Products and Services PROCESS AUTOMATION. Industrial Process Measuring & Control Equipment

Products and Services PROCESS AUTOMATION Industrial Process Measuring & Control Equipment History International Activities Process Automation (Pt...
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Products and Services

PROCESS AUTOMATION Industrial Process Measuring & Control Equipment

History

International Activities

Process Automation (Pty) Ltd was founded in 1980 with

Our equipment is manufactured to the highest

the objective to manufacture a range of mass measuring equipment for process material handling plants such as

international standards and has been approved by

the Mines, Minerals Processing Plants, Cement and Chemical facilities.

Born & Bred in the Industry Process Automation is a by-product of the massive South African Mining Industry, which was served from conception, and grew into the largest mass measurement instrumentation manufacturing company in the Southern Hemisphere. Finding that the same products serve the needs of similar industries worldwide, Process Automation rapidly expanded into world markets.

various local and international organisations. Equipment has been supplied to many parts of the globe, i.e. Argentina, Australia, Chile, Brazil, DRC, Egypt, Ghana, Greece, India, Ireland, Jordan, Mali, Russia, Saudi Arabia, Tanzania, Zambia and others. A substantial order from Greece has been successfully executed. In the SADC region we supply the neighbouring countries of Angola, Botswana, Mozambique, Namibia, Swaziland and Zimbabwe.

Future Developments Ongoing R & D ensures that Process Automation remains

Process Automation has SABS accredited manufacturing facilities with a total floor space of approximately 5

a leader in the industry. Our manufacturing facility has SABS accreditation recognizing our efforts to produce

800m2 situated in Northriding AH, Randburg, South Africa.

equipment to the highest international standards. We have also obtained ISO9001/2008 accreditation. Our activities are based on a foundation of professionalism,

Five strategically situated offices, provide both Field Service and Sales support. These are located in

total commitment and an unswerving belief in our purpose. Our history of success gives us the pride and

Randburg (Gauteng), Middelburg (Mpumalanga),

confidence to guarantee a satisfactory outcome on every project.

Richards Bay (Kwa-Zulu Natal), Kimberley (Northern Cape), Rustenburg (Northern West) and Cape Town (Western Cape). A fully operational branch in Brazil (South America) is in place with manufacturing facilities and a service department. Agents operate in Angola, China, Egypt, Europe, Greece, Chile (South America), Zimbabwe and Western Australia.

Responsive Service Process Automation prides itself on a large contingent of competent & suitably experienced Engineers. Field Service is provided from our various service/sales centres. User training is provided to assist the customer towards self-sufficiency. User-friendly menu-driven products allow the user to maintain our products to the highest degree.

Markets Targeted The main market segments served :

Contact Tel: +27 462 0222 Fax: +27 462 0615 Email: [email protected] www.process-auto.com

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Mining & Quarrying – All sectors

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Base Metals / Minerals

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Cement & Lime

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Fertilisers

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Mineral Sands

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Paper, Pulp & Wood

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Power Generation

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Petroleum & Chemicals

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Steel & V anadium

P.O. Box 1915

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Grain / Animal Feeds

Randburg 2125

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Sugar, Bagasse & Pressboard

South Africa

148 Epsom Avenue North Riding AH Randburg 2162

Index BRANCHES

BLOCKED CHUTE DETECTION

INTERNATIONAL REPRESENTATION

ULTRASONIC LEVEL

CONVEYOR BELT SCALES

THICKENER INTERFACE LEVEL MEASUREMENT

WEIGH FEEDERS

TILT SWITCH

LOAD CELLS

BELT SPEED & SLIP SWITCHES

BIN AND FLASK WEIGHING

TURN KEY PROJECTS & SOLUTIONS

DENSITY & MASS FLOW SYSTEMS

SERIAL COMMUNICATION, FIELD BUSSES &

UNIRAD RADIATION MONITORS

SCADA SYSTEMS

DENSITY ANALYSERS / CALIBRATORS

QUALITY CONTROL / CERTIFICATION

BENCH & PLATFORM SCALES

ACTIVITIES

METAL DETECTORS

INDUSTRIES SERVED

Head Office - Randburg

Branches & International Representation

Middelburg

Rustenburg

Richards Bay

Kimberley

Cape Town

Brasil

EGYPT

AUSTRALIA

BRAZIL

CHILE

GREECE

INDIA

ZIMBABWE

Conveyor Belt Scales

Process Automation manufactures a variety of belt scales in acknowledgement of our customers varied requirements. The precision available from these scales not only depends on the model type but also (mostly) on the application into which they are to be installed. Our computer-aided analysis of the application(s), allows us to recommend the scale model best suited to meet the application and performance requirements. Process Automation manufactures 14 different scale models.

Weigh Feeders Process Automation manufactures a large range of Weigh Feeders to the clients specific needs and specification. Each Weigh Feeder is custom designed and built to exacting standards and for the precise application thereby avoiding the need for ‘shoe horning’ a standard design to approximate the weighing requirement.

From 500 Kg/h

to 2000 (plus) t/h

Load Cells

Bin And Flask Weighing From 7KG

to 2000t (plus) Process Automation has designed unique 7kg weighing systems/flasks that operate in harsh industrial conditions.

Density And Mass Flow Systems Model NDG 421 Density Gauge. The Model NDG-421 is supplied as a density gauge only, and is normally purchased by clients who wish to measure density only the Mass Flow Computation may be performed in the customers PLC /SCADA system. The NDG-421 is a blind unit that is calibrated via a hand held calibrator (PTU). This option requires that the flow meter signal be routed directly to the PLC (hard wired 4-20mA)

Model MFG 421-AIF Mass-Flow Density Gauge. The Model MFG 421-AIF Mass Flow Gauge, has the capability to accept the 4-20mA flow signal directly from the flow meter and will perform all the computation for Mass Flow. The Mass Flow output data is available via the field bus connection.

Model MFG 421-NIF Mass-Flow Density Gauge. The MFG-421-NIF Mass-Flow Density Gauge has the capability to accept the flow signal input via the Profibus® connection. The PLC needs to write cyclically, the volumetric flow rate to the MFG-421-NIF. Note: The format of this number should be a Siemens S7 format, floating-point (IEEE 744, single precision) representation of flow in engineering units e.g. 526,3 m3/h. All the variables normally associated with Mass Flow may be read from our MFG-421 via the Profibus® connection (Density SGU, Dry flow rate –t/h, totalled dry tonnes – t). No digital/analogue input/outputs are supplied with this system. The Density Sensors comprise a radioactive isotope (source) in holder, gamma radiation detector in housing and pipe clamp assembly.

Unirad® Radiation Monitors FEATURES UNIRAD® is a hand held, portable Radiation Monitor which is Auto Ranging making the measurements simple to read and uncomplicated in operation. UNIRAD also provides keypad selectable units of measurement(uGy/h, uSv/h, mR/h etc), to suit every requirement. In addition to a General calibration, for normal operation where the energy (isotope) is not known, it also has specific calibrations for the more common isotopes used in industry(137Cs, 60Co and 241Am), to provide an increase in measurement accuracy. The UNIRAD® is a combination of three separate instruments. It can behave as follows:

Radiation Survey Meter In this mode the display indicates it is in Survey Mode, it indicates the calibration selected is for the Isotope Caesium (Cs), it indicated that the measured radiation is Safe For The General Public, it indicates on a bar-graph type display the value measured with the Top-of-Scale plus the digital value of the measurement (using the selected Unit of Measurement)

Contamination Mode In this mode the display indicates it is in Contamination Mode, it indicates the calibration selected is for the Isotope Caesium (Cs), it indicated that the measured radiation is Safe For The General Public, it indicates the digital value of the measurement (using the selected Unit of Measurement) together with the error in the measurement (the longer the measurement is allowed, the more accurate will be the result).

Activity Mode In this mode the display indicates it is in Activity Mode, it indicates the calibration selected is for the Isotope Caesium (Cs), it indicates the distance (entered from the keypad) at which the measurement is made from the source of radiation, plus the calculated activity of the isotope being measured (using the selected Unit of Measurement) together with the error in the measurement (the longer the measurement is allowed, the more accurate will be the result).

Unirad® Radiation Monitors MODEL UNIRAD® 350 RP This model provides a compact package with the gamma sensor situated internal to the monitor.

MODEL UNIRAD® 350 RP This model provides for a hand-held Remote Probe arrangement. This version allows the use of a more sensitive gamma sensor. The Remote Probe is connected to the UNIRAD via a 1,5 meter cable.

MODEL UNIRAD® 350 TP This model provides for a Telescoping Probe arrangement, which can extend the probe up to 3 metres. This version is more suited where measurement of difficult to reach applications. This version allows the use of a more sensitive gamma sensor.

DENSIT Y ANALYSERS/ CALIBRATORS

Sample Flasks The Process Automation Sample Flask is designed specifically for drawing manual Density Samples from process lines. It is manufactured from stainless steel and its special shape provides for a minimised errors due to volume. These flasks are available in either 1, 5 or 10 litre capacity.

Unical The UNICAL is a low cost, hand held, portable density sample analyser. It is supplied to match the sample flask volume used. It allows the measurement/analysis of a hand drawn density samples. This is an invaluable tool for the Production Superintendent. The density analyser may also be used to aid with calibration verification of the gamma density gauge.

CAL-200 The Cal-200 is a durable, highly accurate, fixed installation density analyser, requiring mains power. It is supplied to match the sample flask volume used. The CAL-200 allows the measurement/analysis of a hand drawn density sample. This is an invaluable tool for the Production Superintendent. The density analyser may also be used to aid with calibration verification of the gamma density gauge.

On-board Density Analyser/calibration Tool As an option to the Series 420 Mass Flow/Density Gauges, it is possible to incorporate an “On-board” density Hand Sample Analyser. This option will allow the measurement/analysis of a hand drawn density sample - taken from the process. This feature allows the density gauge to keep a time stamped record of both the gauge measured density and the hand sample. This is an invaluable tool for the production manager. The density analyser results may also be used to aid with calibration verification of the density transmitter.

Bench and Platform Scales We offer a range of bench and platform scales, from the most elementary scales for feed control to certifiable scales for payment purposes. Errors as low as 0,15% of calibrated capacity are achievable.

Metal Detectors

Model 50 The Model 50 Metal Detector can be utilized for all industrial applications. They can be customized to ignore conveyed material, discriminate between different types of metals, and detect potentially damaging or undesirable metal.

New Digital Electronics - Microprocessor Based - Bar Graph Display - Membrane Keypad and Function LEDs - Multilanguage Available - Remote Operation Capability - Three Level Password Protection - Event Log - EEPROM Stored Parameters - Self-Test Circuit with Fault Alarm - Noise Reduction

Features t$VTUPN%FTJHOUPöUBOZ$POWFZPS t&BTZ*OTUBMMBUJPO /P/FFEUPDVU$POWFZPS t4XJOH"XBZ"OUFOOB tOptional Belt Clip Detector tOptional Pressure Spray Marking Device or Flag Drop Marker t'JFME3FQMBDFBCMF.PEVMFT t5ISFFZFBSXBSSBOUZ

EXAMPLES OF INDUSTRIAL APPLICATIONS - THE MODEL 50 tAggregate Protects Cone and Roll Crushers tAsphalt Protects Cone Crushers tMining Protects Cone and Roll Crushers tAluminum 1SPUFDUT*NQBDU$SVTIFST tCoal Protects Cone and Roll Crushers tCement Protects Cone and Roll Crushers tWood 1SPUFDUT)PHTBOE*NQBDU$SVTIFST tWaste Wood1SPUFDUT)PHTBOE*NQBDU$SVTIFST tPressed Board Protects Press and Saws tTire Recycling Protects Knives

Blocked Chute Detection

Gamma blocked chute, and point level

Microwave

Ultrasonic Level

Sultan – Acoustic Wave Level The SULTAN is a non intrusive acoustic wave transmitter with flexibility used for measuring liquids and solids. Remote, Integral & SMART units available. Can operate as a 2, 3 or 4 wire system. The SULTAN emits a high powered acoustic wave transmit pulse which signal is processed using specially developed software to enhance the correct signal and reject false or spurious echoes.

Primary Areas of Application - Water/Waste water - Mining - Power Stations

Microwave Point Level Microwave – Blocked Chute The Hawk Microwave Pulse Sender- Receiver Remote System is comprised of three electrically isolated units: the sender unit, the receiver unit and amplifier unit. Primary Areas of Application; Any application where microwave energy is absorbed by the material being monitored, including replacement of traditional contact switching devices used in mining, sand and gravel quarries, cement plants, pulp paper, plastic, rubber, coal fired power plants, steel mills, aluminium smelters, food, pharmaceuticals and other manufacturing fields.

Point Level Gladiator Smart Switch Series The Admittance Switch is a guarded shield sensor design which monitors a change in impedance which is proportional to the admittance between the sensing probe, the product and the vessel wall. It features excellent temperature stability and switch point repeatability. Vibration Switch - the piezo-electrically stimulated oscillating probe vibrates at its mechanical frequency of resonance. If the probe is covered by bulk material, the damping thus generated is registered electronically and a corresponding signal output is actuated. The device is used for level monitoring in all types of containers and silos and for both liquids and solids.

POINT LEVEL Gladiator Smart Switch Series The Conductivity Switch is used for level monitoring of electrically conductive liquids, muds etc in all kinds of metallic and non-metallic containers. The Rotating Switch vane is driven by a slow speed synchronous geared motor. For safe and multi-purpose level monitoring in all types of containers and silos. It can be used with all bulk materials and powders as a point switch.

Thickener Interface Level Measurement

Principle of Operation The ORCA series Sonar transmits a sound pulse through the liquid towards the blanket/interface at the bottom of the tank. The pulse is reflected off the blanket/interface back to the sonar transducer, which is interpreted by the Orca transmitter, compensated for temperature and provides a distance reading to the blanket/interface or height of blanket/interface from the bottom up. An analogue output or comms based output tracks this blanket/interface. The ORCA series also provides a second independent output that can be programmed to track either the clarity of the water (liquid) monitoring the change of suspended solids, or other stratified interfaces or, the fluff/floc layer (where the interface moves independent of the RAS blanket/bed level and needs to be monitored to prevent overflow into the launders). The ORCA processing software monitors the operating efficiency of the sonar transducer. As the efficiency drops off, due to build-up of scum, air bubbles, scaling etc. to the transducer diaphragm, the automatic cleaning mechanism will remove all scum and attached solids to restore the sonar transducers optimum efficiency.

Ultrasonic Level

ORCA – Sonar Sludge Level System The ORCA series Sonar will measure up to two density interfaces simultaneously, either bed level or RAS blanket and floc/fluff layer or clarity of water, using the new ORCA Sonar hardware.

Primary areas of application - Water Treatment Plant - Sewage Treatment Plant - Industrial - Mining/mining processing

Thickener Interface Level Measurement

Mounting Bracket and Electro Actuator Cleaner

7 Crystal Array Sonar Sensor

Typical Bed Level Control

CLARIFIED ZONE

FREE SETTLING ZONE

HINDERED ZONE

COMPACTED ZONE

Sonar Level Sultan Flow – Open Channel Real time flow measurement of liquid materials. Head, flow and flow volume data can be measured.

Primary Areas of Application - Open Channel Flow - Special flow requirements for unusual flow channels - Water treatment - Sewage treatment- Irrigation - Industrial waste - Power waste

Tilt Switch

Model TSCS-901 - Rugged - Reliable - Repeatable - Affordable - Easy to install - Environmentally safe (no mercury) - One piece (no costly external circuitry)

Specifications - Zinc plated carbon steel housing - Optionally PVC or stainless steel - Sealed snap action SPDT switch rated 5 amp. 220 Volt AC non-inductive load / 5 Amp 30 volt - 3 metrer 4 core cable supplied as standard - Internally grounded - 2 second delay - ± 15 degrees sensing angle on any axis - 0 - 65 degrees centigrade operation

Belt Speed and Slip Switches The Model SS-501 Speed Switch is a unitised construction with integrated drive assembly making it a simple task to install the sensor assembly into any belt conveyor stringer. No additional hardware is required. The drive assembly is a rugged construction with proven track record of operation in Mining and Industrial applications. Little or no maintenance required. The tachometer utilized in the SS-501 is identical to that offered for the belts scale therefore minimizing spares holding. Operation under micro-processor control makes calibration a simple push button procedure.

The SS-501 conveyor measurement system can provide the following functionality: - Belt speed measurement - Belt speed switch - Belt slip detection The speed switch provides a relay output whenever the belt speed falls below or exceeds the field programmable Set-point. The Model SS501 is a universal speed-measuring device that is also suited to the following applications: - Measuring the speed or rotational shafts (min. 0,8 RPM). - Measurement of slow belt speeds. - Conveyor belt slip detection. - Automatically cut back the feed rate as the smallest amount of belt slip is indicated. Give warning to the PLC that belt slip has started to occur and steps need to be taken to prevent serious slippage and/or stop the feed immediately. Give early warning first and take action if timely correction action is not instituted. Used for a differential alarm on overland conveyors. Measurement of belt slip on apron feeders and other slow belts and to measure the rotational speed of magnetic separators or other rotational shafts.

Turnkey Projects and Solutions

Serial Communication, Field Busses & Scada Systems For those applications requiring connection to a host/supervisory computer, serial & field bus connectivity is supported. To implement such a system, an Industry Standard supervisory computer (PC, PLC, DCS or similar) may be connected to one or many UNIPRO. Serial connection to the UNIPRO allows for reduced cabling requirements, while providing more information than is normally available from the transmitter. The transmitter will also accept set-point information from the host computer.

The following field bus / networks are supported: - ModBus RTU® - MODBUS PLUS® - PROFIBUS® DP - DeviceNet® - Allen Bradley Remote I/O - Allen Bradley/Rockwell ControlNet - Ethernet

ModBus RTU® Modbus RTU is supported. This is achieved by making use of an Anybus® Modbus RTU module, which plugs into the UNIPRO computer bus. Communication speeds up to 57.6 kbit/s are supported. Termination is via DB-9 connector. Cable is shielded twisted pair (copper). Refer to our drawing WIR-A3-0540 for details.

MODBUS PLUS® Modbus plus® is supported using the MODBUS PLUS® ANY-BUS® module which plugs into the 3000 ANY-BUS Carrier Board on the UNIPRO computer bus. Communication speed is fixed at 1 Mbit/s. Termination is via “special” DB-9 connector. Cable is shielded twisted pair (copper). Refer to our drawing WIR-A3-0394 for details.

PROFIBUS® DP Profibus® connectivity is supported, using the DP implementation. This is achieved by making use of our 3000 Profibus® DP module which plugs into the UNIPRO computer bus. Communication speeds of up to 12 Mbit/s are possible (the actual communication speed is determined by the Host). A dual version of the Profibus® DP module (3000/2

Profibus® DP module) is also available for those applications where dual redundant Profibus® DP networks are installed. The recommended implementation of Profibus® for conveyor scale applications is Profibus® DP. Termination is via Profibus (DB-9) connector. Cable type is special Profibus cable (copper). Refer to our drawing WIR-A3-0512 for details.

DeviceNet® DeviceNet® is supported. This is achieved by making use of an Anybus® DeviceNet® module, which plugs into the UNIPRO computer bus. Communication speeds up to 1 Mbit/s are supported. Termination is via special “Open Style” 5 way Phoenix connector. Cable is special DeviceNet cable with 24 VDC power & shielded signal pair (copper). Refer to our drawing WIR-A3-0544 for details. Note: Some PLC have limitations in memory, resulting in the number of UNIPRO per network being limited.

Allen Bradley Remote I/O Allen Bradley Remote I/O is supported. This is achieved by making use of an Anybus® RIO module, which plugs into the UNIPRO computer bus. Communication speed is variable between 57.6, 115 and 230 kbit/s. Termination is via 3 way Phoenix connector. Cable is shielded twisted pair (copper).

Allen Bradley/Rockwell ControlNet ControlNet is supported in both standard and Dual Redundant versions. This is achieved by making use of an Anybus® ControlNet module, which plugs into the UNIPRO computer bus. Field cabling required is RG-6 quad shield co-axial type (copper). Termination is via BNC connector. Communication speed is fixed at 5 Mbit/s . Co-axial cable distances: 250 m max with 48 nodes. 1000 metres with 2 nodes. 5000 m with repeaters.

Quality Control / Cer tification Process Automation belts scales are approved by the SABS and the Department of Trade and Metrology for Custody Transfer (assized applications).

Process Automation manufactures all equipment in accordance with ISO 9001 procedures.

Process Automation is proudly BEE certified.

Process Automation (Pty) Ltd Company Address: 148 Epsom Avenue, Northriding A/H, Randburg, 2162 Registration Number: 1979/004702/07 VAT Number: 4090103120

Level Six (6) Contributor

60% 30.00%

Ownership Management Control

20.00

Employment Equity

0.00

Skills Development Preferential Procurement

17.52

9.25

Enterprise Development Socio-Economic Development

0.00

0.00 5.00

HR/MLE/312/11 24 November 2011 23 November 2012 Pansy Morapedi

2 December 2012

30.00%

Activities

Process Automation is structured to provide a full range of services, encompassing: - Conceptual Engineering - Research & Development - Application Analysis - Manufacture - Installation & Commissioning - Service Contracts

Industries Served - Mining and Minerals - Petroleum, Synfuels - Chemicals - Food and Beverage - Water and Effluent Treatment - Power - Iron and Steel - Transport Industry

Notes

Tilt Switch

Our services and products have reached countries all over the world and our equipment is manufactured to the highest international standards.

www.process-auto.com

Contact information

Johannesburg(RSA)

Western Cape(RSA)

Kwa-Zulu Natal(RSA)

Rustenburg(RSA)

Tel: +27 11 462 0222 Fax: +27 11 462 0615 [email protected]

Tel: +27 21 982 6490 Fax: +27 86 684 9726 [email protected]

Tel: +27 35 751 1058 Fax: +27 35 751 1059 [email protected]

Tel: +27 14 596 7604 Fax: +27 14 596 6859 [email protected]

148 Epsom Avenue

Icon Bus. Park, Unit A9

16 Macgra Park, Cnr Alumina

Shop 5 Platinum Business Park

North Riding AH

Fourie Str, Brackenfell

Allee & Bronze Bar avenues,

97 Ridder Street, East end

Randburg, 2169

Cape Town, 7560

Alton North, Richards Bay, 3900

Rustenburg, 0299

Northern Cape(RSA)

Mpumalanga(RSA)

Zimbabwe

Brasil

Tel: +27 53 861 1709 Fax: +27 53 861 1890 [email protected] Telkom Bld, Block J

Tel: +27 13 243 1462 Fax: +27 13 243 1312 [email protected]

+263 4 770 977

+55 (21) 2491-1377

[email protected]

[email protected]

Applied Automation Technologies

82 Wes Street, Central

24 Douglas Road, Workington

Cnr Drakensburg & Schmidtsdrift

Middelburg

Zimoco Centre , Harare

Rua João Silva, 229 Olaria, Rio de Janeiro - RJ Brasil, CEP 21031-410

Carters Glen, Kimberley 8301

Mpumalanga, 1050