2015/08 - Bullk Handling Today

T O D A Y

BULK

HANDLING

Endorsed by: CMA l LEEASA l SAIMechE l SAIMH l

August 2015

FIRE SUPPRESSION ON CONVEYOR BELTS SYNAPSE RISK ENGINEERING 1

BULK HANDLING TODAY

February 2012

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positiv/graffictraffic/BHT/Aug15

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BULK

HANDLING

BULK HANDLING TODAY

T O D A Y

August 2015

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The South African Institute of Materials Handling

Sample

The South African Institute of Materials Handling (SAIMH) is a Non-Profit organisation set up with an objective to encourage the transfer of knowledge associated within the fields of Bulk Materials Handling (conveyors, stacker, reclaimers, tipplers, train loading systems, etc.) through a combination of seminars and networking sessions.

The SAIMH is made up of professional engineers, each practising their trade in a variety of organisations who volunteer their time to execute the SAIMH’s objective. The main aim is thus to promote the advancement of the art, science, theory and practice of the Bulk Materials Handling principles and techniques.

Company Affliates as at August 2015 Afripp Projects cc Brelko Conveyor Products (Pty) Ltd Bulkcon CPM Engineering CT Systems cc Conveyor Watch (Pty) Ltd David Brown Gear lndustries (Pty) Ltd ELB Engineering Services (Pty) Ltd Engicon Systems (Pty) Ltd Facet Engineering cc Flexco (SA) (Pty) Ltd

Hagglunds Drives SA (Pty) Ltd Hansen Transmissions SA (Pty) Ltd Hatch Goba (Pty) Ltd lllustech J & A Engineering Services Kimrae Engineering Prolects Loadtech Load Cells (Pty) Ltd MacsteelVRN Martin Engineering Melco Conveyor Equipment Morris Material Handling SA (Pty) Ltd

Osborn Engineered Products (Pty)Ltd PD Engineering Services cc PH Projects Holdings (Pty) Ltd Rio Carb (Pty) Ltd Sandvik Materials Handling Africa Screw Conveyors & Material Handling Senet SEW Eurodrive Spar Western Cape SSAB South Africa (Pty) Ltd Tenova Zest Electric Motors (Pty) Ltd

Tel: (011) 867-0902 l Fax: (011) 867-0036 l Email: saimh@global.co.za l www.saimh.co.za

Simon Curry

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Canada case study With a network spanning across the globe wherever mining activities take place, Tega Industries globally is working with an increasing number of mining companies to optimise processes and find solutions to minimise wear-andtear on valuable processing equipment.

The most recent success story involved a large Canadian diamond mine that was experiencing regular shut downs (every two weeks) due to punctured chutes. A technical team from Tega Industries was dispatched to the site where they undertook DEM analysis

and various work studies to find that the entry and exit velocities of ore were higher than called for in the initial design.

In addition, the material entering the chute was found to be highly abrasive and as a result the materials were causing severe damage to all the existing chutes. In order to overcome the problem, Tega Industries specialists redesigned the chute with appropriate angles and supplied liners to reduce velocities and deal with the abrasive materials.

As a result, the stoppages ceased and production outputs have dramatically improved. The mine has subsequently ordered 14 more chutes and as a result of the positive feedback, Tega Industries subsequently received an order for five similar chutes from a neighbouring copper mine. A further nine mines across the globe are working with Tega Industries to investigate the feasibility of implementing similar solutions based on the feedback and success of the installation on the Canadian diamond mine.

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LIFTING EQUIPMENT ENGINEERING ASSOCIATION OF SA

LEEASA, formed in 2003, is a division of the Chamber of Engineering Technology (COET), a non-profit organisation. The association’s objectives include, but are not limited to: the transfer of knowledge and training within the field of the Lifting Industry, to improve safety, promote the use of standards and to promote Professional and Ethical practices.

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t is represented on the Engineering Council of South Africa (ECSA) and a number of ECSA committees as well as on various task teams at the South African Bureau of Standards (SABS).

What’s in it for you:

As an Individual member who is registered as a Lifting Machinery Inspector (LMI), you may qualify for any concessionary fee granted by ECSA (this could save you over R1 000 a year).

ECSA registered COET / LEEASA members are awarded one Continuing Professional Development (CPD) credit in category

3 each year. CPD is an ECSA requirement to retain registration.

Members obtain a discount on training and seminars validated by the association, especially useful in earning ECSA CPD credits.

Members benefit from the collective power of a recognised and established association and collective co-ordination in dealing with authorities in policy making and matters concerning the industry.

LEEASA has some 500 members (Individuals and Companies).

Tel/Fax: (011) 787-1302, Email: engineer@netactive.co.za, www.leeasa.mirrorz.com BULK HANDLING TODAY

February 2012

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John MacDonald, Service, Sales and Marketing Director of Konecranes Southern Africa

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conveying excellence

Two giant ship-to-shore (STS) cranes arriving in Beira, Mozambique, for Cornelder de Moรงambique (CdM). They have an outreach of 40m and a lifting capacity of 65t under spreader.

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This large scalping screen will handle variable ore conditions with a continuous feed load of 6 000 tph

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One of the largest scalping screens ever produced to date

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Aury Africa managing director, Mark Houchin

CS cone crusher

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EVOLVED

INTELLIGENT CONVEYING

Easy Rolling, Longer Lasting Steel Rollers F^`Zkhee^kÃl g^p% iZm^gm i^g]bg` Lm^^e Khee^kl Zk^ ]^lb`g^] mh ^glnk^ Z\\nkZm^ [^Zkbg` Zeb`gf^gm mh ]^ebo^k ^Zlb^k kheebg`% ^gaZg\^] ^_Ë \b^g\r Zg] e^ll ghbl^ iheenmbhg' Ma^l^ khee^kl h__^k fZgr h_ ma^ [^g^Ë ml h_ ma^ F^`Zkhee^k A=I> Zg] Ar[kb] khee^kl' Innovative Technologies Mechanically Fixed Bearing Housing Gh p^e]bg` h_ ma^ ahnlbg` mh ma^ khee^k [h]r' Mabl ^glnk^l lni^kbhk [^Zkbg` Zeb`gf^gm mh ]^ebo^k Z fhk^ ^_Ë \b^gm% jnb^m^k Zg] ehg`^k eZlmbg` khee^k'

“superior bearing alignment”

Cost Effective and Long Lasting

Megaroller Steel Roller Specs

More accurately aligned bearings means less stress on the bearing operation resulting in longer bearing life. The Megaroller Steel Roller’s easier rolling bearings also produce less friction and less noise.

Roller Options ;b&]bk^\mbhgZe khee^kl :gmb&Kng ;Z\d Khee^kl for incline belts

Main Benefits

Revolutionary design concept for steel rollers ;^mm^k [^Zkbg` Zeb`gf^gm >Zlb^k% lfhhma^k kheebg` Ehg`^k eb_^liZg Jnb^m^k hi^kZmbhg <Zg hi^kZm^ Zm ab`a^k li^^]l

Fhk^ ^g^k`r ^_Ë \b^gm ]n^ mh ^Zlb^k rolling bearings K^]n\mbhg bg mhmZe \hlm h_ hpg^klabi compared to traditional steel rollers Ehp^k fZbgm^gZg\^ \hlml >qm^g]^] [^Zkbg` eb_^liZg ;^mm^k k^mnkg hg bgo^lmf^gm

Available diameters *+0ff *.+ff Available Shaft Options +. L^kb^l hg *+0ff ,) L^kb^l hg *+0ff *.+ff Gauge Length Range *1)ff mh *2*1ff Shaft material Options Fbe] Lm^^e LmZbge^ll Lm^^e

Our leading products

HDPE Rollers

Hybrid Rollers

Impact Rollers

Steering Frames

F^`Zkhee^k A=I> Khee^kl are an innovation in reinforced high-density iher^mare^g^ !A=I>" conveyor rollers.

Megaroller Hybrid Rollers are unique combination steel / high-density iher^mare^g^ !A=I>" conveyor rollers.

Megaroller’s Impact and Rubber Disc Return Rollers absorb the impact of large loads of ore falling onto conveyor belts to prevent damage.

Megaroller’s unique Multisteer conveyor belt steering frames are the key to effective conveyor belt management.

CONTACT US: www.megarollerindustries.com | info@megaroller.co.za | +27(0)12 250 2365

Standard Shaft Variations Hi^g&^g]^] <ehl^]&^g]^] <nlmhf laZ_ml Ë gblabg` hg k^jn^lm' ;^Zkbg`l Zl i^k \nlmhf^k li^\bË \Zmbhgl'

World leader in conveyor idlers

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Danie Gerber, recently took over the reigns as CEO of MB Plant SA

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AFRICA’S PREMIER CONSTRUCTION AND MINING TRADE FAIR

OR CE F NS! TRANSTRATIO N E I FREEINE REG /en/ ONL a.comion c i r f trat .bca wwwors/regis visit

International Trade Fair for Construction Machinery, Building Material Machines, Mining Machines and Construction Vehicles.

WWW.BCAFRICA.COM

MMI/BCA/Quirk/CEN

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BULK HANDLING TODAY

August 2015

Cherry-picking Ronald Erasmus, managing director of Eqstra Heavy Equipment

Karen van Diggelen, Eqstra Industrial Equipment general manager for marketing and communications

Link-Belt mobile crane

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Terex dump truck

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Figure 1. Collapsed bearing

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Figure 2. Pulley shaft

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FCB CAPE TOWN 10008448CT/E

Keeping Africa running smoothly.

Engen is committed to an African success story. In Africa, industries operate under extreme conditions different from any other place in the world. Thatâ&#x20AC;&#x2122;s why we do more to develop our tailor-made range of lubricants. We use top-of-the-line technology and only the best ingredients. The result is an advanced technology product that meets industry requirements and reliability expectations. And our dedicated team on the ground ensures that you have access to what you need when you need it.

Contact the Engen Customer Service Centre (CSC): +27 21 403 5090 or visit www.engenoil.com.

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10008448CT Engen_Africa Print Ad_Bulk Handling Today_176x130E.indd 1

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August 2015

2015/02/12 2:08 PM

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Tough demands have met their match.

With a hydraulic drive system from H채gglunds, you get compact, durable power - without foundations or gearbox. A full range of rugged motor types and complete solutions for monitoring and control give you total assurance, even in the most demanding applications.

Let us know your demands.

H채gglunds Drives South Africa (Pty) Ltd P.O.Box 2851, 1610 Edenvale, Johannesburg Phone: + 27 (0)11 454 4933, Fax: +27 (0)11 454 5088 E-mail: info@za.hagglunds.com, www.hagglunds.com

Our drive is your performance.

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Simon van Wyk

• Consequence • Likelihood

Inherent vs.

Residual • Comparative Analysis • Treatment Options

Risk Identification

• Monte Carlo Analysis • Tornado Graphs

Probalistic Analysis

• Heatmaps • Risk Profiles • Risk Ratios

Profiling

Contingency • Level of uncertainty P90/P80 • Finanacial contingency value

Hazard • Conceptual stage Study 1 Hazard • Design Options Study 2 Hazard • Detailed Design/ Construction Study 3 Hazard Study 4

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Table 1: Guiding Questions THEME Establish the client’s expectations

Establish the client’s level of risk maturity

Connection between ‘what is needed’ and ‘what adds genuine value’

Fill in the gaps to achieve best practice levels

QUESTIONS NOTES Has the client provided a Scope of Works The SoW would have typically formed part of the tender (SoW) statement? notification, request for quotation or as a direct statement by means of a letter.

Have you had a meeting face to face with The is over and above what is stated in the SoW. Often clients the client to ask “what do you want or need”? put forth a SoW but when delivering in accordance with the SoW they indicate it is not what they actually wanted.

Have the project objectives been clearly This is a fundamental set of information that forms the fabric of documented viz. crystal clear? the risk identification and management as it is inextricably linked to potential risks that may impede the success of a project.

Are the objectives, if set, Specific, Measurable, It is critical that project objectives are realistic and talk to the Achievable, Realistic and Timeous (SMART)? heart of the project’s success. As such, this should be verified to ensure risk management services are focused to add value in this space.

Does the client (project team) demonstrate a This will become evident if a risk policy, framework, manual sound level of risk management understanding? and/or procedures apply e.g. some clients insist on using their management system. If none of these documents are available, it may be prudent to engage the client to ascertain their respective position in terms of risk management.

Does the client/project have its own dedicated A formal position within the organisation and/or project would Risk Manager/Practitioner? suggest a level of risk ownership and contributes to risk management.

Is the client audited for compliance with Formal audits would suggest that the client is to some degree certain best practice standards e.g. ISO ’compliance driven’, which may contribute to an affinity to 9001, 14001 (in terms of ISO 19011), 55001? managing risks. By way of example, ISO 9001, 14001 and 55001 are all risk-based management systems.

Does the client manage incidents?

If a formal incident management system is in place, this data can be used to inform activity-based risks which are usually linked to contingency management or, at the very least, a form of redundancy management e.g. Emergency Response Plan.

Have you determined what the need for risk The ‘need’ is an important question to answer as it talks to the management is on the project? heart of the risk management philosophy of the client and/or project. In some instances, compliance is important whereas other clients may use risk management to drive decision making.

This understanding will aid the approach in terms of customising the risk management solution.

Have you established the ‘value add’?

A seemingly simple question, but, in reality, it is difficult to answer. Even with clients who have established Project Lifecycle Processes for various stages e.g. in engineering the Front End Loading process applies. While driven by compliance in such instances, the question remains valid, what is the value add?

The nexus of this answer talks to the philosophy that the client (project team) employs and needs careful engagement.

Have you discussed the deliverables with This questions links to the first ‘theme’ in this table but is your client/ project team? repeated here because the link between what is needed and what adds value has merit. Be sure to engage at each phase in the project so that your client is well invested in the risk management process.

Has your client/project team dictated compliance Standards are typically not ‘regulated’. However, if adopting a or alignment to specific best practice standards? certain standard(s), make sure the deliverables are provided to meet such standards. By way of example, ISO 31000:2009 sets 11 key principles and provides a generic risk management process and framework which can be applied. There are no compliance metrics, therefore the risk consultant needs to walk the client through the process and, where gaps occur, effort should be put in to realign, thereby ensuring a level of conformance or best practice. The gap will vary depending on the risk appetite.

Is your client/project team on-board?

It is important to sensitise yourself with the management style of the client/project team. Experience shows that, in certain instances, Project Managers believe they are also risk experts yet when interrogated further know little about the art of risk management. If one can establish the management ethic as it relates to risk management it will become a key attribute to decisions that the risk consultant will need to take i.e. risk management may be viewed as an overhead to ensure compliance, as opposed to adding value to project management decision making. Communication and consultation is therefore essential to ensure a common view is attained and maintained.

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Figure 2: Basic Principles for optimal risk consulting services

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MARKET FORUM

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MARKET FORUM

The new 12 cylinder stage IV / Tier 4 final diesel engine

A double girder top riding electric overhead crane

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MARKET FORUM

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MARKET FORUM

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Welcome to HBC‐radiomatic SA (PTY) Ltd From the competent consultation up to sales and services. We will find a radio Solution for you.

Unit 7 The Stewards Industrial Park C/o Main Reef & Beryl Street The Stewards Benoni Phone : +27 11 421‐0004/25 +27 10 020‐0607,0608,0609

QUADRIX

MICRON 5

Fax : +27 11 422‐2571 www.hbc‐radiomatic.co.za

HBC radiomatic SA

MICRON 7

HBC data logger

Useful information at your disposal • The HBC data logger stores different operational data of machine utilization, for example the usage time of drive functions.

• HBC user identification. Data is collected for individually users.

• Determins how long the crane was used and by which user.

• The collected data can be helpful in various situations, for example in service cases.

• The data is read out via Bluetooth® interface and visualized with HBC developed software.

DATA LOGGER