Pipes, Pumps and Valves Africa Sept / Oct 2016 by Lifting Africa

Sep / Oct 2016

ENDORSED BY SAPMA , SAPSDA SAVAMA, AND VAMCOSA

ELECTRA MINING REPORT BACK WIDE RANGE OF PREMIUM PUMPING SOLUTIONS

Pumps and Valves Africa - Q3 - 2016

IFC

Pumps and Valves Africa - Q3 - 2016

Contents COVER STORY Unearthing Low Voltage Motor Potential In Mining

ENDORSED BY SAPMA , SAPSDA SAVAMA, AND VAMCOSA

Sep / Oct 2016

PERSONALITY PROFILE 8 SAPSDA News 9 VAMCOSA News 10 From the Desk of Pamela du Plessis, MD of Invincible Valves: Water (H2O)

Integrated Pump Technology Cites Move Towards OEM Pumps

New CURVE Range to Revolutionise Slurry Pump Industry

Hi-Tech Local Pumps for Russian Refinery

Vesconite Bearings Tenders For Large Pump Bearings Supply

C.R.I. End Suction Pumps – Performance Beyond Technology

Wide Range of Premium Pumping Solutions

Extending the Life of Pumps and Fans

What Are The Differences In Positive Displacement Pumps?

What Happens to Power & Efficiency When a Pump Wears Out?

Why The Wilden Air Operated Diaphragm Pump is a Flexible Choice

ELECTRA MINING REPORT BACK

Electra Mining 2016 Report Back 28 International Owner’s Investment Boosts Leading African PVP Expo

Complete Mobile On-Site Air, Power, Light, And Now Also Pump Solutions From A Single Source 32 Spectacular Varisco Range Displayed At Electra Mining

Highest Precision as Standard 34 Straightforward ES05 Valve Series from Aventics Introduced

SASPDA GOLF DAY REPORT BACK 38 Predict, Measure and Correct for Electrical Run-Out With Thermaspray’s Burnishing and Degaussing Processes 40 BUYERS GUIDE (PUMPS) 43 BUYERS GUIDE (VALVES) 45

WIDE RANGE OF PREMIUM PUMPING SOLUTIONS

Pumps & Valves Africa

Sales Manager: Surita Marx

Tel: (011) 475 0010 Cell: 083 281 5761 Email: info@pumpsandvalves.co.za www.pumpsandvalves.co.za Production: Jackie Nene

Index to Advertisers ABB OFC Agrico OBC BMG 39 27 CRI Dosetech 31 Invincible Valves 7 Klinger 41 Mather and Platt 22 35 Preeflow Pumps and Abrasion IFC Pumps, Valves and Pipes Conference 42 Pipes, Pumps and Valves Conference IBC SAM Engineering 15 SAPSDA 18 Tri - Pumps 25 37 Vamcosa Vasconite 46

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

Unearthing Low Voltage Motor Potential In Mining Advances in automation and electrical technology are the key to addressing those challenges faced by today’s mining and minerals sector. However, it is not just new technologies that need to be exploited. Established technologies, like electric motors, have progressed to offer the sector some exciting opportunities.

s a minimum requirement, electric motors for the mining and mineral sector need to:

Mining and mineral sector challenges

−− Meet global mining industry requirements, yet be flexible for adaptation to local legislation

Whether you are in management, maintenance or an original equipment manufacturer (OEM), the top three challenges upon which everyone within the mining and minerals sector agrees are:

−− Be robust to meet the aggressive nature of the environment

1. Maximize productivity

−− Be highly reliable and never be the component in the drive train responsible for unplanned downtime

The goal is to maintain or increase tonnage mined per worker.

In addition, the electric motor needs to be backed by an array of services that cover every stage of its life cycle. Only with the right electric motor and the correct support package can the challenges faced by the industry be met.

As the mines mature and the easy-to-reach high grade ores are tapped out, companies need to either mine low grade ore bodies or move to remote regions which are difficult to access because of climate, altitude or unstable politics. Whatever the decision, there is now an increased need for reliable equipment to make sure the mines avoid shutdown. Today’s electric motors can be fitted with intelligent instrumentation that tracks the temperature of bearings and windings and monitors vibrations, thereby vastly improving the reliability and safety of the machine. This accelerates and simplifies access to information, alerts operators to potential problems and reduces maintenance with extended equipment life cycles. All of which keeps the process turning and production moving.

Reasons why motors fail

Bearing failures −− −− −− −−

Excessive motor temperatures Contamination due to inferior bearing seals Lubrication related issues Vibration and shock loading

Winding failures −− Poor or ineffective cooling design −− Excessive number of starts

Corrosion −− Inadequate materials used for the application −− Insufficient sealing system design

External damage −− Fan cover material not suitable −− Fittings and connectors not rugged enough −− Terminal box design not suitable for application

2. Improve performance and operational efficiency Energy efficiency has never been a major issue in mining. This is changing, as customers become aware of the prospect of saving hundreds of thousands of dollars by reducing motor energy consumption. Energy use can represent 40 to 60 percent1 of a mine’s operating costs. Yet today’s highly efficient motors, drives and mechanical power transmission products can significantly reduce energy consumption.

3. Enhance safety Safety covers mechanical, physical and electrical processes,

Pumps and Valves Africa - Q3 - 2016

COVER STORY with a safety incident more likely if maintenance is not preplanned. For this reason, when choosing a motor supplier, it is vital to consider the life cycle services provided with the motor.

1. Changing mind set Several practices are prevalent in the mining sector and need to be reviewed.

Replacing motors Some mines have a policy of replacing motors, often on a two-year cycle. Yet today’s motors are designed to the highest levels of reliability, meaning that they can survive in the mining environment for in excess of the warranty periods. With planned preventive maintenance the motors can last several decades.

Replace vs rewind Often a rewind can adversely affect a motor’s efficiency and may incur a higher cost than buying and installing a new model. Studies show that the first rewind of a new electric motor can result in as much as a three percent reduction in efficiency. It can also, in some cases, cost more than a new motor. A far better plan is to adopt a preventive maintenance program, such that hasty or continuous rewinds are avoided. Such a program will include condition monitoring to anticipate any potential failure and will detail a spare parts management procedure to keep the installed base operational. Insulation class choice Many specifications call for Class H insulation which covers motor winding temperatures up to 1800C. However, achieving such a high temperature use comes at a price. The winding tends to be fragile and cannot withstand vibrations. It can also lead to premature bearing failure due to overload

Case study A global mineral producer had a policy of scrapping motors because of the corrosive nature of the calcium carbonate, within its mine, on the motor’s bearings. However, using the latest motor technology the company discovered an energy efficient design that stood up to the hostile environment. Now they no longer scrap their motors and keep them running for a lot longer. The company says it is more likely that the gearboxes or the belts will be the cause of most of the breakdowns. of the motor and windings. An alternative is to use the more robust Class F with built-in vibration protection.

2. Legislations, regulations and directives Motors that meet globally recognized standards, such as IECEx and MEPS (minimum energy performance standard) provide the minimum requirement within the mining sector. Several countries, like China, Russia and South Africa, have local standards or adaptations that a motor supplier must be able to accommodate. For instance, mines in South Africa follow their own shaft dimensioning criteria. ABB goes beyond what the standards specify by providing third party certificates such as IECEx for motors, even though not officially required. ABB’s production, quality systems, as well as products themselves, are regularly audited and certified by independent bodies. Furthermore, to meet the specific local requirements, a motor supplier needs to be adaptable. ABB’s range of IEC low voltage motors have many options that provide the flexibility of design and build that the localized industry demands.

3. Technical competence For those mines building new lines or refurbishing existing ones, it is important to involve ABB at the start of any project;

Pumps and Valves Africa - Q3 - 2016

COVER STORY

during the front-end engineering design (FEED) stage. ABB understands, for instance, that a conveyor drive system failure is extremely costly, which makes motors and mechanical power transmission equipment a top priority. ABB can advise on all technical concerns such as: −− Temperature rise −− IP-classification −− Insulation type −− Compatibility with other products, such as couplings, gearboxes and variable-speed drives −− Bearing systems and shaft shields Apart from an in-depth understanding of legislations, regulations and directives, ABB will often know the latest implications of energy efficiency rules, overall equipment effectiveness (OEE), harmonics and drive train integration. And most importantly, ABB can spot pitfalls in technical specifications that can lead to over-dimensioning, unnecessary energy use and higher maintenance costs.

4. Support from start to finish ABB offers a range of services covering each step of a low voltage motor’s life cycle: −− Pre-purchase −− Ordering & delivery −− Installation & commissioning −− Operation & maintenance −− Replacement & upgrade −− Retrofit & recycling

Dedicated mining team ABB appoints specialists for each component of the drive train, from bearings, couplings, gearboxes, low voltage motors and variable-speed drives. Supporting this team are helpdesk engineers, available to answer any technical queries, along with a global field service team, trained to help install, commission, operate and maintain the drive train.

Local coverage Because of the locations of the mines, ABB is able to support its products locally in all countries. This covers the needs of end-users and OEMs and extends from delivery expectations to location of stock – whether placed by the manufacturer in central stock warehouses, in a bonded store or held within the customers site.

Installation & commissioning Correct installation and proper maintenance play an important role in maximizing reliability. ABB takes these factors into account from initial design onwards.

Certified workshops Mines must have a process in place for equipment on explosive atmospheres and above all the work has to be carried out by competent personnel. ABB’s certified Ex workshops are critical in making sure that maintenance is done to strict requirements that comply with IEC/EN standards to keep the original product certificate valid.

Pumps and Valves Africa - Q3 - 2016

Workshops help with installation and commissioning and provide support whenever needed, leading to fast response times, thereby supporting reliability, availability and safety.

Condition monitoring Once installed, often in explosive atmospheres, the motors have to be serviced correctly in order to maintain their high levels of safety. Condition monitoring, for example, can keep tabs on rotor winding, bearings and power supply quality. Other services such as diagnostics, remote monitoring and predictive maintenance are also available.

5. Application experience With some 125 years of experience, providing high end, low voltage motors for the mining sector is not a new initiative for ABB. Its references extend from iron ore mines in Northern Sweden to coal mines in Australia to copper mines in Chile, as well as many other minerals being mined across the world. ABB’s mining motors are based around proven and reliable cast iron and explosive area motors. To meet the challenges of the mining sector and the higher ingress protection classes, robust component parts are used such as heavy duty bearings on the drive end, a steel, rather than plastic, fan, and higher quality paint finish; all of which go a long way to building inherent reliability. ABB invests heavily in R&D and has ground breaking technologies that can be used in mining. ABB is also refining and perfecting its standard induction motor range, including pushing the efficiency levels towards IE4 and beyond.

6. Low voltage motors Flameproof mining motors & cast iron mining motors An extension to ABB’s low voltage IEC mining motors range is available with Ex d flameproof protection for use in underground mine (group I) applications together with a range of cast iron mining motors. The two motor ranges are available from two to eight pole pairs, with higher pole combinations or two-speed motors available on request. The motors feature an IP66 enclosure for maximum protection against the ingress of high pressure water, dust and volatile substances and are insulated to class F. Higher class H (180°C) is available as an option. Depending on frame size, the motors have a cast iron or steel fan; a more robust choice than the plastic fans used in less demanding applications. The rotor and stator of the orange-colored motors have special varnish corrosion protection that enhances the reliability by preventing moisture ingress between laminations and the winding insulation. A space heater is available, as standard on Ex d motors and optional on cast iron mining motors, to keep the motor’s internal temperature above ambient, thereby avoiding condensation. Safety and reliability is further enhanced with the use of PTC type winding temperature detectors.

By sharing your motor specifications, ABB can analyse and advise on what is right for your needs. ABB has a wealth of know-how about all applications including: – Conveyors – Pumps – Hoists – Crushers and mills – Drills and working – Fans and compressors machinery – Separators – Vehicles – Flotation cells Labyrinth bearing seals offer improved protection against moisture ingress than traditional rubber lip seals. The labyrinth seal is maintenance-free, unlike traditional sealing methods, which need to be replaced. The use of stainless steel for the rating plate, nipples and bolts offers enhanced corrosion protection. In addition, bolt heads on the Ex d motor range, feature a shroud to protect against falling rocks or stones damaging or inadvertently unwinding the bolts.

Flameproof mining motors The motors are an evolution of ABB’s long-life explosive atmosphere range. This range has been used for decades in group II and group III surface industries such as oil & gas and marine. The motors operate to the latest IEC standard efficiency levels.

– Output: 0.55 - 710 kW – Poles: 2 to 8 – Frame sizes: IEC 80 – 450 – IE2 and IE3 efficiency class – Available voltages: 230 – 1000 V (DOL)

Cast iron mining motors Based on the proven process performance motor platform, this range is used above ground and underground in nonhazardous mines and open pit quarries that typically mine iron ore, platinum, gold and rare earth metals. Applications include conveyors, pumps, fans, smaller winches, crushers, smaller mills, floatation tank agitator motors. – Output: 0.55 - 1000 kW – Frame sizes: IEC 71 - 450 – Poles: 2 to 8 – IE2, IE3 and IE4 efficiency class – Available voltages: 230 – 1300 V (DOL)

COVER STORY

ABB - for all your motor-driven applications

ABB South Africa (Pty) Ltd Conan Jones Tel: +27 11 617 2168 Email: Conan.Jones@za.abb.com Web: www.abb.com/motors&generators

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

PERSONALITY PROFILE

vision where he was responsible for the overall profitability of this division. The Trading division housed all the non Voith agency products. The main products in this division were Power Transmission Couplings, Submersible Pumps for Mining and Sewage industry, Laser Alignment equipment, Conveyor Motion Monitors, Clutches and Industrial Brakes. Lester Fine retired from Voith Turbo (Pty) Ltd in 2014 and together with the ex Managing Director of Voith Turbo (Pty) Ltd, they acquired from Voith, the Grindex submersible pump distributorship for Southern Africa and started a new company called Integrated Pump Technology. He was appointed the Managing Director of Integrated Pump Technology in June 2014. He is now retired and is currently a director of SAPSDA. Lester Fine

Qualifications • Bsc Engineering (Chemical) University of the Witwatersrand 1969) • GDE University of the Witwatersrand (1972) • MBA Wits Business School (1984)

1st Monthly salary and First Employer. I distinctly remember the pricely sum of R260.00 pm. I was offered a position at AECI Umbogintwini Plant for R240.00 pm but before accepting I was made an offer by Hussmann, an Industrial and Commercial Refrigeration company. As this Company was based in Johannesburg and I could still stay at home and save accommodation costs, I accepted even though Refrigeration was not really my field and was more suited to a Mechanical Engineer,

Work experience Lester Fine qualified in 1969 as a Chemical Engineer and worked in the Industrial Refrigeration and Chemical Plant Design and Manufacture fields for a period of 14 years. During this period and over the subsequent 20 years he held several management positions with major International Companies. The positions held over this period included, Senior Process Engineer, Operations Manager, Technical Manager, Divisional Manager, Marketing and Sales Manager and Managing Director. After completing an MBA in 1984 he joined Flexibox (Pty) Ltd, a subsidiary of UK based Flexibox International, a major manufacturer of Mechanical Seals and Power Transmission Couplings for the petrochemical industry. In 1990 he was appointed Managing Director of Flexibox (Pty) Limited, a position he held until 1988 when Flexibox International was acquired worldwide by John Crane. Lester spent the following 2 years integrating the local Flexibox subsidiary into the John Crane (Pty) Ltd operation. During this period he was also appointed as divisional manager of the John Crane Gland Packing Division and served on the Board of Management. He joined Voith Turbo (Pty) Ltd after leaving John Crane and was appointed to the Board of Management of Voith Turbo (Pty) Ltd during 2002. At Voith Turbo he held the position of Manager Trading Di8

Pumps and Valves Africa - Q3 - 2016

Challenges facing the Pumps and Valve Industry. I have noticed over the past 10-15 years a distinct reduction in the Academic and Practical knowledge in the discipline of fluid transfer, i.e Pumps, Valves, Piping and related ancillary equipment. This demise of experience is common to both Supplier and end user. The older generation of Engineers, Foremen etc, are retiring are not being replaced. There are fewer and fewer qualified Mechanical Engineers coming through the system to replace the retirees. Sales representatives are trained on the job and rarely have any formal training or qualifications. This scenario presents both opportunities and challenges. I think we are all aware of the challenges posed by low commodity prices, little or no new investment in Mining and shrinking manufacturing capability. These challenges, however present many opportunities for Industry as a whole. Training organisations such as SAPSSDA have an opportunity to fill the knowledge transfer gap and thus have an important role to play. Companies that provide on and off site specialised repair and maintenance facilities are experiencing a boom as more and more End Users outsource their maintenance. Fewer Mines, Chemical Plants, Terminals and Petroleum Refineries have comprehensive specialised “in house” repair and maintenance facilities to maintain and operate the complex equipment they operate. In distressed economic times End Users repair mechanical equipment rather than replace. OEM’s and suppliers who offer comprehensive quality repair and maintenance facilities have experienced growth in their operations over the past few years. I also see a resurgence in interest in local manufacturing as local importers and manufactures are considering or have already commenced investigations into local manufacture of certain equipment and spare parts as the weak rand makes their local products more competitive. The outlook for the Pump and Valve Industry, in my opinion, is showing signs of climbing out of the trough.

APSDA News

The Pump Industry is Set to Get a Boost in Training by Partnering With Government to Develop Unit Standards Specifically Focused at The Pump and Related Industries

Gareth Langton (Chairperson)

APSDA has always provided training and each module of the courses is presented by different experts in their field from the SAPSDA Member Companies at the facilities hosted by the various Member Companies. The courses contents have been compiled from a practical point of view. The training compromises of an introductory and an advance course: 1. The introductory course is a practical orientated course with the main objective to assist companies involved with pumps and pumping systems to expose their employees to the pump industry equipping them with a basic knowledge of pumps and related products. The approach taken for this course is to give non-technical staff such as administration staff, buyers, store men, logistical and sales staff an elementary understanding of how pumps function and get these delegates “pump literate”.

2. The Advanced course is structured to suit any person responsible for/or involved in the managing, specifications, design or purchasing of pumps and their related equipment. Slurries and fluids and test methods and standards are just some of the fields that would be covered in this course. A Pump test will also be viewed by the attendees. Each subject will be presented by an expert in his specific field. The Association, has been approached by the Technology Localization Implementation Unit to assist in the development of NQF units standards for our industry. This process is traditionally very expensive and time consuming, however the partnering between government and the association

will assist in reducing these burdens on the members of the association and assist in expediting the process. On completion of the standards, the Association will become the “custodian” of the unit standards and will provide ongoing assessment of the quality of the training given. This will ensure that the standard meets the requirements of the industry and the training material remains relevant. Should you require any further information regarding SAPSDA please do not hesitate to contact the SAPSDA chairman, Mr. Gareth Langton, at gareth.langton@klinger.co.za

Gareth Langton (Chairperson) Mobile: +27 (0) 82 467 7551 Email: gareth.langton@klinger.co.za Web: www.spsda.co.za Pumps and Valves Africa - Q3 - 2016

AMCOSA News

Designation – Why Is It Not Having The Desired Effect? Despite designation of our sector over two years ago, we continue to see closures within our supply chain, with many companies facing tough decisions such as retrenchments, business rescue, and significant restructuring. One would think that with this protection of the industry in place, we would have seen a significant improvement in orders placed upon local manufacturers and a reduction in import statistics. However, this is not the case, with still close to 80% of the market being dominated by imported valves

here are a number of unresolved issues that continue to hamper the success of designation and this is not just in the valve sector. The other 18 or more sectors who have been designated are experiencing similar challenges. Firstly, there is a lack of buy-in from state-owned entities, and while there are a few who have genuinely taken local content on board, many show total disregard in adhering to the legislation. The legislation mandating designation is in place, but there is still no procedure in place to sanction transgressors (both government and private sector). The Valve Instruction note clearly states that the first gate-keeper would be a local content of minimum 70%, discharged through local manufacturing activities and job creation, and then the 80/20 or 90/10 criteria for BBBEE and price. However, this is not the case, with Imported products being purchased through BBBEE companies still being the decider for procurement personnel in SOC’s. While we all agree that BBBEE and transformation are of critical importance, these two policies need to be better aligned, so that they work together rather than against each other. The decision around what needs to take priority must be determined through cohesive, easy to understand policy, which is backed by procedure and substantial consequence if not adhered to. Then there is the significant proposed cost of verifying the local content threshold, which cannot be absorbed by the manufacturers, and if carried by the SOC’s will result in more added cost. This is counterproductive to the intention of designation. It is difficult to understand how local content should be calculated and verified because one size does not fit all and designation of different sectors (valves, bus bod10

Pumps and Valves Africa - Q3 - 2016

Mark Wilson

ies, trains) is not specified in the same manner. Therefore, a single calculation, formula or standard cannot practically be used. The valve designation prescribes that each valve must have 70% of its value through locally carried out activities, and raw material - not 70% of the total project value or that 70% of the total value must be sourced locally. This interpretation is sometimes not clear to bidders on Government Tenders. The policies have to talk to each other, to ensure the success of both local content and BEE outcomes. State-owned entities need to get serious when it comes to procuring locally manufactured products. Over and above all of this, there needs to be a critical engagement between state-owned entities and industry, to discuss standards, import substitution and local product development. We cannot be globally competitive without increasing volumes and we will never see the transformation of the industrial sector if the return on investment is as unattractive as it is currently. High input costs, as well as issues around labour, skills shortages and onerous payment terms on projects, make the valve industry a difficult place to be in and cash flow can become a nightmare for most manufacturers. Whilst there are many proposed projects intended for rolled-out, the process is slow and leads to a position of either “feast or famine” for manufacturers within our sector. While we have seen some successes and we enjoy a solid working relationship with the DTI, we can only hope that our continued engagement and efforts with all stakeholders will yield substantial results shortly.

VAMCOSA www.vamcosa.co.za

Skf Ranked as One of the World’s Most Sustainable Companies For the 17th year in a row, SKF has been listed as one of the most sustainable companies by the Dow Jones Sustainability World Index (DJSI).

he Group’s performance within supply chain management and overall environmental management programme once again ranked highly in the survey.

Rob Jenkinson, Director, Corporate Sustainability, says, “Our long-running inclusion in the DJSI is something that we are all very proud of within SKF. Sustainability issues for businesses have evolved during this period, with an ever increasing focus on reducing negative environmental impacts and doing more for society as a whole. We maintain our focus on understanding these issues and the role we can play to help address them – now, and in the future.” “Doing so is good for society, the environment and makes long term business sense for SKF, our customers and suppliers.” The Dow Jones Sustainability Indexes were launched in 1999 and are the longest- running and most prestigious global sustainability benchmarks worldwide. In addition, SKF is also a member of the FTSE4Good Index and Ethibel Sustainability Index (ESI) Excellence Europe.

SKF South Africa (Pty) Ltd. Tel: +27 11 821 3500 Telefax: +27 11 821 3501 Website: www.skf.co.za

From the Desk of Pamela du Plessis, Managing Director of Invincible Valves: Water (H2O) Water (H2O) is a polar inorganic compound that is a tasteless and an odourless liquid. No one person or living thing can live without it …. Most precious resource known to man!

he water crisis is the top of the South African agenda at the moment. With dams hitting an all time low, but still water is pouring out of manholes, taps are left running, rain water is being pumped back into the ocean and gardens are still being watered around the country. It makes little to no sense as to how South Africa finds itself in this precarious situation. We as South African’s have to pick up the pieces and take the initiative as well as make the effort to save every drop possible. Considering no household and no industry can survive without water, we will have to “carry the can” on behalf of the South African Government and start educating the nation on water matters. Conserving water by any means. Some may say that it’s too little too late, but we have to trust that every effort will have a positive impact in the future. This indeed is a long term crisis that won’t be solved any time soon. Globally, we are seeing Climate change like never before. Adverse weather conditions are becoming the absolute norm and therefore our current drought will last longer and be upon us sooner than we imagine. The amount of people that are oblivious to the current situation is astounding and therefore I appeal to all companies to educate your staff, contractors, stakeholders and families on the current water crisis as we are all in this together. Brings new meaning to The Long Walk!

Invincible Valves Pamela du Plessis Tel: +27 (0) 11 822 1777 Fax: +27 (0) 11 822 3666 Email: enquiries@invalve.co.za Web: www.invalve.co.za Pumps and Valves Africa - Q3 - 2016

Integrated Pump Technology Cites Move Towards OEM Pumps

head.

There is a marked move in the mining sector towards installing OEM pumps.

his is according to Colin Adams, managing director of Integrated Pump Technology, who says that this recent change in the market has turned the previous trend of sourcing cheaper replicated pumps on its

“It is always tempting in difficult economic times to purchase lower cost capital equipment without doing a full assessment of the actual owning and operating costs which should include aspects such as performance, reliability and aftermarket support,” Adams says. “Any short term cost saving will rapidly fade into insignificance if the pump does not meet its hydraulic performance and this situation will be exacerbated if an inferior component fails causing catastrophic damage,” he continues. The high cost of unplanned downtime due to a pump installation that fails can impact directly on productivity of an operation, and therefore on profitability. “And this is a scenario that we have seen often over the last few years where end users have purchased pumping equipment that is not engineered to cope with the harsh African operating conditions,” Adams says. Integrated Pump Technology was established as the official Southern African distributor for the well-respected Grindex range of electrical submersible pumps, and later the company added the Italian manufactured Faggiolati pump brand to its product portfolio. Both are Original Equipment Manufacturer (OEM) pump brands and as such have strong legacies when it comes to product research and development. Product development is essential as this includes the incorporation of latest hydraulic technologies and materials of construction to ensure that

The Grindex dewatering pump range

Grindex pumps have a proven track record in dewatering

pumps will meet operational requirements. This is something that maintenance personnel on mines are fully cognisant of and this knowledge needs to be transferred to buyers and management who may not always consider the performance and reliability approach when making the purchasing decision. An example of technology being leveraged in Grindex pumps is the unique air valve that has been integrated into the dewatering pump range. This allows the impeller to pass air instead of water past the motor in a dry run condition. Another feature in the dewatering range which ensures optimal operational performance is the patented SMART motor protector which provides thermal overload, phase loss and phase rotation protection. The Grindex sludge range has all the advantages of the dewatering range coupled with a recessed vortex impeller and split hydraulics with replaceable rubber linings. This makes these pumps capable of greater solids handling with increased abrasion resistance. “There is so much more than just the purchase price that must be considered when purchasing pumps, and the most basic question that needs to be asked is whether an operation can afford the risk of buying on the cheap,” Adams concludes.

Integrated Pump Technology Colin Adams Tel :+27 (11) 918 9034 Email : colin@pump-technology.com Website: pump-technology.com 12

Pumps and Valves Africa - Q3 - 2016

New CURVE Range to Revolutionise Slurry Pump Industry South African slurry pump manufacturer Pump and Abrasion Technologies has taken the exciting and bold step of designing and manufacturing a new range of slurry pumps tailored specifically for the needs of the market.

ver the past 11 years, Pump and Abrasion Technologies (PAT) have established themselves in the market as a trusted and well-respected supplier of heavy duty slurry pumps with their Battlemax, BattleStream and BattleSub ranges. Having identified a need in the market for new technology, Managing Director, Jaco Buitendag, says that PAT made a strategic decision to take a clean sheet approach to developing an innovative and more technologically advanced slurry pump solution. “Over the past three years we have worked with our clients to identify key improvements that could be made to existing slurry pumps. We applied the latest technology in developing the new CURVE range which we believe will revolutionise the slurry pump industry,” says Buitendag. Initial testing of the CURVE pumps have shown remarkable results with regards to TOC reduction, longer wear life, improved efficiency, lower power consumption throughout the product lifecycle and improved safety during maintenance. The results of testing against these key considerations are proof that PAT is answering all the current challenges faced by mining operations today. “What our research and knowledge of the industry showed was that current slurry pumping technology has not changed much over the past 50 years. With the rate of technological advancements happening in all aspects of mining, 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,” Buitendag explains.

The end result of over three years of research and product development from clean sheet is the CURVE range – a benefit saturated product that now enables PAT to strengthen their clients’ operations. The crucial factor to the CURVE’s outstanding performance lies in its design. The technical design approach entailed focusing on the internal hydraulic layout – two fundamental elements of which prompted special attention. These elements are the specific geometric size and the exact profiles of hydraulic passage through the pump. Buitendag explains that when plotting 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. Energy consumption was also a key design consideration and was evaluated across the entire product lifecycle. The result in the end product is that the CURVE range’s hydraulics delivers low energy consumption for a far longer period. The slurry centrifugal pump’s layout was also critically evaluated to identify areas with potential for improvement in order to guarantee increased efficiency. “One of the additional objectives we strived to meet in the CURVE’s development was for lower costs for mines when adopting this new technology. Keeping this in mind, we designed the CURVE so that its new technology can be retrofitted to legacy pumping systems with minimal changes to existing piping. What this means for our clients is that out-dated equipment can now be upgraded with minimal operational impact and capital output,” says Buitendag. Ultimately, what the CURVE will offer the mining industry is a slurry pump that reduces the total ownership cost by 40% – 60%, reduces downtime by up to 80%, improved safety for personnel fitting and working with the pump, and boasts shorter delivery lead times thanks to product availability and strategic distribution partnerships. “These are concerns that we hear from the African market as a whole on a monthly basis,” says Buitendag. “We sought to address these needs and more and are extremely proud of the product that we have been able to bring to the market. With the innovative advancements we have made, coupled with our industry track record of unwavering client support and delivery, we are ready to make the CURVE into an industry leader.”

The next CURVE in Slurry Pumping!!! Pump and Abrasion Technologies Jaco Buitendag Tel: +27 (0)12 666 0904 Email: info@pumpab.co.za Pumps and Valves Africa - Q3 - 2016

Hi-Tech Local Pumps for Russian Refinery KSB Pumps and Valves South Africa has won a sizeable contract to supply advanced magnetic drive pumps to a large refinery in Russia where they will be used to pump potentially hazardous gas oil, Goudron and Mazout products. vanced nature of the pumps, quality construction and the long-term ability of our global group to support and maintain the pumps within a mission critical environment. The pumps also needed to be specially manufactured to withstand extreme operating temperatures of between -70˚C and 380˚C, as well as withstand pressures of up to 40 Bar as per API requirements.

Jan van Vuuren of KSB Pumps and Valves

he locally developed RPHmdp pumps were selected for their ability to completely separate the driveends from the wet-ends of the pumps which are in contact with the dangerous materials being circulated. Instead, KSB’s RPHmdp pumps use separate magnetic drives to power the impellors and so negate the need for the traditionally used Plan 53 pumps. The magnetic drive pumps require significantly less maintenance and are a safer option than the older Plan 53 pumps, which are complicated and require pressure regulated seals on either end of the pump to prevent hazardous liquids from leaking with potentially disastrous consequences. The older pumps also require constant management and maintenance to ensure that they are 100% sealed and operational at all times.

Strict requirements By contrast, KSB Pumps and Valves product manager, Jan van Vuuren, says the 18 locally developed RPHmdp pumps supplied for the project do not require seals and therefore do not need nearly as much maintenance nor supervision as the old type. “In the case of the Russian Samara Transneft Refinery project, the deal was awarded to KSB Russia on merit of the ad-

Pumps and Valves Africa - Q3 - 2016

“This was vetted by our Russian counterparts who conducted an in-depth inspection of our manufacturing facility to ensure production of the highest quality would be met and that API standards were in place. In addition, KSB Russia representative, Vladimir Dragonman, also needed to be satisfied that the South African operation would be able to provide full back-up and support of the pumps whenever required. Needless to say, we far surpassed his expectations and he went back to Russia more eager than ever to continue with the deal,” says Jan. He continues that another key reason why the refinery, one of the largest of its type in the world, chose RPHmdp pumps is due to the pumps’ good track record at a number of petrochemical companies throughout the world (including Sasol) where they are successfully using these pumps in place of the old Plan 53 pumps. In Russia, and globally, the company has also sold hundreds of standard-type RPH pumps to the petrochemical industry and these have proven to be well supported throughout their lifespan by the company. The popularity of magnetic drive pumps has also been spurred by stricter requirements of TÜV and other verification agencies for seal-less pumps to be used in chemical and petrochemical plants where potentially hazardous materials are being handled. In addition, the pumps are easily serviced, do not need constant supervision and have wet-ends that are fully interchangeable with the company’s standard RPH pumps making for commonality of spares and maintenance. “With European standards calling for seal-less pumps and the movement towards simplicity, reliability and durability in the petrochemical and other industries, we are confident that the KSB RPHmdp will become the defacto pump

Specialised pump for world’s largest refinery

KSB Pumps and Valves locally has developed a unique and specialised pump for the pumping of the highly dangerous Isobutane with HF (Hydrofluoric Acid) on behalf of one of the world’s largest refineries, PCK Schwedt. The chemical is regarded as one of the riskiest materials on earth to pump and called for special engineering to manufacture one of the company’s special magnetic drive (RPHmdp) pumps entirely out of Monel, which is one of the few materials able to withstand the acidity of the Isobutane HF chemical.

CP S MP PU

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KSB Pumps and Valves South Africa, Annett Kriel Tel: (011) 876 5600, Fax: (011) 822 1746 Email: Annett.Kriel@ksb.com

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wherever potentially hazardous materials are required to be pumped under difficult conditions,” concludes Jan.

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By comparison, the RPHmpd pump only exposes the wet-end of the pump to the chemical and the driveend is completely separated. This makes it safer and much more cost effective than Plan 53 pumps.

KSB Pumps and Valves’ locally developed RPHmdp pump is finding favour across the globe in the petrochemical industry

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“When finished it will cost twice the price of a standard magnetic drive pump as a result of the difficult manufacturing process, but this pales into insignificance if one were to try and manufacture the pump according to the traditionally used Plan 53 pump which requires double seals, pressure balanced valves and a number of other technical requirements to prevent the dangerous chemical from leaking.

“Monel is super tough and is so difficult to work with that few people anywhere in the world are prepared to even try. It is tough to drill, difficult to machine and takes hours to perform the simplest machining. However, here in South Africa and in our manufacturing facilities in Germany we are able to work with it and are currently in the process of manufacturing the pump as specified.

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

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Pumps and Valves Africa - Q3 - 2016

Vesconite Bearings’ Koos Finger with some of the large bearings that the company has in stock

Vesconite Bearings Tenders For Large Pump Bearings Supply Thermoplastic bearing manufacturer Vesconite Bearings is tendering for the supply of the largest Vesconite pump bearings that it has ever supplied.

They would be desired because of their dimensional stability, since the polymer that they are made from does not swell, as well as for their good wear properties, since the lifespan of bearings made from this polymer is longer than that of many competing materials. Potgieter confirms that the bearings are standard stock items but would need to be machined down to the exact sizes specified in the tender. Other specifications that Vesconite Bearings has recommended to suit the material are that the bearings’ wall thicknesses measure 10% of the shaft sizes and that the bearings’ lengths are the same as the outside diameter of the bearings.

It is likely that, if the tender is approved, it will take a year to receive the final contract for the bearings.

This is surmised by Vesconite Bearings technical consultant Paul Potgieter, who comments that the bearing manufacturer has never had a pump-bearing order for pumps with shafts measuring from 490mm to 580mm in diameter.

The Asia Pacific region is the leading consumer of hydropower, with the BP’s 2016 Statistical Review of World Energy noting that the region uses 40.5% of all hydropower energy that is produced globally.

“I would imagine that the bearings will be supplied to a hydro project,” says Potgieter, who is in discussions with a third party who is supplying a primary contractor for the project.

China, India, Japan, Vietnam and Pakistan are among the countries with the largest hydroelectricity consumption in the Asia Pacific region.

Bearings of this size would be typically supplied for marine applications in which they would be used in rudder and stern tubes, or would be supplied to the sugar industry, which sometimes requires similarly large bearings.

Vesconite Bearings Paul Potgieter Tel: +27 11 616 1111

he bearings are believed to be required by a large water utility in Asia, and it is likely that they will be used in a hydro-electric project that pumps significant quantities of water over large distances.

Pumps and Valves Africa - Q3 - 2016

This is because a pump of this size will take a long time to engineer, says Potgieter.

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Wide Range of Premium Pumping Solutions SAM Engineering proudly manufactures SAMCO pumps, consisting of a wide range of premium pumping solutions. As a fullservice company, we strive to add continued value to the industry with extensive knowledge and excellent service delivery, providing pump design, manufacture, and testing services to meet the demands of our clients as well as international standards for quality and safety.

For decades, SAM Engineering has always been a partner in providing real value to support the industryâ&#x20AC;&#x2122;s pumping needs. We recognise the need for your business to maintain a competitive edge by maintaining a consistent level of performance and efficiency for all projects undertaken. Our value added services are unique in that they extend beyond the design, manufacture and installation of pumps to ensure that systems not only meet quality requirements, but also maintain performance throughout equipment life, from assessing your needs on-site to offering a full in-house testing facility so that we can make sure that your pumping system keeps performing optimally.

stablished in 1986, SAM Engineering is one of the leading centrifugal pump manufacturers in Africa, primarily serving the demands of the mining, petrochemical and wastewater industry as well as process applications such as food, chemical, and pulp and paper where chemical resistance and anti-corrosive properties are a high priority.

SAM Engineering is ISO 9001:2008 certified. This certification is an international standard that recognises commitment to high quality service delivery and customer satisfaction. Operating efficiencies of our units compare favourably with accepted industry standards. Furthermore, our pump units undergo rigorous testing at our on-site testing facilities to certify the accurate performance of our products prior to installation.

Adding value to your pumping system is what makes SAM Engineering the preferred pump manufacturer. As a full-service pump manufacturer, we are committed to delivering the highest level of support to solve the operational challenges that our clients face through value-added service options. We donâ&#x20AC;&#x2122;t just manufacture a range of quality process pumps, we provide a full solution from start to finish to ensure that the sales process is as smooth as possible and at your every convenience.

SAM Engineering Tracey Mandy Tel: +27 (0) 11 823 4250 Fax: +27 (0) 11 823 4943 Email: tracey@sameng.co.za Website: www.sameng.co.za

Pumps and Valves Africa - Q3 - 2016

Extending the Life of Pumps and Fans Optimising the lifetime of a pump or fan can be assured through upgrading, and the use of monitoring techniques, says Lars Kahlman, Senior Application Specialist at SKF.

umps and fans are the foot soldiers of the process industry, but their quiet dedication means they are often ignored.

This is done at the operator’s peril, because when these components break down – or run below optimum efficiency – the whole process suffers. Manufacturing and process companies are under huge cost pressures at the moment, making it vital to maximise assets and maintain uptime. Only recently, a processing giant was forced to run its Finnish refinery at 70% utilisation following a malfunction in one of its cooling systems. The problem is expected to cause production losses of several tens of millions of euros – which drives home the importance of the humble fan to overall profitability. The specific refinery problem was caused by a new air cooler, which was installed during a recent maintenance turnaround – showing that even brand new components can cause problems. If a component is malfunctioning, the temptation is simply to replace it. However, an upgrade – by relubricating, or changing a bearing set, for example – often makes more sense. Replacing a part can mean huge upheaval, as the old machine is removed and a new one installed. People underestimate how much is involved in this process. Upgrading can avoid all that – and is likely to cost less. In fact, upgrades are a necessary part of building plant efficiency over time. When commissioning a new plant, there is rarely enough money upfront to buy the best equipment across the board. However, it can actually be better – both economically and technically – to upgrade equipment over time. It helps operators focus on equipment with reliability issues and avoids ‘design overkill’ on the original plant. A word of warning: safety must never be compromised. Plants that are specified with too much emphasis on cost reduction run the risk of being ‘under designed’ – and that can be dangerous.

Reliability and efficiency In most cases, pumps and fans are upgraded to improve two things: reliability or efficiency. A good example of a pump reliability upgrade is changing the lubrication system. In hot, humid regions – or a humid 20

Pumps and Valves Africa - Q3 - 2016

Optimising the lifetime of a pump or fan can be assured through upgrading and the use of monitoring techniques_Lars Kahlman_SKF Senior Application Specialist

environment like a pulp and paper mill – there’s always a danger of bearings corroding through water ingress. Atmospheric moisture gets into the oil sump and condense, and is transferred to the bearing by the oil rings. Just 200ppm of water in oil is enough to degrade bearings fast. A common solution is to fit an oil mist lubrication system e.g. the SKF Alemite ones, which sprays micro-sized droplets of oil at the exact lubrication point. It guarantees fresh oil in the system and cures water ingress. This type of system is becoming more common: around half of all refineries in the US are now using oil mist systems in their pumps. One of the most effective efficiency upgrades is to introduce a variable speed drive (VSD) to the pump or fan. Done properly, this can slash energy consumption by a huge 30%. However, the electrical output of the drive can cause arcing – which can destroy the bearing in a very short time. In extreme cases, this can happen inside three days.

The answer is to upgrade the system, most notably by fitting insulating bearings such as SKF’s Insocoat bearings (ceramic coated) or using hybrid bearings (ceramic rolling elements), which withstand electrical arcing. This is particularly important for smaller motors. Other measures – such as brushes, earthing, insulating couplings and special condition monitoring – can also help to alleviate the problem. On the surface, it appears that introducing VSDs is adding a problem. However, the huge saving in electricity far exceeds the extra cost of fitting the VSD and upgrading the bearing system.

Fan fare Fans have many similarities with pumps – but it’s true to say that fans often start with worse original design conditions. It is important to upgrade pumps and fans to improve reliability or efficiency for increased uptime At SKF we have a portfolio of upgrades and productivity . such as self-aligning bearing systems, fan oil lubrication systems etc. that can help to boost their switching to a back-up pump. efficiency and reliability. For certain types of fan, the scope There are often hundreds of pumps in a process plant or for upgrade is even larger than it is for pumps. refinery. The challenge, as always, is to process the vast As with pumps, VSDs can help to boost the energy efficien- amounts of data generated by the sensors. cy of fans. Again, insulated bearings help to extend component lifetime. Another problem – far more common on fans Online monitoring can be used to nurse a ‘problem’ machine than pumps – is misalignment. This is even more prevalent back to health – by monitoring it more frequently than simfor large fans, which are commonly used in industries includ- ilar machines. It also allows machines in hazardous areas to be monitored without endangering staff – or, at least, by ing pulp and paper, cement and metals processing. minimising the number of times they have to check the maAn effective solution is to specify a self-aligning and axial chine. free bearing, such as SKF CARB toroidal roller bearings. This That said, there are some things – such as a leaking seal, corrects angular and axial displacement, while a standard yet is a sign of impending failure – that a sensor cannot spherical roller bearing takes the thrust loading. When upspot. In these instances, it is vital that operators make visugrading, it is common to replace both standard roller bearal assessments of components and supply this information ings with the new arrangement – rather than simply insertalongside the automated online data. This operator-driven ing one self-aligning bearing. reliability (ODR) is another vital factor in keeping pumps and fans running for as long as possible. Skilled operators get to Close monitoring With or without an upgrade, it’s possible to further extend know their equipment – and will spot things that even a sothe lifetime of pumps and fans by keeping a close eye on phisticated sensor will miss. them through online asset monitoring. This technique is commonly used to monitor expensive, process-critical equipment by spotting problems as they happen. For example, it can detect the tiniest changes in bearing vibration – giving an early indication of impending failure, and allowing remedial action to be taken before the problem escalates into inefficiency or even catastrophic failure.

It is usually applied to expensive machinery, but the emergence of reliable, affordable sensors – and the ability to process large amounts of data – means it can also be used with smaller equipment such as pumps and fans. Equipping each pump or fan with sensors, including a transmitter, as done in SKF Wireless Machine Condition Sensor, allows the creation of a sensor network. Output data can regularly be analysed and acted upon. For example, sensors can identify whether cavitation is developing in a pump – allowing operators to respond to the problem by adjusting its running speed, or

ODR has become popular in applications such as pump farms in refineries, and can make a huge difference in performance: at SKF, we have seen that ODR has helped increase mean time between failures (MTBF) by 15%, while decreasing maintenance costs by more than 10% in this area. These two approaches – online monitoring and ODR – are complementary to one another, and are best used side by side. In each case, a skilled operator – one at the machine side, the other analysing process data – is using their experience to help squeeze more performance and longevity from a pump or fan.

SKF South Africa (Pty) Ltd. Tel: +27 11 821 3500 Fax: +27 11 821 3501 Website: www.skf.co.za Pumps and Valves Africa - Q3 - 2016

What Are The Differences In Positive Displacement Pumps? The world of Positive Displacement Pumps is very large and growing. As a manufacturer of custom process skids and pumping skids, I often get questions about the various types of pumps out there. We have to be familiar with a large variety of high-pressure pump technologies in order to design a system that will emulsify or homogenize fluids.

igh pressure for me is defined as anywhere from 300 psi to 10,000 psi. Once you get into this pressure realm, you are outside your typical material transfer pumps. A small sampling of low-pressure pumps would include: »» Centrifugal pumps »» Lobe pumps »» Pneumatic Diaphragm pumps »» Solenoid Piston pumps

This wikipedia article on pumps covers just about everything you'd need to know actually. What isn't really discussed in any detail, however, is practical experience that leads to choosing the right pump or how to design a system around such a pump.

High-Pressure PD Pumps Once you start emerging into the world of high pressure above say 300 psi, your options start to become limited and things like fluid viscosity start to play a more significant role.

Rotary Gear Pumps At 300 or 500 psi you can use Rotary Gear and pumps by manufacturers like Waukesha, Viking, Tuthill, Zenith and more. These pumps use 2 rotating gears set inside a housing with fairly tight tolerances between the gear outer edges and the housing inner wall. The tighter the tolerance between these surfaces, the more pressure the pump can theoretically handle. These pumps typically have a difficult time pumping water-like viscosities even though their pump curves are based on water. These pumps perform better with higher viscosity fluids because there's less chance the fluid will slip outside

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that gap between the gear edge and inner housing wall. The slip is fairly significant and something to think about. With that slip comes a lot of noise. The pumps hammer and bang when struggling against these high pressures and low viscosities. If you are pumping water-like viscosities at these pressures, they might not be the best pump for you. The nice thing about these pumps, however, is that they typically come in sanitary or hygienic designs good for pharma and personal care. That said, you can fabricate EHEDG sanitary homogenizer systems using these pumps:

These pumps work in a completely different manner altogether by actually trapping material between a set of checking valves where it’s nearly impossible for fluid to migrate or slip back. The problem here is that these pumps cannot handle higher viscosity fluids much above 3000-4000 cps (pancake batter) nor can they be used where 3A or EHEDG are required. However, they are easily cleanable, but do not bear those certificates. Improvements can be made to handle higher viscosity by using a feed pump to pressurize the inlet. These pumps can accomodate really high pressures now in the 10,000 psi range. Cat Pumps manfactures such pumps and Sonic Corp has used them to in high-pressure Sonolator homogenizer systems that operate routinely at 5,000 psi to make fine emulsions.

Progressive Cavity Pumps Progressive Cavity (PC) pumps are another option at this pressure region of 300-500 psi. These pumps use a long spiral-shaped auger that rotates inside an elastomeric stator and moves fluid progressively along the auger. Slip can occur in a similar manner at the space between the rotating auger and the stator. The good news with these pumps is that there is no real gap between the rotating and stationary components because the metal rotor can essentially make contact with the elastomeric stator. Now slip occurs due to compression of the elastomeric element. These pumps handle water-like viscosities much better than the rotary gear type, but suffer flow losses due to intake efficiency drops when the viscosity is high.

There are other Reciprocating Plunger pump companies such as Lewa, SPX and more but these pumps are terrifically expensive per GPM as compared to Cat Pumps. All told, it’s not as simple as Googling Positive Displacement Pumps to find what you want. You’ll get 973,000 results ranging from storefronts for mini Jabsco vane pumps to obscure images of home-made pumping systems that look more like my kid’s go kart than a bone-fide system I’d want in my manufacturing plant.

Reciprocating Triplex Plunger Pumps Pumps and Valves Africa - Q3 - 2016

What Happens to Power & Efficiency When a Pump Wears Out? When a pump experiences internal wear, its performance drops. Flow is reduced and efficiency plummets. But what happens to power? Does it drop, stay the same or increase?

he answer to this question depends on how a pump wears internally. In extreme cases, when the impeller is completely worn, there will be no flow and hardly any power. But in many cases, tight clearance parts, such as wear rings and bushings, are the first to wear.

is external (such as a more classic example of an external bypass line) or internal (leakage), as in this example. We can now overlay a pump curve over the system(s) curve(s) as shown in Figure 3. Point A (4,100 gallons per minute [gpm], 170 feet) is an intersection of the pump curve and system curve when there is no leakage (theoretically, zero clearance). In other words, the flow through the impeller is the same as the flow entering and exiting the pump. Point B is the intersection of the pump curve with a “new” system curve when clearance is non-zero. We can see that the flow through the impeller increased to 4,600 gpm (system resistance decreased due to opened clearance), resulting in a reduced new head of 155 feet. Drawing a horizontal line at 155 feet gives us a pump flow of 3,900 gpm and a leakage flow of 700 gpm through the rings. At the original (zero clearance) operation, the pump was drawing 270 horsepower (hp) at 4,100 gpm (point AP on the power curve). At a new, increased flow (4,600 gpm), the power went up to 285 hp (point BP), reflecting the extra power draw required to recirculate the liquid through the clearance. An observer using a flow meter at the piping doesn’t know anything about the internal recirculation. All he or she sees is 3,900 gpm leaving the pump and 285 hp registered by the power readout (assuming zero motor losses for simplicity). As a result, there are two conditions of the pump observed parameters: 4,100 gpm, 170 feet, 270 hp before clearance opened up; and 3,900 gpm, 155 feet, 285 hp after clearance opened up.

Figure 1. Parallel circuit: Flow through the impeller is greater than the actual pump discharge/suction flow by the amount of leakage. (Graphics courtesy of the author)

The first case implies 65.2 percent efficiency (4,100 x 170/3960/270), and the second case shows 53.6 percent efficiency. Three things happened as clearance opened up:

Figure 1 shows a flow path through a pump: Flow (Qpump) enters a pump and leaves it. But the flow through the impeller (Qimp) is actually a bit higher as leakage (QL) (returning from the impeller outer diameter [OD] back to suction through the clearance) joins the incoming flow (see Equation 1). As a result, two hydraulic systems are operating in parallel: the main system (discharge side), which is what the flow meter reads, plus the internal recirculation system, which depends on the wear ring clearance (see Figure 2). The resultant system curve is constructed from the basic rules of system hydraulics: flows added at each head value. This process is the same whether the circuit 24

Figure 2. Two systems in parallel. The pump flow joins with leakage recirculation to produce impeller flow.

Pumps and Valves Africa - Q3 - 2016

the drop in efficiency to the cost of repair to restore performance. There is a way to estimate the drop of efficiency versus clearance value, as shown in previous columns as well as at my periodic sessions of Pump School. As a parting quiz: What do you think would be the energy cost, in dollars, lost for a large, 2,000-hp double-suction pump when its clearance doubles? The closest answer will have the chance to be published in the occasional “Readers Respond” section of Pumps & Systems.

ABOUT THE AUTHOR Dr. Nelik (aka “Dr. Pump”) is president of Pumping Machinery LLC, an Atlantabased firm specializing in pump consulting, training, equipment troubleshooting and pump repairs. Dr. Nelik has 30 years of experience in pumps and pumping equipment. He may be reached at pumpmagazine.com. For more information, visit pumpingmachinery.com/pump_school/ pump_school.htm. Figure 3. Pump operating points

• System flow dropped. • Pump power increased. • Pump efficiency decreased. Periodic field testing of pump performance can show the presence of any deterioration of the pump’s internals. Interestingly, the data on power can tell the difference between the types of internal wear—for example, if the wear ring clearances have worn out or if the impeller itself is deteriorating (as might be the case with highly abrasive pumpage or corrosive chemicals). Coupled with vibration analysis, a performance audit may help users determine the next course of action—whether repair is needed or continuation of operation—by relating

Figure 4. Change of performance with clearance (The solid line represents conditions before the clearance was opened, and the dashed line represents conditions after clearance was opened/worn.)

Pumps and Valves Africa - Q3 - 2016

Why The Wilden Air Operated Diaphragm Pump is a Flexible Choice The first air operated diaphragm pump was invented by Jim Wilden as unique but reliable, utilitarian pump. He founded Wilden Pump and Engineering in 1955 and the air operated diaphragm pump was launched.

he pump since then has been copied and redesigned overthe years, but the basic principle remains the same â&#x20AC;&#x201D; reciprocating action of the diaphragms provides suction in one direction and pressure in the reverse. The air operated diaphragm pump is a work horse and offers many benefits. For example:

Flexible operation The diaphragm pump can self prime, and if the parts are wetted lift up to 29 ft.. The pump can run dry too. If someone starts the pump and gets called away forgetting to turn the pump off, it's no problem. The pump will continue to run even with no fluid flowing without any adverse side affects. The pump will stop (dead head) if the discharge valve is closed or the system pressure increases above the pump air supply pressure.

This makes it the perfect pump to use on filter press applications. The air operated diaphragm pump can be submerged in a sump or placed in hazardous areas where ex-proof equipment is required.

(Make sure you let your supplier know these requirements) Flexible material options The pump can be made from a variety of materials. The wetted path can be cast iron, aluminum, stainless steel, Hastelloy, Polypropylene and Kynar. There are multiple elastomer options such as Buna-N, Neoprene, EPDM, Viton, and there are even thermoplastic options like Polyurethane, Wilflex (polyurethane & EPDM), Geolast (polyurethane & Buna-N), and Teflon. The 316 stainless steel components can be ordered with a high polish finish meeting EHEDG standards, and the materials can be assembled in any configuration necessary to handle clean, dirty fluids, chemicals, abrasive, caustics, acids, viscous, oils, foods, beverages, bio-pharm solutions.

Pumps and Valves Africa - Q3 - 2016

Easy to Repair Finally, air operated diaphragm pumps are easy to repair. There are few moving parts and with simple hand tools just about anyone can disassemble, replace parts, and reassemble the pump.

Most of these options are offered in food grade too If you are currently using and air operated diaphragm pump and are looking for an opportunity to decrease your energy costs, talk to us about the Wilden Proflow Shift. The most energy efficient air operated diaphragm pump on the market.

By Tom Kolling http://blog.dlthurrott.com/why-wilden-airoperated-diaphragm-pump-is-a-flexiblechoice?utm_campaign=MOFU&utm_ content=39764122&utm_ medium=social&utm_source=linkedin

Flexible installation The pumps can be in a fixed location as part of the system or mounted on a portable cart easily moved from one location to another inside the plant. The pump can be trailer mounted as is often done for driveway sealing too.

Pumps and Valves Africa - Q3 - 2016

Electra er Le 80 Mining ad 0 El s A Exh ec n ib 2016 tr d B it a M r or a s n in d Ge Report in A n g w er Af ar a ric en ted Back a e Ov

It's been an amazing show with 20 ss Sal thousands of visitors attending 16 At es ! the five days of Electra Mining Africa. They came to see to see the latest innovations across mining, industrial, electrical, power, transport and related industries. Engaging with over 800 exhibitors, visitors have seen many new products launched at the show and new technologies unveiled. CRI Pumps They were also able to see machinery and equipment in action during hundreds of live demonstrations. The valueadd free-to-attend seminars offered an excellent learning platform and the co-located conferences delivered great insight and knowledge to the delegates.

PUMP AND ABRASION 28

Pumps and Valves Africa - Q3 - 2016

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Pumps and Valves Africa - Q3 - 2016

International Owner’s Investment Boosts Leading African PVP Expo The new owners of one of Africa’s biggest trade shows will have a new international and educational focus when it opens in Johannesburg next year.

umps, Valves & Pipes Africa 2017 (PVP 2017), presented by INDUTEC, is the largest and most comprehensive trade-show dedicated to the conveyance of liquids, gasses and slurries.

Brad Hook is the organiser dmg-ems Africa’s Commercial Director and he told Pumps & Valves Africa that 2017 brings a fresh approach for the show at The Gallagher Conference Centre in Johannesburg, South Africa, from May 17 to 19. “The show, along with a portfolio of events, was acquired in March by dmg events ME - one of the world’s leading exhibition organisers,” says Hook. “Development and investment are part of dmg’s strategy and PVP 2017 will benefit hugely. This is the 10th edition of the show, which is part of INDUTEC a well-established expo South African expo that attracts visitors and exhibitors from around the world.” In 2017 PVP will also host a conference with leading industry speakers, and full details will be released over the next two months. “This a key foundation for the show’s expansion,” Hook told Pumps & Valves Africa. Hook said that PVP 2017 will focus on the five key areas of the market:

nomic pumping and transport solutions to capitalise on the continent’s reserves.

• Infrastructure New government backed developments mean expertise is required across a diverse range - from the transportation of liquid concrete to sewage.

• Agriculture Mechanisation and population growth is increasing demand for the latest pump and pipeline technology.

• Extractive industries Africa is a world player now demanding the efficient solutions from oil and gas transportation to mining. “These are the key growth and investment areas across Southern Africa and under new ownership dmg has identified the markets and the visitors, buyers and specifiers, which we will match with the pumps, valves and pipes supply chains,” Hook told Pumps & Valves Africa. “And all of this is tied to the future economic success of the continent. In the energy sector, oil and gas production are vital for growth, while across the extractive sector cost-effective solutions are vital.” You can find out more about visiting the show, exhibiting or attending the conference at

www.indutecafrica.com

• Water Tech This vital resource needs increasingly sophisticated management to meet the continent’s future demands

• Energy To meet demand in the oil, gas & petrochem sector for eco-

Pumps and Valves Africa - Q3 - 2016

Complete Mobile On-Site Air, Power, Light, And Now Also Pump Solutions From A Single Source Atlas Copco Portable Energy leads the market as a single source supplier of turnkey on-site mobile solutions with the development and extension of its pump portfolio to complement the division’s already well-established range of compressors, generators and light towers.

“

The shared synergies between Portable Energy’s three pillars - compressors, generators and light towers – made the development of our dewatering pump ranges to form a fourth pillar within the division a natural progression,” explains Portable Energy Business Line Manager, David Stanford. He notes that pumps are not new comers to the Atlas Copco portfolio with small hydraulic as well as pneumatic and electrical submersible pumps having been part of the offering for quite a few years. “We have now made a solid strategic commitment which will ensure that our pumps enjoy the same focus and investment as our compressors, generators and light towers and I am really most pleased that our hard work is finally coming to fruition.” Roll out of the expanded pump portfolio which relates to both pressure and flow-rate capacities, will take place over the coming months. The efficient and safe removal and disposal of water from a job site is fundamental to maintaining safety and productivity. “Performance under pressure within the most challenging environments is where our pump ranges perform to their

maximum,” affirms Stanford. Suitable for transporting or lifting water with abrasive solids in suspension, the pumps are ideal for applications such as construction and mine-site dewatering and diversion of flood water or streams. The comprehensive range of electrical submersible and self-priming diesel pumps available from Atlas Copco Portable Energy provide solutions for virtually any mobile dewatering application within the flow range of 210 – 16500 l/min. The portable dewatering pump range saw further extension in January 2016 with Atlas Copco’s acquisition of Varisco. “Varisco’s Padua location has become the dedicated global competence centre for pump development within Atlas Copco Portable Energy complementing our other two global competency centres in Antwerp (air) and Zaragoza (power and light),” adds Stanford.

Performance under pressure within the most challenging environments is where our pump ranges perform to their maximum The new motor design of the Weda 50 and 60 electrical submersible pumps has resulted in improved power to weight ratios. The Weda hydraulic parts deliver enhanced performance with flow management from 225 to 16 500 litres per minute with a maximum head of 85m. Stanford also reveals that as a result of customer demand, a diesel driven open canopy range will also be introduced in Q4 2016. “The same unique value proposition and forward-thinking approach that underpin our compressor, generator and light tower ranges are assigned to our pumps,” notes Stanford. “It is about continuously improving product performance, reliability and efficiency to take on even the most stringent conditions and here engineering and manufacturing excellence, environmental consciousness and expert service all come into play.” “Portable Energy’s value proposition differentiates us as a preferred supplier of portable energy products that are inherently energy efficient, light-weight, compact, easy to move and transport, meeting customers’ exact needs and contributing to enhanced customer productivity at the lowest cost of ownership over the products’ lifetime.” The division’s six-point value proposition begins with a focus on customer needs.

Pumps and Valves Africa - Q3 - 2016

purpose, all Atlas Copco products are engineered and not assembled. “We take cognisance not only of our own manufacturing processes but also of the customer’s working environment through the provision of energy efficient products.

In order to produce products that are fit for customer purpose, all Atlas Copco products are engineered and not assembled Atlas Copco Portable Energy is committed to creating customer value through anticipating and exceeding future needs while never compromising on environmental principles. In order to produce products that are fit for customer

In closing, Stanford points out that Atlas Copco Portable Energy customers invest in so much more than just a product, they invest in a massive support network that includes factory trained technicians that deliver fast, reliable, expert service to help maintain uptime and production levels. “As their long-term portable energy partner, our customers are ultimately the winners as they are now able to choose their all-inclusive on-site mobile compressor, generator, light tower and pump solutions from a single source,” concludes Stanford.

Atlas Copco David Stanford Tel: +27 11 821 9000 Fax: +27 11 821 9106 www.atlascopco.com www.atlascopco.co.za

Spectacular Varisco Range Displayed At Electra Mining At Electra Mining 2016, Letaba Dewatering will be displaying the Varisco J-series as well as a range of ST-R trash pumps. Visitors can also expect a number of new higher head self-priming pumps, which have been added to the J-series family. These will form part of Letaba’s dominant show-stopping display next to the lake.

etaba Dewatering have been selling quality Varisco self-priming pumps since 1992, and the company now boasts one of the largest and most successful rental fleets in Southern Africa, where it mainly supplies industry with Varisco diesel and electric driven pumps. According to Letaba Dewatering Rental Manager, Ignatius Fourie, the Letaba Dewatering Rental division supplies Varisco self-priming pumps because they are easy to maintain, and also because of their durability. Further to this, Letaba not only stocks Varisco pump spares for their customers, but also for their own rental fleet. “We stock a high level of spares in order to provide customers with excellent after-sales service.” The Letaba Group is continuously expanding their rental fleet of pumps at an attempt to stay up-to-date with industry demands. Their successful product range includes self-priming centrifugal pumps, electric submersible pumps, single and double diaphragm pumps, as well as slurry pumps.

Letaba Dewatering T:+27 (0) 11 923 7000 / 011 452 1351 www.letabapumps.co.za Pumps and Valves Africa - Q3 - 2016

Highest Precision as Standard The dosing sector is subject to a progressive miniaturization, as dosages have to be more economical and precise. Specific quantities and microdosing of fluids with different viscosity such as adhesives and solder pastels, are of extreme importance to medical technology, aerospace, electronics, photovoltaics as well as automotive industries. preeflow® offers the optimal solution and aims to fulfill the growing customer demands.

iscoTec has been passionate about manufacturing dosing and dispensing components for semi- and fully automatic production lines and assembly processes for over 20 years. The customer is offered a precise, reliable, fast and sophisticated technology to perfection. The dosing dispenser of preeflow®, ViscoTec´s own brand, has become the global champion of volumetric metering systems and at the same time the driving force of the company. The preeflow® eco-PEN doses over a wide range of applications viscous, structure sensitive and solid containing fluids with outstanding quality. However, the performance of a dosing process is not only dependent on the technology, but also on the construction, specifically to the degree of quality assurance during production and before delivery.

Promise of High Quality The inspection of all preeflow® components is subject to highest quality requirements and it is ViscoTecs philosophy that these requirements are observed at all times. The volumetric dosing precision of 1 % and repeatability of > 99 % can, on the one hand, be attributed to the exact, high-quality production of the eco-PEN components. On the other hand, this accurate performance is only achieved through the additional strict, internal quality standards for each element and system. Finally this high quality standard is reflected directly in the dosages, as seen in image 2. This gives 100% justice to the preeflow® principle: “smaller, more precise and more economical”. It is evident, that preeflow® has mastered microdispensing to perfection, resulting in consistent quality in fully automatic processes which thus means process reliability. The sophisticated rotor and stator production is one of the most important core competencies and will be particularly protected. Fluctuations in quality are avoided straightaway.

millimeter.Each rotor stator system is subject to a standardized, constant, detailed examination, consisting of multiple processes. ViscoTec is always one step ahead of its market participants. A variety of devices form part of the quality assurance. For example a 100 % control of the stators dimensions is carried out with a measuring device based on the technology of computed tomography. The chamber volume of each rotor stator system is inspected by standardized tests based on weight and image analysis. The stators are measured with the help of a computer program which calculates the volume, in order to maintain a defined, minimal deviation. In addition, outstanding quality is ensured by 100 % pressure and performance tests. The results of these performance tests are each measured with an ultra-high resolution microscope, as well as visually evaluated. The eco-PEN dispenser, including eco-DUO and the new eco-SPRAY, are fitted with the chemical resistant elastomer VisChem as standard. Specially developed for ViscoTec, this rubber compound is characterized by its outstanding compatibility with aggressive material, together with optimal mechanical strength.

Characteristic features of preeflow® dispenser Strict controls have an effect in direct comparison to other dosing systems as highlighted as follows: independent studies show that the eco-PEN from preeflow® provides excellent dosing values compared to those of a jet dispenser and of

With regard to quality assurance and the testing of the raw materials of the elastomer for the stator, each batch that is delivered is controlled by specially defined parameters. This ensures that the basic raw materials always reach a consistent standard.

Cutaway view of an eco-PEN

The production of a stator is carried out to perfection thanks to miniscule tolerances. Elastomer elements can be manufactured with an accuracy of 100th of a

Pumps and Valves Africa - Q3 - 2016

Quality Assurance employee performing a stator check using a measuring device based on computed tomography technology

quality and competent advice on a global level. Even in the most remoted places of the world 24/7 service & support could be ensured, resulting in a high degree of flexibility. All preeflow® products are available from stock. Image evaluation being used to test the stators of an eco-PEN

a time-pressure system. The preeflow® eco-PEN reached a process capability index value of cP = 4.26, whilst other systems were only capable of reaching a value of cP < 1,33. These results show that the eco-PEN dosed outstanding results within a very narrow distribution of the measurements in mg range.

Service & Support around the globe preeflow® works together with qualified distributors worldwide, many of whom have been working in cooperation with ViscoTec before preeflow® was founded in 2008. These business relationships are based on many years of mutual support in knowledge and experience. It is through these long-running partnerships that preeflow® customers benefit from a very high level of service, which means reliable, high

fection!

automotive

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Thomas Diringer, Manager Business Unit Components & Devices ViscoTec Pumpen- u. Dosiertechnik GmbH Amperstraße 13, D-84513 Töging a. Inn Phone +49 8631 9274-441 E-Mail: thomas.diringer@ viscotec.de · www.preeflow.com Elisabeth Lenz, Master of Business Management (CCI) ViscoTec Pumpen- u. Dosiertechnik GmbH Amperstraße 13, D-84513 Töging a. Inn Phone +49 8631 9274-447 E: elisabeth.lenz@viscotec.de · www.viscotec.de

electronic

We are looking for a business sales partner for our micro dispensing equipment.

medical tech.

bio chemistry many more

You can find more information on our website!

Diagram showing the comparison of dosing results of a jet-, time-pressure-dispenser and preeflow® eco-PEN

www.preeflow.com

Pumps and Valves Africa - Q3 - 2016

Straightforward ES05 Valve Series from Aventics Introduced Tectra Automation, part of the Hytec Group of Companies, has brought the Aventics ES05 Essential Valve System series to South African shores. Launched at the Hannover Fair 2016 earlier this year, the ES05 series now offers a clever, economic and user-friendly solution for applications with standard requirements in industrial automation. Designed specifically to reduce the number of components, assembly is completed with one single tool, making life easier for distributors, machine manufacturers and system integrators with the added benefit of reducing the risk of faults.

he ES05 series was developed by Aventics in response to customers’ requests for a simple, flexible and efficient standard valve with reduced components – tailored to their application. “The new series, therefore, focuses on ease of handling for distributors, machine manufacturers and system integrators,” explains Malan Bosman, Pneumatic Product Manager, Tectra Automation. “They can configure their customised solution online from a set number of readily available components. Assembling a valve system has never been faster or easier.” The ES05 is a modular system and, as all components are unique and only one tool is required for the job, incorrect installation is virtually impossible. All fittings are of the same type and tightened with the same torque, which further simplifies assembly and prevents errors. The portfolio includes the Essential Test Box, which enables testing for the correct function and valve leak-tightness before installing the valve systems – something particularly useful for volume users. Orders are supplied as complete assembly kits.

Tectra introduces ES05 valve series pic 2: One single tool is all that’s required to assemble Aventics’ new ES05 Essential Valve System series from Tectra Automation

The valves come in a robust housing made of high-performance polymers and are especially stable and compact. Users connect the end and base plates, and can extend the system in pairs up to 12 single or double solenoid valves. The valves are controlled via single wiring with a type CI plug ac-

Tectra introduces ES05 valve series pic 3: A modular principle: All components of Aventics ES05 Essential Valve System from Tectra Automation can be ordered separately.

cording to ISO 15217, a D-Sub connection with 25 pins with Aventics AES valve electronics from Tectra Automation, or an integrated IO-Link interface. AES supports all common fieldbus and Ethernet protocols. If necessary, the pilot coils can also be turned at a later stage to realise mixed connection configurations. With a switching time of less than 35 milliseconds for all valve functions, highly dynamic action is guaranteed for short cycles. With single wiring, the ES05 complies with protection class IP65, so the valve system can also be installed in decentralised locations, even in environments exposed to splash water. All other connection types comply with protection class IP50. Tectra introduces ES05 valve series pic 1: The new Aventics ES05 Essential Valve System series from Tectra Automation is suitable for general applications in industrial automation, logistics, and machine construction

Pumps and Valves Africa - Q3 - 2016

Tectra Automation, Malan Bosman T: +27 11 971 9400, malan/bosman@tectra.co.za Website: www.hytecgroup.co.za

58 23 0/ 35 358 .za o -2 82 822 eb.c za . 1) w ) 01 011 @m c.co ( c ( c 7 s +2 +27 vesc alve : l l Te Fax: cva .acv w :a ail : ww Em eb W 3 2-

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Pumps and Valves Africa - Q3 - 2016

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Pumps and Valves Africa - Q3 - 2016

Predict, Measure and Correct for Electrical Run-Out With Thermaspray’s Burnishing and Degaussing Processes Burnishing, de-magnetization and measuring of electrical run-outs by thermal and plasma coating solutions specialist, Thermaspray, aids with improving the mechanical reliability of rotating equipment inside motors and generators resulting in reduced failure risks, extended component life and improved uptime.

n-service monitoring of both mechanical and electrical runout will improve the mechanical reliability and reduce the risk of failures and subsequent costs of motors, generators and specifically the lower shaft and bearing housings. Discussing the two types of runouts, Metallurgical Engineer at Thermaspray, Shaik Hoosain, explains that a mechanical runout by a dial indicator is not done in-situ. Electrical run-out measures the deviations in the electrical properties of the material and cannot be measured with a dial indicator. Electrical run-out is detected by means of in-service eddy–current proximity probes on these motors and generators. Proximity probes measure and monitor the relative vibration or motion between a shaft and its stationary bearing surface.” Electrical run-out is concentrated around the metallurgical variations around the circumference of the shaft where these metallurgical variations lead to electrical conductivity and magnetic permeability of the shaft affecting the probe

We measure and correct electrical run-out through a process called burnishing track signal. Sources of electrical run-out include metallurgical variations or changes, forging, heat treatment, grinding, magnetism, stress effects, handling and plating. For a true and accurate in-service measurement, the electrical run-out is measured and corrected prior to the assembly of the equipment. “We measure and correct electrical runout through a process called burnishing that involves the rolling of a blunt tool against the surface of a work piece with a force being applied by the tool,” continues Hoosain. Metallurgically, burnishing is a cold working process that 40

Pumps and Valves Africa - Q3 - 2016

improves the surface characteristics of components and is mainly performed on materials to improve the surface strength and roughness. As soon as the yield point of the material is exceeded, plastic deformation occurs which leads to a smoother surface profile. Burnishing is performed by revolving the final ground/machined part in a lathe and using a diamond burnishing tool.

worn, out of balance, poorly lubricated etc. Surface imperfections such as scratches, out-of-roundness or non-concentricity with respect to the bearing journal are mechanical imperfections which will appear as vibrations that will result in measurement errors. These will be picked up as signals by the eddy-current proximity probes.

The probe track area, where the run-out is measured, is cold worked to ensure a perfectly round, parallel and smooth surface. After completion of the burnishing process, the residual magnetism in the part, measured using a residual field indicator and a Gauss meter, is removed using demagnetizing coils.

Typical equipment using probe tracks include boiler feed pumps, 50% boiler feed pumps, turbine rotors, compressor rotors, blower rotors, pinion shafts and cryogenic pump rotors. Burnishing, de-magnetization and measuring of electrical run-outs all performed in Thermaspray’s well-equipped workshops according to the relevant ISO standards.

After the burnishing process, electrical run-out can then be measured using an electrical run-out indicator apparatus on a lathe or inspection bench. Electrical run-out is measured every 1° through 360° and plotted on graphs using specialized, calibrated equipment and applicable software.

Thermaspray, in a joint venture with Cape Town-based Surcotec, offers an extensive portfolio of engineering and thermal spray coating solutions that extend component life cycles to assist OEM and end-user clients across southern Africa in reducing costs and increasing production.

Discussing eddy-current proximity probes for shaft vibration monitoring, Hoosain says that the probes are positioned over a specially machined probe track area adjacent to each bearing journal. The signal from the eddy-current proximity probe is a function of the gap between the probe tip and the target material. If the run-out changes in service, the difference is registered by the probes and will indicate to operators and engineers that the equipment is damaged e.g.

The companies’ world-class quality wear- and corrosion-resistant thermal spray coatings, Plasma Transferred Arc (PTA) cladding and Polymer coatings (in partnership with Plasma Coatings USA and Diamant Metalplastic Germany) are augmented by a host of specialised allied services.

Thermaspray, Mariette Broodryk Tel: +27 (11) 316 6520, www.thermaspray.co.za

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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 42

Pumps and Valves Africa - Q3 - 2016

Organised by

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 GEAR 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 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

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 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

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

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

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

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

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

SAM Engineering Tel: (011) 823-4250 Fax: (011) 823-4943 Email: sales@sameng.co.za Web: www.sameng.co.za Pumps and Valves Africa - Q3 - 2016

PUMPS MULTISTAGE PUMPS

POSITIVE DISPLACEMENT PUMPS

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

Hawk High Pressure Pumps

PERISTALTIC PUMPS (HOSE 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

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 PISTON PUMPS

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

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

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

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

TRASH 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

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

PLUNGER PUMPS SUBMERSIBLE PUMPS

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

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 44

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

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

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

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

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

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

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

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 46

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 PNEMATIC - SPRING RETURN

PNEMATIC - 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

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

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Pumps and Valves Africa - Q3 - 2016

AGRICO Centre Pivots & Linear Irrigators

With outstanding standard specifications and many options:

NEW: Internet Control

Irrigators are galvanised in-house; Cablesaver reduces theft; the cable to minimum 100 microns (1.8 times the ISO 146 standaard). This gives Windsaver machines are stable and is placed inside the pipe, where it cannot be tampered with easily. guaranteed for 4 years. 80% longer life expectancy.

Autoflush flushes the machine every time the pump starts.

The AGRICO 3-legged center is exceptionally strong.

Pumps and Valves Africa - Q3 - 2016

AGRICO one stop service: Survey, design, manfacture, delivery, installation and after sales service.