Pumps and valves africa novdec 2016 web by Lifting Africa

ENDORSED BY SAPMA , SAPSDA SAVAMA, AND VAMCOSA

Nov / Dec 2016

VARIABLE SPEED WASTE WATER PUMPS A GLOBAL LEADER IN PUMP TECHNOLOGY

Pumps and Valves Africa - Q3 - 2016

Distributors of :

Ghana: Godfrey Mwachande Tel: +233 24 623 0543 Email: godfrey@tripump.com

South Africa: Dirk Grobler Tel: +27 11 6095240 Email: dirk@tripump.com

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

Tanzania: Jannie Rossouw Tel: +255 28 257 0393 Email: jannie@tripump.com

Pumps and Valves Africa - Q3 - 2016

Zambia: Larry Mapani Tel: +260 21 221 8140 Email: larry@tripump.com

Contents COVER STORY ENDORSED BY SAPMA , SAPSDA SAVAMA, AND VAMCOSA

Rapid Allweiller Geared For Complete Pump Solutions

Nov / Dec 2016

ASSOCIATION NEWS South African Pump Systems Development Association Introduces Company Accreditation Certification For Its Members. 7 Optimizing Progressive Cavity Pump performance

Pump And Abrasion Technologies® Show Expert Capability In Development Of New Curve™ Pump 10 Variable Speed Waste Water Pumps

OMAL Innovative Valves and Actuators in Sub-Saharan Africa, Only From Tectra Automation 14 When Bearings Wear

Weir Minerals – A Global Leader In Pump Technology

How to Decide Between Low & Medium Voltage for Motor & Starter Systems 20 Grundfos – A Global Leader In Water Technology Solutions

5-Minute Fix to Troubleshoot a Diaphragm Pump

Vesconite Bearings Provides an Outlook for the Pumps Industry for 2017

Good Level Control On Flotation Concentrators

AVK Southern Africa Opens R200-million Alrode Plant

High-Quality Angle Seat Globe Valves for Use in Pure Steam Applications

Emergency Shut-Off Valves Increase Reliability At Serbian Refinery

Afromix Intorduces the AFX150 Peristaltic Hose Pump

Babcock Delivers Plant Services For Strategic Pipeline Project

Precise Control With Segment Disc Valves

Grindex Maxi SH Reaches Heights In Dewatering

BUYERS GUIDE PUMPS

BUYERS GUIDE VALVES

VARIABLE SPEED WASTE WATER PUMPS A GLOBAL LEADER IN PUMP TECHNOLOGY

Pumps & Valves Africa

Sales Manager: Surita Marx

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

Index to Advertisers AESSEAL 13 Atlas Copco 35 Brehnor 22 CRI Pumps 27 Ernest Electro OBC Mather & Platt 17 Pipes, Pumps and Valves Conference 6 Preeflow 19 PVP 11 Rapid Allweiller OFC SAMCO IBC SAPSDA 33 SPP 8 Tectra Automation 15 Tri-Pumps IFC VAMCOSA 31 Invincible Valves 9

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 - Q3 - 2016

COVER STORY

Rapid Allweiller Geared For Complete Pump Solutions Consistent quality and service has been the hallmark of many small entrepreneurs who have developed their business to a level that today they have become the benchmark in their respective industry. The legacy of the partnership founded in Booysens, Johannesburg in 1932 by A.J Hindry and H Day has remained to this day, still a family business, known as Rapid Allweiler, a leader in the pump industry in South Africa under the leadership of CEO, Caroline Houghton, granddaughter of the founder, A. J Hindry.

nder the guidance of the original partners the company grew considerably into becoming a leader in the centrifugal pump industry. This led the way to forming a partnership with Allweiler AG, Germany, the oldest pump company in Germany, established in 1860. Allweiler AG acquired 35% of the company with the balance being held by the family. This partnership continues to flourish today. Initially, the company acted as the Allweiler distributor before setting up to manufacture the in-line centrifugal pumps locally, as well as specifically engineered products to meet market demands, utilising over 220 years of combined national and international pump and engineering experience. Their team of experts provide pumping solutions for just about any industry requirement, whether itâ&#x20AC;&#x2122;s chocolate or water that has to be moved. The company benefits from Allweilerâ&#x20AC;&#x2122;s research and development (R&D) in Germany which complements the local companyâ&#x20AC;&#x2122;s own R&D facility in Isando, falling under the TUV ISO 9001: 2000 quality management systems. The company also has a full test facility with state-of-the-art equipment enabling a variety of testing options from simple flow + head to full ISO 9906 acceptance test. Rapid Allweiller has a complete line of products that provide its customers with the latest and most efficient solutions for all types of applications. The product lines include two and three spindle Screw Pumps, centrifugal pumps, propeller pumps, progressive cavity pumps, peristaltic pumps and

Pumps and Valves Africa - Q3 - 2016

COVER STORY macerators. The pump series includes vertical pumps, block units, pumps with magnet drive, immersed pumps, pumps for very thick liquids as well as pumped solids and multistage pumps for high heads. In keeping with current trends, the new Smart Technology IN-1000 series, electronic & fully automated pump monitoring system has been introduced into the product line-up. Operations are monitored continuously and automatically, with active logging and storage for evaluation of any process, should unusual operating conditions occur, both audible and visual alerts are triggered and shown on a graphics capable visual display. Another milestone in the development and growth of Rapid Allweiler is their exclusive working association with the Quantum Foundry Group from 2013, which has given them the advantage in developing high quality, competitive and timeous supply for all their castings needs. The Quantum Foundry Group supplies all the companyâ&#x20AC;&#x2122;s castings requirements which commenced with stainless steel and progressed to cast Iron and Ductile in 2014 and impeller castings coming on line in 2015. This association has given Rapid Allweiler an opportunity to set the benchmark for lead times and has added an enormous advantage in flexibility and delivery for their clients. â&#x20AC;&#x153;Since taking over as CEO some twelve years ago, I have had to perform at the highest possible level, being a female in a male dominated industry. Fortunately I have managed to modernise the company by restructuring effectively, which has changed the corporate image, especially in the manufacturing process and the general work environment. By

introducing rental and also pump repair and maintenance facilities, our scope of after sales service has increased tremendously. We are able to offer on-site service weekly/ monthly/annually and will tailor the servicing schedules to suit site operating conditions,â&#x20AC;? said Caroline Houghton.

Rapid Allweiler Pumps 08600 RAPID www.rapidallweiler.co.za Pumps and Valves Africa - Q3 - 2016

PIPES, PUMPS & VALVES CONFERENCE DATE: 17-18 MAY 2017 VANUE: Indutec, Gallagher Estate, Midrand

Book Your Seat Now!!! For more information on contact Surita Marx conference@pumpsandvalves.co.za Cell: 083 281 5761 Tel: (011) 047-2400

Call For Papers Sponsorship Opportunities Available

Pumps and Valves Africa - Q3 - 2016

17â&#x20AC;&#x201C;19 MAY 2017

APSDA News

South African Pump Systems Development Association Introduces Company Accreditation Certification For Its Members.

Gareth Langton (Chairperson)

For a long time, companies involved in the South African pumping industry have been in need of some form of recognition and accreditation for their commitment to the economy.

fter much deliberation, the SAPSDA executive committee has now introduced an accreditation system whereby the pumping industry will be able to be rated on its performance viewed on four pillars of sustainable business within South Africa. All member companies will be able to apply for the accreditation, and after due assessment by the committee, will be awarded one of 4 levels.

The categories to be assessed will be: • Empowerment • Social Development • Localization • Membership Participation Accreditation for each category will be shown as stars on the membership certificate; and a logo will also be given to each applicant that could be used in corporate correspondence for the valid period of certification. Stars will either be white (non-compliant or no assessment), or depending on the level achieved be bronze, silver or gold.

The accreditation process will be managed by a committee of peers within the industry and will ensure that no undue influence may gained by improperly disclosing manufacturing activities. The process will also be auditable, should any objections be lodged. There is also no extra cost to SAPSDA members as we are all already overburdened with unnecessary expenses.

Gareth Langton (Chairperson) Mobile: +27(0)82 467 7551 E-mail: gareth.langton@ klinger.co.za Website: www.sapsda.co.za

Pumps and Valves Africa - Q3 - 2016

Head Office

Cnr Horne & Brine Ave, Chloorkop Ext 1, Kempton Park, Gauteng, South Africa Tel: +27(0)11 393 717 7/9 Fax: +27(0)86 243 8255 E-mail: sales@spppumps.co.za Web: www.spppumps.com

KZN Office SPP PUMPS SA, EXCLUSIVE DISTRIBUTOR for SUB-SAHARAN AFRICA

VH Series

¾ Tried-and-tested Robust Technology for Deep Vacuum Ranges ¾ Two-stage liquid ring vacuum pumps in close coupled version with mechanical seal

Tel: +27(0)21 852 3962 Fax: +27(0)86 669 4006 E-mail: saleskzn@spppumps.co.za

PE Office

Tel: +27(0)41 364 0204 Fax: +27(0)41 364 0254 E-mail: ft@spppumps.co.za

CT Office

Tel: +27(0)31 700 3773 Fax: +27(0)31 700 4824 E-mail: rh@spppumps.co.za

Pumps and Valves Africa - Q3 - 2016

Optimizing Progressive Cavity Pump Performance Finding the right variable frequency drive enables the use of top drive motor’s full torque potential throughout the entire speed range.

inding the right VFD enables the use of top drive motor’s full torque potential.

loads, and how to most efficiently operate within any torque limits.

Not all variable frequency drives (VFDs) are created equally, therefor it is critically important to find the best brand and model for a specific application.

GM noticed the MagnoDrive didn’t run very well between 70 and 150 rpm and as part of their effort to address the low rpm performance issue, GM contacted us to see if we had a potential solution.

General Magnetic (GM) of Calgary, Alberta, Canada recently found this to be the case regarding a large 85-horsepower MagnoDrive Permanent Magnet PCP Top Drive Motor it developed. The MagnoDrive was designed to drive progressive cavity pumps (PCPs). MagnoDrive offers several advantages over the conventional induction motors that typically power PCPs, including reduced energy consumption, greenhouse gases and maintenance, and increased safety for field operators.

A VFD: the key Progressive Cavity Pump operating component The operating component that enables the motor to run at any speed and torque within its operating envelope is a VFD (also known as a variable speed drive, VSD). It is typically programmed to manage all possible situations, providing the advanced supervisory control that determines when to stop and start the motor, how fast it should go under varying

Identifying the ideal VFD through research and testing We determined that the relatively new ACS880 VFD appeared to be a very good fit. We ran the ACS880 at all speeds and torques and it allowed the MagnoDrive to operate at full torque at low rpm, high rpm and anywhere in between with equal efficiency. Al Duerr, GM founder, CEO recently told me, “We tried many VFDs, and the ACS880 is clearly one of the best we have tried. I think it is important that we have had great support from ABB.” By working closely with the customer and thoroughly understanding the nuances of their technology, we were able to find the optimal drive for their specific application.

ABB SA (Pty) Ltd, Tel: +27 11 617 2168

www.invalve.co.za

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

If it’s not INVAL, then it’s not INVINCIBLE Pumps and Valves Africa - Q3 - 2016

Pump And Abrasion Technologies® Show Expert Capability In Development Of New Curve™ Pump. With its newly launched CURVE™ range of slurry pumps, Pump and Abrasion Technologies® (PAT) have proven that they possess the know-how and the infrastructure to deliver first class slurry solutions and excellent service. This, says Managing Director Jaco Buitendag, is the first step towards their goal of becoming the undisputed first choice as a provider of slurry pump solutions across Africa.

“

One of our main goals in developing the CURVE™ was to offer customer tailored solutions. Every aspect of the CURVE’s™ design is based on feedback from clients across the continent and so we feel that this is currently the only pump on the market to address every one of their operational needs,” Buitendag explains. “And now that we successfully launched the CURVE™ to the South African market at Electra Mining and to the world at the International MINExpo held in Las Vegas, we feel that we are well on our way to becoming a renowned worldwide leader in the design, manufacture and application of heavy duty slurry pumps.” Buitendag goes on to say that by establishing an extensive network of sales and service ‘hubs’ throughout Africa in order to provide efficient client service, they are committed to being a trusted global partner. The final CURVE™ product was three years in the making and emerged from a clean sheet approach. It boasts features that indicate the extent of PAT’s expertise and experience in the slurry pump market. The products in the CURVE™ range offer decreased energy consumption throughout the product life cycle, TOC reduction, longer wear life, increased efficiency and improved safety for personnel during both installation and maintenance.

Buitendag contends that the slurry pumping industry was overdue for the launch of a cutting-edge pumping product saying that no significant advancements had been made to products on the market for almost 50 years. “With the rate of technological advancements happening in the mining industry we felt that a new slurry pumping product was desperately needed in the market. We proceeded to allocate a significant portion of our development resources to collecting customer feedback and packaged this into what we feel represents the new generation in slurry pumps,” says Buitendag. “The end result is a benefit saturated product that enables PAT to strengthen our clients’ operations.” In designing the CURVE™, PAT’s expert design and engineering team relooked the traditional internal hydraulic layouts found in most slurry pumps. Leaning on their knowledge of what the market requires, they created an innovative design which was applied to the specific geometric size and the exact profiles of hydraulic passage through the pump. “When plotting the specific geometric size against total lifecycle cost there is a point where capital and operational costs achieve a combined optimum. Every model in the CURVE™ range is sized to hit this optimum and deliver the lowest ownership cost to the end-user,” Buitendag explains. Knowing that cost is always a key factor for mining operations, PAT’s designers ensured that low energy consumption was prioritised in the CURVE’s™ design and that the CURVE™ could be retrofitted to legacy pumping systems with minimal changes to existing piping. “We are extremely proud of the product that we have been able to bring to the market. The innovative advancements we have made are a result of the combined capabilities of our entire team. Thanks to their expertise, we now have a product that offers a reduction in downtime by up to 80%, a 40-60% reduction in total ownership costs and – thanks to our strategic distribution – shorter delivery lead time,” Buitendag concludes. This ensures that the CURVE™ lives up to its motto: The next CURVE in slurry pumping. More information on the CURVE™ is available at www.pumpandabrasion.co.za

Pump and Abrasion Technologies® Email: info@pumpab.co.za Tel: +27 12 666 0904/5 www.pumpandabrasion.co.za 10

Pumps and Valves Africa - Q3 - 2016

17–19 MAY 2017

THE LARGEST AND MOST COMPREHENSIVE AFRICAN TRADE-SHOW DEDICATED TO THE INDUSTRIES INVOLVED IN THE CONVEYANCE OF LIQUIDS, GASES & SLURRIES.

Pumps, Valves & Pipes Africa 2017 will take place from 17–19 May 2017 at Gallagher Convention Centre, Johannesburg, South Africa. If you are looking to build your business into Africa, generate new leads, find out about new projects and meet new partners, then PVP Africa is the trade show for your business.

www.indutecafrica.com

Organised by

Pumps and Valves Africa - Q3 - 2016

Variable Speed Waste Water Pumps KSB Pumps and Valves recently introduced the PumpDrive variable speed system for effective and controlled pumping of waste water. The variable speed system has been especially designed to overcome problems experienced when pumping waste water. The PID controller increases the speed up to a maximum value, which triggers the required flushing effect. The current control task is temporarily put on hold for this process. After the defined flushing period, the flushing function stops, and the system returns to

This can be activated either automatically or manually by operators using a control panel its previous, controlled operation. Flow velocity monitoring is another new feature that is designed to improve operating reliability of pumps in the field. It ensures that the minimum flow velocities specified at the time of selection are met in order to keep the pipes free from deposits. If the flow velocity falls below the programmed minimum, PumpDrive can either transmit a fault message to the control station or start the flushing function to remove any deposits from the piping. The flow velocity is computed by the variable speed system based on measured electric values of the drive. No external sensors are required. Up to six PumpDrives can be combined into a controlling unit via plug-in bus lines, which allows the user to operate six pumps in parallel. This unit starts and stops the pump sets in line with demand while ensuring that the operating load is distributed evenly. It compensates the failure of individual components without interrupting the operation. All PumpDrives are designed for motors with ratings of up to 55 kW with a harmonised design.

Effective pumping of waste water is possible with PumpDrive variable speed systems

hree innovative functions have been seamlessly incorporated into the system to allow the most effective operation of pumps in the field. These include establishing a complete water column almost immediately during start-up. This is done through a system which allows the pump to be taken to maximum speed within four seconds and maintained for three minutes so that an appropriate flow passes through all piping elements before the system starts its controlled, demand-driven operation. This ensures that the discharge line and pump casing are completely primed with the fluid to be handled. Another unique feature of the variable speed system is the so-called flushing function. This can be activated either automatically or manually by operators using a control panel.

Pumps and Valves Africa - Q3 - 2016

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

Pumps and Valves Africa - Q3 - 2016

OMAL Innovative Valves and Actuators in Sub-Saharan Africa, Only From Tectra Automation Tectra Automation, part of the Hytec Group of Companies, is the sole sub-Saharan Africa and South African supplier of the OMAL range of valves and actuators, including the niche range tailored for use in the oil and gas industry. What separates OMAL valves and actuators from competing OEMs is that the entire manufacturing process is under OMAL’s internal control. All valves and actuators are engineered, manufactured, assembled and tested in OMAL’s three state-of-the-art production facilities in Northern Italy. • Ball valves for high pressure: designed specifically for compressed natural gas (CNG) service, the OMAL HERCULES series of ball valves for high pressure is a threaded-end ball valve series that equips CNG compressors and dispensers that require high cyclicity and long reliability. Its design has resulted in durability equal to six times more than that of any other OEM’s valves used previously by OMAL’s customers around the world. • Empowered valves for the chemical industry: engineered to meet the most severe standards required by the chemical industry, OMAL designed a Stainless Steel Flanged Ball Valve called the PRO-CHEMIE-60 series. It has been tested for Endurance Fugitive Emission Gas-Testing for 60 000 cycles – and certified by third party agents. These valves are tailored to prevent emissions entering the atmosphere and to protect people and the environment. The standards for these valves are among the most stringent regulations worldwide. Cast Iron Ball Valve. Ball valves are supplied in any grade of steel and exotic alloys with all the configurations for seals and gaskets

he production facilities include a modern R&D laboratory where the manufacturer’s products are subjected to daily stress tests that ensure delivery of top performing, high quality, reliable and safe valves and actuators. This means that Tectra Automation now has the resources to supply complete fluid control solutions for automation processes that require high reliability, high cyclicity and long durability. These solutions consist of high-efficiency valves and actuators that lead to a low impact on energy consumption, ultimately empowering performance.

• Pneumatic actuators: manufactured in aluminium, carbon steel, stainless steel and heavy-duty carbon steel means that Tectra Automation has a large portfolio of pneumatic actuators for a wide field of applications. Because they are based on the Scotch Yoke system, these

Tectra Automation’s range of OMAL products include: • Ball valves: comprising floating ball valves in wafer, split-wafer-contraction or split-body; and trunnion-mounted ball valves designed for most heavy-duty applications and high-pressure services. They are supplied in any grade of steel and exotic alloys with all the configurations for seals and gaskets. This range can be engineered to comply with any specification from any end user. 14

Pumps and Valves Africa - Q3 - 2016

DAN pneumatic actuator. Pneumatic actuators are manufactured in aluminium, carbon steel, stainless steel and heavy-duty carbon steel

valves for process machines. The pneumatic axial valves make up OMAL’s patented VIP-series. They are a special threaded-end brass axial valve designed for pneumatic applications with a life of 500 000 cycles. Their compact size makes them ideal for use in machines with limited space. “The quality management systems used by OMAL are so thorough that a unique number can be used to trace any item through production back to raw material,” comments Malan Bosman, Product Manager, Pneumatics, Tectra Automation. “This speaks volumes of OMAL’s valve and actuator quality, and Tectra Automation upholds the OEM’s valve and actuator warrantees.” Angle seat pneumatic actuated valve suitable to work for one million cycles without downtime

Tectra Automation, Malan Bosman T: +27 (0) 11 971 9400, W: www.hytecgroup.co.za

actuators are lighter, more compact and less air-consuming, and have a long, maintenance-free lifetime. Dual-stage pneumatic actuators, which are designed to control the actuator stroke and flow dosing of the operated valve, also form part of actuator range from Tectra Automation. Actuators with an integrated manual override allows for emergency operation when there is no power available. HD Actuators developed in CS have been designed specifically for oil & gas, but can be used in all types of service such as BDV, ESDV, SDV and HIPPS, among others. • Pneumatic valves: this range comprises automatic valves like the angle seat and axial valves. Suitable to work for one million cycles without downtime, angle seat valves are Y-shaped pneumatic valves with integrated and plastic-cased actuators. They can be manufactured in bronze or stainless steel and, with high velocity cycles, are the preferred 73757_Tectra Automation_Pump and Valves.indd 1

2016/08/11 4:27 PM

Pumps and Valves Africa - Q3 - 2016

When Bearings Wear It’s a fact of life that all bearings, even the most highly engineered, will eventually wear and require either repair or replacement. This article explores the options for engineers working in the paper and pulp industry.

earings are critical components that are used heavily in both pulping and paper production machines. Buried deep in the heart of each machine, they ensure that rotating parts move smoothly, efficiently and with minimal friction.

minimising machine downtime. The problem with bearing replacement is that it’s often impossible to determine how damaged a bearing has become until it’s dismounted and removed from the machine, by which time of course the line has stopped.

In many instances, bearing designs are highly specialised to meet demanding conditions; for example, operation in areas such as suction rolls where there is constant exposure to moisture, or in dryer sections with high levels of humidity and heat. Installed and maintained correctly, and protected by appropriate lubrication systems, bearings should provide a long and trouble free operating life.

If a new bearing is required then this can be costly and, as few suppliers keep such specialised or expensive components in stock, may require a special factory order, which can take weeks or in some cases months to fulfil. The alternative is to remanufacture the bearing.”

Unfortunately, it is not always possible to maintain bearings under ideal conditions, as bearings expert and SKF Business Unit Manager, Rudolf Groissmayr, explains. “Bearings can wear prematurely and fail unexpectedly for many different reasons. The most common causes include poor or incorrect lubrication, failed seals, misalignment of shafts, and changes in machine operating conditions. These often arise if attempts are made to increase line speeds or steam temperatures in dryers as a means of improving output; this can, however, move the bearing performance envelope outside its original specification”. Although it’s unusual for a bearing to fail unexpectedly – the latest condition monitoring and oil analysis systems should provide sufficient advance warning to prevent such an occurrence – it is common to find bearings suffering from indentations and micro-fissures in rolling surfaces and raceways that, over time, affect the performance and efficiency of the bearings and thus of the shafts or cylinders that they support.

Bearings can wear prematurely and fail unexpectedly for many different reasons Ultimately, regardless of how carefully engineered, installed and maintained they are, bearings that are in constant use will eventually reach a point where they require either repair or replacement. Although there are arguments in favour of each approach, in the current economic climate, where mills face a combination of intense global competition, rising input prices, there is a strong impetus wherever possible to repair rather than replace bearings. Rudolf Groissmayr manages one of SKF’s Industrial Service Centres, specialising in the remanufacture of bearings for the pulp and paper sector. He notes that, “One of the biggest challenges for production or maintenance engineers is

Pumps and Valves Africa - Q3 - 2016

“Remanufacture is possible in over fifty percent of applications and can normally be carried out within days and at a considerably lower cost than purchasing a new product. It is also possible to remanufacture a bearing – especially older bearings – to a higher standard of quality and performance than the original part.” Besides productivity gains, Rudolf Groissmayr sees some real environmental benefits of remanufacturing bearings. “Not only are there real commercial and technical benefits for mill operators, there is also a powerful argument in favour of environmental sustainability, as remanufacturing uses up to 90 percent less energy than that required to produce a new component.” The purpose of remanufacturing, however, is not generally to produce a bearing better than the original but to increase its service life. It should be recognised that remanufacturing is an extremely demanding process that requires specialised knowledge and equipment to ensure that the bearing properties are maintained and guarantee continued reliability once the product is back in operation. “Working with a specialised supplier is essential”, says Rudolf Groissmayr. “Not only will they have the capabilities to carry out the work quickly to the highest standards, they will also be able to help a customer understand why the bearing was damaged in the first place and to assist with subsequent machine optimisation to minimise the risk of subsequent failures.” Not all bearings are suitable for remanufacture. Those with heavy damage or fractures are generally only fit for recycling. The remanufacturing process therefore begins with an expert assessment of bearing condition, to determine both suitability for remanufacture and the type and extent of work required. An important aspect that is often overlooked is to assess bearing condition in the context of its application, taking into account the bearing load, lubrication conditions and time in operation; this enables the nature of the problem that has caused the damage to be fully understood.

A clear distinction has to be made between problems of subsurface-initiated fatigue and surface-initiated fatigue. The former describes the shear stresses that appear cyclically immediately below the load carrying surface of the rings and rolling elements. These stresses cause microscopic fissures that gradually extend to the surface and, as the rolling elements pass over these fissures, fragments of the surface material spalls or breaks away. Bearing raceways with damage caused by subsurface-initiated fatigue are not normally suitable for remanufacture, while those suffering from surface initiated fatigue can generally be restored by honing or grinding.

Remanufacture is possible in over fifty percent of applications and can normally be carried out within days and at a considerably lower cost than purchasing a new product When a bearing arrives at an SKF remanufacturing centre, it is visually inspected and parameters such as residual magnetism and clearance are checked. The bearing is then disassembled and cleaned before the component parts are carefully inspected and their dimensions measured. This includes standard measurement of ring wall thickness and ovality, with the option of ultrasonic testing to detect subsurface micro-cracks. Additionally, measurement of hardness, roller diameter set variation and outer dimensions can be added depending on the condition of the bearing and the criticality of the application. This initial assessment phase is then followed by the sub-

mission of a customer report and a recommendation for further actions. The subsequent remanufacturing process is undertaken in a dedicated production facility, combining advanced automation and control systems with the engineering knowledge of experienced technicians. The remanufacturing process is effectively divided into four categories: service level 1 (SL1) covers inspection and analysis of failures; service level 2 (SL2) covers the process of restoring bearings that have not been used but may have degraded due to lengthy or incorrect storage; service level 3 (SL3) covers the remanufacture of bearings, primarily by polishing processes, with the reuse of existing components; service level 4 (SL4) is for the extensive remanufacture of bearings requiring the replacement of components and grinding of raceways. In each case, remanufactured bearings are reassembled, quality inspected and marked for traceability before being packed and returned to the customer. Rudolf Groissmayr believes that bearing remanufacture offers considerable advantages. â&#x20AC;&#x153;Our experience has shown that remanufacturing can help paper mills reduce their annual bearing replacement costs. This can vary, depending on the business model, but can typically be between ten and twelve percent. Just as importantly, the relatively short lead times mean that, with careful planning, bearings can be remanufactured during normal line shutdown, thereby minimising any loss of productivity. Finally, the potential energy savings also make remanufacturing an attractive option from an environmental perspectiveâ&#x20AC;?.

SKF, Samantha Joubert, Tel: +27 11 821 3602 E: Samantha.joubert@skf.com, W: www.skf.co.za

Suppliers of pumps and valves to the mining and industrial sectors for over 60 years. Stockists of Tianjin small submersible, vertical multi-stage and close coupled water pumps. Suppliers of the following: M+P Split Casing Pump

Multi-stage Pump

E.I.M.

Viking Gear Pump

Tel: 011 824 4810

Fax: 011 824 2770

Web: www.matherandplatt.com

26 Nagington Road, Wadeville, 1422, Gauteng mather&platt A5.indd 1

2015/07/17 11:08 AM

Pumps and Valves Africa - Q3 - 2016

Weir Minerals – A Global Leader In Pump Technology As a leading supplier to the global mining industry, Weir Minerals is committed to building products that improve efficiency and ultimately reduce the total cost of ownership for customers. The business’ R&D strategy for developing and building new products and services is one reason it remains an industry leader.

W Rob Fawcett, Sales, Marketing and Engineering Director at Weir Minerals Africa

eir Minerals’ engineering experience dates back to 1871 when G & J Weir was an engineering company in Scotland, owned by two brothers. The company made its name in the early years by producing ground-breaking inventions in pumping equipment primarily for the shipping industry at the time. Their double acting Weir steam pumps were virtually standard fitment on British built steamships.

Through the 1990’s Weir’s expansion was accelerated by acquisitions. One of the more significant, early acquisitions was that of EnviroTech Pump systems in 1994, as part of a ten year multi-million dollar acquisition drive. This was followed up in 1999 with the buy-out of Australian pump leader, Warman International, who had been the trusted name in slurry pumps since 1938 and building on that combined experience, Weir Minerals have successfully consolidated themselves as a major player in the global pump engineering and process equipment market. The strength of the Warman® slurry pump lies in the superiority of its advanced hydraulic designs and high performance wear and corrosion resistant materials. A major feature of the design is also the ease of maintenance by virtue of the choice of internal linings and seal system which are easily replaced when worn. The use of hard alloy and elastomer technology in the manufacture of these pumps has contributed to the extended wear in highly corrosive applications. Today, the range of Warman® and Envirotech® pumps available in Africa and Middle East is a comprehensive collection of centrifugal slurry pumps for use in mining and industrial applications. The vertical and horizontal slur18

Pumps and Valves Africa - Q3 - 2016

ry pumps are designed for ultra-heavy applications such as mill discharge, process plants and tailings pipelines, as well as special applications. The range also includes submersible slurry, horizontal dewatering and axial flow pumps. In keeping with the continuous innovations and enhanced designs synonymous with the Warman® brand, the new WBH® centrifugal slurry pump, rewrites the Total Cost of Ownership book for many end-users and deserves special mention. The Warman® WBH® pump range offers more than 20 design enhancements to the state-of-the-art Warman® AH® slurry pump, including a fully adjustable and rotatable throatbush that allows the wear to be spread more evenly, thereby maintaining the pump in peak performance for longer periods. The ‘One Point’ front liner adjustment allows the operator to both rotate and axially move the liner to minimise the front impeller gap to reduce wear and maintain performance. This adjustment can be made with the pump running, thereby minimising downtime. In South Africa, Weir Minerals has a firmly established infrastructure with 3 manufacturing facilities, including a heavy bay foundry, 9 sales and service centres, and a strong pres-

The range also includes submersible slurry, horizontal dewatering and axial flow pumps ence in the major mining areas across the rest of Africa and the Middle East. The regional headquarters are in Johannesburg. The business’ value proposition of providing the “lowest Total Cost of Ownership”, underpins their commitment to excellence. Facilities have been strategically established close to the customers it serves, thus giving customers the highest level of aftermarket and service support throughout the product life cycle.

The Warman WBH features a one point front liner adjustment

automotive

WANTED: DEALER LED/LCD

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The installed base of Warman slurry pumps are supported by the extensive service footprint in Africa

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medical tech.

PV Weir HBF furnaces have a melting and pouring capacity of up to 18 t

‘’ Weir Minerals has invested significantly in its own in-house foundries. In 2006, a greenfields foundry was commissioned in Isando, Gauteng that would fulfil Africa’s needs and also contribute to an export market for small castings. In addition to this, the company acquired heavy bay foundry capacity in Port Elizabeth in 2012,” said Rob Fawcett, Sales and Marketing Director (Africa and Middle East). The acquisition of these foundries has given Weir Minerals the ability to produce an individual casting up to 18 tons. The foundries currently produce upwards of 600 tons of castings per month, but are well geared to increase this output to 1000 tons if required. “Our comprehensive portfolio of performance pumps and superior mineral processing equipment, including the addition of Trio crushing and screening products, places Weir Minerals in the forefront of industry. The business’ consistent drive to innovate and push design parameters will continue to deliver the best technologies, materials and solutions for its customers. All of these developments are complemented by innovative approaches and synergies provided by the ever present internet of things,” concludes Rob Fawcett.

Weir Minerals Africa (Pty) Ltd Rob Fawcett, T + 27 (0)11 929 2706 www.minerals.weir

bio chemistry many more

You can find more information on our website!

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Pumps and Valves Africa - Q3 - 2016

How to Decide Between Low & Medium Voltage for Motor & Starter Systems End users must consider many variables to choose the better solution.

n overlap between 460 and 4,000 volts exists where multiple types of motors and starters are readily available. The question, though, is which one is better? Like most engineering questions, not only does the cost need to be considered, but also the differences in each operating voltage in the context of the application. Low-voltage variable frequency drive Image 1. Low-voltage variable frequency drive (Images and graphic courtesy of Power Electronics)

Even with the small range of motor ratings, there are more than a few variables. Here are a few assumptions to help simplify the discussion: The ratings of 500 to 2,000 horsepower (hp) and 460 volts or Low-voltage variable frequency drive (Images low-voltage (LV) versus and graphic courtesy of Power Electronics) 4,000 volts (4kV) or med i u m -vo l t a g e (MV) supply voltage will be compared, though larger LV and smaller MV options are available. The motor comparison will be based on 1,800 revolutions per minute (rpm) and totally enclosed, fan-cooled (TEFC) or open drip proof (ODP) because these types are the most common.

MV motors typically include copper bar rotors compared with the cast aluminum rotors of LV motors. The copper bar rotor is higher in efficiency, but the copper bars are a major reason for the higher cost. The performance difference in the higher-efficiency copper rotor is expressed in a slightly faster speed at full load (less slip). The tradeoff for higher efficiency and a higher rpm level is lower starting torque. High starting torque loads or applications that cannot be started unloaded, combined with voltage drop on the line when starting, can lead to a motor not coming up to speed.

Choosing a Starter The motor starting amps of 600 percent or more and the ability to supply those amps influence the choice of a starter. A 460-volt motor takes about nine times the current of a 4kV motor for the same rating. For reference, a 500-hp LV motor would be rated for 580 amps versus 70 amps at 4kV. Understanding what the utility will allow or what the grid can support should be part of the evaluation for determining the starting method. There are three basic means of starting: across the line, also known as direct on line (DOL); soft starting or reduced-voltage starting; and variable frequency drives (VFDs) for starting only or continuous operation. An LV mechanical starter, even for a 500-hp motor, is not practical because of cost. Few power grids can handle the inrush of more than 3,500 amps without significant voltage drop. The common option for LV above even 100 hp is a soft starter. The current can be reduced to 250 to 450 percent of the motor full-load amperes (FLA) depending on the motor loading at starting. LV VFDs are available even at 2,000 hp or larger. They are made by taking the largest single-stage VFD from a vendor,

When the cost of a 500-hp LV motor is half of its MV cousin and the two are compared, the question of â&#x20AC;&#x153;which is betterâ&#x20AC;? is expected. Looking at the motors, it would seem they are similar in frame (size). At 2,000 hp, the LV and MV motor are close in cost. So why is there a cost difference? Are there other differences? What is not obvious is the performance difference. 20

Pumps and Valves Africa - Q3 - 2016

Table 1. Cost comparison of starting methods

of the motor FLA using a VFD. So a 2,000-hp motor will only need a 500-hp VFD if 25 percent is required. The VFD also can be used to start multiple motors, reducing the cost per LV or MV motor. Large motors using a starting VFD need a bumpless transfer to line. The bypass package should include a closed transition synchronizing system.

Other Considerations There are differences in the equipment beyond horsepower and voltage that end users should consider. Most LV drives are not Institute of Electrical and Electronics Engineers (IEEE) 519 compliant as standard, common on MV VFDs. Most utilities require IEEE 519 compliance in some form. The MV VFDs can include short-circuit protection and a disconnect for a relatively low cost. For the LV VFD, it must be added to the switchgear or a custom package. Larger-horsepower installations may come with the expectation of a longer operating life in excess of 20 years, so specifications may need adjustment.

A NEMA 1 medium-voltage variable frequency drive

typically around 500 hp, and putting two together to achieve 1,000 hp or three to reach 1,500 hp. With each added block, the price goes up. As a result, the soft starter, which may only be 30 to 50 percent of the VFD cost, can look attractive. The reduced cost of VFDs in recent years and their ability to improve process efficiency have made them a more common choice. Even when not required, VFDs are often requested because of the familiarity with the technology; their reduced cost and flexibility make them easy to apply. For MV, the options of DOL, soft starter and VFD are available. At 500 hp, there is a large difference between the MV and LV VFD price. The cost narrows as the horsepower increases. The MV VFD amperage is so small, the cost difference from 500 hp to 1,000 hp may increase 20 percent while the LV doubles. For MV, the least expensive is DOL, followed by soft starting and the VFD for starting only. A VFD used for starting only is less expensive than one used for continuous operation, and this option is becoming more common in many applications where there is little or no advantage to VFD speed control. The concept is the same for LV and MV. The VFD “starts” and then a contactor bypasses the VFD, putting the motor across the line. The VFD will start a load with the minimum amps for any system, using only the motor’s FLA in normal applications. The short start time means the overload rating can be used for the motor starting, while the actual amps required for starting are all that is needed from the VFD. If the motor can be started unloaded, the VFD needs only to be sized to the current the motor used as it starts. With a pump curve and motor data, the vendor can calculate maximum current required for starting. A lightly loaded motor at starting may pull 25 to 50 percent

All induction motors are reliable, but an MV motor with formed coils that has been vacuum pressure impregnated statistically is more reliable than an LV random-wound motor winding that has been dipped and baked. If reliability is important for the application, an LV motor spec will call out IEEE 841, which is similar to American Petroleum Institute (API) 547 for MV. LV motors cannot meet the higher API 541 specification—this is why critical service motors will be MV even at 250 hp. As previously mentioned, LV motors use a cast aluminum rotor and are considered non-repairable compared with an MV copper bar rotor. The commercial pressure on LV VFDs and soft starter products means replacement of a product line in five years or less. MV VFDs and soft starters will have a longer product life cycle and should provide an upgrade path to the next generation. No one wants to commission a 1,000hp motor and VFD to find out parts will be available for only the next six months. Asking about the obsolescence policy is a good start—even better is to ask if parts are still available for the model previous to the one under consideration. If the application is going to run 24/7, the LV VFDs will have a three- to five-year life if running near full load. The MV design should be closer to 20 years, so users should request an LV cost for a 20-year design life to get a fair comparison. Typically, the LV VFD will jump at least one frame size. The cost of the LV and MV will be similar. Cabling between the motor and starter is another variable. The reduction in cabling cost is a reason to use MV. If a VFD is used continuously, the recommended cabling must be factored—a long cable run can have a large impact on the project budget. Service and maintenance should not be overlooked. With the current product range, a soft starter or VFD with the same form and function will not be much different in LV and MV. Also, the VFD should be wall-mounted and not need rear-access for servicing, which adds to building costs.

Pumps and Valves Africa - Q3 - 2016

lenging to fit the new equipment in an existing facility. In an existing control room, adding air conditioning can be a $50,000 surprise cost to handle a large VFD. An option for LV and MV is a National Electrical Manufacturers Association 3R packageâ&#x20AC;&#x201D;the unit is outside, requiring no control room space and no air conditioning. The MV units can be rated for 55 C and require no air filters. To understand if LV or MV is better, users should start with the utility and not the motor. Understand what the utility requires for large motor connections and what the grid will support, as well as the cost if the service needs improvement. Knowing this information narrows the choices.

Image 3. A custom medium-voltage variable frequency drive

Starting a large motor often requires new utility service. Utility requirements and cost can change the calculation for determining which is better. The total cost of setting a new 460-volt service for a large motor can be as much as the motor and starting method. Additionally, most MV VFDs can accept utility voltage, such as 6.9kV or 13kV, directly with an output of 4kV for the motor, avoiding setting a new transformer cost. Large motor controls require1 space that may Engineering News Ad White.pdf 2015/09/14 07:03:26 PM make it chal-

End users should evaluate the application requirements for reliability based on application. If the application is continuous, consider the life expectancy of both operating voltage equipment. VFDs are more common and reliable, even in large horsepower applications. After considering all variables, end users will be able to recognize the better solution.

ABOUT THE AUTHOR James Nanney is director, Industrial Division, of Power Electronics. He is a member of the API motor committee and the author of numerous papers and articles. For more information, visit power-electronics.com. Nanney may be reached at jnanney@power-electronics.com.

CMY

Design, Manufacture and Maintenance of Axial Flow Pumps

info@brehnor.com www.brehnor.com

Pumps and Valves Africa - Q3 - 2016

Grundfos – A Global Leader In Water Technology Solutions Grundfos pump manufacturer is amongst the industry leaders when it comes to providing solutions in the treatment of water in the areas of energy consumption, waste water disposal and reticulation. Established in 1945 in Denmark, the company produces more than 16 million pumps annually which are exported to every corner of the globe, in order to provide the growing world with a variety of solutions to cope with the environmental issues as a result of climate change that beset many nations. Grundfos believes that climate change presents a major challenge to themselves as well as the rest of the world. As the climate challenges, it creates a vicious circle of climate change, water- stress and energy consumption. “We are a world leader when it comes to providing solutions for pump applications. Our business is continuously expanding with the addition of new innovations, not only to the technology but also in the creative ways we approach our customers’ needs and market demands. In our solutions we are conscious of maintaining a balance between human, social and environmental concerns without impacting on the environment and the planet’s natural resources”, said Rishaad Ebrahim, Director of Engineering at Grundfos South Africa.

oday Grundfos is the world’s largest manufacturer of circulators, covering approximately 50% of the world market for these pumps. Circulator pumps for heating and air-conditioning as well as other centrifugal pumps for industry, water supply, sewage and dosing are the main product lines. Additionally Grundfos produces standard and submersible motors as well as stateof-the-art electronics for monitoring and controlling pumps. The Grundfos Remote Management is an internet based remote monitoring, management and reporting system for pump installation. It provides remote access to data and alarms from pumps, pump controllers and auxiliary equipment like sensors and meters. Users have access to data from pump installations that are registered to their own account.

In our solutions we are conscious of maintaining a balance between human, social and environmental One of the recent innovations to the company’s business model is the introduction of a pump rental facility for their current customers and further down the line to extend this to the market in general. “Grundfos pumps are used in many facets of industry and environmental control so when a pump breaks the financial implications and environmental impact are normally severe. When this happens, we are now in a position to offer temporary solutions with our rental programme”, says Ebrahim. Grundfos has set up a separate facility for their rental business which is currently low key but plans are on the table to increase the concept to a broader base which will include long term rental. With the Remote Manage-

ment facility available in the Grundfos pumps, the company as well as customers will be in a unique position, having the advantage to monitor the performance levels and utilisation of the pumps with a high degree of accuracy. “The rental concept was started in Johannesburg six months ago and already we have exceeded expectations. Our plan is to roll out the facility in Cape Town in early 2017. We are not the pioneers in pump rentals but we are however pioneers in the Grundfos group globally”, concluded Rishaad Ebrahim.

Grundfos Web: za.grundfos.com Tel: +2710 248 6000

Pumps and Valves Africa - Q3 - 2016

5-Minute Fix to Troubleshoot a Diaphragm Pump Follow these six easy steps to address common installation and operation problems.

ir-operated double-diaphragm pumps (AODD) are preferred in transfer applications because their simple design makes them easy to operate and cost-effective to repair. To achieve top performance, end users must install and operate these pumps correctly. In a matter of minutes, common issues can be corrected with the right information.

Here are six quick steps that can help you fix common problems during installation and operation.

1. Check the inlet air line size and pressure. Installing an air line that is too small is the most common mistake users make when installing an AODD pump. Using too small of an air line will starve the pump of the fuel— compressed air—it needs to operate at peak performance. Upgrading to a larger air line is an easy fix that takes a few minutes. Double-diaphragm pumps come in all shapes and sizes, based on the application and fluid requirements. Larger AODD pumps (1-inch and greater) require more compressed air and larger air lines than smaller pumps to operate at full capacity.

The appropriate air line size for a pump is located in the manufacturer’s installation and operation manual. As a general guideline for AODD inlet air line sizes, match the air line hose size to the air inlet port size on the air valve. Inlet air pressure also plays a key role in getting the most out of a pump. Diaphragm pumps operate on a 1-to-1 ratio, meaning the pressure of the inlet air feeding the pump is directly related to the fluid pressure at the pump’s outlet. For example, if the target outlet pressure of a 1-inch, 50-gallon-per-minute (gpm) pump is 100 pounds per square inch (psi), the inlet air pressure entering the pump’s air valve must be greater than or equal to 100 psi. System backpressure and fluid viscosity will impact the outlet fluid pressure. Too little backpressure may cause the pump to run inefficiently because the ball checks may not check as quickly. Too much backpressure can cause the pump to stall if the fluid pressure overcomes the air pressure to the pump. To control the performance (flow and pressure) of an AODD pump, install an air regulator assembly to control the incoming air pressure (see Figure 1, C). Installing the correct air line size with an air regulator will solve the most common AODD pump installation problem.

2. Inspect for muffler icing and restrictions. Diaphragm pumps can generate high decibels at full speed, a main reason mufflers are recommended during installation. The AODD air motor requires compressed air to operate. As the compressed air enters the air valve and channels through the pump center section to exhaust through the muffler, rapid temperature changes occur. At the muffler exhaust, air temperature is below freezing and can cause icing-related issues that are common in humid environments. Erratic pump operation, inlet air with high levels of moisture or visible frost on the outside of the muffler are indications of an icing-related issue that is decreasing pump efficiency. Here are suggested solutions to eliminate these issues: Chemical transfer with air-operated double-diaphragm pumps (Images and graphics courtesy of Graco Inc.)

Pumps and Valves Africa - Q3 - 2016

• Decrease the air pressure to the pump.

• Increase the pump size to operate at lower speeds (i.e. lower air pressure). • Exhaust air to a remote location using an exhaust port tube. • Add an air line filter with a water catcher and drain to collect condensation. • Install an air line heater to raise the exhaust air temperature above freezing. • Adjust the pressure dew point temperature with an air compressor dryer. Solutions to icing can range in difficulty depending on the application and environment, Figure 1. Recommended installation of an air-operated double-diaphragm pump but reducing the air pressure to the pump is one of the quickest and most effective ways to reduce icing. 5. Slow the pump down to prime.

3. Inspect sealing surfaces for leakage. A wise maintenance technician once said, “There are two types of pumps—those that leak and those that are going to leak.” Leakage is a common problem in all pump types. A few simple fixes can ensure the fluid stays in an AODD pump. First, pumps, especially plastic pumps, must be torqued to the manufacturer’s recommended rating. Materials relax over time—often referred to as cold flowing—which can cause sealing surfaces to loosen and create leak paths. Refer to the pump manual for torque values, and follow the bolting patterns to reduce the threat of leakage. Reuse of polytetrafluoroethylene (PTFE) O-rings is another cause of leakage at sealing surfaces. A downfall of PTFE is resilience. Once a PTFE O-ring has been compressed, it is not capable of regenerating its original shape. Replace all pump PTFE O-rings when servicing an AODD pump. After properly torquing the pump according to manufacturer recommendations and ensuring all sealing O-rings have been replaced after service, the AODD pump should be leakfree. Save significant rebuild time later on by ensuring the PTFE O-rings are replaced when the pump is rebuilt.

4. Ensure proper tubing and piping size. Pump inlet and outlet fluid port diameters vary based on the flow rate required. Inlet and outlet hose sizes must match the pump’s size. A primary concern is the risk of cavitation, which can increase repairs and maintenance costs. Changing tubing and piping size after installation is relatively fast. Knowing the correct size at installation eliminates the time and effort required to make a modification later. For example, if a 1-inch pump has a half-inch inlet hose connected, the pump will not be able to operate at full capacity without the risk of cavitation. This risk increases dramatically as the desired fluid viscosity rises. In this example, the 1-inch pump should have a 1-inch inlet and outlet hose attached to prevent cavitation. It is also recommended that an AODD pump be installed with a flexible inlet/outlet connection rather than being hard plumbed. As pump speed increases, vibration increases, which elevates the risk of loosening a hard plumb connection, creating the potential for leakage.

AODD pumps are popular when self-priming is required. Creating a low-pressure zone—less than the atmospheric pressure of 14.7 psi—inside the fluid bowls is how the AODD pump draws fluid. If air pressure supplied to the pump is too high, the pump will change over too quickly and there will not be enough time for the fluid to be drawn into the pump. To solve this priming issue in a matter of seconds, slow down the pump by using the air regulator to decrease the air pressure entering the air valve. Once the pump speed has been reduced and the fluid has had enough time to enter the pump, increase the air pressure and operate the pump at a faster speed.

6. Clear any fluid line restrictions. Certain restrictions create backpressure that may negatively affect the pump and potentially create cavitation that will increase maintenance. Take a minute to inspect the pump and connected piping to ensure there are no visible restrictions. Look for the following at both the pump’s inlet and outlet: • closed or partially closed valves • clogs or kinks in the line • too much hose or length of distance Listen carefully to the pump as it operates. Listen for erratic operation, which may be caused by an inlet hose that is too small or a problem related to icing. Hearing what sounds like gravel running through the pump or seeing flashing around the manifold elbows indicates cavitation and the need to correct the inlet or outlet tubing size or reduce the pump speed. Also, be sure to keep an eye out for kinks in the inlet and outlet lines or any valves that could be closed or restricted. Spending a few minutes up front to ensure proper installation will save a tremendous amount of time correcting problems later. Following these steps can help end users spend less time trying to figure out problems with their AODD pumps and more time pumping.

ABOUT THE AUTHOR Michael Sandlin is the global product marketing manager in the Process Division for Graco Inc. He may be reached at 612-379-3701 or msandlin@ graco.com. Pumps and Valves Africa - Q3 - 2016

Vesconite Bearings Provides an Outlook for the Pumps Industry for 2017. The global economic slowdown continues to affect many of our pump-industry custom-ers, with several of our smaller customers having downscaled or closed down. Many of our larger customers, meanwhile, have engaged in merger and acquisition activity to re-duce costs, ensure market share and expand their product range and distribution net-work. They have also sought to develop new technologies and solutions that give them a competitive edge, moving into aftermarket support and even starting to manufacture in developing countries where they hope to increase sales.

ome general trends that Vesconite Bearings has observed in 2016, and which are likely to continue into 2017, include the following:

1. Making pumps energy efficient

Many pump users are intent on reducing their energy demands. The electricity used in pumping is considerable so the benefits of reducing electricity consumption and costs through right sizing and minimising vibration, heat and noise are key. Environmental concerns also weigh heavily on many, and the reduction of CO2 emissions plays an im-portant part in many pumping-system buying decisions. Fact box • The US Department of Energy has been developing the Energy Conservation Stand-ard for Pumps, which will require the manufacturers of end suction close-coupled, end suction frame-mounted, in-line, radially split multistage vertical in-line diffuser casing, and vertical turbine submersible pumps to meet certain minimum efficiency levels (http://www.pumpsandsystems.com/blog/doeissues-final-rule-regulate-pump-efficiency-us-first-time )

• Many countries have submitted emissions-reduction goals under the United Nations Framework Convention on Climate Change (https://www.eia.gov/forecasts/ieo/ emissions.cfm ).

Vesconite Bearings’ solution Our bushings have a low co-efficient of friction and make pumping more efficient. This translates into a reduction in energy consumption. 2. Keeping life-cycle costs down Maintenance considerations continue to play a role in purchases. Many users of pumps wish to purchase reliable equipment that will not let them down in the middle of a produc-tion cycle. They are aware that work stoppages reduce earnings and profits, and are choosing products that will assist with their core production activity while not costing an arm and a leg. Fact box • The Hydraulic Institute and Europump have developed a guide to pump life-cycle costs, including initial, maintenance, energy and other costs (https://www1.eere. energy.gov/manufacturing/tech_assistance/pdfs/pumplcc_1001.pdf ) The organisations show that maintenance and energy costs are the highest costs for a medium-sized industrial pump over a typical life cycle.

Vesconite Bearings’ solution Our pump bushings have been proven to last longer than traditional bronze material and rubber products and this gives a pump a longer lifecycle. Our bushings also reduce wear to connecting parts, reducing maintenance costs further. 3. Selling is harder in some industry sectors Pump users in the mining, marine and oil and gas sectors, among many others, have been hard hit by the slowing global economy. Pump users in these sectors are trying to extend the use that they get from their pumps and are not as ready to purchase new equipment. Fact box • The World Bank has revised its 2016 global growth forecast to 2.4%. It has described growth in advanced economies as sluggish, and noted that commodity prices have been low and that global trade has been weak (http:// www.worldbank.org/en/publication/global-economic-prospects ).

Vesconite Bearings’ solution Stressed companies can source pump bushings and wear rings from Vesconite Bearings where only these need to be 26

Pumps and Valves Africa - Q3 - 2016

replaced. This saves these companies from having to buy all components that are found in repair kits, when only certain components are required. 4. Food and water concerns Food producers and water utilities are increasingly concerned about the health and safe-ty of the equipment that they buy. They are aware that equipment needs to be shown to be safe for food preparation, safe for use in water distribution and proven not to contami-nate the environment. Fact box

Fact box

• Many countries have regulations that describe the handling, preparation and storage of food as well as legislation governing water quality. These describe various regulated contaminants in food and water. Pump manufacturers serving these industries are in-creasingly cognisant of health and safety regulations in the industries they serve.

• Half of people globally live in cities currently.

Vesconite Bearings’ solution

Vesconite and Vesconite Hilube are approved for food contact by the Laboratories Na-tional D’Essais and contact with drinking water by the Water Regulations Advisory Scheme. Vesconite Hilube also has NF61 approval for use in potable water applications in the US. 5. Urbanisation and pressure on infrastructure Urbanisation levels are increasing in many of the markets that Vesconite Bearings oper-ates in. This has put pressure on ageing water and gas infrastructure.

• Some 70% of the global population will live in urban areas by 2050. • One in four of the world’s urban population live in slums. (https://21stcenturychallenges.org/urbanisation-2/ ) Our products are being used in potable water and butane gas supply in regions where urbanisation is increasing. Our global reach means that our products are dispatched within days of ordering them. Caption 1: Some of the Vesconite Hilube bearings that are used in pumps globally (P1070187_8078 col core crop.jpg) Caption 2: At the Vesconite Bearings factory in Virginia, in the Free State (4 P1040712 copy col core.jpg)

Vesconite, Charlie Simpson, Tel: +27 11 616 1111

Pumps and Valves Africa - Q3 - 2016

Good Level Control On Flotation Concentrators “The link between level control and profitability on a flotation concentrator is often under-estimated or even overlooked, and yet accurate control measurement is the key to increased lifespan for plant and plant equipment, thereby increasing its operational profitability,” said Richard Rule, director of eDart Slurry Valves, based in Jet Park, Johannesburg.

he purpose of a flotation concentrator is to recover the most amount of valuable mineral to the concentrate, whilst at the same time keeping the quantity of concentrate down to a minimum, which enables the highest recovery of valuable mineral at the desired grade to be achieved. This is known as the ‘grade/recovery curve’ for the concentrator. Rule added, “The aim on a typical platinum concentrator is to reduce the volume of concentrate to be approximately 1% of the volume of the plant feed, while recovering more than 85% of the metal. The volume of concentrate that will be produced as a result limits the extent to which the grade should be allowed to reduce in order to increase recovery. “The control system on all concentrators strives for the optimal point on the grade/recovery curve. The level control valve is the final piece of equipment in the process of valuable mineral reporting, either to the concentrator as product, or being lost to the tails as waste.” If the level measurement is above the setpoint, the grade produced will drop as the volume of concentrate increases, but the recovery will increase, and conversely when the level is below setpoint the recovery will drop off and grade will increase. “It is clear to see that maintaining a stable level at setpoint is vital to achieving an optimal performance of the flotation concentrator – if this does not occur then profitability is reduced dramatically. A 1% increase of recovery at optimal grade at a typical large flotation plant can equate to hundreds of thousands of Rands profit per month. On marginal concentrators it could be the difference between a viable mine operation or not,” said Rule.

Required good level control parameters eDart believes that the following para-meters need to be considered carefully in order to obtain good level control: • Process parameters being known and kept within the design envelope. • Plant layout designed with good level control in mind. • Level control valves selected and sized correctly. 28

Pumps and Valves Africa - Q3 - 2016

• Valves installed, commissioned and maintained correctly. • Level measurement and control working optimally. • Advanced control system for flotation banks comprising more than two flotation machines in series. Brian Whitehead, technical plant superintendent for Northam (Booysendal) added, “We have in the past called on eDart to assist us in resolving technical problems that have arisen with equipment. After getting to grips with the challenges we faced, eDart delivered an effective and long lasting solution. As an OEM, eDart is not only passionate about its unique customer solutions, but also commits to ensuring that its products perform exceptionally well. It is this customer commitment and relationship building that sets the company apart.” “eDart has been active in the supply of slurry valves to the mining and related industries since 2004 and this accumulated wealth of experience enables us to assess customer requirements and offer a tailor-made solution,” concluded Rule. “Plant layout and valve technology selection, for example, are but two critical elements to operating a more profitable plant. eDart is about the provision of effective solutions to the environment within which our valve technologies are to be applied, ensuring customer requirements are not only successfully met, but met in the most efficient way.”

eDart, Richard Rule Tel:+27 (0)11 823 6620 Email: richardr@edart.co.za Web: www.edart.co.za

AVK Southern Africa Opens R200-million Alrode Plant AVK Valves Southern Africa marked the opening of a R200-million valve manufacturing facility at Alrode in Gauteng, South Africa in September, becoming the first in its sector to comply fully with the Department of Trade and Industry’s local content legislation.

he plant was opened by Niels Aage Kjær, the founder and Chief Executive Officer of AVK Holding A/S, Trine Rask Thygesen the Denmark Ambassador to South Africa and Malebo Mabitje-Thompson, the Deputy Director-General of the Department of Trade and Industry.

Training facility The plant includes a 1 200m2 training facility, 2 500m2 office area and 2 000m2 logistics and warehouse space. Hubbard says the investment has enabled AVK to achieve the scale From Left to right, Lars Kudsk-CFO-AVK Holding A/S, Tjaart Van der Walt- Director AVK Holding S.A, Paul and capacity to meet not Hubbard-Chairman of AVK Holding S.A, Trine Rask Thygesen-Denmark ambassador to South Africa, Malebo only South African require- Mabitje Thompson-Deputy Director General of Department of Trade and Industry, Niels A Kjaer- Owner AVK Holdings A/S, Peter Thomson- Managing Director Premier Valves Group and Brian McGugan -Managing ments but also to expand Director AVK Valves S.A in the sub-Saharan market. The valve manufacturing controlled machines. AVK also has shot-blasting and coating facility supplies products to the water, waste water, mining, facilities, right to the back end of the factory, which has been industrial, gas and fire protection markets. completely overhauled. AVK Valves emerged from Premier Valves Group (PVG) when the Danish valve manufacturer AVK acquired a majority AVK hopes to train 1 500 people this year in its Academy. stake in 2014. Since the acquisition, AVK Holding Southern This Academy will offer training to non-AVK employees from Africa has created 150 indirect jobs and 114 permanent jobs, across the company’s value chain. The training will include 84 of them for artisans, across the company’s value chain as people with varying levels of experience in order to support it developed the new factory in Alrode next to the Premier skills development at all levels. Valves plant. The core aim of the training programmes is to help employees and industry to understand how to consult and install

The new AVK factory is dedicated the range of valves correctly. to manufacturing AVK products High standards which before had to be imported When AVK is called out for repairs they invariably find that from Denmark and other countries the valves are not installed according to AVK standards. Locally manufactured products The new AVK factory is dedicated to manufacturing AVK products which before had to be imported from Denmark and other countries. AVK has changed the layout, improved the engineering process and invested in computer numeric

Instructors replicate real-world conditions in the training programme to reduce problems relating to incorrect installation.

AVK Southern Africa (Pty) Ltd, +27 12 653 8313 www.avkvalves.co.za Pumps and Valves Africa - Q3 - 2016

High-Quality Angle Seat Globe Valves for Use in Pure Steam Applications Valve solutions must satisfy strict demands when used in complex pure steam systems, such as those in the foodstuff or pharmaceutical industries. The GEMÜ 505 and GEMÜ 555 pure steam valves are manufactured from highquality materials, which offer advantages in terms of both functionality and servicing.

n the foodstuff industry in particular, but also in the chemical and pharmaceutical industries, products must sometimes be manufactured aseptically. As a result, stringent requirements are placed on the purity of the working media used during manufacturing and even the steam used. If steam comes into contact with surfaces or directly with liquid or gaseous products during aseptic production, this contact must satisfy the purity requirements of the products. The solution is found in complex pure steam systems at product requirement level. The valve solutions used here must therefore satisfy very strict demands. GEMÜ is able to meet these requirements with the aseptic GEMÜ 505 and GEMÜ 555 globe valves.

Aseptic globe valve impresses in terms of both function and maintenance The pneumatic (555) and hand-operated (505) angle seat globe valves have been specially developed for isolating pure steam in close collaboration

with well-known customers from the pharmaceutical industry and provide a genuine alternative to the valve types which are usually used. They require significantly less maintenance than diaphragm valves, for example, and are easier to clean than ball valves. The globe valves are available in nominal sizes DN8 to DN80. Thanks to the metal bellows and selected seal materials, the temperature of the medium can range from -10 to 180°C. The butt weld spigot connections are designed and available in accordance with common standards such as ASME BPE, DIN 11866 or DIN EN ISO 1127.

High quality at a reasonable price All media-wetted parts are manufactured from high-quality stainless steel (316L) in order to meet the stringent requirements placed on the quality of the components used in the systems. The valve body is mechanically polished with high precision on the inside and electropolished on the outside. With this surface finish, GEMÜ is able, thanks to the body geometry on the inside of the body as well as extensive technical expertise, to produce Ra values of down to 0,4 μm. Particular importance was also given to the seal materials, which also satisfy the stringent requirements of the FDA. The seals were tested according to USP Class VI at 121°C. Even in the actuators, the materials and the processing of the individual materials are impressive, as is the case with the stainless steel bellows, which accomplishes up to 100 000 cycles without problems and enables the actuator to use non-ferrous metals, for

Pumps and Valves Africa - Q3 - 2016

example. The valve seat is made of inert acid and heat-resistant thermoplastic synthetic material (PTFE). The valve plug itself is welded to the valve spindle and is also smoothed in order to eliminate the otherwise usual 'dirt pockets', which occur with valve plug solutions that are bolted together. The welded valve plug also ensures that this is connected permanently to the valve spindle, thereby increasing plant reliability. Because of these and other finer points, both valve variants provide a long service life including outstanding material properties and body geometries.

Traceability guaranteed The stringent requirements placed on products in the pharmaceutical and foodstuff industries call for, amongst others, the traceability of all media-wetted parts in order to guarantee product quality and product reliability. For this reason, valve bodies, the retaining nut, seat, valve plug, spindle, bellows and actuator seal of the 555 and 505 are manufactured in specific batches. As a result, material test certificates in accordance with 3.1 DIN EN 10204, amongst others, can be issued and supplied with the product where necessary. In addition to the design of the valve as a low maintenance fitting in terms of material, it was also ensured that an actuator change can be carried out quickly, directly on the piping. This means it is possible to perform cost-effective maintenance and repair work and protects materials over the long term. If desired, the valve solution can also be automated, for example by switching from manual to pneumatic operation or by attaching electrical position indicators or positioners for open/close control.

GEMÜ Valves Africa Claudio Darpin Tel: +27 (0)11 462 7795 E: claudio.darpin@gemue.co.za www.gemu-group.com

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VAMCOSA

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Pumps and Valves Africa - Q3 - 2016

Emergency Shut-Off Valves Increase Reliability At Serbian Refinery With a large investment in its new mild hydrocracking and motor fuel hydro-treatment facility, the NIS Gazprom Neft refinery in Serbia aimed to upgrade its production quality to Euro Level 5. To do so, it needed to match all European standards for safety and emissions. This meant that safety and compliance with regulations would be key criteria when selecting all systems and applications needed for proper refinery operation. Specifically, this applied to the critical valves selected for the burner management systems on the heaters, as well as the truck and jetty loading system.

or any refinery, unplanned shutdowns are the equivalent of excessively high costs. For this reason, on-off and safety valves are needed to ensure maximum reliability. Moreover, a valve’s failure to close in an emergency can have a major impact on people’s health and the environment. As the valves handle explosive and toxic hydrocarbons, they must retain their initial gas shut-off tightness and be able to demonstrate a low fugitive emission level that complies with European standards over their entire operational life cycle. Otherwise, valve stem leakages can take place and impact an operator’s well-being as well as pollute the environment. To prevent this from happening, there are regular shutdowns for valve inspection scheduled regularly every four years. Safe, reliable and simple For the safety shut-off and venting applications in the newest truck and jetty loading station, the NIS refinery selected Metso Jamesbury high-performance valves. This included the fire-fighting system and new hydroc-

racking unit heater. The type of ball valves chosen by NIS Gazprom Neft, namely Jamesbury Series 7000 and 9000, fully comply with the regulations relevant to the applications in the refinery. With their patented lip-seal design and the unique Xtreme seat sealing technology, these valves provide superior long-term bubble tightness and prevent overpressure during sudden temperature rises. This is an extremely important safety criterion for applications with highly inflammable media, such as that used in the burner management systems on the refinery’s heaters and in the truck and jetty loading system. Another requirement the NIS refinery had for the valves was their official compliance with the most stringent safety regulations. Notably, all Jamesbury valves are fire-safe according to API 607 and approved according to IEC 61508 SIL 3, guaranteeing their resistance to adverse conditions. Further safety protection is provided through Neles ValvGuard, the intelligent safety solenoid with a partial stroke testing feature. Moreover, on both the Jamesbury ball valves and the high-performance Wafer-Sphere butterfly valves, which were also included in the delivery package, the shaft sealing is designed to fulfil ISO 15848-1 BH and TA-Luft/VDI

Pumps and Valves Africa - Q3 - 2016

2440. This means that their fugitive emissions level is also in full compliance with related regulations. Besides their conformance with strict European safety requirements, all valve types delivered are designed with third-party criteria seen as the minimal standard, and therefore, provide many additional benefits. Specifically, their simple design preserves superior tightness throughout the high cycling and minimises the cost of operation and maintenance. Securing high-quality production The total valve package delivered to the NIS refinery included several different valves types, actuators and instrumentation with relevant approvals and certificates for emergency shut-off and venting applications. Now, the new valves with long-term tight shut-off help keep the plant and truck loading area emission levels compliant with the relevant European standards, allowing uninterrupted operations. This complete solution has enabled NIS Gazprom Neft to achieve the desired run-time targets for its hydrocracking process, securing continual high-quality production of gasoline and diesel fuels without any risk to personnel or the environment. After all, every detail is important in potentially hazardous applications. The implemented modernisation programme at the refinery ensured that everything in the constructed facility is now designed to meet its targeted Euro 5 standards.

Metso South Africa Tel: +27 (0)31 502 9350 Email: steve.clark@metso.com Web: www.metso.com

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Pumps and Valves Africa - Q3 - 2016

Afromix Intorduces the AFX150 Peristaltic Hose Pump The AFX150 is one of the largest peristaltic hose pumps available in the world and was exhibited by Afromix at Electra Mining Africa 2016, in Johannesburg.

“

Since the introduction of the AFX range in 2014, the growth in demand for these pumps has increased by between 20% and 30% and has produced a notable shift in our business”, says Afromix MD, Eugene Els.

“At first we focused on the reselling of pumps and maintenance parts but the demand for a better product enabled Afromix to produce the AFX series.” The AFX is a robust pump and was specifically designed for mining applications, such as filter-press feed, thickener underflow, corrosive and abrasive slurry transfer, chemical and acid dosing and water treatment. Earlier this year the AFX150 was added to complete the series that now include 11 size variations. The 150mm pump weighs up to 2 560 kg depending on the type of gearbox and motor fitted into the pump.

Ernest Wermuth, Afromix application manager explains: “The pumps can run dry indefinitely without damage and is effective in pumping anything you would usually battle to pump. The AFX pumps are fully reversible, able to pump in either direction and require no check valves or seal water flush systems. They also feature a suction lift capacity of up to 9.5m.”

The hose is the heart of the pump, and through our facility in the UK, we have developed a design that has produced very good results from on-site tests Considerable research and development to improve longevity and streamline the manufacturing process has been part of Afromix’s investment focus. Wermuth points out that the hose has been a key focus for the company. The roller design of the hose is available in various materials, which eliminates wear and friction on the roller. Therefor minimal maintenance is required as the hose is the only working part of the pump. “The hose is the heart of the pump, and through our facility in the UK, we have developed a design that has produced very good results from on-site tests. These modifications improve the wear life of the hose and reduce power consumption of the unit by between 25% and 50%, compared with the competitor pumps.” 34

Pumps and Valves Africa - Q3 - 2016

result, Afromix has received overwhelmingly positive feedback from clients around the globe. The AFX series has enjoyed great success at mines in South Africa, the Democratic Republic of Congo, Zimbabwe, Zambia, Namibia, Botswana and Swaziland, as well as Canada, Mexico, the US, the Philippines, Spain and Finland. Due to the success of the pump range, Afromix is expanding its business interests into North America and has also recently opened a new hub in Poole, in the UK.

Due to the success of the pump range, Afromix is expanding its business interests into North America The Johannesburg based head office recently relocated into a much larger business premises, enabling them to significantly increase the amount of stock needed to be readily available for local customers. “It is our aim to have a customer-centric approach in order to offer our clients a hands-on, personalized service and build good relationships,” concludes Els.

“The AFX pump can produce huge cost savings in terms of capital, as well as operational costs,” says Wermuth. As a

Afromix Nadine brockman Email: Nadine.brockman@afromix.co.za Tel: 011 397 6911 Webs: www.afromix.co.za

Pumps and Valves Africa - Q3 - 2016

Babcock Delivers Plant Services For Strategic Pipeline Project Babcock’s commitment to delivering trusted engineering support services to industry saw their plant services division assisting Transnet in successfully completing one of the country’s most ambitious engineering and construction projects to date. Babcock supplied mobile cranes and other mechanical construction equipment to four of the main contractors working on Transnet’s New Multi-Purpose Product Pipeline (NMPP).

he NMPP is one of the largest and most complex multi-product pipelines in the world, covering an underground distance of 715 kilometres, designed to transport liquid petroleum fuel from Durban to Gauteng and neighbouring regions. Without the NMPP, South Africa’s inland areas including Gauteng, the country’s economic epi-centre, would have faced severe fuel restrictions as demand was fast outweighing supply. The new-24 inch main pipeline replaced the existing 12-inch Durban-Johannesburg Pipeline (DJP) which had been in operation since 1965 and was reaching the end of its economic lifespan. Charles van der Westhuizen, Senior Sales Representative for Babcock’s plant services division, says that the four main contractors that Babcock supplied were Group Five Oil & Gas, Goss & Balfe, Mei Construction & Services and Msweli Industrial Projects, all of which worked on the Heidelberg/ Nigel section of the project where Terminal 2 was constructed. The project commenced in 2008 and comprised the construction of 160 kilometres of 16-inch steel inland pipelines; a 550 kilometre 24-inch main trunk pipeline; three inland pumping stations; and two accumulator terminals in Durban and Johannesburg respectively, with the aim of transporting three types of fuels along the pipeline 36

to the inland terminal 2 at Heidelberg, from where the fuels will be supplied to various parts of the inland. The three fuels being transported are gasoline/ petrol (both unleaded 93 octane and unleaded 95 octane), diesel (both low-sulphur diesel and ultra-low-sulphur diesel) and jet fuel. “Babcock’s involvement in the NMPP project commenced in July 2013 with the supply of specialised equipment and broad range of expertise,” says van der Westhuizen. He adds that among the plant supplied by Babcock over a period of three years for the project included 14 mobile cranes, ranging from 8 tonne to 220 tonne, three tractors with 12 metre trailers, a 300 KVA generator, 35 generators in the 25 KVA to 50 KVA range, 10

Pumps and Valves Africa - Q3 - 2016

single diesel welding machines, and approximately 110 inverters. Babcock is a leading supplier of engineering support services and plant to the energy, process, mining and construction industries in Africa. The plant services division has a combined inventory of more than 40 000 items and specialises in the provision of mobile crane services, rigging equipment and expertise, abnormal transport, and welding and mechanical construction plant to meet the needs of any large or small contractor. The equipment and machinery for the NMPP project was supplied and serviced by Babcock’s Sasolburg branch. Babcock is the largest empowered mobile crane and plant service provider in South Africa with a substantial fleet of

safety and clear communication and planning while their QR code scan and tracking system monitors the life cycle of every single item of inventory so as to have instant access to the items’ hire history, service intervals and related parts.

Van der Westhuizen says that the company operates to a safety first philosophy, striving to exceed standard safety requirements by ensuring all personnel are competent, qualified and well trained on what they need to do and that equipment for hire is serviced, certified, inspected to standard and ready for operation. The company moves equipment into place with a focus on

In addition Babcock’s equipment is serviced after every hire and inspections are carried out every three months to guarantee the highest in safety and operational standards. Babcock’s track record currently stands at 20 years without a single product fail or injury. The NMPP represents cutting-edge innovation in concept, design and im-

plementation and is expected to deliver significant benefits, particularly environmental and socio-economic, by enabling economic growth, reducing road congestion and road maintenance costs and lowering carbon emissions associated with road transport. The pipeline is a legacy project designed to serve South Africa for decades to come and is expected to be a strategically important world-class asset for the long term.

Babcock Charles van der Westhuizen charles.vdwesthuizen@babcock. co.za

MOBILE CRANES

cranes managed by highly skilled operators and comprises modern, well-serviced mobile cranes with lifting capacities from 8 to 600 tonnes, distributed nationally and within the other South African Development Community countries.

Precise Control With Segment Disc Valves Segment disc valves work on a very simple but effective principle. The central throttling elements – the segment discs that glide and seal against each other – are positioned in the valve body perpendicular to the flow direction. On a non-rotatable aligned segment disc whose geometry determines the flow rate and characteristic, a movable disc having the same number of segments is shifted by a tangentially engaging rod in such a way that the free cross-sectional area of the segments changes continuously.

egardless of the prevailing pressure difference, a spring assembly constantly presses the movable disc onto the fixed disc. As a result, the flow direction is variable and the valve can be installed in any position.

as well as vapours, even if these are contaminated by particles. The wide range of applications includes areas such as building materials, chemical and power plants, pipelines, water supply and disposal, as well as shipbuilding.

This special design makes segment disc valves one of the few valves that combine control precision even in extreme operating conditions with a high seal tightness and very low exposure to wear.

This ingeniously simple but effective valve design is available up to nominal size DN800.

Segment disc valves and Segment disc orifices Perfect and variable control with high precision over a wide flow range is made possible by the segment disc valves from Schubert & Salzer. Due to the robust design and the reciprocal flow direction, segment disc valves are suitable for fluids

Macsteel Fluid Control Keith Hedges Tel: +27 (0)82 575 9354 Email: keith.hedges@macfluid.co.za Web: www.macsteel.co.za Pumps and Valves Africa - Q3 - 2016

Grindex Maxi SH Reaches Heights In Dewatering Today many high head applications are forced to use several pumps connected in series or an oversized single pump solution to reach the required performance. And neither of those solutions is without complications.

his scenario has changed with the recent launch of the double stage Grindex Maxi SH which enables customers to better size a pump solution for a specific application. Colin Adams, managing director of Integrated Pump Technology, says that importantly this also allows a far more cost effective solution to be achieved. The Grindex Maxi SH pump, available with a 37 kW (50 Hz) motor and equipped with two wear resistant impellers as well as a double diffuser, is ideal for high head dewatering applications which call for high discharge pressures. The pump is robustly constructed and will offer users optimum performance coupled with reliability. The proven impeller hydraulic technology enables a discharge head of up to 140 metres. Adams say that by adding a mere 30kg to the already lightweight Grindex Maxi H platform, Grindex engineers were able to produce a pump with an overall weight of only 270 kg that is capable of reaching these high heads without comprosing on any of the other characteristics of the wellknown Grindex brand. “The Grindex Maxi SH has a small footprint yet still offers this high performance to weight ratio,” Adams says. The Grindex Maxi SH pumps incorporate the Grindex impeller adjustment sleeve, a familiar sight on the Grindex Matador range. This offers users a simple way to easily adjust the impeller and suction cover tolerance to regain as-new performance after wear. Adams says that a lot of interest was shown in this pump at the recent Electra Mining Africa exhibition, and the first units have already been received at Integrated Pump Technology’s warehouse.

More about integrated pump technology Integrated Pump Technology is the sole importer and principal distributor for the Grindex range of dewatering, slurry and sludge pumps for Southern Africa. The company’s product line-up also Faggiolati submersible drainage and wastewater pumps, mixers and aerators and Oerlikon Leybold Vacuum pumps. A network of 16 strategically located, specialised pump distributors supported by dedicated account managers ensure

Pumps and Valves Africa - Q3 - 2016

The double stage Grindex Maxi SH enables customers to better size a pump solution for a specific application

effective service and customer support. Headquartered in Johannesburg, a newly built 1 200 m2 service facility supports this distribution structure in terms of sales, repairs and rental offerings. The facility encompasses a state of the art automated pump test facility and boasts a highly experienced service team. Grindex submersible pumps have been available in South Africa for 25 years and are a household name in mine dewatering.

Integrated Pump Technology Colin Adams Tel :+27 (11) 918 9034 Email : colin@pump-technology.com Web: pump-technology.com

PUMPS ANSI PROCESS PUMPS

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

C.R.I Pumps S.A. (Pty) Ltd Tel: 011 805 8631 Fax: 011 805 8630 Email:cri@cripumps.co.za Web:www.cripumps.co.za BOREHOLE PUMPS

C.R.I Pumps S.A. (Pty) Ltd Tel: 011 805 8631 Fax: 011 805 8630 Email:cri@cripumps.co.za Web:www.cripumps.co.za CENTRIFUGAL PUMPS

Agrico Tel: +27 (0) 21 950 4111 Fax: +27 (0) 950 4208 alfred.andrag@agrico.co.za Web: www.agrico.co.za

C.R.I Pumps S.A. (Pty) Ltd Tel: 011 805 8631 Fax: 011 805 8630 Email:cri@cripumps.co.za Web:www.cripumps.co.za

FIRE PUMPS

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

vacuum pumps and valves

SA Biotech Tel: 011 938 3581 Fax: 086 586 8501 Email: info@sabiotech.co.za Web: www.sabiotech.co.za

HOT OIL PUMPS

C.R.I Pumps S.A. (Pty) Ltd Tel: 011 805 8631 Fax: 011 805 8630 Email:cri@cripumps.co.za Web:www.cripumps.co.za

Air & Vacuum Technologies (Pty) Ltd Tel: 0861 VACTEC (822 832) / 011 318 3241/2/3/4/5 Fax: 086 522 9188 Email: burnm@vactech.co.za Web: www.vactech.co.za JET PUMPS

DIAPHRAGM PUMPS

Air & Vacuum Technologies (Pty) Ltd Tel: 0861 VACTEC (822 832) / 011 318 3241/2/3/4/5 Fax: 086 522 9188 Email: burnm@vactech.co.za Web: www.vactech.co.za

SPP Pumps SA (Pty) Ltd Tel: 011 393-7179 Fax: 086 425 7595 Email: sales@spppumps.co.za Website: www.spppumps.com HORIZONTAL SPLIT CASE PUMPS

C.R.I Pumps S.A. (Pty) Ltd Tel: 011 805 8631 Fax: 011 805 8630 Email:cri@cripumps.co.za Web:www.cripumps.co.za LOBE PUMPS

END SUCTION PUMPS vacuum pumps and valves

C.R.I Pumps S.A. (Pty) Ltd Tel: 011 805 8631 Fax: 011 805 8630 Email:cri@cripumps.co.za Web:www.cripumps.co.za

Air & Vacuum Technologies (Pty) Ltd Tel: 0861 VACTEC (822 832) / 011 318 3241/2/3/4/5 Fax: 086 522 9188 Email: burnm@vactech.co.za Web: www.vactech.co.za

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

C.R.I Pumps S.A. (Pty) Ltd Tel: 011 805 8631 Fax: 011 805 8630 Email:cri@cripumps.co.za Web:www.cripumps.co.za

SAMCO PUMPS (Pty) Ltd Tel: +27 35 751 1202 Fax: +27 35 751 1204 E: joffre@samcopumps.com Web: www.samcopumps.com

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

SA Biotech Tel: 011 938 3581 Fax: 086 586 8501 Email: info@sabiotech.co.za Web: www.sabiotech.co.za

LGP PUMPS (LOW PRESSURE GAS PUMPS)

Air & Vacuum Technologies (Pty) Ltd Tel: 0861 VACTEC (822 832) / 011 318 3241/2/3/4/5 Fax: 086 522 9188 Email: burnm@vactech.co.za Web: www.vactech.co.za

Pumps and Valves Africa - Q3 - 2016

PUMPS MULTISTAGE PUMPS

Agrico Tel: +27 (0) 21 950 4111 Fax: +27 (0) 950 4208 alfred.andrag@agrico.co.za Web: www.agrico.co.za

POSITIVE DISPLACEMENT PUMPS

Hawk High Pressure Pumps

Tel: (031) 274-8555 (010) 010-0144 Fax: (031) 205-4332 (011) 822-2868 E: sales@hawkpumps.co.za Web: www.hawkpumps.co.za

vacuum pumps and valves

SPP Pumps SA (Pty) Ltd Tel: 011 393-7179 Fax: 086 425 7595 Email: sales@spppumps.co.za Website: www.spppumps.com

SA Biotech Tel: 011 938 3581 Fax: 086 586 8501 Email: info@sabiotech.co.za Web: www.sabiotech.co.za

TRASH PUMPS

C.R.I Pumps S.A. (Pty) Ltd Tel: 011 805 8631 Fax: 011 805 8630 Email:cri@cripumps.co.za Web:www.cripumps.co.za

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

SELF-PRIMING PUMPS

PISTON PUMPS

Hawk High Pressure Pumps

Tel: (031) 274-8555 (010) 010-0144 Fax: (031) 205-4332 (011) 822-2868 E: sales@hawkpumps.co.za Web: www.hawkpumps.co.za PLUNGER PUMPS

Hawk High Pressure Pumps

Tel: (031) 274-8555 (010) 010-0144 Fax: (031) 205-4332 (011) 822-2868 E: sales@hawkpumps.co.za Web: www.hawkpumps.co.za

C.R.I Pumps S.A. (Pty) Ltd Tel: 011 805 8631 Fax: 011 805 8630 Email:cri@cripumps.co.za Web:www.cripumps.co.za

SPP Pumps SA (Pty) Ltd Tel: 011 393-7179 Fax: 086 425 7595 Email: sales@spppumps.co.za Website: www.spppumps.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

VANE PUMPS

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

Agrico Tel: +27 (0) 21 950 4111 Fax: +27 (0) 950 4208 alfred.andrag@agrico.co.za Web: www.agrico.co.za

Pumps and Valves Africa - Q3 - 2016

vacuum pumps and valves

SA Biotech Tel: 011 938 3581 Fax: 086 586 8501 Email: info@sabiotech.co.za Web: www.sabiotech.co.za

SAMCO PUMPS (Pty) Ltd Tel: +27 35 751 1202 Fax: +27 35 751 1204 E: joffre@samcopumps.com Web: www.samcopumps.com WELL PUMPS

VERTICAL SUMP PUMPS

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

C.R.I Pumps S.A. (Pty) Ltd Tel: 011 805 8631 Fax: 011 805 8630 Email:cri@cripumps.co.za Web:www.cripumps.co.za

VALVES AIR VALVES

Tectra Automation Tel: +27 (0) 11 971-9400 Fax: +27 (0) 11 971-9440 malan.bosman@tectra.co.za Web: www.hytecgroup.co.za

BUTTERFLY VALVES

C.R.I Pumps S.A. (Pty) Ltd Tel: 011 805 8631 Fax: 011 805 8630 Email:cri@cripumps.co.za Web:www.cripumps.co.za

DIAPHRAGM VALVES

Tectra Automation Tel: +27 (0) 11 971-9400 Fax: +27 (0) 11 971-9440 malan.bosman@tectra.co.za Web: www.hytecgroup.co.za Invincible Valves (Pty) Ltd Tel: +27 (0) 11 822 1777 Fax: +27 (0) 11 822 3666 E: enquiries@invalve.co.za Web: www.invalve.co.za GATE VALVES

Agrico Tel: +27 (0) 21 950 4111 Fax: +27 (0) 950 4208 alfred.andrag@agrico.co.za Web: www.agrico.co.za BALL VALVES

C.R.I Pumps S.A. (Pty) Ltd Tel: 011 805 8631 Fax: 011 805 8630 Email:cri@cripumps.co.za Web:www.cripumps.co.za

Mine Track & Tools (pty) Ltd Tel: 011 412 4536/1665 Email:info@minetrack.co.za Web: www.minetrack.co.za

Tectra Automation Tel: +27 (0) 11 971-9400 Fax: +27 (0) 11 971-9440 malan.bosman@tectra.co.za Web: www.hytecgroup.co.za

KayTar Valves Tel: +27(0) 21 987 8292 E: clinton@kaytarvalves.co.za Web: www.kaytarvalves.co.za

Tectra Automation Tel: +27 (0) 11 971-9400 Fax: +27 (0) 11 971-9440 malan.bosman@tectra.co.za Web: www.hytecgroup.co.za

VAG-Valves South Africa Klamflex Pipe Couplings Tel: 0117625326 Fax: 011 7625674 R.Loggerenberg@vag-group. com Web: www.vag-group.com

Invincible Valves (Pty) Ltd Tel: +27 (0) 11 822 1777 Fax: +27 (0) 11 822 3666 E: enquiries@invalve.co.za Web: www.invalve.co.za CONTROL VALVES

Agrico Tel: +27 (0) 21 950 4111 Fax: +27 (0) 950 4208 alfred.andrag@agrico.co.za Web: www.agrico.co.za

VAG-Valves South Africa Klamflex Pipe Couplings Tel: 0117625326 Fax: 011 7625674 R.Loggerenberg@vag-group. com Web: www.vag-group.com

CHECK VALVES

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

C.R.I Pumps S.A. (Pty) Ltd Tel: 011 805 8631 Fax: 011 805 8630 Email:cri@cripumps.co.za Web:www.cripumps.co.za

Invincible Valves (Pty) Ltd Tel: +27 (0) 11 822 1777 Fax: +27 (0) 11 822 3666 E: enquiries@invalve.co.za Web: www.invalve.co.za

DIAPHRAGM VALVES

C.R.I Pumps S.A. (Pty) Ltd Tel: 011 805 8631 Fax: 011 805 8630 Email:cri@cripumps.co.za Web:www.cripumps.co.za

Mine Track & Tools (pty) Ltd Tel: 011 412 4536/1665 Email:info@minetrack.co.za Web: www.minetrack.co.za

VAG-Valves South Africa Klamflex Pipe Couplings Tel: 0117625326 Fax: 011 7625674 R.Loggerenberg@vag-group. com Web: www.vag-group.com

Pumps and Valves Africa - Q3 - 2016

VALVES KNIFE GATE VALVES

C.R.I Pumps S.A. (Pty) Ltd Tel: 011 805 8631 Fax: 011 805 8630 Email:cri@cripumps.co.za Web:www.cripumps.co.za

Mine Track & Tools (pty) Ltd Tel: 011 412 4536/1665 Email:info@minetrack.co.za Web: www.minetrack.co.za

Invincible Valves (Pty) Ltd Tel: +27 (0) 11 822 1777 Fax: +27 (0) 11 822 3666 E: enquiries@invalve.co.za Web: www.invalve.co.za

SLEEVE VALVES

MANUAL

VAG-Valves South Africa Klamflex Pipe Couplings Tel: 0117625326 Fax: 011 7625674 R.Loggerenberg@vag-group. com Web: www.vag-group.com

Tectra Automation Tel: +27 (0) 11 971-9400 Fax: +27 (0) 11 971-9440 malan.bosman@tectra.co.za Web: www.hytecgroup.co.za

ACCESSORIES

KLINGER South Africa Tel: +27 (0)11 842 8300 Fax: +27 (0)11 827 8663 Email: gareth.langton@ klinger.co.za Web: www.klinger.co.za

PLUG VALVES

Tectra Automation Tel: +27 (0) 11 971-9400 Fax: +27 (0) 11 971-9440 malan.bosman@tectra.co.za Web: www.hytecgroup.co.za

Fluidworx (Pty) Ltd Tel: (011) 452 5059 Fax: 086 551 2440 Email: info@fluidworx.co.za Web: www.fluidworx.co.za 42

KLINGER South Africa Tel: +27 (0)11 842 8300 Fax: +27 (0)11 827 8663 Email: gareth.langton@ klinger.co.za Web: www.klinger.co.za PIPES PNEMATIC - DOUBLE ACTING

ACTUATORS

Agrico Tel: +27 (0) 21 950 4111 Fax: +27 (0) 950 4208 alfred.andrag@agrico.co.za Web: www.agrico.co.za

vacuum pumps and valves

SA Biotech Tel: 011 938 3581 Fax: 086 586 8501 Email: info@sabiotech.co.za Web: www.sabiotech.co.za

MECHANICAL PACKING

Tectra Automation Tel: +27 (0) 11 971-9400 Fax: +27 (0) 11 971-9440 malan.bosman@tectra.co.za Web: www.hytecgroup.co.za ENGINEERED PLASTICS

KLINGER South Africa Tel: +27 (0)11 842 8300 Fax: +27 (0)11 827 8663 Email: gareth.langton@ klinger.co.za Web: www.klinger.co.za

Pumps and Valves Africa - Q3 - 2016

C.R.I Pumps S.A. (Pty) Ltd Tel: 011 805 8631 Fax: 011 805 8630 Email:cri@cripumps.co.za Web:www.cripumps.co.za

Tectra Automation Tel: +27 (0) 11 971-9400 Fax: +27 (0) 11 971-9440 malan.bosman@tectra.co.za Web: www.hytecgroup.co.za PNUEMATIC - SPRING RETURN

PNUEMATIC - DOUBLE ACTING

Invincible Valves (Pty) Ltd Tel: +27 (0) 11 822 1777 Fax: +27 (0) 11 822 3666 E: enquiries@invalve.co.za Web: www.invalve.co.za

Tectra Automation Tel: +27 (0) 11 971-9400 Fax: +27 (0) 11 971-9440 malan.bosman@tectra.co.za Web: www.hytecgroup.co.za

Pumps and Valves Africa - Q3 - 2016

KEEP SOUTH AFRICA CLEAN WITH RELIABLE AND LONG LASTING SEWAGE PUMPS FROM

Hm 38 36 34 32 30 28 26 24 22 20 18 16 14 12 10 8 6 4 2

TES 174

TES 162 TES 148 TES 148W

1 2 3 4 5 6 7 8 9 10 11 12 13 14

ADVANTAGES Patented cutting system for clog-free pumping - No tearing or chopping - Same cutter for complete range of pumps - Cutting all possible articles in sewage water eg. condoms, sanitary towels, rags, panty hose etc. - Adjustable blade, cutting size is adjustable from outside

CUTTING CONE

e Supplied by:

rnest lectro ngineering (Pty) Ltd.

Pumps and Valves Africa - Q3 - 2016

Telephone: (011) 792 9550/1/2 Fax: (011) 792 9553 e-mail: eeeaman@mweb.co.za Website: www.ernestee.co.za