it uses surface or ground water, and whether it impacts downstream water resources. By implementing state-of-the-art water management systems, mining companies will start to realise the importance of the water they use and will therefore recognise the scarce resource as an invaluable asset in their operations.

9Endress+Hauser magazine

sources on the mine, whether potable water, raw water or water contaminated with chemicals. The embedded Heartbeat Technology in our flow meters ensure you are at all times aware of the health of your flow meters and the reliability of the measurements received.

BPG H4: Water treatmentThere are various water treatment processes (from basic to advanced) in development to optimally treat any form of mine water. The BPG H4 describes the technical methodology which a mine must apply to identify the constituents of concern that may require mine water to be treated for sustainable reuse or discharge, as a last resort.

Various mine water treatment plants in the Mpumalanga area utilise Endress+Hauser Proline range of flow meters as well as the Liquiline liquid analysis platform with Memosens digital sensors, often in quite harsh environments. Using Memobase Pro and Heartbeat Technology, the lifespan of sensors can be optimised by continuously monitoring the condition and status of sensors.

BPG G2: Water and salt balanceThe most fundamental building blocks of a mine water management system is often considered to be the water and salt balance of a mine. Without the accurate and effective water and salt balance, it is impossible to plan, implement, assess and manage the WC/WDM at a mine.

The water and salt balance can be used as a tool to:• Audit the water usage from

various sources.• Identify where water is wasted, or

usage is too high.• Quantify balances by

measurement.• Locate and quantify sources of

seepage and leakage.• Identify and quantify pollution

sources.• Assist in decision-making.

Although the Endress+Hauser Proline range of flow meters are calibrated using a certified calibration rig, the mine will be required to prove the accuracy of their water balance by doing traceable flow

verifications every 6-12 months. With the Heartbeat Technology embedded in each Proline flow meter, the verification certificates can be obtained using a laptop (no additional tools or modems) or even remotely over an industrial fieldbus network, where available.

BPG G3: Water monitoring systemsAn effective and well-designed water quality monitoring programme is an essential component of the WC/WDM measures at any mine. The following are some of the important aspects for the success of a monitoring strategy:• Your monitoring strategy should

allow for discrete as well as reliable continuous monitoring.

• The programme should be implemented according to the detail design and specified sampling procedures.

• A detailed operating and maintenance programme must be implemented.

• Data should be populated in a data management system.

• There should be regular audit and quality assurance of the monitoring programme.

One of the ways Endress+Hauser can support a mine in their monitoring programme is by implementing standard or customised smart water monitoring systems. This includes an easy-to-implement solution consisting of the Liquiline water quality measurement system, an edge device connecting to the Endress+Hauser Netilion services and customised app or dashboard, to monitor measurement points remotely. With an Application Programming Interface or API, the data can be made available in the relevant data management system of the mines.

Promag 400

By utilising Heartbeat Technology in the Liquiline liquid analysis systems, the mine can be assured to receive early warning of faulty devices or parameters, so it can be addressed timeously, ensuring accurate and reliable data always.

To ensure reliable water usage and quality monitoring, including leakages and pollution events, accurate and reliable measurements are required. Heartbeat Technology in measurement devices organises clear, standardised diagnostic messages of what needs to be done to maintain the plant economically based on necessities. Along with this it enables predictive maintenance and delivers evidence for operational reliability and process safety. As the devices run their own diagnostics, proof tests are only necessary in maximum extended cycles.

By connecting all the process measurement instrumentation to the Endress+Hauser Netilion hub, using any of the available industrial communication protocols, the customer will have access to all the process variables, health information as well as any maintenance, events and product documentation.

Visit Netilion.endress.com to experience the latest in Endress+Hauser innovations or Endress.com for information or assistance on any of our products.

Netilion Smart Systems App

Source: Water Conservation and Water Demand Management guideline for the Mining sector in South Africa – Department of Water Affairs (now the Department of Human Settlements, Water and Sanitation).

10 Food & Beverage

Satisfying the growing appetite for IO-link in manufacturingThe manufacturing industry is constantly evolving due to changing consumer demands. This has resulted in a cycle of continuous improvement to drive operational efficiencies whilst minimising resource usage and the impact to the environment. Data has therefore become the preferred resource to facilitate these initiatives.

Much excitement has been created by IO-Link technology due to its advanced features such as parameter storage and detailed diagnostics. IO-Link is defined as a short-distance, bi-directional, digital, point-to-point, wired (or wireless), industrial communications networking standard (IEC61131-9) used for connecting digital sensors and actuators to either a type of industrial fieldbus or a type of industrial Ethernet. The primary goal of IO-Link is to improve sensor or field-level device communication capabilities through a standardised interface. IO-Link is a proven technology for extracting more information from low-level devices across a range of manufacturing environments. Endress+Hauser is a pioneer in digital communication and plays a

leading role in the implementation of HART, PROFIBUS DP/PA and FOUNDATION Fieldbus technology. As a market leader, Endress+Hauser continues to implement the groundbreaking Industrial Ethernet trend and was the first manufacturer worldwide to offer process automation field devices with PROFINET in addition to EtherNet/IP. IO-Link is the youngest member in the portfolio of Endress+Hauser devices and brings the digitalisation to our basic instruments. By digitally communicating data from sensors back to the PLC, this technology helps many organisations save on cabling costs, integration time and expand the amount of I/O available.

Digital communication unlocks benefits throughout the plant life cycle:• Efficient integration by using

standardised functions.• Faster commissioning and start-up.• Increased accuracy due to digital

signal transmission.• Effective maintenance by having

diagnostics with cause and remedy.• Plug-and-produce device exchange

through automatic parameter handling.

Process orchestration is typically done with an Automation Control System, which interconnects the controllers of each skid by using EtherNet/IP or PROFINET as the data exchange backbone. In auxiliary circuits, e.g. heat exchangers, devices such as the Picomag flow meter, provide additional process data to increase plant efficiency and up-time. Since IO-Link is fully digital, multivariable measurements from each sensor are possible (e.g. volume flow, temperature, totaliser).Simple measurement points such as pressure, level and temperature as well as valves can be easily integrated using IO-Link. The IO-Link master bundles the information and can store the sensor parameterisation for plug-and-produce device exchange. Intelligent 4-wire devices such as the Proline Promass S 300 can be directly connected using EtherNet/IP or PROFINET, enabling full transparency and seamless integration down to the field level.

Endress+Hauser Kiosk appOur customer magazines provideinteresting insights into industrialprocess engineering

Endress+Hauser DC Values appThe DC Values app offers comfortable access to several thousand DC values for all kinds of different media types in thefield of process automation

Endress+Hauser ExiCalculator appThe ExiCalculator app performs time-consuming mathematical operationsusually done by hand. It is easy, simpleand intuitive

ENDRESS+HAUSER APPS

Endress+Hauser Operations appGet access to up-to-date information about installed instruments

Endress+Hauser SmartBlue appComfortable and secure access to your devices. Particularly, in places difficult to reach or hazardous areas, it is very useful to be able to commission and operate thedevice via the SmartBlue app

Endress+Hauser Scanner appEndress+Hauser Scanner app is a simple way to capture and register assets and tags (e.g. instruments, valves, pumps, motors, etc.) in the Endress+Hauser Analytics web application.

ENDRESS+HAUSER APPS

The innovative way of working with IO-Link

Simply operate, configure and present your IO-Link devices with your tablet Benefit from the convenient and clearly structured iPad or Android app Work mobile thanks to integrated WLAN, Bluetooth LE and built-in battery

• Simply operate, configure and present your IO-Link devices with your tablet

• Benefit from the conveniet and clearly structured iPad or Android app

• Work mobile thanks to integrated WLAN, Bluetooth LE and built-in battery

The innovative way of working with IO-Link

Simply operate, configure and present your IO-Link devices with your tablet Benefit from the convenient and clearly structured iPad or Android app Work mobile thanks to integrated WLAN, Bluetooth LE and built-in battery

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Benefits of IO-Link• Simple configuration of sensors, which were not “smart” before.• Parameterisation can be done through engineering system or software tools.• Only one stock item is required.• Tuning of device parameters and output is possible in process.• Support of IO-Link Events: Standard Alarm, Warning and Notification.• NE107 Diagnostics: all Endress+Hauser IO-Link devices support the

“Device status” parameter.• Consistency with all other digital protocols.

The Endress+Hauser IO-Link Portfolio

Mpumalanga sales team

16 Faces of Endress+Hauser

People for Process Automation

Mfanafuthi MpungoseQ: What is your secret talent that no one knows about?A: I am a Zulu acappella composer and choreographer!

Q: Describe your life with a quote from a movie.A: I’d rather use the movie title, The Good, the Bad and the Ugly – ask no questions hear no lies…

Jan BothaQ: If you could throw a parade of any calibre through the office,

what type of parade would it be?A: It would be a Jamaican one, MAN! They have a vibe, and their

rhythm combined with the energy is beautiful for me.Q: What’s your favourite song to sing in the shower?

A: Don’t Worry Be Happy, Here’s a little song I wroteYou might want to sing it note for note

Don’t worry be happy, In every life we have some trouble But when you worry you make it double

Don’t worry be happy, Don’t worry be happy NOW.

Daniel KhaoleQ: At which store would you like to max out your credit card?A: Takealot, online shopping. I like the fact that I can shop at any time – even in my pyjamas – and I have a variety of product choices. I also save on petrol, don’t have to worry about parking hassles and annoying crowds.Q: Who would you most like to swap places with for a day?A: Dr Patrice Motsepe. Born in Soweto from a poor background and humble beginnings he climbed the success ladder and ended up as the only black billionaire in South Africa! He started the first black-owned mining business in the country through his determination, hard work and desire to succeed. A good example that hard work, determination, humble beginnings and drive can have lofty outcomes.

Charl McAllisterQ: Which four individuals, living or dead,

would you like to eat dinner with the most?1. Elon Musk, 2. Leonardo da Vinci,

3. Robert Oppenheimer, 4. Robert De NiroQ: What is the funniest thing that has

happened to you recently? A: My vehicle auto answered my mobile phone and I was caught singing

Elton John’s Rocket Man for a few seconds by one of my customers.We both had a good chuckle about my questionable singing skills!

17Endress+Hauser magazine

Everest Base Camp TrekThe ups and downs of getting to “the top of the world”

The BeforeI do not subscribe to the bucket list concept, (I believe for many people it is more important to have something on their bucket list than actually doing the activity), but I’ve been fascinated with Mount Everest since a very young age. I always knew I would be making the trek to at least Everest Base Camp before I got too comfortable in my cosy lifestyle. So with only 10 months having passed since a major multi-fusion neck operation, I prepared a speech for my wife explaining to her why I wanted to go on this expedition with grand analogies of soaring eagles and caged-up cockatoos. However, to my surprise, convincing her to “allow” me to trek in the Himalayas for almost three weeks was far easier than expected. It made sense when she subsequently insisted that we relook at the pay-out amount of my life insurance policy.

The TrekThe trek took us 12 days to complete, nine days to EBC and three days back. With cotton wool stuffed in our ears to muffle the dubious sounds of the small aircraft, our group of eight landed at Lukla Airport, widely considered to be the most dangerous airport in the world and appropriately so, my Mount Everest adventure then began, a period that can definitely be described as one of the most interesting times of my life… so far.The initial tranquillity of the first few

days of hiking in the forested lower parts of the Himalayas came to an abrupt end with a cheeky 500-metre ascend to 3 500 metres above sea level. The sudden loss of oxygen hits you on the chest like a sledge hammer and you soon realise that you are resting more often than a government employee.Our Nepali guide, an older man with little to no sense of humour but the wisdom of a thousand fortune cookies, saw every rest stop as an opportunity to explain to us the dangers of altitude sickness, a real risk at altitudes above 3 500 metres above sea level. This was sadly evident when two people from different groups later died at Base Camp due to the effects of altitude sickness, and countless more getting medically evacuated by helicopter.On the third day of trekking, already sucking air like a fish out of water, the little breath I had was taken away by the first glimpse of Everest. For the first time I really understood why legends like Edmund Hillary and

Tenzing Norgay would risk life and limb the conquer this beast. After eight days of hard trekking through testing terrain and over treacherous expansion bridges, having lost two hikers from our group to food poisoning and another to altitude sickness (they survived), we prepared for the final approach to Mount Everest Base Camp. The Yeti, as it is affectionately known, was not going to make it easy for us. After a four-hour climb at -15˚C, with a head wind that feels like it’s going to cut you in half, we reached the dizzy height of 5 365 metres above sea level. I hung a string of Buddhist prayer flags as is the tradition and celebrated with a few sips of the beer

I carried up the mountain before it froze to an undrinkable state.Early the next morning a small group of us started our climb to the summit of Mount Kala Patthar, 5 650 metres above sea level. This was by far the most challenging part of my trip. With 50% less oxygen than at sea level, we unceremonious felt the effect of the high altitude and we had to rest for 60 seconds every 5-6 minutes of the hike. Finally, as the sun rose behind Mount Everest, we reached the summit to be met by what must be the most amazing view in the world. Standing on the top of the world with a 360-degree view of hundreds of snow-peaked ancient geological giants, one cannot help but feel euphoric (…documented by a semi-naked photo to be seen by only a selected few).

Supplied by FP Aldrich, Project Contracts Manager at Endress+H

auser

53Know-how

Innovations with a vision Endress+Hauser continuously develops its range of products, solutions and services together with its customers. This makes everyday life in the process industry easier, safer and more efficient while creating new opportunities – even in outer space.

18 Innovation with a Vision

52 changes

Innovation with a visionEndress+Hauser continuously develops its range of products, solutions and services together with its customers. This makes everyday life in the process industry easier, safer and more efficient while creating new opportunities.

53Know-how

Innovations with a vision Endress+Hauser continuously develops its range of products, solutions and services together with its customers. This makes everyday life in the process industry easier, safer and more efficient while creating new opportunities – even in outer space.

19Endress+Hauser magazine

Endress+Hauser is venturing into the world of mixed reality: the combination of virtual elements and real surroundings are set to make the installation, operation and maintenance of measurement devices significantly easier.Mixed reality is leading the operation and maintenance of measurement devices into a new dimension by making it intuitive. “By means of mixed reality, abstract technical knowledge and available data can be linked and shown graphically. To achieve this, mixed reality combines the real environment with a computer-aided perception. Image-processing algorithms allow virtual elements to be placed in a room through mixed reality glasses such as Microsoft’s HoloLens. Unlike augmented reality, the user is not only able to see these three-dimensional elements but can also interact and control them using gestures – just like in a computer game.” Up until now, mixed reality has not been used to its full extent in industrial applications. In contrast, E+H aims to simulate every work step.To develop convincing solutions for users, several customers were asked

at the start of the project what they would like to use mixed reality for. The responses included training, installation and maintenance, with the transfer of knowledge being the common denominator. “In many manufacturing companies the turnover rates are high, while professionals are scarce, mixed reality allows devices to be operated with little prior knowledge and also enables experts to work even more efficiently.”Wiring instructions were implemented as the first application. This was followed by a set-up function that allows employees to parameterise the measuring device by marking the maximum and minimum level of a tank with two virtual disks. Previously the technicians had to first carry out complicated calculations. Another function displays the instruments’ maintenance status with virtual signal lights in different colours that hover above the devices. The app is also able to identify the fastest way to the measuring points, depending on the situation. Production downtimes in large-scale plants are very expensive, which is why the potentials arising from

efficient maintenance are especially prominent. The VisionBlue functions could help maintenance staff troubleshoot any issues themselves in future without having to acquire additional specialist skills.

A database of technical faults to allow for automated diagnosis will also be implemented. The application will be able to identify the problem through the symptoms entered by the user and then provide instructions to solve it. Just like all the other VisionBlue functions it will be fed with data from Endress+ Hauser’s Netilon IIoT ecosystem. A remote-call function is also in the pipeline: in this case, thanks to a tablet PC camera, an external specialist will be able to see exactly what the employee on site sees, and provide suitable support.In order to meet as many customer requirements as possible, there are plans to develop the mixed reality application for various mobile devices: complex functions such as navigation for the HoloLens and more simple applications such as remote support.

Do you want to learn more?www.za.endress.com/� l51

MAXIMIZE+ CAPITALIZE

You gain more options to fi t your needs, build-up product quality, increase safety, reduce costs and minimize risks.

We understand how you are challenged every day to enhance your plant’s safety and performance.

The new Liquiphant FTL51: rock-solid reliability

• Liquiphant is well-known for being a versatile, robust and easy to use point level switch

• With safety by design, developed according to IEC 61208,it perfectly fi ts to SIL2/SIL3 applications

• Heartbeat technology detects corrosion directly and minimizesthe verifi cation eff ort considerably

Master your medium with the new Endress+Hauser Liquiphant

• Point level measurement and density measurement together with the density computer FML621

• Developed acc. to IEC 61508 SIL2 and SIL3 in homogenous redundancy • Proof test out of the control room and on site via push button or test

magnet (proof test wizard via DTM and SmartBlue App)• Devices designed with process safety in mind, such as reliable

sensor technology and gastight feedthrough for housings protecting personnel and preventing electronic damage.

• SmartBlue App for Heartbeat Technology: Diagnostic, verification and monitoring (via Bluetooth)

• Heartbeat Technology, a trend-setting and innovative sensor verification and self- test concept to increase plant availability and improve productivity with optimised predictive maintenance strategy.

• Heartbeat monitoring with trend analysis (tuning fork resonance frequency trend)

20 Products

21Endress+Hauser magazine

Imko, an Endress+Hauser company, offers a wide range of moisture measurement technology, such as TRIME and SONO measuring devices, which operate on the basis of the TDR measuring principle. These patented products offer advantages that are unparalleled on a global scale when it comes to customer applications, which include:

• A very broad moisture measuring range of 0% to 100% over a temperature measuring range of -40°C to +150°C.

• Moisture measurement is accurate to within ±0.1%.• A wide range of applications including being able to measure

conductivity, mineral concentration and temperature. Measurements under extreme conditions are reliable. This is especially important when it comes to fresh concrete, foodstuff bulk goods and liquids such as acetone.

• Continuous measurement during processes without sample conditioning.

For more information visit www.za.endress.com/en/media-center/news-and-press-releases/acquisition-imko

Moisture MeasurementPatented technology from IMKO

Wish you were here!

Hannover Messe

Customer Tour

COMING SOON!2020

Water and Waste Water VIP Customer Seminar

23 - 27 SEPTEMBER 2019LOCATIONS FOR THE WEEK

Endress+Hauser Group Services, Reinach, SwitzerlandProduct Center Flowtec, Cernay, France

Product Center Conducta, Gerlingen, Germany

Total Cost: R28 000Includes: Accommodation, food, social activities

and all transfers related to the seminar

EXCLUDES: FLIGHT COSTS

FOR MORE INFO, CONTACT:Hennie Pretorius

Industry Manager: Water & Waste Water Email: hennie.pretorius@endress.com

011 262 8068 / 083 410 6996

22 Upcoming customer events

For more information contact

events.za.sc@endress.com

23Competition

Connect with usFor the latest updates, events and process automation news, join us on our social media channels. Visit Endress+Hauser Group on Facebook, Twitter and LinkedIn.

www.facebook.com/EndressHauser

@Endress_ZA

www.linkedin.com/company/endress-hauser-group

Email your picture to marketing.za.sc@endress.comClosing date: 31 September 2019

Win a voucher worth R1 000

Competition winners

Share the Love!

Competition

Chabu Mushibi and Phillip Chanda, Kansanshi Copper Mine Zambia

Helgard van Der Bijl, Inoxpa SA

Send us a photo of yourself holding a recent wazzup magazine, or spot the sign at our events and take a picture with the sign and send it to us to be entered into the competition draw.

Contact

Endress+Hauser (Pty) Ltd5 Commerce Crescent WestEastgate Ext. 13, Sandton

Tel: +27 (0) 11 262 8000Fax +27 (0) 11 262 8062info.za.sc@endress.comwww.endress.com