THE SOUTH AFRICAN MECHANICAL ENGINEER
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Pumps ƒ Valves ƒ Systems
GIW MDX Technology Cuts Pump TCO by Millions In operation at a major copper mine in Chile, MDX technology dramatically increased pump wear life, saving millions of dollars in maintenance, energy, downtime and other costs. GIW Industries, the leader in the design, manufacture and application of heavy duty, centrifugal slurry pumps, announced that its installation of MDX pump technology at a major Chilean copper mine has resulted in a dramatic reduction of total cost of ownership (TCO) for those pump applications - amounting to millions of dollars in savings for the customer.. TCO for slurry pumps includes not only the initial cost of the pump, but also factors such as wear life, annual cost of parts, labor, energy and downtime for maintenance. KSB Pumps and Valves (Pty) Ltd www.ksbpumps.co.za
LSA
2
MDX
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HVF
Chris Reay
Chairman of the Working Committee: Communications (SA Institution of Mechanical Engineering)
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ils
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The monthly circulation is 4 326
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SAIMechE Training Workshops : 20 April 2013 - 30 June 2013 Programmes and Registration Form obtainable from Carey Evans, Tel. 031 764 7136 or carey@saimeche.org.za Event Code
Workshop Title
Start
End
Region
A6313
The Road to Professional Registration
24-Apr
24-Apr
Durban
E3113
Heat Transfer in Practice
24-Apr
25-Apr
East Rand
A0713
Pressure Equipment Regulations
8-May
8-May
Durban
F3213
Duplex Stainless Steels
8-May
8-May
Secunda
E2513
Materials Selection - Processes, Parameters & Performances
9-May
9-May
East Rand
A6413
Tank Design, Construction & Installation
15-May 16-May
Durban
B6013
Inventive Solutions to Engineering Problems
15-May 16-May
Port Elizabeth
C3013
Root Cause Failure Analysis
15-May 16-May
Cape Town
E6313
The Road to Professional Registration
22-May 22-May
East Rand
A0613
The Engineer As Manager
23-May 24-May
Durban
C6313
The Road to Professional Registration
29-May 29-May
Cape Town
E3013
Root Cause Failure Analysis
29-May 30-May
East Rand
A5713
Total Productive Maintenance
30-May 30-May
Durban
C2613
Corrosion Control
5-Jun
5-Jun
Cape Town
E6413
Tank Design, Construction & Installation
5-Jun
6-Jun
East Rand
A5813
Continuous Flow Processes: Methodology for Engineers
6-Jun
6-Jan
Durban
A3013
Root Cause Failure Analysis
12-Jun
13-Jun
Durban
D6013
Inventive Solutions to Engineering Problems
12-Jun
13-Jun
Vanderbijlpark
F0913
ISO 9001 - 2008
19-Jun
19-Jun
Secunda
F6613
Effetive Negotiation Methodologies for Engineers
20-Jun
20-Jun
Secunda
C0613
The Engineer As Manager
20-Jun
21-Jun
Cape Town
A2613
Corrosion Control
26-Jun
26-Jun
Durban
B3013
Root Cause Failure Analysis
26-Jun
27-Jun
Port Elizabeth
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COVER STORY
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COVER STORY
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PIPES, PUMPS & VALVES
John Thomson, managing director of Exhibition Management Services (EMS)
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PIPES, PUMPS & VALVES
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Academic
Most Challenging Project Career Path
Most Rewarding Project
Commentary
Achievements
we’re engineered to share
PPS allocates a record R3 billion to its members. Now that’s a unique benefit of mutuality.
For more benefits and info, SMS ‘MECH’ and your NAME to 42097, visit www.pps.co.za or consult a PPS product-accredited financial adviser. PPS is an authorised Financial Services Provider. *PPS members with qualifying products share in the profits of PPS Terms, conditions and standard SMS rates apply
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Jannie Bekker CEO of L&B Industrial Power
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After: A completed rewinding
Before: a motor for rewinding
A pump assembly, ready for delivery
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What is mechatronics?
What do you drive now and what would you drive if money was no object?
What’s your real job?
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Nico Serfontein, Think Blue project leader
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THE SOUTH AFRICAN MECHANICAL ENGINEER Untitled-2 1
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POWER
GENERATION
T O D A Y
PROMECH PUBLISHING Tel: (011) 781-1401 Fax: (011) 781-1403 Email: samecheng@promech. co.za Website: www.promech.co.za Managing Editor: Susan Custers Editorial: Kowie Hamman Advertising: Mark Bennett Circulation: Catherine Macdiva DTP: Zinobia Docrat/ Donovan Vadivalu Disclaimer PROMECH Publishing does not take responsibility for the opinions expressed by individuals.
Copyright
TICKER TAPE
All rights reserved. No editorial matter published in “Power Generation Today� may be reproduced in any form or language without written permission of the publishers. While every effort is made to ensure accurate reproduction, the editor, authors, publishers and their employees or agents shall not be responsible or in any way liable for any errors, omissions or inaccuracies in the publication, whether arising from negligence or otherwise or for any consequences arising therefrom. The inclusion or exclusion of any product does not mean that the publisher or editorial board advocates or rejects its use either generally or in any particular field or fields.
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The TKE system’s burner
The control system for the TKE burner
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Recipients of Certified Energy Manager (CEM速) and Energy Manager In-Training (EMIT) certificates for the 2011/12 year in South Africa.
Recipients of the Certified Measurement and Verification Professional (CMVP速) certificates for the 2011/12 year in South Africa
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MAN ITEMS Y BE OFF CAN ER FROM ED STOCK
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MULTI_ALLOYS_MECHANICAL_ENG_130x1 1
12/20/12 9:45:24 PM
ai_ait_44.0_en aik
Protect Your Belt Conveyors with Voith Fluid Couplings They have been in service for decades under the toughest conditions – and have proven themselves worldwide. Voith fluid couplings protect belt conveyors and drive components by providing smooth acceleration and torque control allowing for frequent loaded starts with the least amount of stress on the drive and belt.
In multi-motor drives they ensure precise load distribution. Result: fewer downtimes – and the service life of the belt and the drive components is increased. The latest product innovation is the Voith TurboBelt 780 TPXL. info.vtza@voith.com www.rsa.voithturbo.com
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Keith Cain (left) and Simon Welding from Saint
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B
Screen Mass
D
C
A
Pump Mass RESTRAINT RESTRAINT RESTRAINT Pinned Links
Figure 1: Variation of dynamic magnification factor with damping and frequency (Clough, 2003)
Figure 2: Proposed client model of screening unit
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RESTRAINT
Member
Member Type
Section
1
H-Section
152X152x30
2
Angle
70X70x6 254X146x37
3
I-Beam
4
Taper-Channel 140X60x16
5
I-Beam
IPE 200
Figure 6: FEA model: Von Misses stresses (Max stress = 75 MPa < 355 MPa OK)
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Figure 8: Relationship of mass participation and frequency with underpan empty
Figure 10: Mode shape at pump motor (Not significant)
Table 2: Compression & Buckling Checks to SANS 2009
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Member
Member Type
Section
1
H-Section
152X152x30
2
Angle
70X70x6
3
I-Beam
254X146x37
4
Taper-Channel
140X60x16
5
I-Beam
IPE 200
6
Box Section
140x60x16
Figure 11: Critical frequency ‘x’ in resonance region (Structure at Full Capacity)
Figure 12: Critical mode shape shown with direction of arrows (structure at full capacity)
Figure 13: Critical frequency ‘x’ out of resonance region (Structure at full capacity)
Figure 14: Critical frequency ‘x’ out of the resonance region (Structure at full capacity)
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Figure 15: Final Design Structure
Figure 18: Effect of partial fixity of bracing members twisting of top beams at a displacement of 10%
Figure 16: Stress range of the final structure at steady state response
Figure 17: Effect of partial fixity of bracing members on the natural frequency Hours/Day
Days/Year
Years
Cycles (x10^9)
Duration of Applied Load
24
360
20
9.953
Stress Range (MPa)
1.2
Connection Type (Pinned Bolted)
E LogCo
d
Log δ
m
12.5169
2
0.2509 3
Standard Allowable Cycles 599.179 (x10^9) Corrected Allowable Cycles 921686.146 (x10^9)
So 47 Ratio: 0.0%
OK
Table 4: Fatigue Analysis (BS 7608: 1993)
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GEA Grasso V-Series Reciprocating Compressor • Superior COP values at full and part load operation • High reliability and high quality wear resistant parts • Modest investment and low maintenance cost • Easy to install and to package • Wide capacity range
GEA Refrigeration Africa (Pty) Ltd 19 Chain Avenue, Montague Gardens, 7441 PO Box 36815, Chempet, 7442, South Africa Tel. + 27 21 551 4034, Fax + 27 21 551 4035 industrial@gea.com, www.grasso.co.za
engineering for a better world
GEA Refrigeration Technologies
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New half page V ad 2013 Grasso.indd 1
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MARKET FORUM
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MARKET FORUM
Bosch Rexroth’s new external gear pump, Silence Plus
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Three WEG regenerative drives
The new blue WEG electric motor
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Our Most Efficient Low Dewpoint Dedicated Outdoor Air Systems Just Got More Efficient Introducing the DryCool™ Standard
Outdoor Air System (DOAS) can provide the
HCU and DryCool ERV Systems
recommended ASHRAE 62.1 outdoor air at
with digital scroll technology. When
dewpoints so dry it will handle the entire latent
™
cooling a space, you deliver air colder than the
load, while at the same time using less energy than
desired space temperature. Likewise to dehumidify
a standard cool/reheat unit. Now with the addition
a space, you deliver air dryer than the required
of digital scroll technology, we have made the best
space dewpoint. A single Munters Dedicated
system even better.
Contact Munters so we can show you how to let your space sensible device control what it controls best, space dry bulb and let Munters equipment control what it controls best, space moisture. Contact your local representative to determine savings in your geographical region.
Munters (Pty) Ltd Tel: +27 11 997 2000 • E-mail: info@munters.co.za Web: www.munters.co.za • 0860 MUNTERS THE SOUTH AFRICAN MECHANICAL ENGINEER
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Excellent Minerals Solutions
WARMAN® Centrifugal Slurry Pumps ENVIROTECH® Centrifugal Slurry Pumps ISOGATE® Slurry Valves Lower your operational costs with the Weir Minerals Solution In slurry and dewatering pumping, processing and control applications where the cost of ownership often outweighs capital cost as a priority, we help our customers address such issues as longevity, capacity, efficiency of operation and maintenance. Warman® slurry and Envirotech® dewatering pumps are among the world’s most comprehensive range of pumps for use in mining, chemical and industrial applications. These pumps are designed for ultra heavy duty applications such as mill discharge, process plant and tailings, high pressure pipelines, as well as other speciality applications.
Expertise where it counts
Robust design and rugged heavy-duty construction, the Isogate® slurry knife gate valve is designed for long life and high reliability. The Isogate® valve range now also includes Autoball™ 3 way check valves, swing check valves, and a diverse range of mechanical and pneumatic pinch valves. Copyright ©2012, Weir Minerals Africa (Pty) Ltd. All rights reserved. WARMAN is a registered trademark of Weir Minerals Australia Ltd and Weir Group African IP Ltd; ISOGATE is a registered trademark of Weir do Brasil Ltda; AUTOBALL is a trademark of Weir Minerals Australia Ltd.
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For more information contact us on: +27 (0)11 9292600 www.weirminerals.com