Pumps and Valves Africa May / June 2016

ENDORSED By SAPMA (South African Pump Manufacturers’ Association) and VAMCOSA (The Valve and Actuator Manufacturers Cluster of South Africa)

Q 2 -2016

PUMPS BUYERS GUIDE VALVES BUYERS GUIDE

Pumps and Valves Africa - Q2 - 2016

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New mill discharge pump range!

Why do you need it?

– because the new Metso series of Mill Discharge slurry pumps encompass all the experience coupled with an understanding of today’s market needs and demands for improved sustained performance and lower cost. Specifically designed from its inception for mill circuit applications, the MDM hard metal and MDR rubber lined double adjusted slurry pumps offer sustained performance with maximum time between mill shutdowns.

Get in touch, and find out how we can help!

Metso is a leading process performance provider, with customers in the mining, oil and gas, and aggregates industries. Discover more at www.metso.com/pumps.

BEE Ownership Compliant metso.com – email: mmsa.info.za@metso.com 2

Pumps and Valves Africa - Q2 - 2016

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Contents COVER STORY Unmanned Dredging Made Simple by Tri-Pump

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ASSOCIATION NEWS SAPMA News 6 VAMCOSA News 7

ENDORSED By SAPMA (South African Pump Manufacturers’ Association) and VAMCOSA (The Valve and Actuator Manufacturers Cluster of South Africa)

Q 2 -2016

SAPSDA News 8 CEO PROFILE Pamela Jane du Plessis, Managing Director of Invincible Valves (Pty) Ltd

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Wayne Holton, Fluid Technology Distribution Manager of BMG

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Protect Performance Critical Surfaces with Thermal Spray Coating Solutions for Improved Pump Efficiencies 12 Kingler Mzansi Best for the Industry

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BMG Maintenance Free Heavy Duty Couplings

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Unique Pump Design Specifically for Fire-fighting With Foam

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6/9/2016 7:58:15 AM

Pumps & Valves Africa

Zero-leakage API Pump 18

Sales Manager: Helen Benetts

Growth for EnerMech Valves Capabilities with Africa Investment

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INVT BPD Series With AC Input Solar Pump Inverters

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Tel: (011) 047-2400 Cell: 083 281 5761 Email: info@pumpsandvalves.co.za www.pumpsandvalves.co.za Production: Jackie Nene

How to Improve Pump Energy Efficiency 20 Pump Selection Tool 22 Xylem Launches the World’s First Wastewater Pumping System with Integrated Intelligence 27

Index to Advertisers

BAUMA REPORT BACK 28 More Power with Tsurumi’s Tandem Operation Kit

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Ensuring Uninterrupted Service for Energy Sector Pumps

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SIL3 For South African Valve Manufacturer

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APE OBC

Servicing the Petrochemical & Bulk Fuel Storage, and Air-Pollution Control Industry 34

BMG 13

SMC Meets Market Demand with long-life Angle Seat Valve

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Grundfos Expands in Africa 36 AZ-Armaturen South Africa Continues to Grow

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Mitech Launches Locally Manufactured Globe Valve

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Simplified Control Options for Irrigation Systems

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Construction of New Pipeline from Mombasa to Nairobi to Take Longer

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Atlas Copco

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Electra Mining

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Franklin

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IDV

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Invincible Valves

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Klinger Lifting Equipment Conference

37 IBC

Metso IFC SAM Engineering Tri-Pump

17 OFC, 41

BUYERS GUIDE 44 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.

Pumps and Valves Africa - Q2 - 2016

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Unmanned Dredging Made Simple by Tri-Pump

Dealing with slimes and slurries is an on-going problem for many sites. From the use of traditional dredges to the Patented SlurryRat®...cleaning out process ponds or tailings dams is what Tri-Pump does. We offer a wide range of services using our specialised equipment and highly trained staff to provide our clients with a number of choices - from self-operated rental agreements; Tri-Pump managed contracts or outright purchases.

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erefct for the safe and easy removal of mineral sediments from process pomds, dams, tanks & lagoons.

The SlurryRat®is designed for mining and abrasive industries, quarries, sand & aggregate plants. The combination of suction.agitation with constant movement of the unit through a pond or structure allows effective and efficient removal of slurry, and dilivery to the next processing stage at the required rate.

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Pumps and Valves Africa - Q2 - 2016

Slurry can come in ernomous varieties of particle size, aggregation, distribution, cohesiveness, flow characteristics, sedimentation rates and specific gravity.

The SlurryRat® is generally sized to meet the clients’ requirements. Typical suction water agitation dredging usually achieves 15-20 % solids for SG’s up tp 3.0. Flows from 20 to 100m3 per hour of slurry fluid can be achieved.

The Tri-Pump Group is a pump solutions company supplying global brands and pumping solutions to the African mining industry and have been active in Africa since 1996.

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Correct pump sizing

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System engineering excellence

Buying equipment ties up critical capital, maintenance, parts, service, storage and administration also add to your cost utilizing rental and on-site services that provide secure 24/7 access to best–in-class technology and pumping experts could be the right solution for you.

Tri-Pump DRC Workshop For all your services, repairs & maintenance needs.

The Tri-Pump Group supply products, technical support, training spare parts, and servicing of products either on site or in one ofTri-Pump’s service facilities in Africa in alignment with our company values.

Core Competencies Reliable suppliers of dewatering and slurry pumping equipment and spare parts. Supply or rental of emergency pumping equipment across Africa. Design of dewatering systems. Open pit mine dewatering . On-site preventative maintenance. On-site trouble shooting. Servicing and repairs of pumping equipment. Dredging. Supply equipment and spare parts for agricultural sector. Training on all products sold

Here’s why: •

Automatic self-priming from dry

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Robust design for rough handling

NEW Tri-Pump Rental Division Zambia Tri-Pump Rental Division for trusted solutions to your dewatering needs.

We offer unmatched expertise with global experience delivered locally. Being available and close by makes us true business partners who understand your needs. Partner with us and ensure you get the right equipment for the job When there’s fluid to move – and downtime is not an option – you want pumps you can trust.

Whether it’s a question of water, wastewater, or industrial fluids, Godwin pumps have earned a worldwide reputation for reliability.

Tri-Pump DRC now has there own fully operational Xylem approved workshop with test facilities in Likasi

Zambia: Larry Mapani Tel: +260 21 221 8140 Fax: +260 21 221 8084 Email: larry@tripump.com Ghana: Godfrey Mwachande Tel: +233 24 623 0543 Email: godfrey@tripump.com Tanzania: Jannie Rossouw Tel: +255 28 257 0393 Fax: +255 28 257 0392 Email: jannie@tripump.com South Africa: Dirk Grobler Tel: +27 11 6095240 Fax: 086 208 0981 Email: dirk@tripump.com

DRC: Hannes Vermeulen Tel: +243 82 601 5240 Email: hannes@tripump.com

Pumps and Valves Africa - Q2 - 2016

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ASSOCIATION NEWS

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APMA News

It’s hard to believe we are almost through the first half of 2016, the years just seem to go faster and faster. This year has been a challenging one from the onset, with the severe drought having a major impact on the farmers, but it has also had a negative impact in some other areas of business in general.

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his, not to mention the sluggish mining industry causing business to be slow to say the least. These are but two key industries that the pump suppliers in South Africa supply to and service these markets.

In general, pump companies feel that market conditions are extremely tough now and some have to look at re-aligning their business to the market.

The market is supressed, and difficult with major end users having budget constraints that are forcing projects to be placed on hold. With the mining industry in a bad state overall and with downsizing and closures on the rise, placing a strain on the economy in general.

Because of the market pressure and price sensitivity, more and more end users are turning to the cheaper Chinese imported pumps that are very basic, low focus on energy conservation or pump efficiencies placing even more strain on an already challenged Eskom supply.

Some of the larger established pump manufacturers are having to retrench and restructure and are experiencing lower than expected market growth when comparing 2014 to 2015.

In general, the feeling is that there will be little to no growth in the SA pump market over the next 12 to 18 months.

Should current trends prevail, due to the economic pressure, government spending or lack thereof, within water projects which, if history has taught us anything this cannot be a guaranteed process and the pump industry remains unoptimistic to say the least that there will improvement in the near future.

Companies are also feeling the challenge due to customer spending habits – moving to cheaper models – BBBEE regulations that affect purchasing decisions more and more as time passes, labour costs are also a big factor for the local manufacturers versus the 100% local imports to remain competitive.

To add to the already challenged markets we find ourselves also entering the third year of the three year wage agreement concluded in 2014, SAPMA (the South African Pump Manufacturers Association) is already thinking ahead 6

Pumps and Valves Africa - Q2 - 2016

Lorraine Smart

towards the terms of the next agreement. With industry negotiations scheduled to commence in March next year, it is vitally important that you consider whether you will play a part in shaping the terms and conditions of employment that will govern your business for ideally the next three years.

If you want to play a part and make your voice heard, you can only effectively do so by joining and actively participating in the affairs of SAPMA. SAPMA is the only recognised employer body in the pump sector that can carry your views into next years’ round of industry wage and conditions of employment negotiations.

SAPMA is an independent Employer Associations affiliated to SEIFSA representing the views of employers in the South African Pump Manufacturing sector.

Discussions amongst the membership of SAPMA have already begun, don’t get left behind. Join SAPMA and play your part, your views are important and should be heard.

To become members you can contact the Chairman lsmart@grundfos.com or SEIFSA Theresa Crowley - Theresa@seifsa.co.za

Local valve manufacturers are still under tremendous pressure despite an upswing seen in quoting, orders are still few and far between. It is hoped that things turn around quickly in the next two months, otherwise the reality will be not only the loss of jobs but the closure of a few long standing firms.

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AMCOSA welcomes LW Tanks, an Air Valve manufacturer based in KZN, as a new member of the cluster.

Other News: Terms of reference for Stakeholder Engagement signed off.

Within the VAMCOSA cluster, there are a number of key technical working groups whose mandate is to work together with state-owned entities on various topics. The Mark Wilson main intention behind these consultative groups is ensuring that designation and localisation are implemented successfully. To achieve this goal, industry and state-owned entities should work in close collaboration.

Some of the outcomes to be achieved include: The development of South African based numerical standards. The standardised system should allow the opportunity for local manufacturers to demonstrate that equivalent local products are as good as imported counterparts, thereby encouraging greater local participation.

Identifying potential products for local manufacture, where either import replacement, import substitution and or research and product development could take place.

To develop a better understanding on the part of industry of what is required by state-owned entities, to ensure that the local market is able to meet their demands and quality standards. The technical working groups should bridge the gaps between state procuring entities and the local industry’s capability and capacity.

The structured framework provided by the Terms of Reference document for the technical working group ensures that engagement is fair, transparent and inclusive of all stakeholders, including the competition commission, the Department Of Trade And Industry (DTI) the SABS as well as the CSIR and the Department of Science and Technology (DST), among others.

Current technical working groups include: ◊ Water working group ◊ Eskom working group ◊ Eskom nuclear working group ◊ Transnet working group ◊ Export ◊ Transformation

Now that there is a structured framework for the operationalisation of technical working groups, it is envisaged that the petrochemical, oil and gas working groups will come on stream in the near future.

Vamcosa Career Day At Fumana Comprehensive High School:

ASSOCIATION NEWS

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AMCOSA News

The VAMCOSA Career Day is a flagship event in the on-going outreach project “Discover Your Career in Valves” that D Three – Discover, Develop, Deploy Services Pty (Ltd) - is delivering on behalf of the Valves and Actuators Manufacturers Cluster of South Africa (VAMCOSA). The project aims to identify candidates from underprivileged communities at high school level and provide mentorship through a collaborative relationship with VAMCOSA members, with the view to recruiting the highest performing students into the local manufacturing sector following formal apprenticeship and training.

In addition to providing learner support in the classroom through mentorship and site visits to factories, the Career Day offers learners the opportunity to interact directly with employees from companies in the valve-manufacturing sector.

Interactions of this nature provide learners with a relatable example of how becoming an artisan can be a means to overcome many of the obstacles that less privileged young South Africans encounter when trying to access tertiary education.

A second event targeting the grade 9 learners was held on the 15th April to an equally enthusiastic reception. “VAMCOSA and it’s members are really enriching the student’s learning here at Fumana,” says Mechanical Technology teacher Thulisile Moreriane, “the companies involved have helped us with equipping our classrooms as well as encouraging our learners to try their very best,” she states.

VAMCOSA members who set up stands at the career day include Cobra, RGR Technologies, Dual Products, Paltech Advanced Valve Technology, Ithuba Valves and Industrial Supplies cc, Ainsworth Engineering, Premier Valves, Mitech and Tega Industries South Africa (who is a member of Sampec), among others.

Other News: The Valve and Actuator Manufacturers Cluster of South Africa (VAMCOSA) is pleased to announce its endorsement of the 3rd Manufacturing Indaba, which will take place on 28 and 29 June 2016, at Emperors Palace, Ekurhuleni, South Africa – please come and visit our stand.

Pumps and Valves Africa - Q2 - 2016

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ASSOCIATION NEWS

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APSDA News

Eight years ago SAPMA decided to include all parties associated with the manufacture of pumps and pump systems. This change allowed pump manufacturers, pump importers, pump repairers as well as associated product suppliers and end users to join the association, ie: motors, valves, seals, consulting engineers, end users and even students were allowed to apply for membership. opment Association (SAPSDA) The main focus of SAPSDA is to develop the pump industry not only in South Africa but will aim to develop the industry in all Southern African countries.

As SAPSDA has a large pool of individual members with the expertise to assist in solving specific pump problems the association offers a consulting service to the industry by utilizing these individual members.

The membership categories remain unchanged with the local manufacturing member companies representing the majority of the association.

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Membership of SAPSDA is open to both local and international companies, consultant; individuals as well as students who are involved with or related to the pumping industry in Southern Africa.

The restructuring was modelled on the association structure of the South African Stainless Steel Development Association (SASSDA) and as from the 20th January 2014 the name of the South African Pump Manufacturers Association (SAPMA) was changed to the South African Pump Systems Devel-

The pump industry in Southern Africa is also the biggest user of castings in South Africa and it is a high priority in the goals set for SAPSDA to have a working relationship between SAPSDA members and that of the South African Foundry Industry since the foundry industry has the biggest influence on the survival of pumps being manufactured locally in South Africa.

he decision to change from an employers association to a development association was taken much later (in 2011/2012) – the reason being that the DTI required the PUMP CLUSTER to be formed under the auspices of a development association. The alternative was to for the pump cluster under the auspices of the Capital Export Council – as was the case with the valve cluster.

Training is still the main driving force in the development of the Pump Industry in Southern Africa and the SAPSDA training courses cover every aspect of the Pump industry focusing on Pump Systems as well as Seals, Electric Motors, Couplings and Drives. Each subject is presented by an expert in their specific field.

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Pumps and Valves Africa - Q2 - 2016

The Introduction Course is a practically orientated course with the main objective to assist companies involved with pumps and pumping systems to expose their employees to the pump industry and equip these employees with the basic knowledge of pumps and related products. The approach taken for this course is to give non-technical staff such as receptionists, accounting and administration staff, buyers, store men, logistical and sales staff an elementary understanding of how pumps function and get these delegates ‘pump literate’.

The Advanced course is structured to suit any person respon-

The SAPSDA Training courses are presented on a regular basis in Gauteng and are also presented once a year in KZN and Cape Town.

SAPSDA have also successfully presented courses in Namibia, Zambia and Botswana. SAPSDA can also tailor training courses to meet the specific needs and requirements of a company.

ASSOCIATION NEWS

sible for/or involved in the managing, specifications, design or purchasing of pumps and their related equipment. Slurries and fluids, test methods and standards are just some of the fields that are covered by this course. A pump test will also be viewed by the attendees.

SAPSDA Fiona Knell Cell: +27 (0)72 889 2789 Email: fiona@sapsda.co.za Website: www.sapsda.co.za

Pumps and Valves Africa - Q2 - 2016

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Pamela Jane du Plessis, Managing Director of Invincible Valves (Pty) Ltd In this year 2016, what improvements or changes has the company made in order to compete in the market?

The company has engaged with all its stakeholders to ascertain how we can assist them in these current economic times.

Since, we have been able to negotiate better local discounts as well as venture cross border sourcing quality products at discounted prices to enable our esteemed customers to continue doing business. Therefore, by reducing our costs we are able to offer better prices into the marketplace.

We are in the process of staff empowerment and education which in turn is creating a more efficient and cost effective ways of tending to your business needs and requirements. The concept of reconditioning valves has indeed become an option for many users out in the field and therefore we find that we are tending to many more opportunities than ever before.

Currently we are in the process of diversifying our business, adding additional ancillary services and products which in turn will enhance our customer experience. These services are directed to the mining, petro chemical, power generation, water, sewerage, gas works and general industries around the country and beyond.

Going forward we are constantly investigating innovative ways to enhance our product range at the best possible price, seeking long term solutions for daily issues on the plant. We are here to service the industry and are open to change on an ongoing basis.

What has been the development of the market for your company in 2015 and the forecast for this year?

2015 was a very difficult year for ourselves and many others within the industry. With the closure of some mines in the country due to unstable markets, labour issues and unrest, we found ourselves in an incredibly difficult situation. We anticipated a repeat year for 2016, a year of ups and downs, unstable markets, industrial action etc. Although we never anticipated an upswing in this year, our day to day experience suggests otherwise, at this stage we are pleased to report that in actual fact we have found it to be quite the opposite. This is due to many factors some within our control and other that are not.

We have ventured north of our borders, although a challenging operation it has been a growing experience for the business as a whole.

We have had an extremely busy first quarter and trust that business will continue in this way. We will continue to offer quality products at the best possible price with an exceptional service to all of our customers, no matter how big or small.

Invincible Valves Pam du Plessis Tel: 011 822 1777 or 011 026 7413 Fax: 011 822 3666 E-mail: pamdp@invalve.co.za Web: www.invalve.co.za 10

Pumps and Valves Africa - Q2 - 2016

Wayne Holton, Fluid Technology Distribution Manager of BMG In this year 2016, what improvements or changes has the company made in order to compete in the market?

BMG has recognised that our supply of slurry valves to the mining sector has declined and to mitigate the risk of this exposure, we are integrating the sales of our valves manufacturing business (Klep Valves) into BMG with the view of leveraging our distribution network more wisely to reach markets we have traditionally not supplied into i.e. paper and pulp, sugar and processing. Local manufacturing of our diaphragm, pinch and wedge gate valves will continue with best practices being implemented throughout the manufacturing process.

What has been the development of the market for your company in 2015 and the forecast for this year?

During 2015 BMG experienced steady growth of our industrial valves range.

BMG recognises that 2016 will be a soft year with economic growth forecast at less than one percent. We will continue looking for new opportunities in 2016 to develop our industrial valves range together with our supply partners with the intention of offering our customers the best products and solutions possible.

BMG – Bearing Man Group, Wayne Holton, Tel: (011) 620 1500 Email: wayneh@bmgworld.net, Web: www.bmgworld.net

Pumps and Valves Africa - Q2 - 2016

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Protect Performance Critical Surfaces with Thermal Spray Coating Solutions for Improved Pump Efficiencies The application of Thermaspray’s protective thermal spray coatings reduce degradation processes on performance critical pump components to extend operating life and improve pump efficiencies for optimised uptime and increased production.

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umps are essential in many heavy industries including mining, petro-chemical, and power generation.

As they normally operate in extremely stringent and corrosive environments, they are subject to degradation processes such as mechanical wear, corrosion and cavitation which assault the performance critical surfaces in pumps, leading to increased vibrations, a reduction in service life and a continuous decline in throughput and pump efficiency.

Over the last decade there have been significant technological advancements in the field of thermal spray coating technology with new coating materials and spray processes that significantly outperform the more traditional coatings.

Thermal spray refers to a coating process where the coating is produced by the projection of a molten stream of particles onto a surface. “Thermal spray is a collection of techniques which include HVOF (High Velocity Oxygen Fuel), plasma, flame spray, arc spray, etc. used to apply materials to substrates,” explains Paul Young - Spray Shop Manager - at Thermaspray. “These techniques can be applied in any industry such as mining, printing, etc. where there are surfaces suffering decay.”

“The manufacture of critical components from optimal wear and corrosion resistant materials are often restricted by cost considerations, so most of the work that we do is on new pump parts for key Original Equipment Manufacturers (OEM) customers but refurbishment is possible on parts that have not been too severely damaged,” explains Young. To prepare a new or worn part for coating, we take it down to

the substrate and we have the necessary experience and capabilities to produce the final product, new or refurbished, to Original Equipment (OE) specifications.”

New uncoated parts such as impellors, rings diffusers, casing rings and shafts, are normally received from the OEMs disassembled. Once Thermaspray has applied the relevant coatings, the parts are returned to the OEMs for re-assembly. The application of protective coatings to OE parts offers substantial cost saving benefits to end-users. Coated OE performance critical parts can be refurbished and re-used whereas uncoated OE parts are normally so badly damaged that refurbishment is impossible. “Coating of OE parts often facilitates assembly as parts are easier to slide on and off.”

Young also points out that small faults can occur on parts during the manufacturing process. “Coating these defective parts is a faster and much more affordable process compared to scrapping and manufacturing a new part. We have the capabilities to take a new part back to what is should be.

We can also assist with bringing an undersized part back to size.” Young adds that they also apply thermal spray coatings to spares so that when they are used for replacement, they are already protected.

According to Young, Thermaspray is able, to refurbish worn parts that have not been too badly damaged by corrosion, erosion, wear & tear, caused by rust, acid, salt water, etc. “As these parts are uncoated, we first have to remove the damage – dents or corroded areas - before applying the thermal spray coatings.” The removal of the coating material through a grinding process and reapplying the coating can extend both the pump and the coated part’s service life by up to two to three times. By increasing MTBF (Mean Time Between Failures) the extension of the replacement period will lead to substantial savings on replacement costs and keep downtime to a minimum. “Furthermore, refurbishment of a used pump can deliver savings of between 45 and 65% of the cost of a new pump,” concludes Young.

Thermaspray, in a joint venture with Cape Townbased Surcotec, offers an extensive portfolio of engineering and thermal spray coating solutions that extend component life cycles to assist OEM and end-user clients across southern Africa in reducing costs and increasing production. The companies’ world-class quality wear- and corrosion-resistant thermal spray coatings, Plasma Transferred Arc (PTA) cladding and Polymer coatings (in partnership with Plasma Coatings USA and Diamant Metalplastic Germany) are augmented by a host of specialised allied services.

Thermaspray, Mariette Broodryk Tel: +27 (11) 316 6520/8/9 / Email: mbroodryk@thermaspray.co.za www.thermalspray.co.za 12

Pumps and Valves Africa - Q2 - 2016

Kingler Mzansi Best for the Industry Klinger supplies the industry with the best possible products available in the market place ensuring client’s pumps and valves operate to maximum efficiency

Yvonne Maduna (Standards Director) and Gareth Langton (business development manager from Klinger Mzansi

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echanical packing and gaskets are two critical elements for the pumping industry. Klinger Mzanzi, through its manufacturing entity in Gauteng, ensures that the best products are designed and manufactured not only for the South African market place but also for the export market.

that our products meet international standards.”

All the products are compliant with international standards and manufactured to ISO 9001 specifications.

Because quality and traceability are so critical to our Industry, Klinger’s products are all manufactured under a strict ISO 9001:2008 quality management system. Batch numbering ensures manufacturing accountability from raw material receipt to final inspection and dispatch.

Yvonne Maduna, Standards Director, comments, “As specialists in this sector we also play a pivotal role in educating our customers. We strive to participate in finding workable solutions to customer challenges.”

“The company is continually striving to manufacture the best products for our customers and all our products are tested regularly ensuring they meet Klinger International Group requirements.”

“Many view gaskets as consumable items, but unless you understand the technology behind the application, incorrect utilization may often occur.

Maduna concludes, “Our continuous assessments ensure all products are manufactured correctly and through our R&D facility we are always looking at new developments and technologies so our customers get the best products for their business.”

One of the key success factors within the company is the emphasis on research and development. Gareth Langton, Business Development Manager, explains, “The R&D facility has the capability to develop specific products for customer needs. There are no SABS standards for our products so we have invested a great deal into the R&D facility to ensure

Klinger Mzansi Tel: 011 842 8300 Email: sales@klinger.co.za www.klinger.co.za Pumps and Valves Africa - Q2 - 2016

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BMG Maintenance Free Heavy Duty Couplings Important components in BMG’s Ironware division, are maintenance-free heavy-duty engineering couplings.

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Timken Quick-Flex and Vulkan GBN heavy industrial couplings are designed for efficient performance in diverse applications - from light duty, high speed/low torque drives, to extremely heavy duty, low speed/high torque drives,” says Carlo Beukes, general manager: Drive Belts & Ironware divisions, BMG. “The primary purpose of couplings is to transmit torque from a driving shaft to a driven shaft and to accommodate shaft misalignment within the drive. Couplings also dampen vibration, torque fluctuations and torsional shock loads, even in arduous applications.

hubs which are attached to the drive and driven shaft. A urethane element wraps around the two hubs and provides a simple, yet effective, drive mechanism. The only spare part required is a standby element that can be quickly changed when necessary.

Inserts, which are resistant to chemicals, are manufactured from different grades of urethane to suit various industries.

The red insert is suitable for most high speed applications with high levels of vibration, the stiffer blue insert is designed for higher torque applications and the black insert can withstand extremely high torque requirements, replacing grid and gear couplings.

An advantage of these flexible couplings over conventional units is direct replacement with The primary purpose of couplings is to virtually all comparable sized couplings. Quick-Flex couplings “Through careful and accurate transmit torque from a driving shaft require no lubrication and are product selection, correct also easy to install and maintain. installation and appropriate to a driven shaft and to accommodate care of couplings, substantial shaft misalignment within the drive Due to the high torque capacisavings can be made in ty of this range, the selected QF reduced maintenance costs and minimal downtime. These solution is often smaller than the replaced coupling. This procedures also increase the L10 lifetime of the product.” leads to a major weight saving on the drive and also reduces stress on other components.

Timken Quick-Flex couplings consist of two steel coupling Three different elements per size are available, each with a different torque rating. The flexibility of this design makes the range suitable for many applications - from high speed/ low torque/excessive vibration drives, to a low speed/high torque application.

Important features include excellent balance allowing for high speed applications up to 12 000 RPM, low maintenance with no lubrication requirements and hugely reduced downtime. These couplings accept angular misalignment up to 2º and parallel shaft displacement up to 7.92 mm.

Once the two coupling hubs, insert and cover have been installed and aligned for the first time, the coupling hubs do not need to be moved again for the life of the equipment. Unlike a standard jaw-type or gear couplings, there are no metal to metal contact between the hubs. This prevents any possible damage to the ironware during an element failure. The urethane insert can be easily changed without moving the hubs or shafts and no re-alignment of components is necessary.

Timken Quick-Flex and Vulkan GBN heavy industrial couplings – available exclusively in Southern Africa from BMG - are designed for efficient performance in diverse applications - from light duty, high speed/ low torque drives, to extremely heavy duty, low speed/high torque drives

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Pumps and Valves Africa - Q2 - 2016

Quick-Flex couplings are compatible with shaft sizes from 10 mm to 286 mm and can accommodate a wide speed range – from below100 rpm, to 12 000 rpm. Torque ratings range from 43 Nm to 188 795 Nm, depending on the selected el-

BMG – Bearing Man Group, Carlo Beukes, Te: (011) 620 1500, Email: carlob@bmgworld.net Web: www.bmgworld.net

www. same ng.co .za

BMG is committed to providing a 24 hour customer process support for production efficiency and reliability centred maintenance. This service is enhanced by an advanced technical and design support across all functional disciplines.

CS X

MP PU

Vulkan Flexomax GBN couplings, available in 16 sizes with nine designs, have customisable options to meet the requirements of restricted applications.

CP S

MP PU

These torsional flexible couplings have a maximum torque of 1 288 800 NM and shaft diameters up to 600 mm. This range is equipped with specially designed elastic elements which work in compression, allowing for maximum torque transfer, heat dissipation and product longevity. These polyurethane elements are resistant to water, oil and dust.

CP 7

MP PU

This range has a modular design that enables the integration of brake discs, pulleys, shear devices and spacer shafts within the coupling. Radial removability of the coupling elements is possible, without having to move the connected machinery. No lubrication is required during assembly or disassembly.

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

MP PU

HM

These compact couplings allow for compensating axial, radial and angular misalignments and also protect the drivetrain from shock loads.

E DL N

The flexibility of this design makes the range suitable for many applications - from high speed/low torque/ excessive vibration drives, to a low speed/high torque application

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

P -C

BMG’s Vulkan Flexomax GBN maintenance-free couplings are suitable for applications that include low speed shafts of machinery driven by electric motors. For example, mills, conveyor belts and tippers, as well as all machinery with high loads.

C

PO

ement and cover design based on the blue element specifications.

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.

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

Pumps and Valves Africa - Q2 - 2016

15

Unique Pump Design Specifically for Fire-fighting With Foam Foam is the only way to effectively fight certain fire scenarios. To generate such foam, a foam agent must be precisely admixed to the extinguishing water flow first. Then, air is added as a third component and expands the ‘premix‘ to a fire-fighting foam.

W

e designed the highly sophisticated FireDos proportioners to contribute to the effectiveness of stationary fire-extinguishing systems through powerful technology.

Product Outline The FireDos proportioner is driven solely by the extinguishing water flow.Electrical energy is not required. The purely mechanical system is made-to-last and highly reliable.

The water motor drives a specially designed pump which delivers the foam agent into the extinguishing waterflow. There is a direct linear relationship between the extinguishing water flow rate in litres per minute and water motor’s number of revolutions.

The more water flows through the water motor, the more foam agents is admixed. Thus, the quantitative ratio of foam 16

Pumps and Valves Africa - Q2 - 2016

agent and extinguishing water, which is referred to as the ‘proportioning rate’, always remains constant.

A portion of the pressure in the extinguishing water line is used as an energy source to drive the water motor. The below graph shows that clever dimensioning of the FireDos proportioner can keep the pressure loss very low.

The Advantages ÒÒ DESIGNED ESPECIALLY FOR FOAM AGENTS The proportioning pump that is driven by the water motor is self-priming and can deliver even extremely viscous fluorinefree and/or alcohol resistant foam agent without limits. ÒÒ DRIVEN SOLEY BY THE EXTINGUISHING WATER No Electricity and hence no emergency power supply is required.

ÒÒ MAXIMUM OPERATING RANGE The required propotion rate is available already from a low minimum extinguishing water flow rate. As prescribed by international sets of regulations, the proportioning rate then is always maintained precisely across the entire operating range. Also the extinguishing water line pressure has virtually no influence. ÒÒ EASY TO OPERATE Operating the proportioner just includes a few ball valves to vent the proportioner in the beginning and to put it into a state ready for operation. ÒÒ STURDY AND MADE-TO-LAST Only high-quality components and materials are used. All pressurized cast parts are designed for a testing pressure of 64 bar.

GREEN AND COST-SAVING TESTING THE PROPORTIONING RATE Extinguishing systems must be tested regularly to guarantee their functionality in case of a fire. The same applies to the proportioner The optional return line connection can be used to pass the foam agent back into the tank while its quantity is measured under live operating conditions.

The extinguishing water flow rate is measured at the same time, allowed to calculate the proportioning rate.

Following, please find an example of an installation layout allowing an extremely simple testing: »» Both fluids stay separate »» No foam or premix is generated. »» This eliminates the risk of contamination and violations of law »» Not consuming foam agent means saving cost.

»» There is no need for costly disposal of foam or premix. ÒÒ DIRECT RESPONSE TO THE EXTINGUISHING WATER FLOW As soon as the water flows, the water motor starts working ÒÒ EXACT PROPORTIONING AMOUNT and hence driving the proportioner. There are no valves The proportioning pump delivers no more than what is which have to be actuated and could be an error source. really needed. The remaining foam agents will remain its ÒÒ CLOSED SYSTEM No extinguishing water is lost which would have to be drained into the sewer system or passed back to the water tank!

tank and is not moved.

ÒÒ QUICK INSTALLATION AND START-UP All components are supplied firmly connected as one unit which is tested for functionality and tightness at our factory.

On site the water motor is integrated into the extinguishing water line in which no special stabilization stretches are required. The proportioning pump is firmly mounted and connected to the foam agent tank through a suction line and an optional return line, both of which must be provided by the installer. There is nothing more to do.

The Unit can be started up immediately after installation.

Any further adjustment is neither necessary nor possible. ÒÒ TESTING THE PROPORTIONING RATE This can be done precisely, not having to generate foam or premix.

No other proportioner brand all around the world holds as many approvals: ÒÒ Factory Mutual (FM) ÒÒ VdS ÒÒ Germanischer Lloyd ÒÒ Numerous national approvals The use in all types of extinguishing systems is possible without limits: Sprinkler and deluge systems, dry and wet extinguishing systems.

DoseTech (Pty) Ltd Tel : 0861 111 544 Fax : 021 510 2218 Email: mgf@dosetech.co.za Web: www: dosetech.co.za.

Pumps and Valves Africa - Q2 - 2016

17

Zero-leakage API Pump

KSB South Africa specified high-efficiency magnetic couplings from EagleBurgmann for the newly designed API 685 process pump.

T

he re­quire­ments for pumping hy­dro­car­bons in petro­chem­i­cal plants and re­finer­ies are very high in terms of per­for­mance, ef­fi­ciency, and emission limits. An in­creas­ing number of process pumps with magnetic cou­plings as per API 685 are being used here. For several years EagleBurgmann and KSB have been co­op­er­ at­ing to design a magnetic coupling pump. The new zeroleak­age RPHmdp refinery pump stands for the ex­pe­ri­ences of the KSB design en­gi­neers, EagleBurgmann's co­or­di­nated magnetic coupling program, and the com­bi­na­tion of an existing pump hy­draulic with the matching magnetic cou­ plings.

Adjustable magnetic coupling design The uni­ver­sal MAK modular concept for pumps – for initial in­stal­la­tion or retro­fitting – is based on two proven magnet variants, de­pend­ing on the re­quire­ment: samar­ium-cobalt for op­er­at­ing tem­per­a­tures up to 300 °C, and neodymium ferrum boron up to max. 120 °C. As a result, the coupling size

For several years EagleBurgmann and KSB have been cooperating to design a magnetic coupling pump ef­fec­tive product cir­cu­la­tion in the interior of the magnetic coupling ensures lu­bri­ca­tion and heat dis­si­pa­tion and guar­ an­ tees high op­ er­ a­ tional safety – even for low-vis­ cos­ ity media. Bearings that can be cooled or heated are also op­ tion­ally avail­able. The gas from prob­lem­atic gas-con­tain­ing media is removed from the con­tain­ment shell chamber by a hollow shaft which con­se­quently prevents the risk of the sliding bearings from running dry.

An overview of the advantages ◊ Optimized circulation guidance to improve the bearing load capacity and cooling of the containment shell

KSB includes a mag-drive pump type series in its API range

can be op­ti­mally adapted to the required op­er­at­ing con­di­ tions and ca­pac­i­ties.

Dif­fer­ent con­tain­ment shell ma­te­ri­als with the least elec­ tri­cal con­duc­tiv­ity for minimum eddy current losses are offered as well. A carbon fiber re­in­forced PEEK con­tain­ment shell is used for ap­pli­ca­tions up to 120 °C which elim­i­nates com­pletely eddy currents and seals with a maximum degree of ef­fi­ciency. Due to the oc­cur­ring loads, a metallic highper­for­mance con­tain­ment shell with a lam­i­nated struc­ture, which reduces eddy current losses to a minimum, is used for more de­mand­ing ap­pli­ca­tions up to 300 °C with higher speeds and pres­sures.

High-precision bearings for higher safety The magnetic cou­ plings are supplied with high-pre­ ci­ sion sliding bearings to securely bear the pump shaft. The bearing absorbs the axial and radial forces of the impeller; an 18

Pumps and Valves Africa - Q2 - 2016

◊ High-grade sliding bearing and magnetic materials enable a wide range of use. ◊ No eddy current losses due to carbon fiber reinforced PEEK containment shell and therefore no heating – increased safety, especially for high speeds. ◊ Resistance to a great number of aggressive media. ◊ Resistant to jolts caused by ductile material properties. ◊ High pressure limit with 42 bar, in conformance with the API 685 standard

Operating range Torque: • 1.879 Nm (magnet material: NdFeB) • 1.348 Nm (magnet material: SmCo) • Pressure: ... 45 bar • Temperature: -40 °C ... +300 °C • Rotational speed: 3,600 rpm

EagleBurgmann, Tel: (011) 457-9000 www.eagleburgmann.com

Growth for EnerMech Valves Capabilities with Africa Investment EnerMech has invested R 5.3 million (£250,000) to provide a door-to-door valves service for South Africa’s industrial services and energy industries.

T

he international mechanical engineering group has equipped two mobile PSV valves testing rigs capable of delivering valve certification and servicing to the doorstep of South African customers.

Some clients prefer not to have their safety valves going off-site so we go to them Staffed by eight PSV technicians working on rotation, the two units can operate within a 2000km radius of Cape Town and provide a rapid response service to valves clients in the gas, iron, steel and chemical industries.

The investment in the rigs has proved highly popular with client companies, which under South African law require safety valves to be recertified every one to three years. The smaller rig can service valves up to 4” while the larger unit is capable of 12” valve certification and has pressure gauge testing up to 40,000psi.

EnerMech Valves General Manager in Africa, Stephen David, explained: “Some clients prefer not to have their safety valves going off-site so we go to them. Our highly mobile response team prevents delays, improves process safety and we act as a ‘safety net’ for the client needing sourcing of new valves and spares.”

Smart logistical and route planning means clients can benefit from multiple visits on a typical round-trip. Through their regular visits, EnerMech technicians are able to predict when a valve could be expected to fail and can optimise the scheduling of a full maintenance programme to minimise client downtime.

Stephen David said there is a bright outlook for EnerMech’s Valves Division in South Africa.

He added: “There are lots of exciting opportunities and quite a bit of this lies outside the traditional oil and gas sectors in which EnerMech operates. In addition to the mainstream heavy industries, we are working in sectors as diverse as brewing and pulp and paper, and I

can see our wider offering, including recent introduction of Industrial Services in the region, being of widespread appeal with those varied businesses.”

UK-headquartered EnerMech has more than 100 staff based in Africa and operations in South Africa, Ghana, Nigeria and Angola. It has invested more than £4 million in establishing a local presence in each country and developing the infrastructure to deliver a fast response service for each of its seven business lines.

EnerMech Valves Stephen David www.enermech.com

Pumps and Valves Africa - Q2 - 2016

19

How to Improve Pump Energy Efficiency Engineers that specify an appropriate mechanical sealing system on their pumps can significantly improve the energy efficiency of a manufacturing plant as it is estimated that around 10 % of electrical power is used for pumping equipment .

resulting in a cost for lost process fluid and clean up. And, of course, if the liquid or process fluid that is leaking is heated, it is losing costly energy from the system. So, be it with flanges, valve stems or pump seals, it is necessary to think of the seal not only as preventing process fluid contamination and leakage to external atmosphere but as an important part of conserving energy within the system.

Mechanical seals on pumps are probably the most delicate components and we use seal flush plans to change the environment that the seals operate in and that makes them flourish and provide reliable operation. Flush plans are formalised by the American Petroleum Institute in their standard API-682, the custodian of the flush plans, where they are detailed in standardised formats.

Choosing the right mechanical seal is one of the most effective ways of doing this

U

nsurprisingly, regulatory bodies and engineers are focussed on improving the energy efficiency of pumps and pumping systems. Choosing the right mechanical seal is one of the most effective ways of doing this.

The purpose of a mechanical seal is to ‘seal’ the process fluid - whether it is toxic or expensive, the objective is to keep it within the system and pipe work to avoid it seeping out and

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Pumps and Valves Africa - Q2 - 2016

A survey was carried out by the Fluid Sealing Association (FSA) for pumps incorporating a total of 28,000 seals where the process temperature exceeded 200°C (400°F). The chart below shows the most popular flush plans used and, by comparison, the energy absorption of each. It is interesting to note that flush plan 32, the second most commonly specified in the survey, is by far the highest energy user.

Looking at studies on different flush plans undertaken by the FSA, we compare some single seal flush plans (21, 23, 32 and 62) with a hypothetical case study. The configuration is a hot oil pumping application with single stage, end suction centrifugal pump (API 610 compliant), based on:

ness save around 400,000 kW of energy a year. When this saving, which equates to a 96% reduction in energy costs, is spread across multiple pumps and multiple locations the potential savings are huge.

Conclusion

Pumped fluid:

hydrocarbon at 315°C (600F)

Specific gravity:

0.8

Specific heat:

1.67 kJ-°C (0.4 BTU/lb-°C)

System pressure: 345 kPag (50psig) in seal chamber Pump driver:

50 HP (typical)

Sealing devices: Mechanical seals Assumptions: Heat lost at the pump must be replaced at the system boiler / heat exchanger To put these figures into context, if a pump is running 24 hours a day, 365 days a year the difference between flushing a seal using API Plan 32 and API Plan 23 can see a busi-

Selection of inappropriate sealing systems can have a very significant impact on the energy efficiency of a plant. Sealing systems found in many industrial applications, even when functioning as intended, are extremely wasteful of energy.

However, the sealing industry has technologies that can overcome some of this energy wastage and there is increased awareness about these solutions.

Being able to choose between different sealing systems or flush plans requires a good understanding of the principals of their operation and why they’re used. The best way to access this knowledge is to work with a sealing partner that has the understanding of this specialist area.

AESSEAL, Richard Smith Tel: +27 (0) 11 466 6500 www.aesseal.co.za

www.invalve.co.za

Tel: +27 11 822 1777 Fax: +27 11 822 3666 Email: enquiries@invalve.co.za

If it’s no INVAL, then it’s not INVINCIBLE Pumps and Valves Africa - Q2 - 2016

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Pump Selection Tool Because the pump is literally the “heart of the liquid system” on a sprayer, careful consideration must be made in selecting the right pump. Seldom is there only one pump that will do the job. To make a wise choice, you will need to know about pump types, how the pump is to be driven and the flow and pressure requirements for your specific spraying system and application.

Centrifugal and Transfer Pumps (non-positive displacement) In centrifugal pumps, spray solution enters through the center of a rotating impeller that’s driven at speeds up to 6000 RPM. Spray solution is forced to the outer edge of the housing. This centrifugal force is what delivers the liquid to the nozzle. Traditionally thought of as low to medium pressure pumps, Hypro’s centrifugal pumps can deliver from 0-190 psi and flow rates up to 370 gpm.

Because centrifugals have minimum surfaces to wear and no valves, they are very durable, easy to maintain and well suited for pumping abrasive and corrosive materials.

T

o ensure you can closely match the pump to your needs, Hypro manufactures six types of pumps: roller, centrifugal, transfer, diaphragm, turbine and piston pumps.

Because centrifugal pumps operate at higher speeds, the PTO speed must be increased through a speedup gear drive, belt/pulley drive, gas engine drive, or a high-speed hydraulic motor. (Hypro has models specifically designed for each of these applications).

The broad, versatile line includes models with rugged housings of cast iron, polypropylene and stainless steel that stand up to the wide variety of agricultural chemicals.

“Positive displacement” vs. “Non-positive displacement” Hypro’s long line of pumps can be divided into two general categories: “positive displacement” and “nonpositive displacement.” Roller, diaphragm and piston pumps are positive displacement. That is, the flow from the pump is directly proportional to the pump speed. This positive flow is why all positive displacement pump hookups must include a relief valve and bypass line between the pump outlet and the nozzle shut-off valve.

Centrifugal and turbine pumps are non-positive displacement. In these pumps, a rotating impeller creates a centrifugal force that feeds the liquid through the system instead of capturing and discharging a fixed volume “per stroke” as rollers, pistons or diaphragms would do. Therefore, if the outlet is closed, the impeller simply continues to rotate harmlessly. That is why special relief valves are not required in centrifugal pump systems.

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Pumps and Valves Africa - Q2 - 2016

Roller Pumps (positive displacement) Hypro roller pumps are the number one all-around choice by farmers throughout the world. The rollers (from 4 to 8, depending on the model) revolve inside the pump housing

to force the spray solution through the outlet to the nozzle.

Roller pumps have a low initial cost and are extremely versatile. They operate efficiently at PTO speeds of 540 and 1000 rpm and have a wide pressure range of up to 300 psi and flow rates of 2 to 74 gpm.

applications such as spraying fence rows and ditches, and hydrostatic testing.

Roller pumps are self priming and easily adapt to PTO or gas engine drives. Specific seal, roller and casting materials can be selected for compatibility with certain herbicides, pesticides, fungicides and fertilizers.

Pump Drives Diaphragm Pumps (positive displacement) Because of their design, diaphragm pumps provide excellent handling of abrasive and corrosive materials. The pumping cylinders (from 2 to 6) are separated from the piston chambers (Hypro’s are oil-filled) by a synthetic diaphragm.

This keeps the spray solution from contacting and corroding the internal pump components. Diaphragm pumps are compact, self-priming and produce medium-to-high pressures (275 to 725 psi) with flow rates of 3.5 to 66 gpm. Driven by 540 rpm PTO, gas engine or DC motor, diaphragm pumps are used for a variety of agricultural, horticultural and pest control spraying applications.

How a pump is to be driven is often a primary consideration in selecting the proper type of pump. If the power source has already been determined, the following chart may be of further help in selecting the type of Hypro pump that is best suited to your needs.

Pump shaft rotation With many pumps, you need to specify which direction the shaft rotates… either clockwise (CW) or counterclockwise (CCW). Hypro’s rules on shaft rotation are as follows:

Rule #1 “Eyes on the end” Always view the rotation when you are facing the end of the drive shaft. If it turns clockwise, it is a clockwise shaft. Always

Piston Pumps (positive displacement) Piston pumps are not unlike an engine. That is, they have a shaft, pistons and “intake” and “exhaust” valves. On the down-stroke, the inlet valve opens, filling the chamber with solution. On the up-stroke, the outlet valve opens, and the piston forces the solution to the nozzle. Piston pumps deliver relatively low flow rate (up to 10 gpm) at high pressure (up to 400 psi). The replaceable piston cups can be of leather, fabric or Buna-N rubber, depending on the type of solution to be sprayed. They can be driven by 540 rpm PTO, gas engine or electric motor. Their low volume/high pressure capability permits use in general spraying as well as task-oriented Pumps and Valves Africa - Q2 - 2016

23

use this rule for determining rotation of the pump shaft and for the power source shaft (PTO, for example). Once you have determined the rotation of the power source shaft, remember Hypro rule #2:

tion will not keep the solution in proper suspension and too much agitation may cause foaming. Here are rule of thumb formulas for calculating how much additional pump flow you will need for agitation.

Rule #2 “Opposites attract” A clockwise (CW) rotating PTO shaft will require a counterclockwise (CCW) rotating pump shaft, and vice versa. All shaft rotation references in this catalog are based on these two rules.

Every pumping task has an optimum volume and pressure requirement. Determining that optimum (and selecting the pump that delivers it) is key to an efficient and economical spraying system operation. Pressure requirements for agricultural pumps are dependent on both the material to be applied and application targets. Soil-applied herbicides generally require a relatively low pressure pump rating of 30-60 psi with foliar-applied herbicides at the top end of that range and slightly higher. Insecticides and fungicides require higher pressure ratings of 100 to 500 psi. Pressure must be sufficient, in the case of heavy foliage field crops and orchard crops, to penetrate the leaf cover. In the case of orchard crops, pressure must also be sufficient to carry material up and over as well as into the canopy.

A number of factors must be considered to properly determine the total flow you will need from your pump.

Reducing agitation flow requirements Agitation flow requirements can be reduced by using jet agitation in the tank. Jet agitators use a venturi design to multiply agitation output. Depending on the jet agitator model and pressure, one gallon per minute input can provide two to ten gallons per minute agitation output.

If your sprayer is equipped with a jet agitator, consult the operator’s manual or documentation to find the output to input ratio and adjust your flow required for agitation accordingly.

For example: If you calculate a requirement of 63 gpm of agitation and your jet agitator requires 3 to 1 output to input ratio, your pump would only need 1/3 of 63 gpm, or 21 gpm.

They include: • Type of spray operation (broadcast, banding, lowlevel, etc.)

• The chemical’s application rate, ground speed, boom width, hose length, tank agitation, etc.

The spray task is the first consideration in determining flow rate and pressure needs. The following formulas and calculations may help.

Calculating agitation requirements The pump must produce enough flow for both the application rate and tank agitation requirements. Too little agita-

24

Pumps and Valves Africa - Q2 - 2016

Factor in an “Excess Flow” Requirement It is wise to have some excess flow capacity so you will not end up with an undersized pump because actual operation conditions may cause changes in spray system performance (such as normal pump wear, operating at less than rated speeds, etc.). Hypro recommends you add an additional 20% to your calculated total pump flow requirement to compensate for these variables. Plumbing systems have a number of restrictions that will result in a pressure drop from the pump to the actual spray point. These must be taken into account and minimized.

Calculating pump flow for broadcast boom sprayers Chemical application is measured in gallons per acre (gpa), whereas pump flow is stated in gallons per minute (gpm). To calculate the pump flow gpm required by a broadcast boom sprayer, multiply the gpa application rate (from the chemical label, usually 10-20 gpa) by the sprayer ground speed (5-10 mph). Multiply the sum by the boom width on your sprayer (in feet). Then, divide that number by 495. As a formula, it is written like this:

The result will be the pump flow required to deliver the proper application rate at the boom’s nozzles. Then calculate your total pump flow requirement (broadcast): Use this same method for calculating the pump flow requirement for high pressure spraying, such as trees. Even though the application “rate” is usually a visual saturation of the tree, the known gpm factor will be the hand gun nozzle output, which is the rate you use for the calculation.

Calculating pump flow for banding sprayers First, multiply the band width (in inches) by the number of rows to determine the total width (w). Then, multiply the application rate (gpa from the chemical label) by the ground speed (mph). Multiply that result by the total width (w) calculated earlier, then divide the result by 5940. Here’s how the formula appears:

PTO DIRECT-MOUNT Calculating pump flow for hand gun spraying For low-level spraying with a hand gun, such as for lawn and turf care, professional applicators typically “walk” the lawn at about 1,000 sq. ft. per minute. That means the “gpm” rate of the hand gun will generally be the same as “gallons per 1,000 sq. ft.” To determine your total pump flow requirement:

Location of PTO driven pumps and pump drive units may have a significant effect on pump life. Mounting the pump directly to the PTO is always a good choice. Even though nstallation is relatively easy, use caution to ensure the shaft does not get bent or damaged. Always use a quality, properly secured coupler and provide adequate support for the pump itself in order to withstand the extreme bouncing and vibration the system must endure. PTO mounting shields should always be used for maximum safety and protection.

Pumps and Valves Africa - Q2 - 2016

25

TUMBLE ROD MOUNTING If direct PTO mounting is not convenient or desired, then mount the pump in a convenient position on the pullbehind sprayer and connect it to the tractor PTO with a “tumble rod” power shaft. Exercise caution when using this approach to ensure: (1) the tumble rod is level; (2) the hitch pin is the center-point; and (3) turn angles greater than 45° can be avoided. Failure to follow these three points may cause “power shocks” within the pump and drive units and increase wear on seals, gears and, in the case of diaphragm pumps, the diaphragms themselves.

The best tumble rod installation occurs when the distance from the PTO U-joint to the hitch is equal to the distance from the hitch to the pump U-joint. For 540 RPM PTO shafts, the distance from the hitch pin to the pump shaft should be 14 inches. For 1000 RPM 13 ⁄8” PTO shafts, the distance is 16 inches. For 1000 RPM 13 ⁄4” PTO shafts, the distance is 20 inches. Instances where equal distances are not possible, a “constant velocity” shaft should be used.

Power shocks occur when the PTO shaft knuckle and the universal joint at the pump end of the tumble rod turn faster on the inside of the turning angle than on the outside.

To prevent these vibrations, the angle of the tumble rod to the tractor PTO shaft and the angle of the tumble rod at the pump shaft should be as close to equal as possible. This will cancel out the fluctuations.

Aknowledgement Hypro Spray Nozzles http://www.hypro-eu.com/

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Pumps and Valves Africa - Q2 - 2016

Xylem Launches The World’s First Wastewater Pumping System With Integrated Intelligence

Xylem, a global water technology company, has developed the Flygt Concertor, a smart, interconnected wastewater pumping system that senses the operating conditions of its environment, adapts its performance in real time and provides feedback to pumping station operators.

X

ylem says fields tests conducted around the world validated significant improvements with Flygt Concertor, including: energy savings of up to 70% compared to a conventional pumping system; reduced inventory by up to 80% due to flexible performance; clog-free pumping operation and clean wet wells saving up to 80% in vacuum cleaning costs; and a compact design, reducing cabinet size by up to 50%.

Flygt Concertor is suitable for use with wastewater pumps in the range of 2.2 to 7.3 kilowatts (kW) and has a system design that combines IE4 motor efficiency, N-hydraulics, integrated power electronics and intelligent controls. All these features are designed to work in harmony with each other, which results in optimal pumping performance at the lowest cost of ownership, according to Xylem.

To Read All our Magazines Online www.pumpsandvalves.co.za To Advertise Contact Helen on +27 11 047 2400 info@pumpsandvalves.co.za

Concertor features a built-in sump and pipe-cleaning features – a first for a wastewater pumping system Flygt Concertor’s flexible performance represents a significant change in how pumping systems will be selected and managed in order to accommodate different flow rates. In contrast to the fixed performance curves of conventional pumps, Flygt Concertor offers a wide performance field from which to choose the right operating point. This makes selection simple, facilitates performance fine-tuning and, as a consequence, significantly reduces inventory.

ENDORSED By SAPMA (South African Pump Manufacturers’ Association) and VAMCOSA (The Valve and Actuator Manufacturers Cluster of South Africa)

Q 2 -2016

Furthermore, Concertor features a built-in sump and pipe-cleaning features – a first for a wastewater pumping system. Extensive trials show that these features, together with a second generation of Flygt’s patented Adaptive N-technology and an integrated pump-cleaning function, minimize vacuum cleaning costs.

Xylem Water Solutions South Africa (Pty) Ltd Tel: +27 11 966 9300, www.xyleminc.com both option.indd 1

6/9/2016 7:58:15 AM

Pumps and Valves Africa - Q2 - 2016

27

BAUMA REPORT BACK Once again the Bauma exhibition broke records, in size, visitor and exhibitor numbers, to name just a few. The Lifting Africa team was there all week and here reports some highlights The total number of visitors to last month’s Bauma, the world’s biggest construction equipment exhibition, was close to 580,000 – an increase of about 10 % on then previous event, held in 2013.

Visitors to the Munich, Germany, show came from 200 countries. After Germany, the top ten countries of origin were Austria, Switzerland, Italy, France, Netherlands, UK, Sweden, the Russian Federation, Poland and the Czech Republic.

Products were shown by 3,423 exhibitors occupying a record 605,000 m² of exhibition space. Exhibitors from outside Germany were 63 % of the total – higher than ever before, according to event organiser Messe München.

An amazing number of new cranes, transport equipment, components and services was shown for the first time.

The next Bauma in Munich will be held from 8 to 14 April 2019. This year Bauma China will be held in Shanghai between 22 and 25 November 2016

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Pumps and Valves Africa - Q2 - 2016

Pumps and Valves Africa - Q2 - 2016

29

BAUMA REPORT BACK

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Pumps and Valves Africa - Q2 - 2016

More Power with Tsurumi's Tandem Operation Kit In mining and construction applications, pumps often need increasingly higher head as work progresses. Tsurumi’s new Tandem Kit means that rather than installing a potentially costly new pump, higher head can be obtained with the addition of a second pump through tandem operation.

Tsurumi Manufacturing Co., Ltd. was founded in Japan in 1924, and has since been manufacturing, purchasing and selling various pumps and related equipment, with a strong focus on submersible pumps. The company has recently introduced its Tandem Kit, which exhibits power in fields where high head is required, such as mines, and construction and tunnel work sites.

Twice the total head Generally, in applications that need draining at high head such as mines, it is necessary to prepare an expensive pump of a large size that provides high enough output to satisfy the required specifications by itself, or to make a sump pit as a relay point. Particularly, when it comes to draining water from mines, there is a limitation on installation space. Therefore, in such a case, a pump of compact and slim design is required.

For this purpose, Tsurumi developed the dedicated Tandem Kit, which is attached to the casing of the LH and LH-W series pumps that feature high head, high durability and slim design, and have been proven in mine drainage applications. With the Tandem Kit, two pumps of the same model can be easily connected in series. Tandem operation that connects two pumps in series can provide twice the total head of a single pump at a fixed flow rate. The operating principle of this method is the same as that of a multi-stage pump.

Tsurumi has six 3-30 kW pumps that are applicable with the Tandem Kit. Most of these pumps have a dual impeller design. The Tandem Kit can be easily attached to the pumps at the work site. With

this kit, an ultra-high head of a maximum 254 m can be obtained. A head of 400 m is possible with optional features. In many cases of tandem operation, pump models equipped with pressure relief ports are selected, in order to prevent discharge pressure from being directly applied to mechanical seals.

Most of the cylindrical pumps used for tandem operation have a center flange structure that allows discharge piping to be aligned with the center axis of the pump.

However, with general pumps whose discharge port is not aligned with the center axis of the pump, it is difficult to balance the connection between the two pumps, as well as to install the pumps. The center flange structure, on the other hand, enables the pumps to be well balanced in the direction of the pump axis. Therefore, when two pumps with this structure are connected in series via the tandem connector*, they can be installed in a hole of an 8 in to 16 in bore owing to their slim design. (*Note: An intermediate connection pipe may be required depending on the situation.)

Tsurumi offers a variety of heavy-duty, highly reliable pumps that enable continuous operation under the strenuous conditions found in mines, etc. Also available as options are submersible pumps for high-temperature liquids that can handle water of up to 90°C and all stainless steel pumps, in which all liquid contact parts are made of stainless steel (316 stainless steel).

Tsurumi Manufacturing Co., Ltd www.tsurumi-global.com Pumps and Valves Africa - Q2 - 2016

31

Ensuring Uninterrupted Service for Energy Sector Pumps Technologically advanced systems are required on modern-day renewable energy plants, to squeeze every available kilowatt of power out of the plant and gain the right efficiency to ensure the projects’ success.

A concentrated solar power site

In support of these efforts, KSB Pumps and Valves is ready to assist independent power producers (IPPs), to act as a fluid transfer technology partner supplying pumps for renewable energy plants, and to offer support for decades to come. This is in line with its commitment to traditional power utilities where the company has been supplying and servicing products for more than half a century.

According to Stefano Testi, who is responsible for the energy sector at KSB Pumps and Valves, the company is eager to also play a leading role in the development of clean power alternatives. As a world leader in the supply of fluid transfer solutions to the global energy sector, the company wants to leverage its global expertise for the local industry.

Local content “We have the ability to transfer knowledge and skills from across the globe for all forms of power generation, whether it be renewable energy or traditional forms, to our local manufacturing facility and invest in the technology required to procure and manufacture world class pumps locally. Not only will this support the local energy market, but it also ensures that local content requirements are met with world class products. “Even in terms of nuclear power, we are perfectly positioned to supply and support local efforts wherever and whenever they come to fruition. We are also in a position to lend ex32

Pumps and Valves Africa - Q2 - 2016

Stefano Testi of KSB Pumps and Valves says the company wants to work with local IPPs to develop technologies for the renewable energy sector

pertise to other emerging power generation technologies such as concentrated solar energy that is becoming a viable solution for IPPs in this country - especially considering the amount of sunshine days in southern Africa.

solutions for African conditions.

Another emerging market is using pumps as turbines (PaT’s).

With the support of the KSB Group and local knowledge transfer we will be in a better position to also offer energy recovery solutions in Africa.

Stefano concludes, “All our pumps are manufactured to the highest KSB quality standards and conform to all applicable international standards. We have branches across Southern Africa, in West Africa, in East Africa, and have a long track record of supporting our equipment anywhere within the sub – Saharan region. No matter how big or small, we pride ourselves in taking care of our products in the field and have an enviable track record when it comes to after-sales support – particularly in the energy sector.”

KSB pumps for concentrated solar power stations

Common types He continues that KSB Pumps and Valves are being used in the renewable energy market worldwide, supplying boiler feed water, heat transfer fluid, and auxiliary pumps for all applications, available in different sizes and configurations as required. API 610 11th edition heat transfer fluid pumps and auxiliary pumps are locally manufactured, providing tested

KSB Pumps and Valves Annett Kriel Tel: (011) 876 5600 Fax: (011) 822 1746 Email: Annett.Kriel@ksb.com Web: www.ksbpumps.co.za

SIL3 For South African Valve Manufacturer Industrial valve manufacturer Gunric Valves has achieved the highest level of safety, the SIL3 (Safety Integrity Level), for their Metal Seated Butterfly Valves. The SIL3 - for all electrical operated components that operate within a system in a plant, such as a refinery, - is assessed for safety and reliability as well as the impact on the system if it fails.

T

his Certification enables Gunric Valves to offer the Oil, Gas and Water industries a guarantee that when they need to close a particular section that the Gunric Metal Seated Butterfly Valve will close, and will close safely.

The Technology Localisation Implementation Unit (TLIU) assisted Gunric Valves in obtaining the SIL Certification IEC 601. The certification process took four months at a cost of half a million rand.

By obtaining the SIL3, Gunric Valves can now supply locally manufactured products to the industry TLIU is an initiative of the Department of Science and Technology (DST) (hosted by the CSIR), mandated to assist State Owned Companies in realising their localisation programme by improving the competitiveness of strategic suppliers.

By obtaining the SIL3, Gunric Valves can now supply locally manufactured products to the industry, and by-pass the traditional use of nontariff barriers that allowed imported products with similar certifications to keep local products out of the market.

Gunric Valves is a leading manufacturer and supplier of cast and fabricated industrial, high performance butterfly valves in South Africa, and exports to Australasia, as well as into Africa.

Gunric Valves provides customised butterfly and check valves for unique industrial applications. The range is built for extreme pressure and temperature applications and is ideally suited for the water, oil, process, mining, power generation, petrochemical, gas, sugar and steel industries.

Gunric Valves, Tel: +27(0) 11 474 6180/4 Fax: +27(0) 11 474 6136/7 E-mail: sales@gunric.com www. gunric.com Pumps and Valves Africa - Q2 - 2016

33

Servicing the Petrochemical & Bulk Fuel Storage, and Air-Pollution Control Industry Industrial and Designer Valves (IDV) was formed in 1996 to service the petroleum, gas and chemical industries in Southern Africa. It has established partnerships with quality suppliers in order to stock, supply and support superior products to this very specific industry. IDV has offices in Johannesburg, Durban and Cape Town.

O

ur main petrochemical valve brand FZV, is approved by the majority of local and international petroleum, gas and chemical companies and carry all the necessary certifications.

In 1999 IDV became the sole distributors of the Mecair product range to service the pollution control industry with valves, controllers and equipment specifically for dust collectors or fabric filter plants. In 2011 the Goyen range of valves was added to further service this industry. More recently IDV have become the agents for Pentair’s precision filtration products. This incorporates the Mecair and Goyen range of valves. At the same time it has introduced the membrane drying and separation technology to the local market. These products remove water vapour in compressed air lines or from hydraulic fluid in a simple and cost effective manner.

All equipment and services supplied by IDV are guaranteed and supported by the relevant standards and documentation. IDV have experience in successfully handling large projects and contracts. While they prefer to use local technology, they readily draw on the experience of international

Membrane drying technology IDV now offers Pentair drying solutions for compressed air and hydraulic oil, to increase equipment reliability. This is a compelling alternative to Refrigerant or Desiccant drying systems for the following reasons: • Lower output dew points • Maintenance free and reliable • No consumables (refrigerant / desiccant) • Compact, easy to install • Uses no electricity • No moving parts, silent • Adjustable to desired dew point engineering consultants and manufacturers when needed.

Industrial & Designer Valves, Tel: +27 11 475 1024, Fax: +27 86 560 3461 Email: info@idv.co.za, Web: www.idv.co.za

Industrial and Designer Valves Holdings (Pty) Ltd.

Valves for the Petroleum, Gas and Chemical Industry

IDV is the sole distributor in South Africa for GOYEN and MECAIR

Goyen and Mecair offer efficient reverse pulse filter cleaning solutions for air pollution control.

Fire-safe ball valves, gate valves and check valves (double-door wafer and swing type) are internationally approved and CERTIFIED (API 6D), PED and SIL. COMPLETE PRODUCT AND SOLUTION PROVIDERS Tel: +27 11 475 1024 • Fax: + 11 679 5461 E-Mail: info@idv.co.za • Web: www.idv.co.za

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Pumps and Valves Africa - Q2 - 2016

Their technology is acknowledged as market leading, offering tailored solutions for the world’s dust collector manufacturers and system users.

Tel: +27 11 475 1024 • Fax: + 11 679 5461 E-Mail: info@idv.co.za • Web: www.idv.co.za

SMC Meets Market Demand with long-life Angle Seat Valve As one supplier for all customer needs and the worldwide leading expert in pneumatics, SMC Pneumatics recognised a need for the expansion of their fluid control range by means of its recently launched VXB series.

T

he VXB Series is an angle seat valve for air, steam and heated water which has been created to meet market demand for valves that deliver an extended operating life, low levels of air leakage, low pressure loss due to its angle seat structure and is compact in design.

Delivering up to 5 million air and 3 million steam switching cycles, the VXB Series is also fitted with a special rubber seal that minimises internal air leakages to a mere 10 cm³/min or less.

Compact in its design with a height of just 100 mm in the 3/8 valve, the VXB is the ideal solution for applications pertaining to temperature control, hot water systems, industrial washing machines, sterilising and cleaning equipment.

The response to the VXB series has been really positive and we are confident that it will be a popular addition to our comprehensive range Ernst Smith, SMC Product Manager Further design features ensure reduced costs by extending the lifespan and efficiency of the valve through a double protective construction. Foreign particles are also prevented from interfering with the VXB’s performance thanks to a protective seal and a resin scraper.

Ernst Smith, Product Manager at SMC comments: “By listening and responding to our customers’ needs, we set about creating a multi-purpose solution that delivers on cost savings, minimal maintenance, reliability and space savings,” “The response to the VXB series has been really positive and we are confident that it will be a popular addition to our comprehensive range.” concludes Smith.

VXB Process Valve

Available in three port sizes, 3/8, 1/2 and 3/4, the VXB can be ordered in bronze or stainless steel (316L equivalent) with a pilot port location that can be placed in three of its four sides.

For more information on the VXB angle seat valve, visit the SMC new product page:

SMC, Tel: +27 11 568 2407 www.smcpneumatics.co.za Pumps and Valves Africa - Q2 - 2016

35

Grundfos Expands in Africa Water scarcity and rising energy prices increase demands for energy efficient water solutions in the more politically and economically stable markets in Africa. These tendencies make the global pump manufacturer upgrade its activities.

P

eople in Africa increasingly call for solutions, which offer easier access to water for an affordable price. In order to get ahead of this tendency, Grundfos recently expanded its presence in Africa with the opening of new facilities in Nairobi, Kenya, to streangthen its East Africa activities, and in Cape Town in South Africa to complement its existing five star Industrial Green building already situated in Johannesburg.

Energy conservation has never been high on the agenda in South Africa, as energy has always been relatively cheap and available “If we are really going to grow the market, it is important for us to come closer to the customers and offer them better opportunities of seeing, touching and feeling our products. This will now be possible in our Kenyan center’s new premises in Nairobi and our new branch office in Cape Town, 1,400 kilometers away from our South African HQ in Johannesburg. In both facilities we can now demonstrate what Grundfos is able to offer the local markets by doing for example training and presentations to key stakeholders in our market segments,” Lee Carlin, Area Managing Director, explains.

Innovative solutions Energy conservation has never been high on the agenda in South Africa, as energy has always been relatively cheap and available, but energy prices are now starting to increase.

According to Lee Carlin, this makes demand for energy efficient Grundfos technologies increase and promotes interest in renewables solutions.

“In the new Cape Town branch office we can really show our customers, how our innovative solutions can help them save

Be in the Buyers Guide Contact Jackie on Tel: (011) 047-2400 Email: adverts@pumpsandvalves.co.za www.pumpsandvalves.co.za

36

Pumps and Valves Africa - Q2 - 2016

energy, and it will help make us known as the company to go to, if they want renewable water systems and solutions,” Lee Carlin says.

Centre for engagement The new South African branch office will not only lead to even stronger partnerships and relations to the local customers. It will also be centers of engagement with other stakeholders in a country, plagued by severe drought.

“South Africa is currently experiencing its worst drought in over 130 years, and water scarcity as well as energy scarcity are now issues in South Africa. The new facilities offer better opportunities of bringing this discussion to the table, and we plan for example to collaborate very closely with the local government, the Danish Embassy and universities on finding answers to these challenges. We draw inspiration from the success our colleagues have had around the world, in order to provide sustainable solutions in an ever-changing world,” Lee Carlin says.

Grundfos (Pty) Ltd Tel: (+27) 10 248 6000 www.grundfos.com

THE MAGAZINE WILL ALSO BE DISTRUBUTED AT OUR STAND AT ELECTRA MINING

AZ-Armaturen South Africa Continues to Grow

D

uring these tough economic times people tend to cut back and down size. This is not the case for AZ-Armaturen South Africa. The company has been growing and investing continuously during the last few years and has increased its market share in the stagnating valve market. AZ-Armaturen South Africa has invested further and introduced a new CNC (Computerized Numerical Control) machine into the production. The new CNC lathe with live tooling (multiple axes for milling) and latest state of the art technology allows AZ-Armaturen to increase productivity, flexibility and improve quality with their plug valves. This has also furthered AZ staffs education on world class technology. AZ-Armaturen South Africa once again is a true ambassador for their moto “Your Partner for Highest Demands�.

AZ-Armaturen South Africa Pty Ltd Telephone: +27 (0) 11 397 3665

Facsimile : +27 (0) 11 397 3803 Email: info@az-armaturen.co.za Web: www.az-armaturen.co.za

Pumps and Valves Africa - Q2 - 2016

37

Mitech Launches Locally Manufactured Globe Valve

Mitech Control Valves (Pty) Ltd is pleased to announce the launch of their locally designed and manufactured High Pressure Globe Stop Valve.

Mitech CEO, Alli Alberts Mitech General Manager Pieter Badenhorst

H

igh-pressure stop valves are used in the most extreme high pressure and temperature applications. Eskom remains one of the largest consumers of these valve types, with thousands of units required in power plants across the country.

Up until now, there has been no local manufacturing capability to produce the valves required to specification. With no local capability available, cost for the purchase and maintenance of these valves remains high.

Eskom has agreed to install the valves at appropriate test sites for a trial period at their power plants

struction Note for the procurement of valves and actuators.

General Manager for Mitech, Pieter Badenhorst highlights the degree to which the unit is locally produced stating that “although we have to import some of the material used in the manufacturing process such as bar-stock which is not produced in the country at present the valve remains 80-90% locally manufactured.” Using Mitech’s design, locally sourced materials, local castings, machining, assembly and testing, the valve conforms to all the criteria for local content.

Badenhorst explains that it would be very difficult to simulate the extreme conditions that would be required to test their valve in the laboratory, and therefore, Eskom has agreed to install the valves at appropriate test sites for a trial period at their power plants, to fully evaluate the valve’s performance. Mitech has committed to providing technicians working on Eskom’s plants with training as well as a full service manual to ensure effective incorporation of the valve into the power plants.

In answer to this challenge, Mitech has been working in close consultation with Eskom over the last two years, to conCEO of Mitech, Alli Alberts is confident ceptualise, design and locally manthat their product will meet and outperufacture a high pressure stop globe form those that are currently being imvalve that will fulfil the technical and ported. He highlights the importance of safety requirements as well as the local local manufacturing in addresscontent requirements as set out Mitech High Pressure Stop Globe Valve, the first valve of its ing unemployment in South Afin The Department of Trade and kind to be locally designed and manufactured in South Africa rica, and the positive knock-on Industry’s (the dti) designation In38

Pumps and Valves Africa - Q2 - 2016

The Mitech High Pressure Stop Globe Valve undergoing a pressure test at the Mitech factory in Kempton Park

The whole unit comprises of 33 components, most of which are easy to maintain. The body of the valve is a one-piece investment cast design, eliminating threaded or bolted pressure retaining parts. The unit has a fully replaceable seat, which can be extracted while the valve remains welded into the line.

The inner components of the valve can be refurbished using standard tools, as well as two specialised tools, on site. The valve boasts a long lasting packing configuration with live loading as an option.

The anti-rotation pin on the stem ensures that there is Mitech CEO Alli Alberts accompanies media and Eskom engineers at a pressure test of the new high pressure no torsion applied to the packing system. The unit valve features a universal yoke effect that this will have for the economy. “Projects such as flange making it easy to accommodate various actuator dethis should start to make a real difference,� he states. signs. The stellited seat and hardened plug material ensure a The High Pressure Globe Stop Valve demonstrates some im- tight shut-off making it highly resistant to erosion. pressive specifications. The key to the design concept has been simplicity, robust engineering and minimising mainte- Mitech Control Valves, Pieter Badenhorst nance costs.

Tel: (011) 927-4850, www.mitech.co.za Pumps and Valves Africa - Q2 - 2016

39

Simplified Control Options for Irrigation Systems Traditional irrigation systems use a multitude of pilot operated, self actuated, control valves for in-field pressure reduction, and flow control. However, there is much simpler equipment available, which is less expensive to set up, and provides long lasting maintenance-free irrigation operation.

susceptible to dirt, as there are no small passages on any part of the valve.

Flow Control Valves Flow control valves are used to control the flow into any section of the system. They ensure that the amount of water supplied is optimal, and that certain sections do not starve others due to differences in elevation, or resistance to flow. Traditional flow control valves are also pilot operated, and suffer from the same problem as pressure reducing valves, in that they are easily tampered with and vulnerable to dirt. They also require a great deal of ongoing maintenance to function effectively.

They also require a great deal of ongoing maintenance to function effectively.

Maric flow control valves can do the function of most of these applications. These valves are very simple, tamper-proof, and are not vulnerable to dirt. The average expected service life is 20 years. Maric flow control valves control the flow rate chosen, irrespective of pressure fluctuations.

Pressure Reducing Valves PRVs are used wherever the distribution pressure is too high for the irrigation equipment, i.e. in sprinklers, drippers, and any other water-using equipment. One of the problems with pilot operated PRVs is that they can be easily tampered with; they are also very susceptible to dirt due to the small passages in the control pilots and piping. Although blockages are prevented by installing small strainers on the control piping, these become high maintenance items, and detract from the actual activity of farming (growing product).

Ratio reducing valves can do the function of most of these applications. A ratio reducing valve reduces pressure in a fixed ratio, which cannot be adjusted or tampered with. Ratio reducing valves are also not

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Pumps and Valves Africa - Q2 - 2016

In many applications, flow con- This stands to reason when one In very large centre trol valves can be used instead pivots, one may find of pressure reducing valves. For considers the environment in which that the sprinkler instance, in a normal sprinkler, the equipment has to operate, the level at the beginning, you can adjust the amount of first from the pivot, water used by controlling the of education of staff, and the tendency will spray a larger pressure to the sprinkler. If, on to adjust things for the wrong reasons amount of water the other hand, you use a flow than the ones closer control valve instead of a PRV, to the end. It may, you will essentially achieve the same thing. A Maric then, be a good solution to install a Maric flow control flow control valve is a lot simpler, and cheaper, than a valve on a few sections of the centre pivot‌ or even on pilot operated pressure reducing valve. each sprinkler.

Centre-pivot sprinkler systems are a typical application where the Maric flow control valve can be used instead of pressure reducing valves. Let me explain: pressure reducing valves are normally installed on center pivots, so that the sprinklers can be protected from over-pressure, and the flow rate can be set to the ideal setting. A Maric flow control valve will achieve exactly the same end result! If you know the number of sprinkler heads on a centre pivot, and you know the ideal flow rate for each one of them, you know the total flow required.

By simply installing a Maric valve in front of the centre pivot, the ideal volume of water will be supplied to the centre pivot.

Pressure will also be automatically reduced to that which is ideal for the centre pivot.

This will ensure even distribution of water to all the centre pivots.

In the context of irrigation, the purpose of any development in equipment used, has mostly resulted in simpler, and less expensive, options. This stands to reason when one considers the environment in which the equipment has to operate, the level of education of staff, and the tendency to adjust things for the wrong reasons. These factors are particularly true in the African continent.

The use of the ratio reducing valve, and the Maric flow control valve, provide options around simplicity, tamper proof operation, long life and lower initial cost

Ultra Control Valves Tel: 011 452 6514 Fax: 086 547 0555 peter@ultravalves.co.za

Pumps and Valves Africa - Q2 - 2016

41

Construction of New Pipeline from Mombasa to Nairobi to Take Longer The construction of the new pipeline from Mombasa to Nairobi is expected to cost more and take longer than projected; this is according to Kenya Pipeline Company (KPC).

K

PC Acting Managing Director, Mr. Joe Sang confirmed the reports and said that the cost of constructing the pipeline will go up mainly because of the depreciation of the shilling against the dollar since its financing was agreed upon, the shilling was trading at Sh87 to the dollar by then and it is currently trading at Sh101.48.

He further explained the duration will also be increased due to several challenges like delayed finances, delayed agreements on some technical features, removal of squatters from its way and also because of bureaucracy between Kenya Pipeline and other government agencies.

“There are emerging uncertainties that have come up and while we’re doing everything under the sun to deliver the project, applicable laws will be applied accordingly,” Mr. Sang addressed the Public Investments Committee.

A Lebanese construction firm Zakhem International was the company contracted in 2014 to develop the US$ 490m pipeline. The company will also be required to assemble a fibre optic cable along the route, fix four pumping stations for the pipeline and finally upgrade the existing KPC fire-fighting

Workers from the Sudanese oil pipeline in the disputed Abyei area reconstruct the line on June 14, 2013 following an explosion the previous day. South Sudan's army rejected any involvement in the explosion after being accused by Khartoum of backing rebels. AFP PHOTO / STR (Photo credit should read -/AFP/Getty Images)

equipment in Nairobi.

The current existing pipeline that links Mombasa and Nairobi was also built by Zakhem International in 1973 but has however outlived its 30-year lifespan and is prone to ruptures.

Most of the refined fuel imports in Kenya and the imports in transit on the way to other neighbouring countries have to be transported by truck which

is slow and unreliable owing to breakdowns and poor roads.

Zakhem International S.A. is an international Construction, Engineering and Investment Group of Companies founded in 1963 in Lebanon to meet the expanding construction needs of the Middle East and Africa.

Kenya Pipeline Company Ltd. www.kpc.co.ke

EXTRA COPIES OF THE NEXT ISSUE OF PUMPS & VALVES AFRICA WILL BE DISTRIBUTED FROM OUR STAND AT ELECTRA MINING CONTACT HELEN ON 076 751 9228 INFO@PUMPSANDVALVES.CO.ZA 42

Pumps and Valves Africa - Q2 - 2016

Pumps and Valves Africa - Q2 - 2016

43

ANSI PROCESS PUMPS

SAM Engineering Tel: (011) 823-4250 Fax: (011) 823-4943 Email: sales@sameng.co.za Web: www.sameng.co.za AXIAL FLOW PUMPS

Franklin Electric Tel: (011) 723 6500 Fax: (011) 609 2417 info@franklin-electric.co.za www.franklin-electric.com API PROCESS PUMPS

APE Pumps Tel: (011) 824 4810 Fax: (011) 824 2770 E: apepumps@mweb.co.za Web: www.apepumps.co.za BOOSTER PUMPS

Becker Mining Tel: (011) 617 6300 Fax: (011) 908 5806 info@za.becker-mining.com www.za.becker-mining.com

Xylem Water Solutions South Africa (Pty) Ltd Tel: 011 966 9300 Fax:011 5528818 Email: info.za@xyleminc.com Web:www.xyleminc.com

SAM Engineering Tel: (011) 823-4250 Fax: (011) 823-4943 Email: sales@sameng.co.za Web: www.sameng.co.za

Becker Mining Tel: (011) 617 6300 Fax: (011) 908 5806 info@za.becker-mining.com www.za.becker-mining.com

CHOPPER PUMPS

Xylem Water Solutions South Africa (Pty) Ltd Tel: 011 966 9300 Fax:011 5528818 Email: info.za@xyleminc.com Web:www.xyleminc.com

Xylem Water Solutions South Africa (Pty) Ltd Tel: 011 966 9300 Fax:011 5528818 Email: info.za@xyleminc.com Web:www.xyleminc.com FIRE PUMPS

DIAPHRAGM PUMPS

Unique Engineering Tel: (011) 826 6111 Fax: (011) 826 6162 E: sales@uniqueeng.co.za Web: www.uniqueeng.co.za

SAM Engineering Tel: (011) 823-4250 Fax: (011) 823-4943 Email: sales@sameng.co.za Web: www.sameng.co.za

SPP Pumos Tel: (011) 393 7177 E: sales@spppumps.co.za Web: www.spppumps.co.za

Xylem Water Solutions South Africa (Pty) Ltd Tel: 011 966 9300 Fax:011 5528818 Email: info.za@xyleminc.com Web:www.xyleminc.com POSITIVE DISPLACEMENT PUMPS

HORIZONTAL SPLIT CASE PUMPS

END SUCTION PUMPS

APE Pumps Tel: (011) 824 4810 Fax: (011) 824 2770 E: apepumps@mweb.co.za Web: www.apepumps.co.za

SAM Engineering Tel: (011) 823-4250 Fax: (011) 823-4943 Email: sales@sameng.co.za Web: www.sameng.co.za METERING PUMPS

Franklin Electric Tel: (011) 723 6500 Fax: (011) 609 2417 info@franklin-electric.co.za www.franklin-electric.com PROGRESSIVE CAVITY PUMPS

CENTRIFUGAL PUMPS

SAM Engineering Tel: (011) 823-4250 Fax: (011) 823-4943 Email: sales@sameng.co.za Web: www.sameng.co.za 44

Franklin Electric Tel: (011) 723 6500 Fax: (011) 609 2417 info@franklin-electric.co.za www.franklin-electric.com

Pumps and Valves Africa - Q2 - 2016

Ecochem Pumps Tel:011-455-5710 Fax:011-455-5842 rouwellyn@ecochempumps. co.za www.ecochempumps.co.za

Franklin Electric Tel: (011) 723 6500 Fax: (011) 609 2417 info@franklin-electric.co.za www.franklin-electric.com

PROGRESSIVE CAVITY PUMPS

Unique Engineering Tel: (011) 826 6111 Fax: (011) 826 6162 E: sales@uniqueeng.co.za Web: www.uniqueeng.co.za SELF-PRIMING PUMPS

SAM Engineering Tel: (011) 823-4250 Fax: (011) 823-4943 Email: sales@sameng.co.za Web: www.sameng.co.za

TRASH PUMPS

SAM Engineering Tel: (011) 823-4250 Fax: (011) 823-4943 Email: sales@sameng.co.za Web: www.sameng.co.za VERTICAL SUMP PUMPS

SAM Engineering Tel: (011) 823-4250 Fax: (011) 823-4943 Email: sales@sameng.co.za Web: www.sameng.co.za

SLURRY PUMPS

Becker Mining Tel: (011) 617 6300 Fax: (011) 908 5806 info@za.becker-mining.com www.za.becker-mining.com SUBMERSIBLE PUMPS

Becker Mining Tel: (011) 617 6300 Fax: (011) 908 5806 info@za.becker-mining.com www.za.becker-mining.com

Franklin Electric Tel: (011) 723 6500 Fax: (011) 609 2417 info@franklin-electric.co.za www.franklin-electric.com

Walter Meano Engineering Tel: 011 873 8620 Fax: 011 825 1401 Email: wme@mweb.co.za Web: www.versaflo.co.za VERTICAL TURBINE PUMPS

APE Pumps Tel: (011) 824 4810 Fax: (011) 824 2770 E: apepumps@mweb.co.za Web: www.apepumps.co.za

SAM Engineering Tel: (011) 823-4250 Fax: (011) 823-4943 Email: sales@sameng.co.za Web: www.sameng.co.za

Pumps and Valves Africa - Q2 - 2016 9044 - EMA 2016 VISPROM HP AD LIFTING AFRICA 267X90_PATHS.indd 1

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BALL VALVES

Bearing Man Group (BMG) Tel: (011) 620 1500 E: fluidtech@bmgworld.net Web: www.bmgworld.net

CONTROL VALVES

Gunric Valves Tel: (011) 474 6180 Email: saled@gunric.co.za Web: www.gunric.co.za

Premier Valves Tel: (011) 908 3760 Fax: (011) 908 1268 W: www.premiervalves.com

Fluidworx (Pty) Ltd Tel: (011) 452 5059 Fax: 086 551 2440 Email: info@fluidworx.co.za Web: www.fluidworx.co.za

CHECK VALVES

BUTTERFLY VALVES

Fluidworx (Pty) Ltd Tel: (011) 452 5059 Fax: 086 551 2440 Email: info@fluidworx.co.za Web: www.fluidworx.co.za

Ainsworth Engineering Tel: (011) 433 3968 Fax: (011) 433 3623 Email: sales@uvc.co.za Web: www.uvc.co.za

Bearing Man Group (BMG) Tel: (011) 620 1500 E: fluidtech@bmgworld.net Web: www.bmgworld.net

Fluidworx (Pty) Ltd Tel: (011) 452 5059 Fax: 086 551 2440 Email: info@fluidworx.co.za Web: www.fluidworx.co.za

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Premier Valves Tel: (011) 908 3760 Fax: (011) 908 1268 W: www.premiervalves.com

Premier Valves Tel: (011) 908 3760 Fax: (011) 908 1268 W: www.premiervalves.com

Macneil Steel And Valves (MSV) Tel: (011) 822 1802 Fax: (011) 822 1874 Email: sales@msv.co.za Web: www.msv.co.za

Pumps and Valves Africa - Q2 - 2016

Bearing Man Group (BMG) Tel: (011) 620 1500 E: fluidtech@bmgworld.net Web: www.bmgworld.net

DIAPHRAGM VALVES

Ainsworth Engineering Tel: (011) 433 3968 Fax: (011) 433 3623 Email: sales@uvc.co.za Web: www.uvc.co.za

Bearing Man Group (BMG) Tel: (011) 620 1500 E: fluidtech@bmgworld.net Web: www.bmgworld.net Gunric Valves Tel: (011) 474 6180 Email: saled@gunric.co.za Web: www.gunric.co.za

KNIFE GATE VALVES

Fluidworx (Pty) Ltd Tel: (011) 452 5059 Fax: 086 551 2440 Email: info@fluidworx.co.za Web: www.fluidworx.co.za FIRE HYDRANTS

Ainsworth Engineering Tel: (011) 433 3968 Fax: (011) 433 3623 Email: sales@uvc.co.za Web: www.uvc.co.za

Dual Products Tel: (011) 422 4326 Fax: (011) 421 7842 Email: sales@dualvalves.com Web: www.dualvalves.co.za

Fluidworx (Pty) Ltd Tel: (011) 452 5059 Fax: 086 551 2440 Email: info@fluidworx.co.za Web: www.fluidworx.co.za PINCH VALVES

Dual Products Tel: (011) 422 4326 Fax: (011) 421 7842 Email: sales@dualvalves.com Web: www.dualvalves.co.za SAFETY AND RELIEF VALVES

Valcon Valve & Controls (Pty) Ltd

Tel: 011 453 7537 Fax: 011 453 6056 Email: allan@valcon.co.za Web: www.valcon.co.za

Lifting Equipment Engineering Association of South Africa ECSA APPROVED VA 0048

LIFTING EQUIPMENT CONFERENCE

TOPICS TO BE COVERED

DAY 1 (1 CPD Point) Introduction to LEEASA Mobile Cranes DMR 18 MEWPS Overhead Cranes NCOP Tower Cranes Q&A

ECSA REGISTERED MEMBERS WILL EARN 2 CPD POINTS IF THEY ATTEND BOTH DAYS

DAY 2 (1 CPD Point)

How CPD works Lifting Tackle - legal and inspection Mine Health and safety SANS Standards Crane Accidents Training to skill level Heavy Lift project LEEASA Forklifts

DATE: 14-15 September 2016 VENUE: Electra Mining Nasrec, Johannesburg For more information contact

Surita Marx, Email: info@liftingafrica.co.za, Cell: 083 281 5761, Tel: (011) 047-2400

Pumps and Valves Africa - Q2 - 2016

47

APE pumps Pumps at the heart of Africa Mining

Manufacturers of: Vertical industrial turbine pumps Multi-stage high pressure pumps Split casing pumps End suction pumps Petrochemicals

Vertical sump pumps API 610 pumps

Power Generation

26 Nagington Road, Wadeville Germiston 1400, South Africa Tel +27 11 824 4810 | Fax +27 11 824 2770

Waste Water processing

PO Box 14733, Wadeville 1422, South Africa Email: apepumps@mweb.co.za Website: www.apepumps.co.za

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Pumps and Valves Africa - Q2 - 2016