Pipes, Pumps & Valves Africa Sep/Oct 2018

ENDORSED BY SAPMA, SAPSDA, SAVAMA AND VAMCOSA

Electra Mining Report Back Overcoming dry spells

SEP/OCT 2018

Standardised

Customised

Systems-based

You choose. We supply.

Our wide range of standard pumps and valves provides plenty of scope for individual demands. You can select the materials, hydraulic systems and drives. When you’re facing complex tasks, we’re with you from Day One – whether you want planning guidance, specially designed components or help with commissioning. But see for yourself. Test our products for quality and versatility, and discover why KSB is so often first choice.

KSB Pumps and Valves (Pty) Ltd www.ksbpumps.co.za tel: +27-11-876-5600

Our technology. Your success.

Pumps

n

Valves

n

Service

One provider

CONTENT COVER STORY BMG offers SAFi Thermoplastic Valve Solutions

4

INDUSTRY NEWS

ENDORSED BY SAPMA, SAPSDA, SAVAMA AND VAMCOSA

Driving local manufacturing capabilities

6

Electra Mining Report Back

8

SEP/OCT 2018

PRODUCTS & SERVICES GHM Messtechnik South Africa – Specialists by competence

12

PUMPS Krebs brings new level of hydraulic efficiency in slurry applications

Electra Mining Report Back

14

Overcoming dry spells

On the cover BMG-PUM19102018 - PPV

Monday, 22 October 2018 9:26:11 AM

What is a peristaltic pump?

16

Weir Minerals pontoon solution at Madagascar mine

18

Counting the cost between inexpensive short term installation versus more expensice long term installation?

20

Global pump manufacturer obtains level 1 B-BBEE certification

22

Integrated Pump Rental’s SlurrySucker relieves silting at chrome operation 24 The term Internet of Things (IoT) has become far more than a buzzword

26

Forward-thinking municipality uses pumps to generate electricity

28

New Electric Tensioning Pumps

30

VALVES Overcoming dry spells

31

Corflex supplies Pinch valves for tailings projects

34

Industrial slurry valves for harsh mining conditions

36

Innovative vertical gravity samplers designed and manufactured by eDART MITECH Control Valves Open Day

38 40

Well-refreshed 41

BUYERS GUIDE

44

BMG World

Tel: +27 (0) 11 620-1581 Email: williaml@gmgworld.net Web: www.bmgworld.net

Pumps & Valves Africa

Managing Editor:Electra Surita Marx Mining Report Back Tel: +27 (0) 11 475-0010 Overcoming dry spells Cell: +27 (0) 83 281-5761 Email: info@pumpsandvalves.co.za Web: www.pumpsandvalves.co.za Sales: Lusana Mrkusic Email: lusana@pumpsandvalves.co.za Sales: Kyle Rametsen-Spalding Email: info@pumpsandvalves.co.za

Advertisers AC Valves 23 Ainsworth Engineering 29 Air & Vacuum Technology 34 AMD Rotolok 17 Atlas Copco 37 BMG World OFC Corflex Engineering 6 CRI Pumps 30 Ernest Electro 19,43 Hidrostal 7 Invincible Valves OBC KEW Foundry 13 KSB Pumps IFC Macsteel 35 SAM Engineering 33 Stewarts & Lloyds IBC Tectra Automation 25 VAG Klamflex 39

Disclaimer

Opinions in this Publication are those of the authors and do not necessarily reflect those of this publication, its editorial board, its editor or its Publishers SAPMA. or VAMCOSA The mention of specific products in articles and advertisements does not imply that they are endorsed or recommended by this Publication or its publishers in preference to others of a similar nature, which are not mentioned or advertised. Reliance on any information contained in this journal is at your own risk.

While every effort is made to ensure the accuracy of editorial board makes no representations or warranties, express or implied, as to the correctness or suitability contained and/or the products advertised in this publication. The Publisher shall not be liable for any damages or loss, howsoever arising, incurred by readers of this publication or any other person/s. The Publisher disclaims all responsibility and liability for any damages, includes pure economic loss and any consequential damages, resulting from the use of services or products advertised in this publication. Readers of this publication indemnify and hold harmless the publisher, its officers, employees, and servants for any demand action, application or other proceedings made by any third party and arising out or in connection with the use of any services and/or products or the reliance on any information contained in this publication.

Pipes, Pumps and Valves Africa - Sep/Oct 2018

3

PUMPS COVER STORY

BMG offers SAFi Thermoplastic Valve Solutions SAFi valves, strainers and flow control equipment, form an important part of BMG’s extensive range of fluid technology components, and are designed to cope efficiently in arduous conditions, including the mining sector.

“What’s distinctive about the SAFi range, is that all SAFi products are manufactured from the finest thermoplastic materials, combining quality, safety and product suitability, for specific applications,” says Willie Lamprecht, BMG’s national product manager, Industrial Valves. “Since BMG was appointed exclusive distributors by SAFi Thermoplastic Valve Solutions in sub-Saharan Africa a year ago, we have seen a growing demand for thermoplastic materials over conventional alloy metals.

- all manufactured from non-corrosive thermoplastic materials.

SAFI’s most used material - Glass Reinforced Polypropylene (GRPP) has excellent mechanical, chemical and UV resistance, good dimensional

stability and can be easily machined and welded. This material can withstand operation in temperatures from -10˚C to +100˚C. Polyvinylidene Fluoride (PVDF) is a highly resistant thermoplastic, with

“Critical advantages of lightweight thermoplastic materials are resistance to aggressive chemical products, corrosion and abrasion resistance and easy maintenance.”

BMG’s SAFi range incorporates ball, butterfly, diaphragm and check valves, as well as flow control equipment, strainers and accessories

4

SAFi’s lightweight thermoplastic materials are integrated with a robust valve design for reliable performance, easy installation and low maintenance, reduced operational costs and extended service life.

Pipes, Pumps and Valves Africa - Sep/Oct 2018

COVER STORY BMG’s extensive range of SAFi valves, strainers and flow control equipment, form an important part of BMG’s fluid technology components, designed to cope efficiently in arduous conditions, including the mining sector.

a smooth surface, which prevents the development of micro-organisms. This material, with excellent UV, chemical and abrasive resistance, offers longterm stability at temperatures from -20˚C to +120˚C. Polypropylene (PPH) materials have good chemical properties, in particular with salts, acids, alkalis and organic solvents. Other features include excellent mechanical and shock resistance and thermal stability from 0˚C to +90˚C. Chlorinated Polyvinyl Chloride (C-PVC) and PPH thermoplastic with carbon fibres (PP-ATEX materials) are semiconductive and compliant with ATEX specifications for safe use in hazardous environments and potentially explosive atmospheres. This is particularly important in the mining sector.

The trend in the mining sector, to choose thermoplastic industrial valves over standard components, is evident in process applications that include heap and in-situ leaching (ISL),

electrowinning, solvent extraction and acid plants.

logistics, marine, food production, energy and agriculture.

BMG specialists recommend SAFi thermoplastic ball valves for use in on/ off regulation applications in mining.

These thermoplastic ball valves are maintenance-free and have the ability to close faster, also ensuring extended service life.

BMG’s extensive range of components for fluid technology systems and general industrial applications, includes valves, hydraulic hoses and fittings, accumulators, cylinders, heat exchangers, hydraulic motors and hydraulic plumbing, as well as pumps and reservoir accessories.

SAFi DN400 butterfly valves, with LUG type flanges, are also well suited for the mining sector. These robust valves are lightweight and have been designed for easy maintenance and reduced costs. The quality of the thermoplastic used makes this a premier valve, offering optimum performance and extended service life. Different sealing arrangements adds to the versatility of this range.

BMG’s extensive range of SAFi thermoplastic industrial valves is designed to handle corrosive and abrasive materials in demanding industries, including chemical and petrochemical plants, mining, water treatment, transport and

The company’s fluid technology services also cover project engineering and consulting, cylinder design and manufacture, training, repair and testing, as well as on-site container services. BMG also offers total process and lubrication management solutions throughout the African continent.

Contact Willie Lamprecht, National Product Manager, Industrial Valves, BMG, Cell: +27 (0) 72 326-4832, Tel: +27 (0) 11 620-1581 or +27 (0) 11 955-1119, williaml@bmgworld.net, www.bmgworld.net

Pipes, Pumps and Valves Africa - Sep/Oct 2018

5

INDUSTRY NEWS

Driving local manufacturing capabilities There is enormous potential for Southern African manufacturers to increase their market share both locally and internationally. The driving force behind capturing this growth opportunity is the South African Capital Equipment Export Council (SACEEC).

“It is critical for the sustainability of local manufacturing operations that they aggressively pursue opportunities to increase their market share. Not only is this relevant to their increased permeation of the overseas market, but furthermore, they need to capture market share that is currently being monopolised by importers. Recent statistics indicate that South Africa currently imports products to the value of a staggering $83.2-billion. If we were able to shift this demand to the local manufacturing sector, we could realistically create 1.329-million jobs,” says Bruggeman.

Eric Bruggeman, CEO of SACEEC

According to Eric Bruggeman, CEO at SACEEC, part of the Council's mandate is to organise outward selling and inward buying missions. “We identified a need to showcase the offerings of the SADC region’s local manufacturers in an interactive manner. The result is the inaugural Local Southern African Manufacturing Expo (LME) being held at the Expo Centre, Nasrec from 21 to 23 May 2019.”

“Endorsed by the Premier of Gauteng, David Makhura, we believe that the exhibition will enable exhibitors to meet with top decision makers from the inward buying missions already committed to the event. As Industry 4.0 continues to transform the way that manufacturers do business, LME 2019 will provide them with an opportunity to grow their customer base, with the knock-on potential for fostering job creation,” says Charlene Hefer, portfolio director for Specialised Exhibitions Montgomery.

6

Pipes, Pumps and Valves Africa - Sep/Oct 2018

Held during Africa Week, LME 2019 will give local manufacturers from South Africa and other SADC regions a chance to not only display their capabilities and capacities to a captive audience, but furthermore it creates a forum for the exhibitors to network with their peers.

“We are excited about the prospect that local manufacturing operations have to evolve and expand by interacting with the inward buying mission representatives.

Added to this are the benefits derived by the support of SACEEC, together with AREI (Association of Representatives for the Electronics Industry) and the dti (Department of Trade & Industry). We urge local manufacturing companies throughout Southern Africa to capitalise on the unique marketing opportunities of exhibiting at LME 2019,” says Hefer.

To book a stand at LME 2019 or to find out more information about the exhibition visit the website at www. localmanufacturingexpo.co.za Contact: Natasha Heiberg, Specialised Exhibitions Tel: 010-003-3083, info@localmanufacturing.co.za Web: www.localmanufacturingexpo.co.za

The original Screw Centrifugal Pump

Johannesburg +27 (0) 11 704-5333

KwaZulu Natal +27 (0) 31 914-1007

Eastern Cape +27 (0) 82 561-8356

sales.za@hidrostal.com

www.hidrostal.co.za

www.hidrostal.com

OVER 800 EXHIBITORS GENERATED SALES LEADS AND BR

Electra Mining 2018 was an amazing show for Pipes, Pumps & Valves Africa with thousands of visitors attending the fi transport and related industries. Engaging with over 800 exhibitors, visitors have seen many new products launched hundreds of live demonstrations. The value-add free-to-attend seminars offered an excellent learning platform and

The high quality of visitors to the stands, most of whom are senior decision makers, make Electra Mining Africa the together in one place and to meet potential new clients. Hundreds of sales leads have been generated. It’s an impo

Specialised Exhibitions Montgomery is one of the most widely respected exhibition companies in the world with tra The Electra Mining Africa team is highly experienced and brings many years of knowledge, expertise and success to

KSB Pumps

Gorman Rupp

Ecochem Pumps

Amandla Pumps

Monitor Pump

Atlas Copco

Letaba Pumps

Zest WEG

Becker Mining

Pumps & Valves Africa

Weir Minerals

RNE Pumps

RAND AWARENESS AT ELECTRA MINING AFRICA

five days of Electra Mining Africa. They came to see the latest innovations across mining, industrial, electrical, power, d at the show and new technologies unveiled. They were also able to see machinery and equipment in action during the co-located conferences delivered great insight and knowledge to the delegates.

e ideal place to be. It’s busy, it’s interactive, it’s a great place to showcase their products and to get all their clients orted marketing tool for them – which is why they come back again and again!

ade shows, consumer shows and specialist projects currently spanning Europe, the Middle East, Africa and Asia. the show.

SAM Engineering

Rotork

Pump & Abrasion

Bovu Pumps

Kirloskar

Mine Track & Tools

Verder Pumps

Grundfos

Aveng DFC

Dymot Engineering

AZ Armaturen

Hazleton Pumps

KV Controls

AR Controls

Liquid Movers

Global Pump

Netzsch

Actom

Xylem

Celtech Pipes

Prochem

African Pipes, V

Invincible Valves

m Pumps

Valves & Fittings

Bray Controls

Kira Valves

CRI Pumps

ATS 2000

Intergrated Pump Technology

Afromix

Franklin Electric

PRODUCTS & SERVICES

GHM Messtechnik South Africa - Specialists by competence

Since inception, the GHM Group has sought to constantly add layers of expertise and competence through the development and acquisition of brands that not only offer precision measurement, but that also offers a dynamic cross-over of synergies to their customers.

Over the years the group has brought on board leaders in the field of instrumentation, control and measurement, such as Honsberg, Delta OHM, Greisinger, Val.Co, IMTRON and Martens, all offering unique Centres of Competence.

Greisinger Greisinger devotes a great deal of effort to compact designs and is a specialist for hand-held measuring devices, indicators, regulators, and transducers and temperature sensors which combine technology and measurement precision. Over 100,000 devices are delivered yearly to customers.

As a Centre of Competence, based in Germany, for measuring devices, indicators and regulators, as well as temperature sensors, Greisinger bundles the extensive know-how of experienced specialists under one roof. Market trends are tracked by Greisinger and taken into account in the development of new technologies.

Honsberg For decades, the Centre of Competence Honsberg in Germany has been regarded as a top address for measuring and monitoring flow, fill level and pressure in industrial applications. Dependable application engineering and

12

Pipes, Pumps and Valves Africa - Sep/Oct 2018

innovative knowhow from Honsberg specialists coupled with product quality and reliability have made Honsberg a major contributor to the success of our customers and is one of the best performers in the global marketplace.

Martens Sensors are the sensory organs of industrial production.

This sense is GHM Messtechnik South Africa - Jan sharpened at Marten’s Grobler - MD GHM SAa Centre of Competence in Germany, where the special need for measurement precision and inclusion of specific customer requests are developed. The entire spectrum of modern analysis and industrial measuring technology enables GHM to offer product versatility for a broad range of applications.

IMTRON As a manufacturer of metrological components for industrial applications the IMTRON brand stands tall, and its Centre of Competence based in Germany, is one of the most well-known providers in the market. IMTRON specialises in stationary and mobile testing procedures which assure activity in the power and automotive industries with components and systems.

IMTRON’s hardware and software provide important data and facts concerning all measure parameters, on stationary test stands of the auto sector and in mobile applications for test runs and test flights. This extends to power management and seamless monitoring of solar power plants and wind farms.

speed, photometry and light temperature and pressure have earned international recognition for Delta OHM innovation and product technology.

Val.Co Founded in 1982, Val.Co has quickly made a name for itself as a specialist in the industry of measuring and fill level measuring technology due to the quality and dependability of their instrumentation. They are regarded as a key player in the industry due to the experience and expertise of their technicians and have obtained ISO 9001 quality management accreditation.

Val.Co’s Centre of Competence, near Milan, enables them to draft, engineer and manufacture all of their products and systems which used in industrial processes, for the storing of mineral oil products, refineries, lubrication systems, cooling equipment as well as electricity generation plants and galvanic systems for the beverage industry.

In no other area can the collected of data take on such a decisive role as in the field of environmental measuring technology. Delta OHM’s Centre of Competence, in Northern Italy, has over 40 years of experience in the supply of state of the art sustainable components for the field of meteorology.

The entire GHM Group offering of specialised measuring instrumentation is available via GHM Messtechnik South Africa based in Alberton, south of Johannesburg. Managing Director, Jan Grobler, commented “We talk quality-based solutions for industrial applications. With such an array of reputable and timetested instrumentation and technologies, we believe that we are able to meet all industrial measurement requirements effectively whether it be via standard design or customer specific design”.

Measuring instruments, data loggers as well as environmental and weather stations for the capture of acoustic information, vibrations, micro-climate data, air quality CO-CO2, water analysis, relative humidity, wind

Contact Jan Grobler GHM Messtechnik South Africa Tel: +27 (0) 11 902-0158 Email: info@ghm-sa.co.za

Delta OHM

PRODUCTS & SERVICES

Marten’s sensors are utilised in building technology, plant engineering, food and pharmaceutical industries where basically any physical variable can be measured, recorded and evaluated.

BEING IN THE BUSINESS FOR MORE THAN 120 YEARS, WE KNOW HOW TO ASSIST YOU. KEW FOUNDRIES focuses on continuous product development and improvement in order to deliver a range of small to large quality castings.

Specialising in all grades of Grey Cast Iron and SG Iron between 1 kg and 10 500 kg, KEW services a variety of markets from its central location in South Africa.

KEW FOUNDRIES has built the expertise that allows the company to service the requirements of the VALVE Industry, PUMP and WATER RETICULATION Industries, Railways, Materials Handling and Rolling Element industries, just to name a few.

SERVICING ALL AREAS IN SOUTH AFRICA FROM KIMBERLEY SINCE 1893

©Creamer Media 101117CG

Contact us for your casting needs today: Tel: +27 (0) 53 841 0474 Fax: +27 (0) 53 841 0473 e-mail: info@kewfoundries.co.za Web: www.kewfoundries.co.za

Pipes, Pumps and Valves Africa - Sep/Oct 2018

13

PUMPS Krebs slurryMAX HP high pressure pump

Krebs brings new level of hydraulic efficiency in slurry applications The Krebs slurryMAX™ range of slurry pumps from global minerals process specialist FLSmidth has brought new levels of hydraulic efficiency to Africa’s slurry operations.

Offered with a range of material options for liners and impellers, the slurryMAX handles most plant applications across various industries. Its design is based on the success of FLSmidth’s millMax™ range of pumps, whose wear ring technology has created an efficient and long lasting slurry pump.

14

Pipes, Pumps and Valves Africa - Sep/Oct 2018

The slurryMAX features an improved, more efficient impeller and an optional water drain plug for easier maintenance, allowing water that might have settled at the bottom of the pump to be quickly drained.

In the slurryMAX 8 x 6 pump and larger units, a simple removable suction liner assembly allows for easy inspections of the internal components, as well as the replacement of the impeller without removing the discharge pipe. In addition, the volute liner has an integrated back liner that bolts securely to the outer drive side-casing. This makes for easier and hands-free assembly, improving the safety aspects of the pump. Maintenance crews will also appreciate the easyto-use lifting jig, for faster and safer rebuilds.

PUMPS

Krebs slurryMAX pump in lab

Krebs slurryMAX XHP extra high pressure pump

Also in the range is the slurryMAX XHP, which enables customers to design pumping systems with more stages and a higher final discharge pressure. The XHP uses the same wear parts as its HD and XD counterparts, but with an even more robust outer casing than the HP version.

Krebs slurryMAX CCD thickener underflow pump

Other models in the slurryMAX range include the XD version for aggressive applications, boasting thick elastomer liners and a heavy-duty impeller for extended wear life. The slurryMAX HP is the high-pressure version of this model, and is designed for multistage high pressure pumping systems.

Featuring a high pressure outer casing, the slurryMAX HP uses all the same wear-resistant parts as the XD, giving consistent performance and long life.

Predictable and even wear life across all wet-end parts is among the benefits of the slurryMAX pump, as are its heavy-duty shaft and taper roller bearings that cannot be over greased; these long-lasting bearings are rated at a minimum of 100 000 hours.

Willie Van Wyk, Flsmidth (Pty) Ltd Tel: +27 (0)10 210 4820, Email: Willie.vanWyk@flsmidth.com Web: Www.flsmidth.com Pipes, Pumps and Valves Africa - Sep/Oct 2018

15

What is a peristaltic pump?

PUMPS

A peristaltic pump is a positive displacement pump. The word peristaltic comes from the Greek word “peristaltikos”. Peristalsis movement refers to the wavelike muscular contractions of the digestive tract or other tubular structures by which contents are forced onward toward the opening.

In a peristaltic pump, fluid is pushed through a tube or hose by rollers or shoes compressing the tube/ hose. Peristaltic pumps are commonly divided into two categories, namely: • •

Tube Pumps: These are typically low flow and low pressure, utilising an extruded elastomeric tube within the pump.

Hose Pumps: These are typically higher flow and higher pressure, utilising a fabricated rubber hose with internal reinforcement braids.

Can a peristaltic pump handle dense slurries?

Yes, with hose-type peristaltic pumps, high density and high viscosity products are regularly handled with ease.

Is a peristaltic pump the best option for handling chemicals?

One of the advantages of peristaltic pumps is that the fluid being pumped is contained entirely within the hose. There are various tube and hose materials available offering a range of chemical compatibility options. Peristaltic pumps are routinely used for the dosing of chemicals due to their repeatable accuracy.

Where are peristaltic pumps most commonly found?

Peristaltic pumps can be found in a wide variety of applications, typically where other pumps struggle, such as high density and high viscosity applications, self-priming, high suction lift applications, as well as shear sensitive and dry run applications.

Peristaltic pumps can be found in almost every industry from mining and food to water treatment, brewing, paper, pharmaceutical and even fishing.

I am experiencing pulsation problems. what can i do to fix this?

When they are being used, peristaltic pumps inherently create pulsations. If a peristaltic pump is correctly sized and installed, pulsations can be reduced to an acceptable level. However, incorrectly sized and poorly installed pumps can experience high pulsations leading to poor performance and poor hose life.

In certain applications, suitable pulsation dampeners can be installed to alleviate pulsation problems. If you are experiencing pulsation issues, please contact Technical Support in the first instance.

16

Pipes, Pumps and Valves Africa - Sep/Oct 2018

How will cavitation affect the peristaltic pump?

Cavitation issues are not normally associated with peristaltic pumps. Peristaltic pumps generally have low NPSH requirements, and if pumps are correctly selected and applied, cavitation issues can be avoided.

What do I need to know when requesting a quote for an agitator?

If you are not sure what will be required for us to quote you on a mixer, please go to the “request a quote: AMX agitators page” for a user-friendly questionnaire. An AFROMIX applications engineer will then process your requirement.

Are AFX pumps available with flameproof options?

Flame-proof options are available; however, specific requirements should be discussed with Technical Support as Hazardous Area Certification can vary from country to country (e.g. Atex and ETL).

Is there technical support outside of South Africa which is available to clients?

Yes, technical and sales support is available through authorised agents and sister AFX companies. Please contact your local sales representative for more details.

Contact Afromix, Tel: +27 (0) 11 397-6911, Email: sales@afromix.co.za, Web:www.afromix.co.za

PUMPS Pipes, Pumps and Valves Africa - Sep/Oct 2018

17

PUMPS

Weir Minerals pontoon solution at Madagascar mine Regular engagement with Rio Tinto’s QIT Madagascar Minerals (QMM) operation and a good understanding of local conditions allowed Weir Minerals Africa to provide the optimal solution to the customer’s recurring challenge on a process pond.

According to Weir Minerals Africa’s Dewatering Product Specialist Neil Matthews, the mine was experiencing continual collapse of the 20 metre suction hose to the Warman® AH® 12/10 pump mounted on a skid at the back of the pond. This resulted in the need to keep priming the pump and was causing regular downtime.

“Unpacking the issues facing the customer was the first part of upgrading the mine’s process water utilisation,” says Matthews. “We discussed several options with the customer after which our dewatering and engineering teams collaborated closely to design a solution. It was vital to carefully consider the problem in the context of the geographic and site conditions, as well as the local fauna and flora.”

eye of the impeller, thereby ensuring consistent priming,” Matthews says.

One of the most important factors affecting the solution was Madagascar’s weather conditions, which include regular tropical storms and high wind speeds. These have the effect of creating wave action and wind loading on the pond during storms which the pontoon solution has to accommodate.

To address the wave action and minimise possible structural damage, the fixed walkway was designed to incorporate a

To provide the most suitable Weir Minerals products and solutions, the team specified a Warman® AH® 10/8 pump mounted on a Multiflo® pontoon with the pump coupled to a variable frequency drive (VFD) facilitating greater flexibility in dealing with varying site conditions. A second pontoon was fitted with a Warman® AH® 6/4 pump with motor and fixed speed drive as design conditions should remain constant throughout the life of mine.

Both pontoons are connected to a floating docking station which is, in turn, connected to a 20 metre walkway fixed to the bank-side landing.

18

“It is standard practice in most of our pontoon designs to mount the pump sets at 30 degrees to submerge the suction

Having the Warman slurry pump mounted onto the skid solves the customers problem with continually collapsing suction hose.

Engineered-to-order Multiflo pontoons are commissioned at the customer site.

One of the two Multiflo pontoons during installation phase.

Pipes, Pumps and Valves Africa - Sept/Oct 2018

PUMPS

Pumps are mounted at 30 degrees to submerge the suction eye of the impeller.

pivot system on the bank landing structure. This allows the entire assembly, including the docking station, to rotate 90 degrees and still be tied down to the shore during these storms.

“Madagascar is also known for its varied wildlife, including crocodiles,” says Matthews, “so the design of the handrails and other structures needed to prevent crocodiles from gaining access to the deck space.”

These creatures would tend to climb onto the deck to bask in the sun, making it almost impossible for staff to conduct routine maintenance. Restricting this access was achieved by closing all the gaps between the handrails and the separate structures.

“Our design took all the site conditions into account, making for better and more predictable operational reliability,” he says. “Both the pontoons and the pumps can now be easily moved for servicing or for securing during bad weather.”

He highlights that Weir Minerals Africa’s team’s experience with mounting pump sets onto pontoons and their extensive process-related knowledge played a significant role in developing the product offering for the customer.

“It was also important for the design engineers to be present during the commissioning process to ensure support,” Matthews concludes.

Contact Rajen Govender, Weir Minerals Africa (Pty) Ltd, Tel +27 (0) 11 929-2701, rajen.govender@mail.weir, www.minerals.weir

Pipes, Pumps and Valves Africa - Sept/Oct 2018

19

PUMPS

Counting the cost between inexpensive short-term installation versus more expensive long-term installation?

Managing or rather, reducing cost has become the mantra of almost every business.

In the pump industry reliability over a long period of time is a critical requirement for operators, but few seldom consider the importance of proper installation. Cutting cost and opting for an inexpensive installation can be an expensive long-term decision warns Loren Nauss, business development manager of polymer composites at the Henkel Corporation.

Most pump manufacturers advise customers to not only have a foundation with a mass three to five times the mass of the pump, driver and baseplate combined, but also to properly grout the baseplate as it bonds the base to the foundation.

“It is about saving cost and increasing profit.”

More often than not, says Nauss, the lack of knowledge particularly about grouting results in it not being done properly or even at all. Another factor that plays a role is cost.

“It is about inexpensive installation and because there is not a lot of knowledge about the benefits of a proper foundation 20

Pipes, Pumps and Valves Africa - Sep/Oct 2018

with grouting it is considered costly,” he says.

With the possibility of it requiring fabrication of a proper form or an expert to come in and do proper alignments it is often times an initial cost that is just not deemed necessary.

According to Nauss the proper grouting of a baseplate can significantly reduce maintenance practices and, in some cases, eliminate downtime.

“Increasing the longevity and efficiency of one’s investment is a critical element in the pump industry,” he says. “It is about saving cost and increasing profit.” The goal is to make equipment last longer with less issues during the operational times.”

“How many times have you gone to open a drawer or maybe a door at home or in the office and the handle is loose?

Maybe you live with it and leave it as it is or maybe you snug

it up a little with the end of your finger, knowing it is not that critical of an issue. Most of us have done it and it is not too much drama,” he says. “In the industrial maintenance and equipment world, the same situation of a loose fastener is, however, not so forgiving and can lead to a catastrophic chain of events, disrupting throughput of whatever widget or process it is a part of. If we think about why the fasteners loosened up on the door knob or drawer handle, it is likely that vibration and thermal expansion and contraction come into play – this is the exact same root cause of most industrial equipment failures.”

Misalignment can be costly

Also, when there is misalignment more energy is required for the vibrating, meaning more electricity is used and costs escalate further.

“If there is vibration for example it will cause the nut to loosen up as the plates go back and forth,” he says.

Using a thread prevention method or keeping misalignment and vibration to a minimum will reduce maintenance over the long run in any operation.

Do it properly, first time round Nauss says epoxy as a grout is more cost-efficient. Easy to mix and in kit form, it requires low skill to use.

‘If not installed properly alignment will not happen and maintenance costs will escalate”

“Pumps are a common piece of equipment in nearly all facilities and the issues found in pumps overlap all other equipment both big and small,” says Nauss. “The cause and effect of misalignment can be extremely costly.”

A full cure takes about 24 hours and the good adhesive properties work with baseplates of all materials. Concrete, on the other hand, has poor adhesive properties, does not stick to itself or to metal.

It can also significantly be reduced with machinery grouting.

This is when an organic epoxy or inorganic cement-based material is used as a filler between the bottom of a machine base and the top of the concrete foundation or metal equipment skid.

He says with a good foundation the impact of harsh vibration that wears the various pump and motor components down, is already reduced significantly.

“Machinery grouting is little understood and often overlooked,” says Nauss. “It really does unitize the foundation steel baseplate and the equipment. The only way to do this is by using a grout and proper grouting procedures.”

Part of the process, he says, includes understanding how threaded fasteners work and how they interact with a grouting application.

“If you turn a nut or the head of a bolt, you are effectively squeezing the two parts together. The more you tighten the nut, the less the bolt length is used and it is effectively stretched like a spring. The nut should be tightened until the target clamp load is reached. The clamp load is then retained by the bolt head friction and thread friction.”

“Increasing the longevity and efficiency of equipment” With bolted joints designed so that external forces never overcome the clamp load - the very reason why fasteners such as these are used - then why do threaded assemblies fail?

“If one looks at thread friction in more detail then there is only a 15% metal to metal contact allowance meaning some 85% of the fastener is empty or rather just air. The reasons for failure range from relaxation of the bolt to selfloosening, the impact of different thermal expansions or also corrosion.”

Nauss says it is essential to have a level, coplanar surface to mount a pump and driver, allowing for a proper and

PUMPS

Vibration decreases reliability, says Nauss. “It can lead to seals leaking that in turn can result in the wear, abuse and ultimately failure of seals through to bearings strains and premature failure of the equipment.”

precise alignment between the two. If not installed properly alignment will not happen and maintenance costs will escalate.”

“Epoxy grouts vibration damping capability is 26 times greater than concrete. As a product, it is superior when you want to grout things in place. Also, in order to effectively dampen and dissipate vibration you must correctly size the foundation and unitize the foundation steel baseplate and the equipment. The only way to do this is by using epoxy grout and proper grouting procedures.”

He says by acting as a mass damper, vibrations are reduced while it also maintains shaft alignment.

Nauss advises to always use a non-shrink grout as it avoids separation from walls of the plate, thus reducing vibration.

“Also ensure that all the entrapped air has risen to the top of the grout’s surface. Only pour from one side,” he says.

“It is also important to avoid softfoot – machine frame distortion where not all the feet are lined up and caused by an unbonded baseplate, poor leveling and not having enough mass.”

According to Nauss investing in the proper installation of a foundation and of grouting goes a long way in reducing overall maintenance costs.

He says best practice when grouting includes ensuring a clean surface. All soils should be removed while grit blasting metals allows for better mechanical interlocking.

“Make sure the frame or dam is built to OEM pad dimensions and specifications, that the entire surface is clean, dry and level. Seams must also be sealed and cured,” he says. “Do it right the first time and make sure nothing moves and it all stays in place. That is how you increase mean time between failures. By grouting and preventing vibrational loosing you are “increasing the longevity and efficiency of equipment” , saving money and increasing profit.”

Pipes, Pumps and Valves Africa - Sep/Oct 2018

21

Global pump manufacturer obtains level 1 B-BBEE certification PUMPS

KSB Pumps and Valves has become the first OEM pump manufacturer in South Africa to obtain Level 1 B-BBEE certification.

This follows the purchase of a 30% equity stake in the company by the black female-owned Insikazi Synergies (RF) (Pty) Ltd, a company with four business women shareholders including Nonhlanhla Ngwenya, Matshepiso Finca, who have joined the board to play an active role in steering the company in future.

Managing Director of KSB Pumps and Valves, Dr Sven Baumgarten, says, the deal is a first for the multi-national KSB Group, a German company which operates through subsidiaries around the globe.

“Achieving Level 1 B-BBEE Status has marked a significant milestone for us and is evidence of our philosophy of operating globally and thinking locally. For us, transformation is not only a strategic imperative for operating in this market, but something we embrace as a company that will soon celebrate 60 years of operating in South Africa. We are proud to be the first pump and valve Original Equipment Manufacturer (OEM) to achieve Level 1 B-BBEE status.

“Our heritage in South Africa started in the 1920’s and since then has continued with manufacturing of highquality products from our modern manufacturing, sales and serving facilities across the country. Our evolving growth story locally is interwoven within the fabric of South African life and we are fully committed to transformation for the betterment of all.

“Over the years KSB Pumps and Valves in South Africa has grown to employ over 500 staff and a turnover of nearly one Billion Rand. We are poised for further growth in South Africa and in Sub-Saharan Africa and look forward to continuing our long and fruitful partnership with local business and Government,” Dr Baumgarten concludes.

Contact Annett Kriel, KSB Pumps, Tel: +27 (0) 11 876-5600, Email: Annett.Kriel@ksb.com, Web: www.ksbpumps.co.za

KSB Pumps and Valves has become the first OEM pump manufacturer to receive Level 1 B-BBEE certification. Present were front: Tönjes Cerovsky, director, David Jones, regional sales manager Sub-Sahara Africa, Sahana Vaidya, Empower Capital, Matshepiso Finca, director, Nicola Mackay, recruitment and training, Shonah Smith, manager human resources and industrial relations, Zanele Maduna, alternate director and Nonhlanhla Ngwenya, director. Back: Clinton Harris, central functions manager, Friedrich Görgens, engineering manager, Dr. Stephan Bross, director, Dr. Sven Baumgarten, managing director, Jan Avramov, service division manager, Philip Haslam, Empower Capital, Grant Glennistor, operations manager and Michael Erasmus, financial manager.

22

Pipes, Pumps and Valves Africa - Sep/Oct 2018

A.C. Valves cc: 20 years in action The owners Andrew Bergstorm and Collin Scott established A.C. Valves cc from very humble beginnings in 1998 with the aim to recondition valves, and since has grown into a medium sized enterprise, based in Knight, Germiston.

A.C. Valves cc, manufacture and supply Knife Gate Valves to the Mining Industries, Department of Water and Sanitation, Paper and Pulp, and Chemical Industries. We also manufacture on customer request and specification.

At A.C. Valves cc we are constantly striving for product excellence, working hand in hand with customer at all times.

Local Manufacturing: A.C. Valves cc manufacture all of its valves locally.

Quality Control: To provide quality products and services, we have very strict internal quality control, there for testing is done to all valves manufactured by us.

3 Staal Road, Knights, Germiston P.O. Box 13557 Elspark 1418 Tel: +27 (0)11 822 2358 Fax: +27 (0)86 504 2119 Cell: +27 (0)82 467 1200 Andrew Cell: +27 (0)82 467 1196 Collin E-mail: acvalvescc@mweb.co.za Website: www.acvalvescc.co.za

PUMPS

When a chrome mine in the Steelpoort area recently experienced a challenge with a tailings dam overfilling with slurry sediment, it was Integrated Pump Rental and its SlurrySucker Maxi dredging unit that came to the rescue.

Integrated Pump Rental’s SlurrySucker relieves silting at chrome operation “One of our mining customers had a tailings dam that was filled with slurry to over 110% of its capacity and the sediment needed to be remove to ensure optimum functioning of the tailings facility,” Lee Vine, managing director of Integrated Pump Rental, explains.

Integrated Pump Rental’s SlurrySucker dredge units are suitable for dredging and cleaning water capture areas where silt or slimes has become an issue, or where water retention and water holding capacity in process ponds is being threatened.

Equipped with 37 kW Bravo 700 Grindex pump, and with capacity to pump 70 tph of slurry, the SlurrySucker Maxi operates at an average of about 40% concentration, depending on factors such as the material’s specific gravity and how solid the sediment has become.

The SlurrySucker cleaning a tailings dam at a chrome mine

24

Pipes, Pumps and Valves Africa - Sep/Oct 2018

PUMPS

The SlurrySucker desilting a tailings dam at a chrome mine

“The beauty of the SlurrySucker Maxi is that we only need one small area to begin the desilting work,” says Vine, “In this case, we started in one corner of the dam and created a cut by attacking the sediment to create space for more water to re-enter the working area.”

He highlights that the mine needed the dam to remain on line during the dredging, so water would continue to enter the pond from the processing plant.

“The SlurrySucker only needs a 400 mm draught of water above the sediment for the floating unit to operate,” he says. “A dewatering pump takes the top layer of water and feeds it down to the dredgehead, where the slurry is agitated so it can be pumped away.”

The dredging unit is pulled back and forth across the dam, creating a new cut on each journey by removing a lane of silt at a time. Despite its capacity of 75 dry tph, the SlurrySucker Maxi model’s compact design makes it simple to move and operate. It measures just 5,4 metres in length and is long, 2,5 metres wide and 3 metres high.

Contact Lee Vine, Integrated Pump Rental Tel :+27(0) 11 894-2906, Email: lee@pumprental.co.za, Web: www.pumprental.co.za

73757_Tectra Automation_Pump and Valves.indd 1

2016/08/11 4:27 PM

Pipes, Pumps and Valves Africa - Sep/Oct 2018

25

PUMPS

The term Internet of Things (IoT) has become far more than a buzzword Expected to revolutionise the manufacturing landscape, IoT nowadays is a common term in business meetings, sales calls and industry conferences. According to Eaton product managers Nicole George and Jake Wysocki there is no easy answer as to how and when a business should leverage IoT, but they say smart pumps are on the rise and new IoT business models are fast becoming a trend.

When it comes to next generation technologies it is often important to start with definitions. That way one is ensured that everyone is on the same page. While it seems quite an obvious starting point much of the industry confusion often begins with different definitions being used, explains Wysocki.

“Different people have different definitions of an IoT pumping system and unless one is speaking of the same thing it can be very confusing,” he says.

At Eaton, the accepted definition of IoT is network-connected devices that can produce, analyse and exchange data while a pumping system is a pump, motor, starter and the controls to control that system.

“It is all about the data,” says Wysocki. “IoT allows one to connect devices and use data to add value meaning the pumping system becomes smarter.

According to Wysocki smarter pumps are increasingly being sought by customers due to the benefits. Considering the

26

Pipes, Pumps and Valves Africa - Sep/Oct 2018

highly competitive operating environment where low margins remain the norm, equipment needs two attributes – performance excellence and cost efficiency.

Wysocki says more pump manufacturers are therefore integrating IoT technologies into pumps delivering the necessary value-add that customers require.

Leading research company Gartner estimates that at least 20 billion connected devices will be installed globally by 2020.

Already in 2017 more than 8 billion were in use, up 31% from 2016. Total spending on endpoints and services will reached almost $2 trillion in 2017.

The way forward According to George there are many benefits to installing an IoT pump system. “Around the world it is becoming a trend and the number of IoT enables systems is growing as many see the value of these systems, but it is still new technology and often we find that there is still hesitancy on ground level as people are not sure exactly what it is.”

PUMPS

Wysocki says there are four aspects that need to be considered when deciding to install such a system.

Hardware This, says Wysocki, is what is required for data collection.

“The most obvious way to collect data is in the form of sensors,” he explains. “It can be something as basic as a pressure sensor or be more complex depending on requirements.”

Both Wysocki and George advise that when looking at an IoT system one ensures one is installing the right sensors from the get-go.

“Be clear about what data you require as that will determine what is ultimately installed. Also consider visual data,” says Wysocki. This is increasingly being used as video and photographs give the ability to identify solutions far more in-depth as one is receiving better input.”

Transmission Moving the data from the source to the cloud is an integral part of a system and is not always as easy as one might think especially in remote areas with little or few networks.

“Without connectivity to the Internet it just remains a pump. Often the decision on how to transmit data is based on budget or even the availability of networks. Bluetooth, WIFI or Ethernet are some options as is satellite.”

reality glasses where one would literally see a 3-d model of the pump system in question when wearing these.”

Analysis

“Equipment manufacturers are moving towards IoT for a variety of reasons but the biggest is the value that it offers. It makes remote trouble shooting much easier, improves after sales service, introduces more efficiency and ultimately cuts costs.”

This is really the lynch pin of IoT, says Wysocki. “Once the data is collected and stored it is all about the ability to analyse and extract the relevant value-add information.

From very basic analytics about the here and now to the past performance of the pump or then even to predicting the future of it is possible.”

This is where one starts to develop a system where one can with reasonable accuracy forecast how pumps are operating, when maintenance is required, what parts will be needed and when to shut down or not.

User interface Data, however, is pretty useless unless there is an ability to access it as and when required, says Wysocki. “It is important in an IoT system to ensure that a user-friendly user interface exists. There is a lot of development in this regard and mostly data is accessed via phone or an iPad using an app of some sore. But work is under way towards the development of industrial use voice activated devices and even augmented

Real benefit According to George the benefits being seen by companies that implement smart pumps and IoT business models are the driving force in the increased use.

She says it is not just manufacturers that are seeing benefits but it extends across the supply chain.

“Equipment distributors for example are saying it allows them to have the right parts are the right place at the right time more efficiently, while service providers are able to do remote monitoring, predictive diagnostics and solve problems in single trips – quickly and more cost effectively.”

For system integrators, the value lies in very real labour savings due to more efficient start up and commissioning as well as better trouble shooting.

“All of this ultimately reduces the cost of ownership to the end user,” says George.

Photos Supplied by Eaton Pipes, Pumps and Valves Africa - Sep/Oct 2018

27

PUMPS

Forward-thinking municipality uses pumps to generate electricity A technical team serving the requirements of the Drakenstein Municipality in the Western Cape has designed one of the country’s largest pump and turbine stations to be used for water reticulation to the nearby town of Paarl in dry periods, and as turbines to generate electricity for the city during the remainder of the year.

The City’s engineer for water operations, Hein Henning, says the city was faced with the dilemma of having to pump water to its neighbour for just one month a year. For the rest of the year the pump station would be dormant and need hundreds of thousands of Rands maintenance due to possible corrosion, perishing, lubrication and bearing damage to the idle infrastructure.

Instead, the progressive municipality chose to innovate and rather generate an income while simultaneously reducing the requirement for maintenance by effectively allowing the pumps to run backwards against the pressure of water from its elevated Leliefontein reservoir and generate electricity for the region’s electrical grid.

Generating power The commissioning of the pump and turbine station (PaT) effectively brings online one of the largest such project of its kind in South Africa, able to generate 57 kW (all mechanical & electrical efficiencies taken into account) with 3 turbines, which is enough to power the entire region’s water infrastructure of treatment plants, pumphouses, offices and other infrastructure for an entire year.

28

“However, the higher elevation of the reservoir allows us to rotate the pumps backwards to act as small turbines for the rest of the year which is able to generate electricity at more than an 80% efficiency. Unlike turbines however, the pumps are standard stock items from the supplier, KSB Pumps and Valves and does not require specialised support and servicing. What’s more, the pumps are durable enough to allow us to design the infrastructure with a 40-year lifespan.

“With this long lifespan in mind, we decided to make use of KSB pumps as we already have a number of these installed throughout our municipality and are aware of their reliability, as well as long track record of support to our municipality, as well as many other municipalities and water utilities throughout South Africa,” says Hein.

Upgraded pump station Before commissioning the project, the municipality had spelled out its requirement to replace its existing 96 litreper-second pump station with a new one and discussed the ability to generate electricity in the off season with consulting engineers, Aurecon. Having designed and planned a solution, the main contract was awarded to Hidro -Tech systems (PTY) Ltd for mechanical and electrical work.

Kiewiet Viljoen, projects director for Hidro-Tech systems (PTY) Ltd, said the primary role of the project was to develop an efficient and reliable booster pump station to ensure uninterrupted water supply to nearby Wellington.

Only once that need had been fully met could the project managers consider its secondary role to generate power in off-peak season.

“The water comes from the City of Cape Town Wemmershoek Dam and is gravity-fed to our city regions via our main reservoir. For one month of the year during the driest month the pumps need to be switched on to pump 400 litres per second upstream to Paarl where after the pumps would usually be switched off.

“We therefore knew we needed a technologically savvy and reliable service provider and approached KSB Pumps and Valves to procure three KSB ETA200-40 pumps to meet and exceed the requirements of the tender. These not only perform brilliantly as pumps, but in turbine mode have a better than 80% efficiency even considering hydraulic and electrical losses. This speaks volumes for the overall efficiency and design of the pumps,” says Kiewiet.

Leliefontein pump and turbine station (PaT)

Electrical systems integrator, Brian Cooper at the main control HMI

Pipes, Pumps and Valves Africa - Sept/Oct 2018

Kiewiet Viljoen, projects director for Hidro-Tech systems (PTY) Ltd with Drakenstein Municipality engineer for water operations, Hein Henning, at the KSB pumps that are being used as turbines in the wet season

Electrical systems integrator, Brian Cooper, of Hidro-Tech systems PTY (LTD), says despite the relative simplicity of the mechanical design, it does require complex integration of controls to deal with the hydraulic force and convert the electricity generated into a useable form. This required pump speeds to be controlled via a variable speed drive to prevent overspeed as well as convert the wave produced to a pure 50hz wave form that is compatible with the city’s power grid.

“Thereafter the system is designed with full PLC control which can be managed on site via Human Machine Interface (HMI) or can be accessed remotely via computer or a mobile device to give users infinite control and monitoring of the site wherever and whenever required. The industrial network also provides automated control of the entire system including controls of the three pumps, valves, level indicators, flow meters and other parameters that are critical to the systems efficient operation to either pump water or generate electricity.

“In addition to providing seamless control of the system, it also ensures redundancy in all operating conditions and provides emergency measures in the event of failures of any part of the system, including valve controls, bypassing of the system or parameter changes as required to rectify any problems incurred.

we have a wide range of pumps that are suitable for this purpose. With growing pressure on the country’s power generating infrastructure, it pays for local authorities, farmers and landowners with access to water to investigate the installation of PaT systems as a cost effective and reliable source of electricity that is not reliant on wind or sun to drive it,” Stefano adds.

PUMPS

Technology integration

KSB Pumps and Valves’ branches and dealer manager for South Africa, Francois Naude with regional sales manager (Sub-Sahara Africa), David Jones

Project success Following the commissioning of the pump station and turbines the system has begun operating at full capacity and the Drakenstein municipality has started reaping the rewards of its forward-looking water management systems.

“We are pleased with the outcome and commend everybody involved in the project for their innovation and dedication to building a system that can be used as a blueprint by other municipalities around the country and across the globe. It has been a brilliant project with lots of challenges and innovation and the end result being the delivery of a successful project. We will definitely do similar projects with this team in future,” concludes Hein.

Annett Kriel, KSB Pumps, Tel: +27 (0) 11 876-5600, Email: Annett.Kriel@ksb.com Web: www.ksbpumps.co.za

Solution provider KSB Pumps and Valves specialist, Stefano Testi, applauded the project, saying its success paves the way for numerous similar projects throughout the Southern African region, wherever there is a reliable supply of water at a high enough elevation to drive the PaT. “It is particularly useful in areas that would otherwise require the installation of pressure reducing valves to deal with water from high elevations, as a PaT can fulfill the same requirement while generating electricity for nearby infrastructure or communities, especially rural ones.

“KSB internationally is a leader in the supply of PaT solutions and Pipes, Pumps and Valves Africa - Sept/Oct 2018

29

PUMPS

New Electric Tensioning Pumps The new ZUTP-S Series is an extension to Enerpac’s existing line of ZUTP electric tensioning pumps. The ZUTP-S Series features a pendant-operated solenoid valve which is ideal for multiple bolt tensioning applications and allows for singleperson operation. The operator can pressurize and retract the tensioner directly from the pendant. The pump achieves high-pressure without the need for an intensifier. This allows for low-maintenance and less cost for the user.

The ZUTP-S Series is typically used in oil and gas, wind power and power plant applications. It works well when used for critical joints in the assembly of gas and wind turbines, compressors, power shaft couplings and oil and gas pipelines. This tensioning pump is extremely reliable and provides great power and precision.

Key Features

30

•

Two-stage pump design provides high flow at low pressure for fast system fills and controlled flow at high pressure for accurate operation

•

Panel-mounted 6” pressure gauge with a polycarbonate cover set into the protective metal shroud for improved visibility Generates 21,750 psi (1500 bar) of pressure without an intensifier

•

Solenoid-operated valve with 20 ft. pendant for remote control of valve and one-man operation

•

1.7 hp heavy-duty universal motor provides the best performance-to-weight ratio

•

Easy access manual override valve quickly releases pressure if power is lost

•

•

Replaceable 10-micron reservoir breather and inline high-pressure filter helps maintain oil cleanliness for optimum performance

Contacts Neil Watson, Tel: 012 940 0656 Email: neil.watson@enerpac.com Web: www.enerpac.com

Pipes, Pumps and Valves Africa - Sep/Oct 2018

Overcoming dry spells

VALVES

Sea water desalination is booming. Resistant valves are more in demand than ever before.

And John F. Kennedy, the former president of the USA, proved right in the end. Today, sea water desalination has become a standard method of producing drinking water.

As demand for water rises and the world is struggling more and more with water scarcity, desalination is booming.

Valve manufacturers are doing their part to improve the situation. No long showers and less nice lawn in the front garden – this certainly doesn’t sound like the Californian dream. It nonetheless became a hard reality for people in the USA’s most populous federal state. Policy was promoted to ask Californians to lower their water consumption. A severe, four-year drought had led to water becoming scarce, consumption had to be lowered by a quarter in 2016 over 2013.

Drought became an emergency Rainfalls in 2016 did indeed bring the barren spell lasting several years to an end. However, things won’t continue the way they did before the drought became an emergency.

California’s governor Jerry Brown warned of droughts yet to come. As aridity continues to increase, the future drinking water supply in the USA‘s southern coastal states remain under threat.

A need for action thus remains: “Due to rising population numbers and sinking fresh water resources, demand for new technologies is rising in the region,” explains Germany Trade & Invest (GTAI), the economic development agency of the Federal Republic of Germany. Desalination plants for the

production of drinking water are seen as an important part of solving the problem, especially in Florida, California and Texas. There is no question about it, the option is in demand.

Desalination in California California seized the initiative and invested one billion US dollars in the huge Carlsbad Desalination Project (CDP) in San Diego. Its production capacity amounts to up to 200 million liters of drinking water per day, around seven percent of the region’s daily drinking water needs. A further plant is being constructed close to San Francisco, just one of many more to come. Starting in 2020, the plant will produce 75,000 cubic meters of drinking water. Countless valves are installed in the plants, as well as in the power plants needed to drive them. These valves must withstand the most adverse conditions, and media.

There is tremendous opportunity for valve manufacturers.

The American Society of Civil Engineers (ASCE) anticipates massive investments in the water infrastructure in the next two decades in the USA, around one trillion US Dollars are to be invested. One of several priorities is sea water desalination and the associated water transport. Experts believe action is required, as water consumption in 2030 will be around 15 percent higher than in 2015.

Gulf states thirsting for water California is the USA’s most dynamic market for desalination plants, but it is just one of many around the globe for Pipes, Pumps and Valves Africa - Sep/Oct 2018

31

valve manufacturers. New plants are booming especially in the Middle East. Valve manufacturer “Armaturenfabrik Franz Schneider” stayed abreast of demand and founded a subsidiary in Dubai several years ago, AS-Schneider Middle East FZE.

VALVES

The member states of the Gulf Cooperation Council are under increasing pressure to act. Around 140 billion US dollars are to be invested by 2020, to meet growing demand for electricity and desalinated sea water. Industrial valves, that are mostly made from special materials, are installed in the plants. AS-Schneider is able to serve the large part of all processes with its products.

Singapore, too, is betting on sea water desalination plants.

Up until the 1990s, the state imported its water nearly entirely from other countries, most of it from its neighbor Malaysia, using pipelines. Singapore plans to considerably reduce its dependency by the time the bilateral agreements run out in 2061.

55 olympic swimming pools “Singapore began tackling their drinking water supply problem a few years ago,” reports valve manufacturer Gemü. The first major sea water desalination plant “Tuas Desalination”, planned and constructed by Hyflux Ltd., uses reverse osmosis as a method to produce more than 136,000 m³ of drinking water per day. “This amount is enough to fill about 55 Olympic size swimming pools,” reports the valve company.

Gemü supplied more than 760 valves with nominal diameters ranging from DN 15 to 1.400. Additional valves were also sourced from partner companies, providing the customer with a package solution. “The customer could therefore be offered everything from one source,” the company emphasised.

In the sea water inlet, in the filtration/floatation and in the supply – tanks and pump stations – valves made from various disc materials are used, namely 1.4408, bronze or ECTFE coated. Nominal sizes range from DN 65 to 1400, whereas the operating pressure is between 2.5 and 18 bar, depending on the process section. “Pneumatic and electric motor solutions as well as manual operators with hand levers and gears” are used as actuators, reports Gemü.

Valves made from special materials In water pre-treatment and post-treatment, FeCl3, H2SO4, HCl, NaOH is dosed using highly chemically resistant diaphragm valves made of PVC or PVDF. Here, nominal sizes range between DN 15 and 40, whereas the operating pressure is approx. 3 to 5 bar. Float flow meters were also installed, with a nominal size of DN 20 to 40. Gemü: “Chemical dosing is fully automatic so the valves are usually controlled pneumatically”.

Special materials, such as Super Duplex A890, were used for the high pressure and non-return valves on the pump stations in front of the osmosis modules. As Gemü explains, they are actuated pneumatically and equipped with intelligent positioners. In a pump’s start-up phase, the differential pressure can be up to 59 bar. The operating pressure normally lies between 5 and 84 bar, and DN 300 is the nominal diameter for all the valves used here.

32

Pipes, Pumps and Valves Africa - Sep/Oct 2018

Durable butterfly valves The sea water desalination plant in Singapore is part of a large-scale project, with an investment volume of two billion US dollars. TPU, a subsidiary of Tuas Power, operates the Tembusu Multi-Utilities Complex (TMUC) on the island Jurong. TMUC supplies industry customers with steam and power. This integrated approach is designed to increase efficiency and lower consumption of resources. Upon completion in 2017, TMUC will produce 160 MW electricity, 900 tons of steam pro hour and approximately 20 million gallons of water per day.

Gemü and all other manufacturers in the valve sector are aware not only of the opportunity sea water desalination offers, but also of the challenges it poses. “In the desalination market, the ever-increasing complexity of processes demands for butterfly valves to be extremely reliable and durable,” reports Wouter Witzel. The valve manufacturer sets value on a robust, maintenance free design, a vulcanized liner concept and a wide range of selected or specified materials for its butterfly valves.

Preventing backflow Wouter Witsel further developed its Eurocheck type check valve. It is used to prevent backflows in pipework systems, and in sea water desalination. It is a self-acting pivoting check valve of the double disc wafer type. “The design is compact, therefore saving space and very light”. The manufacturers valve range is completed by various actuators.

Wouter Witsel has already received a major order for a water desalination plant in the United Arab Emirates. The company supplied more than 400 fully vulcanised butterfly valves, including manual, pneumatic and electric actuators.

High investments in Australia Water has also become scarce in Australia. The situation is made worse by major population growth, industrial development, increasing pollution and contamination of available resources and global warming. Australia is therefore investing billions in desalination. One of the largest projects is the Wonthaggi Desalination Plant near Melbourne, with a daily production of 440,000 cubic meters of water. A milestone was achieved this year: the first water from the Wonthaggi desalination plant flowed into the Cardinia reservoir, securing the water supply in the southeastern state of Victoria. The project offers numerous advantages, reaching far beyond Melbourne and Victoria.

Valves made by Ebro are being used in the Wonthaggi desalination plant. The company supplied 1830 manual and electrically or pneumatically actuated shut-off valves, varying from resilient‐seated EPDM and PTFE lug‐ type butterfly valves to double‐flanged butterfly valves, with nominal sizes between DN 50 and DN 2200. “All valves are made from AISI 316‐stainless steel interior parts and have a special body coating suitable to resist the aggressive climate conditions,” explains Ebro.

VALVES

Innovations on valves and valve related products will be presented at Valve World Expo Düsseldorf from November, 27 – 29, 2018 at Düsseldorf Fairgrounds.

CS X

MP PU

Already in 1961, president John F. Kennedy was enthusiastic about desalination during the opening ceremony of a desalination plant, speaking of one of mankind’s oldest dreams: turning seawater into drinking water. Back then, the president of the USA, envisaged drinking water could be cheaply produced from seawater by the end of the 1960s.

Alas, the high costs didn’t come down, putting a brake on the rise of this form of drinking water production. In the end, however, Kennedy proved right. Today, the widespread use of seawater desalination has become a reality.

CP 7

CP S

MP PU

A dream becomes reality

• Horizontal Split Water Pumps • CPX/HMX Type • SP Type • Vertical Turbine • CPW Type • CSR Type

MP PU

The number of sea water desalination plants in use around the world will multiply. Reverse osmosis has established itself as one of the common methods. Here, seawater is pumped under high pressure through a semipermeable membrane, trapping and removing salts, bacteria, viruses chalk and toxic substances, such as heavy metals. What remains is potable water.

HM MP PU

All of this despite the fact a huge amount of water is readily available. However, 97,5 percent is saltwater. Making use of the oceans is therefore logical. The trend is making itself felt. As the organisation “Global Water Intelligence” states, the percentage of the global population that will depend on desalinated water will grow from the single-digit percentage range to 25 percent by the year 2025.

E DL N

Number of plants to multiply

VERTICAL SP I

Our range of pump products include: • CP/CPO Series • CP7 Type • Vertical Spindle/ Cantilever Pump • HM Process Pumps • CSW Type • CSY Type • Process Pumps

C

P -C

No seawater desalination plant operates without automation. Festo supplied a plant in Chennai, India, with plant automation solutions. This shows water scarcity is not alone limited to certain regions of the USA, the Arab countries, Australia and some parts of Spain. It is a major problem around the world, made worse by climate change.

The United Nations estimate around 800 million people do not have sufficient access to drinking water. In other words, more than eleven percent of the global population are cut off from the supply of drinking water.

Over 25 years of experience in designing and manufacturing a complete range of centrifugal pumps for a broad spectrum CSO/CP of industrial, process and general applications.

PO

The valves Ebro supplied will shut‐off and control the medium from the seawater pumping station, to the distribution and storage of drinking water. All valves are actuated using either a manual wormgear, or electric and pneumatic actuators. The pneumatic actuators have a tufram coating to make them corrosion-proof, and are also equipped with an emergency handwheel.

w ww .samen g. c o. za

800 million people are suffering

Providing customised pump solutions to various industries

Pump design techniques that ensure our pumps are manufactured to last

High performance - high quality products, excellent service

Alloys to suit all applications Proud Manufacturers of SAMCO® Pumps

Pipes, Pumps and Valves Africa - Sep/Oct 2018

33

Corflex supplies Pinch Valves for tailings project Corflex has supplied an order of 450mm Pinch Valves to operate at a pressure of 25 Bar for a tailings project at Evander Kinross in South Africa.

VALVES

Corflex supplies pinch valves suitable for higher pressures than any other similar Valve.

Pinch Valves are probably the most suitable valve for use in slurry handling, as in the open position they are similar to a rubber lined pipe. When closed they must seal and not be allowed to leak. Other types of valves have problems with abrasive material or pressure. Quarter turn valves such as plug and ball valves, generally have a reduced port which increases the velocity and every time you turn them they are scratched and end up leaking. Knife gates generally have blades that are far thinner than blank flanges for the same pressure and at high pressure can leak or form dished ends.

High pressure sleeve compared to lower pressure Corflex sleeve

Pinch Valves for high pressures have to be built with both safety and performance in mind. To build a 450mm pinch valve sleeve for higher pressures special tooling had to be designed and built to enable the use of larger gauge wire reinforcement in the flange area.

The development of this tooling enabled a 450mm pinch valve to be built for a working pressure up to 35 Bar, a test pressure of 70 Bar and a calculated burst of 105 Bar. The force required to close and seal a 450mm Pinch Valve at 25 Bar is 77 tons to ensure an adequate seal. To build a 450mm Pinch Valve suitable for 25 Bar, a special valve had to be designed and built in every aspect similar to the 500mm high pressure Corflex Pinch Valve.

450mm Corflex Pinch Valves at Evander

These 450mm valves are fitted with 4 x 160mm hydraulic cylinders, which at a hydraulic pressure of 200 Bar would seal the valves against a pressure of +/34 Bar, giving a sealing safety factor in excess of 30%.

Although not required for this project the hydraulic power pack could have been built to automatically close the pinch valves in the event of an electrical power failure, which means the valves can be used as open/closed and non return valves. Typical non return valves in slurry pipelines are not always reliable so this system has excellent advantages.

The hydraulic power pack to operate the valves has a constant recharge system to ensure that the valves stay closed and do not creep open.

Contact Corflex Engingeering, Tel: +27 (0) 11 866-1932, Email: info@corflex.co.za, Web: www.corflex.co.za

Robuschi Roots blowers / exhausters are some of the finest in the world – Made in Italy.

info@vactech.co.za 0861 VACTEC (822 832) www.vactech.co.za 34

Pipes, Pumps and Valves Africa - Sep/Oct 2018

VALVES

Industrial slurry valves for harsh mining conditions

BMG’s range of industrial slurry valves, which has been designed to cope efficiently in harsh mining conditions, includes robust butterfly and knife gate valves, as well as diaphragm and pinch valves.

“These industrial slurry valves - which meet stringent quality and safety specifications - are highly efficient on the mines, for the control and isolation of abrasive slurries,” says Willie Lamprecht, national product manager, Valves, BMG. “Failure of a valve and subsequent leaking of corrosive media can have devastating effects on the safety of personnel and equipment, leading to premature system failure and costly downtime. It is critical that the correct valve is selected for every application, for maximum safety, ongoing operation of the plant and minimum unscheduled maintenance.

“BMG’s highly-skilled team has a thorough understanding of the processes where valves are installed and supports every component with a dependable solutions service, to ensure optimum safety, efficiency and the extended service life of each system.”

In mining operations, selection of the correct industrial slurry valve is based on factors that include the size and shape of particles, pressure, temperatures and chemical content.

Polyurethane-lined knife gate valves are available from BMG in standard sizes between DN 50 and DN 600, with manual, pneumatic and electric actuation. These knife gate valves have a wafer pattern and are manufactured from cast and ductile iron, with Stainless Steel discs. They can withstand operating temperatures of between - 20˚C and +80 ˚C as standard, with higher temperatures on request.

BMG’s range of industrial slurry valves, which has been designed for the control and isolation of abrasive slurries in harsh mining conditions, includes robust butterfly and knife gate valves, as well as diaphragm and pinch valves.

36

Pipes, Pumps and Valves Africa - Sep/Oct 2018

Polyurethane liner abrasion-resistant butterfly valves – in a wafer pattern or with a lugged design - are used for on-off and control of abrasive slurries. Butterfly valves are available from BMG in standard sizes between DN 50 and DN 400.

Locally-manufactured FPV diaphragm valves –

DN

Also in the range, are unlined diaphragm valves, which are suitable for water treatment and general industrial applications.

FPV pinch valves – featuring a design where the sleeve is pinched to close mechanically or automatically by means of hand-wheel or actuator - are ideal for the control and isolation of abrasive slurries.

Open frame pinch valves are available from BMG with a short and long frame design, in sizes between DN 50 and DN 600.

50 and DN 350, with manual or pneumatic actuation - are designed for abrasive slurry applications. These flanged diaphragm valves have a body pressure of PN 10 and can withstand temperatures between -10°C and +80°C. Long-lasting rubber and jumbo rubber linings are suited for full-bore diaphragm valves with a high flow capacity and an efficient sealing capability, which shuts off any flow and prevents leakage. Full bore diaphragm valves also have a low pressure drop because there is almost nothing obstructing the flow of the fluid when the valve is fully opened. This creates little resistance to flow, which makes these valves suitable for fluids with abrasive particles.

BMG’s extensive range of components for fluid technology systems and general industrial applications encompasses valves, hydraulic hoses and fittings, accumulators, cylinders, heat exchangers, pneumatics, hydraulic motors and hydraulic plumbing, as well as pumps and reservoir accessories.

VALVES

The body is made from mild steel, but Stainless Steel is also available for specific applications. These valves, with soft rubber sleeves, have manual, hydraulic and temperatures between -20°C and +80°C.

The company also offers a total process and lubrication management solution, to meet exact market requirements Contact Willie Lamprecht, BMG World Tel: +27 (0) 11 620-1581 Email: williaml@bmgworld.net Web: www.bmgworld.net

Pipes, Pumps and Valves Africa - Sep/Oct 2018

37

VALVES

Innovative vertical gravity samplers designed and manufactured by eDART

To meet the requirement of an international customer, eDART Slurry Valves, a leading South African valve manufacturer, successfully designed, tested and manufactured a Vertical Gravity Sampler (VGSA) for application within the minerals processing sector.

Duane le Roux, Product Manager – Samplers, at the eDart Group said “We received a request from one of our global customers to develop a solution that could enable them to obtain a credible sampling of their gravity fed downward flowing process line. A VGSA is only selected if there is no horizontally sloped gravity fed process line available in which to install a normal gravity sampler assembly (GSA)”.

“After site assessment, it was a concern that sampling from this line ensured that the cutter received enough sample and moreover that this sample was representative. We ran various computerised design configurations and simulations in order to meet the customer criteria and this led to the development of a totally South African designed and manufactured VGSA – the first in the country” he said.

The VGSA has a cylindrical shape and is relatively compact compared to the average size of mining equipment. It is easily installed, requiring only minor alterations to the pipeline to which it is to be installed. The body of the sampler is designed to be replaced once worn. The sampler is made from various erosion resistant materials such as rubber and polyurethane linings, stainless steel and tungsten carbide coated steel.

The specifically zig zag designed baffle plates within the VGSA direct slurry in a non-gravity process line closer together. Eventually a constant stream of slurry is formed.

This slurry stream is then directed straight into a cutter, which has been designed and tested using computational fluid dynamics (CFD) software.

The VGSA is supplied in industry standard pipe sizes (diameter), in order to fit into the process pipelines. For standard models the height of the sampler would be the function of the diameter. This would be determined by utilising simulation software which would consider the mine’s mass balance of slurry. eDART has supplied this type of sampler where there were space restraints within the plant’s layout. In this instance eDART supplied a VGSA with a custom height to fit the customer’s specification, which was verified using computational analysis.

“We believe that our VGSA is a solution in mines where there is no alternative place to offer a traditional eDART sampler product, therefore it is a natural extension of our product offering” commented le Roux.

“Industry is realising the power and convenience of process control samplers versus met accounting samplers, and process control samplers are being considered as a vital tool to mining operations”. Additionally, le Roux said “Sampling from a downward gravity process line is difficult by nature.

Results have indicated that previous solutions that were built to try and sample from a gravity fed downward flowing process were ineffective and not representative. We have countered this by using good computational simulation which has given us with excellent results and client feedback has supported these findings” said le Roux.

“It is important for us to find effective solutions that satisfy our customer’s specific requirements, even if for an uncommon and non-standard application. We credit ourselves for having the design and knowledge skills to offer a reliable solution to any sampling need. At the end of the day it also expands our sampler offering” concluded le Roux. eDART are specialists in the design and manufacture of samplers and slurry equipment and offer external and internal dual/single dart valves, as well as pinch, dosing and slurry valves; pneumatic actuators, instrumentation, samplers, flow analysis technology and related accessories.

Contact: eDART, Tel: +27 (0) 11 823 6620, Email: sales@edart.co.za

38

Pipes, Pumps and Valves Africa - Sep/Oct 2018

THE VALVE & PIPE FITTINGS EXPERTS VALVES • • • • •

Control Valves Butterfly Valves Non Return Valves Gate Valves Sluice Gate Valves

• Knife Gate Valves • Accessories • Solutions for the Water Management

PIPE FITTINGS • • • •

Dismantling Joints Various Couplings Flange Adaptors We accommodate close to all pipe materials

EASTERN AFRICA IG Van Rooyen +27 (0) 76 053 7391 I.VanRooyen@vag-group.com SOUTHERN AFRICA / SADC Kyle Shaw +27 (0) 72 117 6001 K.Shaw@vag-group.com

WESTERN AFRICA EW Ellis +27 (0) 64 860 7869 E.Ellis@vag-group.com VAG-KLAMFLEX OFFICE +27 (0) 11 762-5326 +27 (0) 11 466-8130 www.vag-group.com

MITECH Control Valves Open Day

MITECH Control Valves recently hosted an Open Day where its customers and Pipes, Pumps & Valves Africa were in attendance. Hendri Grobler, Ian Janse Van Rensberg presented Mitech’s latest product innovations. Dan Thysse did a presentation on PCT Engineering’s valve potitioners. Sam Mashava led a tour of their state-of-the-art manufacturing facility, in Kempton Park, Johannesburg.

Mitech Control Valves (Pty) Ltd designs, manufactures, service and repairs a range of control valves, on-off valves, actuators, positioners, desuperheaters and associated valve products in South Africa. In addition to their manufacturing capability, they complement their range with the highest quality imported valves to deliver turnkey valve and automation solutions to our customers globally.

VALVES

Mitech currently exports to most African Countries, Europe, UK, South East Asia, Middle East, Australia, New Zealand and South America. Where they don’t have direct presence, they have partnered with local industry specialists with extensive knowledge of their products.

The success of the company to date has been a result of the commitment it makes to provide its customers with the best possible service and quality of products. All Mitech personnel are committed to the policy of effective quality management and undertake to ensure that all goods and services are supplied to meet their intended purpose. Mitech is committed to a policy of continual improvement in both design and production of its products and undertakes to ensure that safety and environmental protection measures are included in all its activities.

Contact: Ian Janse Van Rensburg, Tel: +27 (0) 11 927 4850 , Email: ianvr@mitech.co.za , Web: www.mitech.co.za

40

Pipes, Pumps and Valves Africa - Sep/Oct 2018

Well-refreshed VALVES All a matter of taste! How about new, highly distinct beer wortsfrom small breweries, or even chocolate beer?

Everything is available, as the beverages industry keeps coming up with new aromas, to make sure consumers won’t have to face dry spells. To keep kegs and bottles always filled, the sector requires high-quality and hygienic machines, as well as plants fitted with valves – forpure enjoyment.

For the beverages industry, everything is in flow – an uncomfortable hiccup is quite the exception. Thirst for mineral water, lemonades and beers remains reliably high. Beverage producers however, keep watching market movements like a hawk. Valve manufacturers are highly aware of this development.

Major producers have swallowed smaller producers and are fighting in the market. “This means a higher level of competitive pressure for the diverse subsuppliers, such as Mankenberg, as the strategic purchasing departments of machine manufacturers are supposed to compensate ‘losses’ experienced selling whole plants,“ emphasises Dietmar Pallasch, head of Mankenberg’s sales force in Germany. Often enough, a shift can

The beer sector requires high-quality and hygienic machines, as well as plants fitted with valves.

occur – for instance away from mass beers towards so-called craft beers, or special beers.

Craft beers in vogue Even if the large breweries continue to dominate beer taps, craft beers are the latest rage. Craft beers are more like a tradecraft, brewed according to own recipes by small breweries. “The number of breweries in Germany and the varieties of beer will continue to grow in the coming years, also thanks to the craft beer movement,” says Dr. Jörg Lehmann, president of the German Brewers Association DBB. While there were around 1290 breweries in 2006, the number increased to 1410 ten years later. Pallasch: “Growth is continuous, but not excessive”.

Last year, the newly founded brewery “Kuehn Kunz Rosen” in Mainz fulfilled a desire to create a recipe for an own beer. Two business partners invested one million euro. Up to 30 hectolitres can be brewed in the plant.

In Münster, the brewery “Läuterwerk” opened its doors in 2015, and the “Finne-Brauerei” was also founded in Münster – a citywhich once counted 150 breweries, yet today only a few. There is no question about it, the economic potential of the craft beer movement has just begun to unfold.

Expanding breweries Seen soberly, the classical breweries still continue to have a grip on the market. The Paulaner brewery, for example, is expanding, and after moving to Langwied, the 4.4-acre site will offer enough space for new buildings.

For old-established breweries, the profitability of sites also is an important argument for change. Carlsberg sees a case for change for its Holsten brewery, in Hamburg. The traditional location in Altona had meanwhile become too small and wasn’t up-to-date anymore. Time for a change.

Modern production and logistics facilities will increase economic efficiency.

At the old site, loading trucks wasn’t allowed at night, due to noise

Pipes, Pumps and Valves Africa - Sep/Oct 2018

41

VALVES Producers of beer manufacturing equipment require valves for demanding tasks.

emissions regulations protecting local residents. From early 2019, around 1 million hectolitres of beer will be produced at the new location, measuring around 67,000 square metres.

Hygienic processes Needless to say, beer isn’t a modern-day invention. In Ancient Egypt, beer was already being brewed. Simple means were employed back then, while today beer of the highest quality is brewed, using modern hygienic processes. Various machines and materials are required to produce beer, not only knowledge of the art of brewing. In Germany, beer is produced according to the Reinheitsgebot (German purity law), the oldest food law.

As such, the main focus for valves is onhygiene.

Valves are used in numerous positions of the brewing process – from the brewhouse to the fermenting cellar to filling. In numerous process steps beer is won from water, barley, hops and yeast. “The soluble, filtered extract gained from the malt when mashing is heated,” explains the valve manufacturer Gemü. This hot wort is then cooled down. Fermentation is the next important step. “For this purpose, yeast and sterile air / oxygen is added to the cooled wort. The oxygen serves to activate the yeast cells. This green beer is piped into the fermentation tanks. The yeast attenuates the extract / sugar in alcohol and carbon dioxide, releasing heat”. Furthermore, the typical beer flavour is created in this main fermentation phase.

Regulating excess CO2 It takes around seven days until the extract content is nearly broken down.

The green beer is pumped into storage tanks to mature and continue fermenting for three weeks, at a temperature of 0-1°C. “The yeast deposited in the fermentation tanks is then withdrawn from the coneat the bottom of the container, washed and can beused for a new fermentation process in part,” explains Gemü.

42

Pipes, Pumps and Valves Africa - Sep/Oct 2018

A complex stainless-steel pipeline system is used to feed the wort into the fermentation tank, withdraw the yeast after fermentation, and move the green beer to the maturing tanks. In order to adhere to the operating parameters, various process variables need to be regulated. In particular, the pressure in the fermentation tank which comes into being because of carbon dioxide build-up must be kept. The saturation of the green beer with CO2 and hence the later beer quality is critically dependent on the pressure,” reports Gemü. However, if the pressure is too high, fermentation is slowed down. A controlled discharge of excess CO2 is therefore necessary. It can also be fed into a CO2 extraction plant, making it available for other processes.

Butterfly and diaphragm valves “The feeding of the wort to the fermentation tank, shifting the green beer and emptying it from the storage tank later can be carried out using commercially available stainless steel butterfly valves,” emphasises Gemü.

The company mounts switchboxes directly on the valve actuators, for actuation and monitoring. Next to the pneumatic pilot valves used to control the butterfly valves, they also allow electrical position feedback to a control room.

Pressure in the fermentation tank is regulated using positioners and process controllers. These controllers are also placed directly on the actuators of the butterfly valves. “They are allocated the specification of set values ‘W’ from the system control unit’s PLC”. Diaphragm valves with electrical position indicators can be used in smaller systems for feeding yeast and ventilating wort.

Higher-quality stainless steel and PEEK Producers of beer manufacturing equipment thus require numerous valves for demanding tasks. “Weuse high-alloyed steels and process optimisations

VALVES

to fulfil the requirements,” states Dietmar Pallasch, head of German sales, Mankenberg. This includes new materials like PEEK (Polyetheretherketone), higher quality stainless steel and polishing of valves.

Valves made by Mankenberg are mainly used in secondary cycles, for pressure reduction of water, steam and various gases. Furthermore, swimmer valves are used. Vent valves are used inwater treatment plants.

Around 30 percent of Mankenberg’s standard valves initially fulfil the requirements of the beverage industry for secondary cycles.

Polished valves in demand According to Dietmar Pallasch, there is “an increase of the wish for polished valves, as the pipes installed already are polished”.

Who wants to remain successful in the market, needs to observe certification requirements for new European and international standards, such as EHEDG, ASME BPE, 3 A and FDA. The requirements “will continuously grow. Welive in an increasingly internationalised world industry”.

Furthermore, the beverage industry expects high-quality materials such as high-alloy stainless steel, and for “minimal prices, as the lot size of components are already noteworthy,” explains Dietmar Pallasch. Customers also demand speedy delivery, quality and, most of all, delivery reliability, next to standards compliance.

A beer pipeline for Bruges Much-loved by all, beer needs to flow. Any way possible. A clever idea of a brewery in Bruges, Belgium, created quite a stir. A beer pipeline connects the brewery in the historical center to a filling plant outside of the town core. This was highly liberating, as beer truckshad to press through the narrow, medieval lanes heavily frequented by tourists several times daily. As six million tourists a year visit Bruges‘ historical center, this was seen as quite a strain, which was also detrimental to transporting beer.

Now 4000 liters an hour flow unhindered to the filling plant – naturally also with the help of valves.

The Wacken Open Air has also taken up on the idea of subterranean beer pipelines. Tractors used to transport beer kegs, battering the festival site. This wasn’t a situation the organisers behind the festival were happy with. Thanks to pipelines, the ground has been saved.

Alcohol-free beer in demand Major events will once again ensure a good amount of beer.

“After the German beer market had shown itself relatively stable in the last three years, the balance stated a slight decline in sales for 2017,” report “the German brewers” of the DBB. Last year, German breweries sold 94 million hectolitres beer, falling short of the prior-year result of 96 million hectolitres.

Nonetheless, the DBB maintains an optimistic outlook: “The number of breweries and the variety of beers will continue to grow in the coming years, also thanks to the craft movement,” as DBB president Dr. Jörg Lehmann draws balance. Further impulses come from positive growth in demand for alcohol-free beers.

“Alcohol-free beers reach a share of 6 percent in Germany – trending towards further growth. Especially alcohol-free mixed beer varieties, such as alcohol-free shandy, were able to grow considerably in the last year”.

Nothing hints towards a dry spell. Despite all fluctuations, valves manufacturers can continue to place their bets on a stable beer market, and thus on advanced components.

The whole range of valves will be presented at the world`s leading trade fair VALVE WORLD EXPO, that will be held at Düsseldorf Fairgrounds from November, 27 – 29, 2019.

Pipes, Pumps and Valves Africa - Sep/Oct 2018

43

PUMPS HORIZONTAL SPLIT CASE PUMPS

AIR OPERATED DOUBLE DIAPHRAGM PUMPS

SLURRY PUMPS

KSB (Pty) Ltd Air & Vacuum Technologies T: +27 (0) 861 822-832) +27 (0) 11 318 3241/2/3/4/5 F: +27 (0) 86 522-9188 E: burnm@vactech.co.za W: www.vactech.co.za ANSI PROCESS PUMPS

SAM Engineering T: +27 (0) 11 823-4250 F: +27 (0) 11 823-4943 E: sales@sameng.co.za W: www.sameng.co.za BOREHOLE PUMPS

Ernest Electro Engineering T: +27 (0) 11 792 9550 E: eeeaman@mweb.co.za W: www.ernestee.co.za

T: +27 (0) 11 876-5600 F: +27 (0) 11 822-2013 E: info-za@ksb.com W: www.ksb.com

SAM Engineering T: +27 (0) 11 823-4250 F: +27 (0) 11 823-4943 E: sales@sameng.co.za W: www.sameng.co.za

T: +27 (0) 11 723-6500 E: info@franklin-electric.co.za W: www.franklin-electric.com

Unique Engineering T: +27 (0) 11 826 6111 F: +27 (0) 11 826 6162 E: sales@uniqueeng.co.za W: www.uniqueeng.co.za CENTRIFUGAL PUMPS

Ernest Electro Engineering T: +27 (0) 11 792 9550 E: eeeaman@mweb.co.za W: www.ernestee.co.z

Unique Engineering T: +27 (0) 11 826 6111 F: +27 (0) 11 826 6162 E: sales@uniqueeng.co.za W: www.uniqueeng.co.za END SUCTION PUMPS

SAM Engineering T: +27 (0) 11 823-4250 F: +27 (0) 11 823-4943 E: sales@sameng.co.za W: www.sameng.co.za FIRE PUMPS

APE Pumps T: +27 (0) 11 824-4810 F: +27 (0) 11 824-2770 E: apepumps@mweb.co.za W: www.apepumps.co.za

FLEXIBLE IMPELLER PUMPS

CHICK HENDERSON

T: +27 (0) 11 704-5333 E: sales.za@hidrostal.com W: www.hidrostal.co.za 44

T: +27 (0) 10 210-4750 E: willie.vanwyk@flsmidth.com W: www.flsmidth.com

Pump and Abrasion Technologies

Franklin Electric T: +27 (0) 11 723-6500 E: info@franklin-electric.co.za W: www.franklin-electric.com

SPP Pumps SA (Pty) Ltd T: +27 (0) 11 393-7179 F: +27 (0) 86 425-7595 E: sales@spppumps.co.za W: www.spppumps.com

FLSmidth Krebs

MULTISTAGE PUMPS

Hawk High Pressure Pumps T: +27 (0) 031 274-8555 +27 (0) 10 010-0144 F: +27 (0) 31 205-4332 +27 (0) 11 822-2868 E: sales@hawkpumps.co.za W: www.hawkpumps.co.za POSITIVE DISPLACEMENT PUMPS

T: +27 (0) 12 666-0904/5 E: sales@pumpab.co.za W: www.pumpandabrasion.co.za SUBMERSIBLE PUMPS

Franklin Electric T: +27 (0) 11 723-6500 E: info@franklin-electric.co.za W: www.franklin-electric.com

Horma Pumps T: +27 (0) 11 452-4300 E: sales@horma.co.za W: www.horma.co.za

Chick Henderson T: +27 (0) 11 624-1400 F: +27 (0) 624-1432 E: rob@chickhenderson.co.za W: www.chickhenderson.co.za HIGH PRESSURE PUMPS

CHICK HENDERSON Chick Henderson T: +27 (0) 11 624-1400 F: +27 (0) 624-1432 E: rob@chickhenderson.co.za W: www.chickhenderson.co.za

Hawk High Pressure Pumps Hidrostal

T: +27 (0) 11 805-8631 F: +27 (0) 11 805-8630 E: cri@cripumps.co.za W: www.cripumps.co.za

METERING PUMPS

PLUNGER PUMPS

Franklin Electric

C.R.I Pumps S.A. (Pty) Ltd

T: +27 (0) 031 274-8555 +27 (0) 10 010-0144 F: +27 (0) 31 205-4332 +27 (0) 11 822-2868 E: sales@hawkpumps.co.za W: www.hawkpumps.co.za

Pipes, Pumps and Valves Africa - Sep/Oct 2018

Stewarts & Lloyds (Pty) Ltd T: +27 (0) 11 917-0778 F: +27 (0) 11 917-0769 E: peterk@sltrading.co.za W: www.stewartsandlloyds.co.za

Unique Engineering

Walter Meano Engineering VersaFlo VSE Pumps

T: +27 (0) 11 826-6111 F: +27 (0) 11 826-6162 E: sales@uniqueeng.co.za W: www.uniqueeng.co.za

T: +27 (0) 11 873-8620 F: +27 (0) 11 825-1401 E: wme@mweb.co.za W: www.versaflo.co.za

VALVES

PUMPS BALL VALVES

TRASH PUMPS

SAM Engineering C.R.I Pumps S.A. (Pty) Ltd T: +27 (0) 11 805-8631 F: +27 (0) 11 805-8630 E: cri@cripumps.co.za W: www.cripumps.co.za

T: +27 (0) 11 823-4250 F: +27 (0) 11 823-4943 E: sales@sameng.co.za W: www.sameng.co.za

Tectra Automation Everyseal T: +27 (0) 16 976-1787/8/9 E: info@everyseal.com W: www.everyseal.com

T: +27 (0) 11 971-9400 F: +27 (0) 11 971-9440 E: malan.bosman@tectra.co.za W: www.hytecgroup.co.za CHECK VALVES

VERTICAL TURBINE PUMPS

VACUUM PUMPS

Industrial Valves & Engineering Supplies (Pty) Ltd Air & Vacuum Technologies T: +27 (0) 861 822-832) +27 (0) 11 318 3241/2/3/4/5 F: +27 (0) 86 522-9188 E: burnm@vactech.co.za W: www.vactech.co.za

Atlas Copco T: +27 (0) 11 318 3241/2/3/4/5 F: +27 (0) 86 522-9188 E: burnm@vactech.co.za W: www.vactech.co.za VERTICAL SUMP PUMPS

APE Pumps T: +27 (0) 11 824-4810 F: +27 (0) 11 824-2770 E: apepumps@mweb.co.za W: www.apepumps.co.za

T: +27 (0) 11 394-2066 F: +27 (0) 11 394-2476 E: sales1@industrialvalve.co.za W: www.industrialvalve.co.za

Mine Track & Tools (Pty) Ltd SAMCO PUMPS (Pty) Ltd T: +27 35 751-1202 F: +27 35 751-1204 E: joffre@samcopumps.com W: www.samcopumps.com WELL PUMPS

T: +27 (0) 11 412 4536/1665 E: info@minetrack.co.za W: www.minetrack.co.za BUTTERFLY VALVES

Ainsworth Valves

C.R.I Pumps S.A. (Pty) Ltd KSB (Pty) Ltd T: +27 (0) 11 876-5600 F: +27 (0) 11 822-2013 E: info-za@ksb.com W: www.ksb.com

RNE Pumps (Pty) Ltd T: +27 (0) 11 452-3528 F: +27 (0) 82 612-0358 E: mark@rnepumps.com W: www.rnepumps.com

T: +27 (0) 16 976-1787/8/9 E: info@everyseal.com W: www.everyseal.com

Invincible Valves (Pty) Ltd T: +27 (0) 11 822-1777 F: +27 (0) 11 822-3666 E: enquiries@invalve.co.za W: www.invalve.co.za CONTROL VALVES

Valcon Valve & Controls T: +27 (0) 11 433-3968/79 F: +27 (0) 11 433-9107 E: ruben@uvc.co.za W: www.ainsworth-valves.co.za

T: +27 (0) 11 805-8631 F: +27 (0) 11 805-8630 E: cri@cripumps.co.za W: www.cripumps.co.za

Everyseal

Everyseal T: +27 (0) 16 976-1787/8/9 E: info@everyseal.com W: www.everyseal.com

T: +27 (0) 11 453-7537 F: +27 (0) 11 453-6056 E: nick@valcon.co.za Web: www.valcon.co.za

VAG-Valves South Africa Klamflex Pipe Couplings T: +27 (0) 11 762-5326 F: +27 (0) 11 762-5674 E: o.galazka@vag-group.com W: www.vag-group.com DIAPHRAGM VALVES

KSB (Pty) Ltd T: +27 (0) 11 876-5600 F: +27 (0) 11 822-2013 E: info-za@ksb.com W: www.ksb.com

Stewarts & Lloyds (Pty) Ltd T: +27 (0) 11 917-0778 F: +27 (0) 11 917-0769 E: peterk@sltrading.co.za W: www.stewartsandlloyds.co.za

Ainsworth Valves T: +27 (0) 11 433-3968/79 F: +27 (0) 11 433-9107 E: ruben@uvc.co.za W: www.ainsworth-valves.co.za

Pipes, Pumps and Valves Africa - Sep/Oct 2018

45

VALVES Mine Track & Tools (Pty) Ltd T: +27 (0) 11 412 4536/1665 E: info@minetrack.co.za W: www.minetrack.co.za

Mine Track & Tools (Pty) Ltd T: +27 (0) 11 412 4536/1665 E: info@minetrack.co.za W: www.minetrack.co.za PINCH VALVES

Macsteel T: +27 (0) 11 838-4028 C: +27 (0) 82 823-7703 E: thanesh.padayachee@macsteel.co.za W: www.macsteel.co.za SLEEVE VALVES

Everyseal Invincible Valves (Pty) Ltd T: +27 (0) 11 822-1777 F: +27 (0) 11 822-3666 E: enquiries@invalve.co.za W: www.invalve.co.za

T: +27 (0) 16 976-1787/8/9 E: info@everyseal.com W: www.everyseal.com PLUG VALVES

GATE VALVES

Ainsworth Valves T: +27 (0) 11 433-3968/79 F: +27 (0) 11 433-9107 E: ruben@uvc.co.za W: www.ainsworth-valves.co.za

Everyseal C.R.I Pumps S.A. (Pty) Ltd

T: +27 (0) 16 976-1787/8/9 E: info@everyseal.com W: www.everyseal.com

T: +27 (0) 11 805-8631 F: +27 (0) 11 805-8630 E: cri@cripumps.co.za W: www.cripumps.co.za

PIPES

Rotork Invincible Valves (Pty) Ltd

Everyseal T: +27 (0) 16 976-1787/8/9 E: info@everyseal.com W: www.everyseal.com

ACTUATORS

T: +27 (0) 11 822-1777 F: +27 (0) 11 822-3666 E: enquiries@invalve.co.za W: www.invalve.co.za

T: +27 (0) 11 453-9741 F: +27 (0) 11 453-9894 E: reshmita.singh@rotork.com Web: www.rotork.com HYDRAULIC TOOLS

REPAIR VALVES

Kiloton VAG-Valves South Africa Klamflex Pipe Couplings T: +27 (0) 11 762-5326 F: +27 (0) 11 762-5674 E: o.galazka@vag-group.com W: www.vag-group.com KNIFE GATE VALVES

Everyseal

Ainsworth Valves T: +27 (0) 11 433-3968/79 F: +27 (0) 11 433-9107 E: ruben@uvc.co.za W: www.ainsworth-valves.co.za

T: +27 (0) 861 707-707 F: +27 (0) 861 707-706 E: sales@kiloton.co.za W: www.kiloton.co.za W: www.onlinetoolshop.kiloton.co.za MANUAL

Everyseal T: +27 (0) 16 976-1787/8/9 E: info@everyseal.com W: www.everyseal.com SAVETY & RELIEF VALVES

T: +27 (0) 16 976-1787/8/9 E: info@everyseal.com W: www.everyseal.com

Agrico T: +27 (0) 21 950 4111 F: +27 (0) 21 950 4208 E: alfred.andrag@agrico.co.za W: www.agrico.co.za HOSES

CHICK HENDERSON

Chick Henderson T: +27 (0) 11 640-1400 F: +27 (0) 624-1432 E: rob@chickhenderson.co.za W: www.chickhenderson.co.za FOUNDRIES

Tectra Automation T: +27 (0) 11 971-9400 F: +27 (0) 11 971-9440 E: malan.bosman@tectra.co.za W: www.hytecgroup.co.za MECHANICAL PACKING

Everyseal T: +27 (0) 16 976-1787/8/9 E: info@everyseal.com W: www.everyseal.com

KEW Foundries T: +27 (0) 53 841-0474 F: +27 (0) 53 841-0473 E: info@kewfoundries.co.za W: www.kewfoundries.co.za

KLINGER South Africa Invincible Valves (Pty) Ltd T: +27 (0) 11 822-1777 F: +27 (0) 11 822-3666 E: enquiries@invalve.co.za W: www.invalve.co.za 46

Pipes, Pumps and Valves Africa - Sep/Oct 2018

T: +27 (0) 11 842-8300 F: +27 (0) 11 827-8663 E: gareth.langton@klinger.co.za W: www.klinger.co.za

Viking Foundry (Pty) Ltd

Directors: W. Fourie (Chairman), N.P. Mnxasana (Non Exec) R Kruger, R. Dye, G.M. Scrutton Branch Manager: R. Dye Company Secretaries: Winhold Limited Reg No 1945/0196

T: +27 (0) 11 873-5093 F: +27 (0) 11 873-5695 E: sales@vfdy.co.za W: www.vikingfdy.co.za

THE RIGHT CHOICE FOR ADVICE & SUPPLY IN ALL APPLICATIONS OF FLUID CONTROL

IRRIGATION

PIPES & FITTINGS

PUMPS & VALVES

FLUID CONTROL DIVISION BRANCHES: ALRODE, BLOEMFONTEIN, BOOYSENS, BOKSBURG, BRITS, CAPE TOWN, DURBAN, EDENVALE, GEORGE, PORT ELIZABETH, KIMBERLEY, KLERKSDORP, MAFIKENG, NELSPRUIT, POLOKWANE, PRETORIA, ROBERTVILLE, SPRINGS, VEREENIGING, VAAL, WADEVILLE, WITBANK, WYNBERG

Customer care: 0860 10 27 99 www.stewartsandlloyds.co.za

48

Pipes, Pumps and Valves Africa - May/Jun 2018