BULK HANDLING TODAY
February 2013
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BULK HANDLING TODAY
February 2013
BULK
HANDLING
T O D A Y
February 2013
Contents On the cover: BMG Tel: (031) 576-6300 www.bmgworld.net
CMA 4
From the Chairman’s Desk
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SAIMH News
Lifting
31 Removing the Guesswork 33 Upbeat Crane Industry 34 Controlling Service Records 38 Market Forum
Cover Story 6
New Backstops for Conveyors
Project Management 9
Making Mining Safer
General 11 In the Hot Seat
Endorsing Bodies
CMA (Conveyor Manufacturers Association) LEEASA (Lifting Equipment Engineering Association of South Africa)
SAIMechE (SA Institute of Mechanical Engineering)
15 Top Truck Exporter
SAIMH (SA Institute of Materials Handling)
Power Transmission
also mailed to members of the RFA (Road Freight Association)
Trucking
17 Local Scraper Winch Motor 19 VSD for Saving Power
Copyright
The monthly circulation is 4 016
All rights reserved. No editorial matter published in “Bulk Handling 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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Proprietor and Publisher: PROMECH PUBLISHING Tel: (011) 781-1401, Fax: (011) 781-1403 E-mail: bulkhandling@promech.co.za www.promech.co.za Managing Editor: Susan Custers Editor: Kowie Hamman Advertising Sales: Surita Marx DTP: Zinobia Docrat and Donovan Vadivalu Subscriptions: Please email us at accounts@promech.co.za if you wish to subscribe to “Bulk Handling Today” at R405,00 (excl postage and VAT) per year; R1 020,00 per year for Africa/Overseas. Printed by: Typo Colour Printing, Tel: (011) 402-3468 FSC (Forestry Stewardship Accreditation)
BULK HANDLING TODAY
February 2013
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CONVEYOR MANUFACTURERS ASSOCIATION
From the Chairman’s Desk 2013 is already in full flight, with training courses, events, Beltcon and so much more already mapped out for us in the year ahead – the calendar of important dates is on the CMA website and has been emailed to you all.
Simon Curry
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013 is a very special year for the CMA – we celebrate our 40th birthday, having launched in 1973 with just five members!
I am proud to have been the CMA’s Chairman for the past 10 years – the growth of the organisation can be attributed to the fact that the prime focus remains to promote the excellence of belt conveying among its member companies and the industry. This is where the true strength of the CMA emanates from and why the training courses offered are highly sought-after and command industry-wide respect.
Our current membership of 74 companies is no small achievement
Exciting events
Our current membership of 74 companies is no small achievement and I’d like to thank every member company for their valuable contribution to, and support of, this very successful Association. On 6 and 7 August, we are once again holding Beltcon – the first Beltcon was held in 1981 – another success story for our industry! This year’s conference and exhibition will be held in a larger venue due to demand. (Please note change of date – confirmed now for 6 and 7 August). I hope to see as many CMA members as possible at this year’s exciting events! Simon Curry
Membership as at Feb 2013 All members subscribe to the CMA Code of Ethics ABB Industry Actom Afripp Projects Atlanta Manufacturing Bateman Engineered Technologies Bauer Bearings International Belt Brokers Belt Reco Bibby Turboflex BMG Bonfiglioli Power Transmissions Bosworth Brelko Conveyor Products CMG Electric Motors Conveyor Watch CPI Technologies CPM Engineering CT Systems David Brown Gear Industries Delras Engineering DRA Mineral Projects DRA Mining (Pty) Ltd Dunlop Belting Products Dymot Engineering Company
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BULK HANDLING TODAY
ELB Engineering Services Facet Engineering Fenner Conveyor Belting (South Africa) Flexible Steel Lacing SA FLSmidth Roymec Hägglunds Drives South Africa Hansen Transmissions SA Hatch Africa Horne Hydraulics Hosch - Fördertechnik (SA) International Belting & Marketing Iptron Technology Joy Global (South Africa) Lesa Mining Equipment and Conveyor Belt Lorbrand M & J Engineering Martin Engineering Megaroller Melco Conveyor Equipment Moret Mining MS Conveyor Pulleys SA Nepean Conveyors OE Bearings Oriental Rubber Industries SA Osborn Engineered Products
February 2013
Pegasus Industrial Services cc PH Projects Holdings Protea Conveyors Read Swatman & Voigt Rema Tip Top South Africa Renold Crofts RSV ENCO Consulting Rula Bulk Materials Handling Sandvik Materials Handling SA Schaeffler South Africa SENET SET Agencies SEW Eurodrive Shaft Engineering Shaw Almex Africa SKF South Africa ThyssenKrupp Materials Handling Timken South Africa (Pty) Ltd Transmission Components Transvaal Rubber Company Unitek Engineers Veyance Technologies Africa Voith Turbo Zest Electric Motors
The South African Institute Of Materials Handling
SAIMH
5IF 4PVUI "GSJDBO *OTUJUVUF PG .BUFSJBMT )BOEMJOH 4"*.) JT B /PO 1SPmU PSHBOJTBUJPO TFU VQ XJUI BO PCKFDUJWF UP FODPVSBHF UIF USBOTGFS PG LOPXMFEHF BTTPDJBUFE XJUIJO UIF mFMET PG #VML .BUFSJBMT )BOEMJOH DPOWFZPST TUBDLFS SFDMBJNFST UJQQMFST USBJO MPBEJOH TZTUFNT FUD UISPVHI B DPNCJOBUJPO PG seminars and networking sessions. The SAIMH is made up of professional FOHJOFFST FBDI QSBDUJTJOH UIFJS USBEF JO B WBSJFUZ PG PSHBOJTBUJPOT XIP WPMVOUFFS UIFJS UJNF UP FYFDVUF UIF 4"*.) T PCKFDUJWF 5IF NBJO BJN JT UIVT UP QSPNPUF UIF BEWBODFNFOU PG UIF BSU TDJFODF UIFPSZ BOE QSBDUJDF of the Bulk Materials Handling principles and techniques. For the SAIMH and the industry as a whole to prosper requires the support of companies such as yours and key individuals from within your organisation who share the same passion and vision within the Bulk Materials Handling industry. The advantages of being a corporate member of the Institute are as follows: t 5P NBLF UIF JOEVTUSZ BXBSF PG UIF QSPGFTTJPOBM TUBOEBSET UIBU PVS NFNCFST QSPWJEF t 5P FODPVSBHF UIF JOUFSDIBOHF BNPOHTU NFNCFST PG UIF JOTUJUVUF PG LOPXMFEHF FYQFSJFODF SFMBUJOH UP BMM BTQFDUT PG UIF CVML NBUFSJBMT IBOEMJOH t 5P QSPNPUF FEVDBUJPO USBJOJOH UP BMM MFWFMT PG FNQMPZFFT XJUIJO UIF JOEVTUSZ 5P JOUSPEVDF BOE FODPVSBHF UIF VUJMJTBUJPO PG MFBEJOH XPSME DMBTT NBUFSJBM IBOEMJOH NFUIPET BOE UFDIOJRVFT t 5P CF BCMF UP USBOTGFS BOE PCUBJO BEEJUJPOBM LOPXMFEHF BU UIF CJ NPOUIMZ KPJOU 'PSVN MFDUVSFT t 5P CF BCMF UP DPNNVOJDBUF UISPVHI UIF NPOUIMZ PGmDJBM KPVSOBM XIJDI JT TFOU UP NFNCFS GSFF PG DIBSHF 5IFTF BSF KVTU B GFX PG UIF BEWBOUBHFT UIBU ZPV XJMM CFOFmU GSPN CZ CFJOH B DPSQPSBUF NFNCFS +VTU HJWF VT B GFX NJOVUFT PG ZPVS WBMVBCMF UJNF BOE WJFX PVS XFCTJUF XXX TBJNI DP [B PS FNBJM VT PO TBJNI!HMPCBM DP [B BOE XF will assist with your enquiry.
Company Affliates as at Jan 2013 MEMBER COMPANIES Afripp Projects cc "GSJQQ 1SPKFDUT DD Bearings lnternational (Pty) Ltd Bateman Engineered Technologies Brelko Conveyor Products (Pty) Ltd #FBSJOHT *OUFSOBUJPOBM 1UZ -UE #SFMLP $POWFZPS 1SPEVDUT 1UZ -UE Bulkcon Bulkcon CPM Engineering CPM Engineering CT Systems cc CT Systems cc Watch (Pty) Ltd Conveyor $POWFZPS 8BUDI 1UZ -UE David Brown Gear lndustries (Pty) Ltd %BWJE #SPXO (FBS *OEVTUSJFT 1UZ -UE Deebar Mining & lndustrial Supplies Deebar Mining Industrial Supplies East Rand&Engineering Services East Rand EngineeringServices Services(Pty) Ltd ELB Engineering &-# &OHJOFFSJOH 4FSWJDFT 1UZ -UE Engicon Systems (Pty) Ltd &OHJDPO 4ZTUFNT 1UZ -UE Facet Engineering cc Facet Flexco Engineering cc (SA) (Pty) Ltd GMR GMR Hydraulics Hydraulics Goba Goba Consulting Engineers Consulting Engineers (SPVQ -JOF 1SPKFDUT 1UZ -UE Group Line Projects (Pty) Ltd )BHHMVOET %SJWFT 4" 1UZ -UE Hagglunds Drives SA (Pty) Ltd )BOTFO 5SBOTNJTTJPOT 4" 1UZ -UE Hansen Transmissions SA (Pty) Ltd )BUDI "GSJDB 1UZ -UE Hatch Africa (Pty) Ltd Illustech lllustech
John King Chains (SA) (Pty) Ltd ,JNSBF &OHJOFFSJOH 1SPKFDUT Kimrae Engineering Prolects .BDTUFFM 73/ MacsteelVRN Martin Engineering Martin Melco Engineering Conveyor Equipment Melco Conveyor Equipment .PSSJT .BUFSJBMT )BOEMJOH 4" 1UZ -UE Morris Material Handling SA (Pty) Ltd 0TCPSO &OHJOFFSFE 1SPEVDUT 1UZ -UE Osborn Engineered Products PD Engineering Services cc (Pty)Ltd PD Engineering Services cc 1%/" . * 1UZ -UE PDNA M&I (Pty) Ltd 1) 1SPKFDUT )PMEJOHT 1UZ -UE PH Projects Holdings (Pty) Ltd Quadrant PHS Renold Crofts (Pty) Ltd 3FOPME $SPGUT 1UZ -UE Rio Carb (Pty) Ltd 3JP $BSC 1UZ -UE Sandvik Sandvik Materials MaterialsHandling HanldingAfrica Africa Screw Screw Conveyors Conveyors&&Material MaterialHandling Handling Senet Senet SEW SEW Eurodrive Eurodrive Shatterprufe a Div. of PG Group Pty Ltd 4IBUUFSQSVGF B %JW PG 1( (SPVQ 1UZ -UE Spar Western Cape Spar Western Cape Super Super Dock Dock Systems Systems Tenova Unitek Engineering Unitek Engineering ;FTU &MFDUSJD .PUPST 1UZ -UE Zest Electric Motors (Pty) Ltd
UPCOMING UPCOMING MEETINGS EVENTS SAIMH SAIMH Golf Day Golf Day
11 October 2012
10 October 2013 ERPM Golf Club
ERPM Golf Club
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February 2013
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COVER STORY
New Backstops for Conveyors Carlo Beukes of BMG Power Transmission Products
A backstop clutch-device is a safety critical component required by law to be fitted onto all conveyor belt systems in South Africa to prevent run-back or run-on of the belt which could injure people in the vicinity of the belt.
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s most conventional backstops run in an oil-filled housing, regular maintenance is also a safety critical factor and has to be carried out on a regular basis even though it means stopping the conveyor system completely to remove and service the backstop offsite.
There is no need to bring the whole operation to a standstill just to replace the lubricant in the device This costly and cumbersome exercise is now a thing of the past with a new series of backstops from Tsubaki which are flushed and refilled with grease in situ, while the conveyor remains in full operation. “Bulk Handling Today” speaks to Carlo Beukes, power transmission product manager at BMG, the sole distributors of Tsubaki products in Sub-Saharan Africa.
Maintenance
“Of the many new features of the BS-HS series of backstop cam clutches, the maintenance aspect is probably the most significant as it not only saves
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February 2013
in terms of longer service intervals, but there is no need to bring the whole operation to a standstill just to replace the lubricant in the device,” Carlo explains. “The smaller sizes in the series, up to 135 mm shaft diameter, are completely maintenance free because they’re pre-greased at the factory, requiring no further lubrication maintenance afterwards. “On the larger sizes, up to 450mm shaft diameter, the service intervals have been extended significantly to anything between 4 000 to 8 000 hours, which is considerably less than for most other makes of backstops,” he adds. “These sizes also have drain plugs which allow for the flushing out of old grease while the belt is running. Refilling takes place in situ with a special grease developed specifically for these backstops.”
Special kit
The maintenance kit and the special grease for these backstops has been developed locally with assistance from Tsubaki engineers who came to South Africa to oversee the first backstop assembly
COVER STORY
facility in the world, outside Japan, being set up at BMG Park in Johannesburg. “The special grease in question is an EP-free lubricant to ensure that the clutch arrangement does not slip as would occur with an EP-additive grease,” explains Carlo. “As it is critical to fill the clutch with just the right amount of lubricant, the maintenance kit helps to control this aspect precisely.” BMG stocks the different sizes and torque ratings of backstops in a kit form. This flexibility allows the company to assemble a backstop for a specific application from a kit within a few hours according to very specific requirements in the different sizes and torque ratings without having to keep stock of the full range.
Compact
Although this cam-clutch closely resembles a bearing, the assembly and installation of the backstop is much more critical than a bearing. “In our special, dust-free assembly workshop each assembled unit goes through a four-hour test sequence on a test rig used solely for this purpose,” explains Carlo. “This performance test includes checking temperature, friction and any wear characteristics, ensuring topnotch assembly, and is a facility offered by no-one else in South Africa.” In addition to all these features, the new series is much more compact than other makes and even Tsubaki’s older models. “This means you can actually fit a much smaller unit for the same torque requirement than before,” Carlo elaborates. “The low maintenance requirements and the fact that our product is lubricated with grease rather than oil, makes this backstop the most cost-effective option on the market.”
The new backstop
Selection
In Carlo’s experience the biggest mistake people make when it comes to backstops is selecting the wrong product for the application. “You can’t select a backstop purely on shaft size, as people very often do,” he says in conclusion.
Each assembled unit goes through a four-hour test sequence on a test rig used solely for this purpose “We’ve come across installations where the backstop is up to 60% under the required rating for a specific application. You have to consider the product being transported on the belt, the belt’s weight, the gradient of the conveyor and many other factors in order to select the right backstop for any given situation. Ideally we need to assess each application personally, or get all the data from the site engineer before we can make the correct selection.” BMG Power Transmission Products, Carlo Beukes, Tel: (031) 576-6300, Email: carlob@bmgworld.net
The test bench in a special, dust-free assembly workshop
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PROJECT MANAGEMENT
Making Mining Safer Stored energy in a tensioned conveyor belt or a lifted load, moving machinery, working at heights, working with crushers, conveyor systems and operating in confined spaces are danger areas in any mining operation. These often lead to fatal accidents in spite of strict standards and procedures governing operations in these areas.
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o gain a glimpse into the specialised field of safety engineering in the mining industry “Bulk Handling Today” speaks to Brian P. O’Connor, senior principle engineer at Anglo American Platinum. “Safety is the most important concern in the mining industry across the world,” he begins.
“A mining operation is an extremely dangerous environment compared with general industry. We are relentless in our pursuit for zero harm to all. Learnings from incidents Brian P O’Connor, Anglo American Platinum are freely shared among the mining houses. Part of my responsibilities is to create awareness and give guidance on engineering related safety standards, procedures and best practice to all our operations to prevent people from injuring themselves and others.
Transport remains the primary agency for fatalities and injuries in the mining industry throughout the world The killers
Transport remains the primary agency for fatalities and injuries in the mining industry throughout the world. This is followed by failure to follow established isolation, lock out and safe guarding standards and procedures on machinery such as conveyors and crushers. Often stored energy is not released before work commences. The other two main agencies responsible for accidents are working at heights and carrying out tasks in confined spaces such as tanks and vessels. Incidents occur during normal operations, but the risks are increased when maintenance operations are carried out. Brian explains, “The main reason is that people are either unaware of the safety standards and procedures in place or they are aware, but don’t follow them. Short cuts lead to short lives.” Due to the volume of and access to safety-related information available today, there is a high level of networking between mining houses and general industry. There is a general willingness to learn from each other to prevent repeat accidents. “We
literally examine hundreds of mining and industrial incidents every year, but it is very rare for us to have to go back and change a standard because of the nature of a specific injury or fatality as the standard is normally comprehensive enough,” he explains. “At most, we sometimes need to add something to an existing standard in order to cover a specific safety aspect which had not formed part of the standard previously. “For example, we received information about a truck carrying large diameter pipes, (something we do on a mine) which turned into a deadly weapon when the driver braked suddenly causing one of the pipes to shoot through the cab, cutting the driver in half. Thus we added to our standard that all trucks carrying a load must have a protective solid barrier between the load-bed and the cabin.”
Exploding pumps
Similarly, safety solutions developed on the mines are shared with other industries and mining engineers across the globe. Brian was instrumental in formulating a solution for centrifugal pumps exploding on a regular basis in mines all over the world. “Although nobody had yet been reported injured, reports of incidents where centrifugal pumps had exploded were discovered. Had there been people in close proximity to the pumps, they would more than likely have been fatally injured,” explains Brian. “Further investigation revealed that there were many incidents where pumps were operated with closed suction and/or delivery valves resulting in a build-up of temperature. The resulting heat and steam created a huge pressure in the pump until it eventually exploded.” The solution to this deadly problem is fitting either a vent pipe or a bursting disk between the valve and pump. The bursting disk is rated at a pressure well below the pump’s casing pressure level and will burst first, thus negating the problem of exploding pumps.
Unexpected danger
It is often a case of the failure of management to identify and recognise risks and the potential dangers of a situation. “For example, three workers were sent into a tank to wash down a three-metre high wall of mud. A simple task which no-one considered dangerous,” explains Brian. “However, the wall of mud did not come down consistently as expected but it suddenly liquefied, killing one of the workers.” BULK HANDLING TODAY
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PROJECT MANAGEMENT
One of the primary risk areas in the mining and minerals industry is conveyor systems, especially in the areas around the drives and pulleys. “We’ve come a long way in addressing the issues around fatalities with conveyors in the mining industry,” says Brian. “Designated guarded areas are clearly identified and when any work is carried out in the guarded designated areas, full isolation and lock-out procedures must be in place. All stored energy in the belt must be released prior to any work taking place which was one of the biggest problems we experienced in the past. Knowledge, awareness, training and adherence to proper risk assessed standards and procedures are the keys to industrial safety management.”
Although nobody had yet been reported injured, reports of incidents where centrifugal pumps had exploded were discovered Prevention
Comprehensive safety management includes being preventative in terms of new equipment purchased by the mine. “We are currently in the process of procuring the first of a series of large rope shovels and being the first of its kind in platinum mining, our obligation is to ensure safety aspects are adequately addressed on these machines,” he explains.
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“Aspects we look at, for example, include ensuring that the people who clean the windows and inspect the boom and service areas on the machine have enough place to stand safely. We check if there’s a lug to attach a safety harness to and are there ways to isolate stored energy and so on. We literally go through the entire machine to uncover potential risks and will then address these issues by recommending appropriate measures be taken to mitigate the risks.”
Part of Brian’s responsibility is to disseminate engineering-related safety information to the different sections within their group of companies to create awareness. “It is important to ensure that everyone understands and recognises the risks within their area of operation. Proper risk assessed standards and procedures must be implemented and adhered to. Most importantly, we share this information with other mines and companies around the world in order to prevent typical fatalities associated with mining in general. This is one area where we definitely don’t want to re-invent the wheel!” Brian says in conclusion. Brian P O’Connor, Anglo American Platinum, Tel: (011) 373-6261, Email: brian.oconnor@angloamerican.com
GENERAL
In the Hot Seat
Heavy duty applications come with heavy duty risks, and the bigger the job, the greater the risk involved. This is certainly the case in the fields of mining and construction.
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Bulk Handling Today” chats to Grant Wilkinson, Alien Systems & Technologies (AST), about the company’s new Astex vehicle fire suppression system. “The system was developed when we looked into protection of vehicles, specifically heavy industrial plant and mining – Bell, Caterpillar, Terex and so on – both underground and above.
All you need is a fuel line to break; with all that diesel and diesel vapour just a flash would be catastrophic Catastrophic consequences
“These vehicles use turbo-charged engines which get very hot. All you need is a fuel line to break, with all that diesel and diesel vapour just a flash would be catastrophic. Factor in tyres, the remainder of the fuel in the tank, working underground…the combination would be deadly, not
only to the driver, but to staff and equipment in other areas too.” These are the critical risks that a risk manager looks at. While they don’t happen every day, it’s enough of a concern to be significant. In fact, these types of fires happen more frequently than you’d think. “Our product automatically detects fire, and includes mechanisms to extinguish it, reducing the consequences,” Grant explains. “It’s a tool for the risk manager and satisfies insurance requirements. Also, when you’re dealing with movement of products, either on conveyor belts or in vehicles, smooth work flow is critical to company performance.”
Fire management
The fully engineered systems incorporate extinguisher-filled stainless steel cylinders with pressure relief valves and flexible siphon tubes to a l l o w variable, heavy-duty mounting.
The system is specifically designed for heavy industrial plant and mining
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BULK i12 nI o# i hHANDLING s aI r i cTODAY a . c o .February ] a 2013 w w w . i h s aI r i c a.c o . ] a 0861 61 61 61
GENERAL
Features includes fire alarm panels contained in IP65 housing, engine trip functionality, optional electric or pneumatic automatic activation system, and heat sensitive devices for reliable early warning of fire. Grant explains that there are currently two methods of fire management. “Dry chemical powder offers good knockdown, which puts the fire out, but the turbocharger remains hot, so there’s still a chance of re-ignition. But now you have nothing left to put the fire out. “Our system uses AFFF foam which is the best extinguishing agent for oil or petrol fires; in fact it’s used by fire departments and other specialist agencies. The best option is water with foam, which extinguishes the fire and cools the turbo, so there’s no chance of re-ignition.” The company provides fire-wire technol- Fully engineered systems are customised to meet specific fire ogy to detect fires automatically, plus control needs a manual push-button option in the There’s still a chance of re-ignition … but now you have cab to shut the engine off. Automatic engine cutnothing left to put the fire out off can be dangerous if the driver is driving up a steep incline, for instance. “We want him to have enough time to park the vehicle and exit safely; a on the market, most of which are imported from time delay allows this,” Grant elaborates. the US or UK. “Astex is local, so we can provide a cost-saving advantage. We’re also able to offer Risk assessment When you’re looking at fleets of 200 mining or non-standard options.” construction vehicles, fire becomes a real problem. This has resulted in a number of products
Since fire hazards can be dangerously diverse, AST prefers to analyse each situation individually.
When you’re looking at fleets of 200 mining or construction vehicles, fire becomes a real problem
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GENERAL
Perhaps someone knows of an area in the vehicle prone to oil or dirt build-up which might need an extra nozzle Fire can be catastrophic
“Before we recommend a system, we do a comprehensive risk assessment, or a ‘Weighted Risk Assessment Control’,” Grant continues. “We’ll go in and involve the owner, the insurer, the vehicle supplier – anyone who may be connected. “We break down all possible risks; maybe there’s a hydraulic bay where they’re using telescopic lifting devices, perhaps someone knows of an area in the vehicle prone to oil or dirt build-up which might need an extra nozzle. We look at each compartment, along with possible consequences of fire in that area, and then implement appropriate detection and extinguishing action,” he explains. The resulting assessment pack is assigned to each vehicle for its lifetime and updated as incidents occur, giving the risk manager full documentation history. “Fire may be an unpredictable element, but that doesn’t mean we shouldn’t be prepared,” concludes Grant. Grant Wilkinson, Tel. 011 949 1157, sales@astafrica.com, www.astafrica.com
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TRUCKING
Top Truck Exporter UD Trucks Southern Africa was once again the country’s top truck exporter, claiming 23% of the market share with a total of 245 units exported into Africa during 2012. Last year, total sales in the export sector grew by a significant 32.9% to 1 065 units when compared with 2011.
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his is according to the latest combined results* released by the National Association of Automobile Manufacturers of South Africa (Naamsa), Associated Motor Holdings (AMH) and Amalgamated Automobile Distributors (AAD). *(Mercedes-Benz South Africa only reported aggregated sales data but Naamsa estimates based on historical trends and forecasting, are included here.)
Jacques Carelse
“We are very pleased with the growth in the export market during the past year, as it is evidence of the great potential still lingering in the southern African truck market,” says Jacques Carelse, managing director of UD Trucks Southern Africa. “It is by now well-known that many of Africa’s economies are consistently growing faster than those of almost any other region in the world, and with that comes aspects like increased infrastructural development which subsequently leads to a greater need for trucks.”
We are focussed on balancing the cost involved in operating a fleet Since taking on increased responsibilities for the region, UD Trucks Southern Africa has expanded its footprint to now include more than 60 dealers in the southern African region, including Botswana, Burundi, Democratic Republic of Congo, Kenya, Lesotho, Madagascar, Malawi, Mauritius, Mozam-
bique, Namibia, Rwanda, Seychelles, Swaziland, Tanzania, Uganda, Zambia and Zimbabwe. “We believe our strength lies in the fact that we are able to offer southern African fleets the support they need wherever they are in the region. In addition, we are focussed on balancing the cost involved in operating a fleet, with the products and service efficiency we offer,” says Jacques.
Marginal growth in 2013
Looking at the year-on-year performance of total truck market, sales increased slightly by 3.9% to 27 747 units. “Even though the market finished 2012 in the black, it was certainly a year filled with many challenges that placed a damper on domestic truck sales,” says Jacques. “Macroeconomic factors like the ongoing Eurozone debt crisis, lower business confidence levels (at 94.1), as well as widespread labour unrest throughout the year, saw truck sales fall around four hundred units short of industry forecasts made at the beginning of 2012. When compared with 2011, sales in the Medium Commercial Vehicle sector increased by 6% to 9 816 units, while the Heavy Commercial Vehicles sector grew by 5.1% to 4 945 units. The Extra Heavy Commercial Vehicle sector retailed 11 894 units, an increase of 1.2% compared with 2011. UD Trucks Southern Africa saw a slight drop in sales to a total of 2 992 units, mainly due to the run in and run out campaign for the new Quon EHCV range launched in March 2012. According to Jacques, total truck sales are expected to continue to grow in 2013, albeit at a low rate of around 3.78%**, to 28 114 units. “We expect the market to be down during the first six months of the year, with a recovery forecast for the latter half of 2013 due to the delayed positive effect of the re-election of President Obama in the USA and an increased local understanding of the Eurozone debt crisis,” Jacques adds. “By July, business confidence should settle down once again, if the various countrywide labour disputes are effectively addressed.” All segments are expected to grow during 2013, with MCVs forecasted to retail around 10 100 units, a 7.8% growth on 2012’s results, HCV by 6.1% to 5 250 units, EHCV by a slight 1.2% to 11 614 units, and Bus sales by 5.3% to 1 150 units. (**AMH excluded in this forecast as they do not report segment details.) Tel: (012) 564-9500, Fax: (012) 564-9532, Email: info.support@udtrucks.co.za, www.udtrucks.co.za
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POWER TRANSMISSION
Local Scraper Winch Motor A locally-manufactured 55 kW 6 pole 525 (550) Volt scraper winch motor, which has been specifically designed to meet the operating conditions in the South African mining industry, has been launched by Marthinusen & Coutts (M&C).
An illustration of the 55 kW, 6 pole, 525 V premium efficiency winch motor
T
housands of such winch motors are currently in use at local mines but procurement pressures over the years have resulted in the quality of winch motors decreasing to the point where the motor MTBF (Mean Time Between Failures) is very short for new winches and subsequent repair costs are very high. This is exacerbated because many companies have historically used low volume manufacturing techniques to produce these motors resulting in less than satisfactory quality and performance.
Richard Botton
However, M&C identified the opportunity to design and manufacture a quality, competitively-priced winch motor based on the increasing cost of electricity, the high installed base, Eskom’s demand on consumers to reduce energy consumption and the limited investment into local high volume manufacturing of these motors.
We have an intimate knowledge of what works and what doesn’t Major advantage
Designated the MAC-200 premium winch motor, the new motor was under development for 18 months with several prototypes having been built and tested. Richard Botton,
A cut-away illustration of the premium efficiency winch motor
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POWER TRANSMISSION
collaboration with mining houses we are currently undertaking plant tests to quantify the improved performance and TCO of these motors.”
Mass production
The design has been optimised to allow mass production to ensure that the product is brought to market at a competitive, acceptable price without compromising quality. Richard indicates that M&C has made a significant investment in mass production in order to meet the anticipated demand and to sustain production levels. “An investment of more than R2-million has been made in specialised equipment such as a CNC lathe machine and a CNC machine centre, and a progression tooling lamination punching facility was completed by August 2012.”
The MAC-200 winch motor offers premium performance with an output power of 55 kW, current of 78.4 A and speed of 987 rpm. Energy efficiency is 93.5 %, complying with the SANS (IEC) 60034-30 requirement for IE2 high efficiency motors. Temperature rise by resistance method is 64.1°C, which exceeds the SANS (IEC) 60034-2 requirements by 15.9°C.
Premium quality lamination steel was used for the rotor and stator of the winch motor
MD, says M&C has had wide exposure to repairing electric winch motors and improving the performance of such motors used in the South African mining industry. “We have a major advantage because we have repaired these motors for many years and thus we have an intimate knowledge of what works and what doesn’t. Repairs are undertaken at our Rustenburg facility which is the largest dedicated low voltage repair facility in Africa.
The use of South African materials and labour as far as possible “An example of where we reduced total cost of ownership (TCO) is at Anglo Coal, where in 2007 we reduced repair and purchasing costs by more than 50% over four years, and this included capital costs. Motor uptime also increased three-fold during that period.” Richard says parameters taken into consideration for local manufacture included the need to design specifically for South African operating conditions, the use of South African materials and labour as far as possible; all of which puts money back into the local economy. “The MAC-200 winch motor has been engineered with TCO in mind. We have covered all bases. The motor complies with the required specifications for all mines and there has been no compromise in terms of quality, performance or efficiency. Verified full load test results are available. In fact, in
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The lock rotor current and torque complies with the SANS (IEC) 60034-2 as well as all mining house specifications. This performance was achieved by the use of premium quality laminations for both the rotor and stator, thus reducing core losses and facilitating repair and increasing efficiency. M&C has opted for robust mechanical design, considered a necessity to cope with the harsh operating conditions underground. Material used in the design was specifically selected with operational conditions in mind. Although the material used for the frame is thicker than the industry norm, the design took into account the logistical requirements of moving the motors around underground by including practical but aesthetically pleasing lifting points on the winch motor. In addition, the frame has been strengthened to accommodate the motor being rolled on uneven terrain in development ends.
Efficiency
Premium shaft material has been used to provide the superior mechanical strength while optimised cooling circuit design has resulted in a temperature rise margin of 15.9°C to specification as well as improved motor efficiency. The motor design also incorporates an improved sealing arrangement to reduce the risk of contamination and ensure optimum performance and reliability in the high dust and moisture environments in which the motors operate. Richard Botton, Marthinusen & Coutts (Pty) Ltd, Tel: (011) 607-1700, www.mandc.co.za
POWER TRANSMISSION
VSD for Saving Power There are certain conveyor applications where conveyors run for long periods of time at reduced or empty loads. This is particularly relevant in underground mining applications where conveyors are frequently used to convey rock to underground silos, to surface or to the rock hoisting skips. The feed to these conveyors is often sporadic, providing the opportunity for running long, lightly loaded conveyors at reduced speeds, where the potential for power saving exists. The process of running conveyors at lower speeds to generate power savings is generally known as ’intelligent conveying’.
Conveyor power requirements
The power required to convey bulk material is required to overcome several resistances to motion. The resistances may be classified into five groups, namely:
¨ Bulk solid and belt flexure resistance. Where the influence of key conveyor variables on conveyor resistances include: ¨ Bulk solid properties ¨ Belt speed and sag ¨ Idler roll diameter and spacing.
Components of idler roll rotating resistance Labyrinth seal resistance drag
The labyrinth seal moment (Mlabyrinth) is proportional to the rotational velocity ( ) if it is assumed that the dynamic viscosity (ȫ) of the rotating grease remains constant. Thus
Mlabyrinth Į
Where the resistance force (Flabyrinth) per roll of diameter (D) due to the labyrinth seal is:
¨ Main resistances
FH
¨ Secondary resistances
FN
Flabyrinth = 4Mlabyrinth/D
¨ Special main resistances
Fsl
¨ Special secondary resistances
Fs2
Bearing friction
¨ Slope resistance
Fst
The total resistance FU is the sum of the resistances Where FU = FH+ FN+ Fsl+ Fs2 + Fst The absorbed power (P) is the product of the total resistance (FU) and the velocity (V). Where P = FUV
Belt conveyors main resistances
The main resistances of belt conveyors are: ¨ Idler roll rotating resistance ¨ Indentation rolling resistance
The total friction moment of each bearing (Mbrg) may be obtained by adding the no load moment (M0) and the load dependent component (M1). Thus
Mbrg = M0 + M1
According to SKF, the no load component is proportional to the product of dynamic viscosity (ȫ) and the rotational velocity ( ) to the power of two thirds. Thus
M0 Į (ȫ )2/3
And the load dependent component (M1) is independent of the rotational velocity. W Where
Fbrg = 4Mbrg/D
IIdler roll rotating resistance
T idler roll rotating resistance The ((Fidler) is a function of belt speed (V idler roll diameter (D), radial (V), lo (Pr), mean bearing diameter load (dm), and the grease temperature (Tg). Thus T
Figure 1: Components of idler roll rotating resistance
Fidler = f(V,D, Pr,dm,Tg…)
T Thus a decrease in idler roll re resistance can be expected for a decrease in belt speed for a p particular conveyor system where th idler roll diameter, radial load, the m mean bearing diameter and grease te temperature is fixed. BULK HANDLING TODAY
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POWER TRANSMISSION
o of the belt cover rubber ((KbiR), the cover indentation p parameter (Pjn), the belt w weight (Wb), the material w weight (Wm), the load distr tribution factor (Wi), and th length of the roller (Ln). the W Where ¨Tbin = KbiR x Pjn x (Wb+Wm)x Wi x Ln A And
KbiR Į log V
B Belt indentation rollin ing resistance
T belt indentation rolling The re resistance (Find) is a function of belt speed (V), idler roll diameter (D), and the
Figure 2: Typical labyrinth seal viscous drag
Belt indentation rolling resistance mechanism
normal load (Pn).
Viscoelastic deformation of the belt drag
Thus a decrease in belt indentation rolling resistance can be expected for a decrease in belt speed and the normal load for a particular conveyor system where the idler roll diameter is fixed.
Conveyor belting is a viscoelastic material which as it rolls over an idler shell, generates an asymmetric pressure distribution on the idler shell opposing the roller rotation. This is illustrated in Figure 3.
Where
Find = f(V,D, Pn)
The tension drag increase (¨Tbin) from the viscoelastic deformation of the belt cover is proportional to the viscoelastic characteristic
96 Plane Road Spartan / Kempton Park Tel: (011) 394 1830 Fax: (011) 975 6504 www.transmission.co.za
Figure gure 3: Belt indentation rolling resistance
Belt and bulk solid flexure mechanism
The belt and conveyed bulk solids flex open and then close as it moves between idler sets. This belt and bulk solid flexure generates an energy loss or a resistance to the forward motion. The bulk solid flexure sets up an outer active and inner passive stress state as the belt opens. Conversely, bulk solid flexure sets up an inner active and outer passive stress state as the belt closes. The active and passive stress planes are separated by a failure plane. This is illustrated in Figure 4.
Belt and bulk solid flexure resistance
Quality Industrial Power Transmission
The belt and bulk solid flexure resistance (Fbs) is a function of belt speed (V), belt width (B), sag ratio (S), idler roll spacing (ac), bulk density (ȡ), and the internal friction of the bulk solids (Øi). Where
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Fbs = f(V, B, S, ac, ȡ, Øi.)
POWER TRANSMISSION
Figure 4: Belt and solid flexure resistance
Figure 5: Distribution of motion resistances for a short conveyor
Thus a decrease in belt and solid flexure resistance can be expected with a decrease in belt speed for a particular conveyor system where the belt width, sag ratio, idler roll spacing, bulk density, and internal friction of bulk solid is fixed.
Distribution of motion resistances
The contribution of each motion resistances to the overall belt motion resistance varies according to Load (%)
Efficiency (%)
100%
97%
75%
97%
50%
96%
25%
94%
Table 1: Motor load versus VSD efficiency
the length of the conveyor. In short conveyors of approximately 80 m long, the secondary resistances of material acceleration, scraper, skirt, loading bed and plough drag, dominate. However in long conveyors, approximately 1 000 m long, the main resistances, such as the belt indentation rolling resistance, dominate. Thus, long conveyors provide a better opportunity for saving power. This is illustrated in Figure 5 and Figure 6.
VSDs
VSDs are the most efficient method to control the speed of induction motors. Within a VSD the normal (Eskom) supply voltage is first converted to DC. This DC voltage is smoothed by a large capacitor bank. Thereafter this DC is converted to a controlled AC voltage. Generally the method BULK HANDLING TODAY
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21
energy Energy
Swiss Confederation Federal Department of Economic Affairs FDEA State Secretariat for Economic Affairs SECO
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IEE 210x275 advert-1 11 12-paths indd 1
February 2013
2012/11/02 11:29 AM
POWER TRANSMISSION
Figure 6: Distribution of motion resistances for a long conveyor
for this is known a Pulse Width Modulation (PWM) (Figure 7). As a result, the constant 50 Hz supply voltage can be controlled, thereby controlling the speed of the motor.
ors on the levels feed a decline or incline conveyor system. The decline conveyor will either convey the ore directly to surface or feed an underground storage silo or ore pass system.
The various components in the VSD have electrical losses. A typical VSD efficiency is equal to or greater than 97%. VSD losses are of the order of 3%.
The conveyors discussed in this section are hypothetical, but based on actual installations and can be considered typical for most underground hard rock applications.
The VSD efficiency will thus remain the same for a 75% load and drop to 96% and 94% for a 50% and 25 % load.
Power saving in VSD controlled conveyor drives
In many underground hard rock mining conveyer layouts, for example, platinum mines, strike convey-
Strike and decline conveyors
This section is based on a typical platinum type operation. The mining parameters and design criteria used to quantify power savings are shown in Table 2. These parameters are in line with underground conveyor design criteria used by most South African mining houses.
Figure 7: Pulse width modulation
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Description
Units
Qty
Mining monthly capacity
t/m
135,000
Mining days per month
d/m
21
Mining daily capacity
t/d
6,429
Shifts per day
s/d
3
Mining shift capacity
t/s
2,143
No of levels
No
5
No of half levels
No
10
ROM lump size
mm
300
Strike conveyor capacity
t/h
180
Strike conveyor belt width
mm
1,200
Strike conveyor belt speed
m/s
1.5
Decline conveyor capacity
t/h
600
Decline conveyor belt width
mm
1,200
Decline conveyor belt speed
m/s
2.5
Strike conveyor belt type
fabric
Decline conveyor belt type
fabric
Decline conveyor maximum leg length m
600
Decline conveyor legs
No
3
Mining electrical cost
R/kWh 0.5
Table 2: Typical underground mining design criteria Absorbed Power Capacity (t/h)
Units
Belt Speed 0.5 m/s
Belt Speed 1.5 m/s
Empty belt kW
5
100 t/h
kW
8
15 17
180 t/h
kW
10
20
Table 3: Belt loading for capacity versus belt speed
Strike conveyor
The strike conveyor is installed on the level to convey ore from the stopes to the decline. The most likely method of feeding a strike conveyor with ROM from the stopes is by load haul dumpers (LHDs) at the strike conveyor tip point. The conveyor may have one or more tip points depending on the mining layout. In general, as the mining advances, the conveyor is extended and the tip point is moved. The most common tip point will consist of a fixed grizzly where the undersize rock feeds the strike conveyor and the oversize is broken manually or by means of a pecker. In some instances tip points have vibrating feeders. A strike conveyor with a fixed grizzly tip arrangement must theoretically remove the bucket load at the same rate at which it was dumped to avoid spillage. The strike conveyor belt width and speed is designed to match the LHD discharge rate, while the absorbed power is determined by the strike conveyor capacity. The strike conveyor will therefore need to run at maximum speed to avoid spillage even when lightly loaded. The only practical time the conveyor can operate at reduced speeds is when it is running empty.
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POWER TRANSMISSION
Reduced belt speed operation power savings
The reduction of the strike conveyor belt speed for a fixed load system introduces the potential for power saving. (Table 3). The VSD controlled strike conveyor must operate at maximum belt speed of 1.5 m/s to avoid spillage. (Operational block, Table 3). The strike conveyor shift absorbed power with VSD control is shown in Table 4. The strike conveyor operating at the design ’fixed belt speed’ of 1.5 m/s is shown in Table 5. Theoretical analysis shows that it is possible to save up to 31% in power by introducing a variable speed drive on the strike conveyors to switch the belt off when it is running empty.
The strike conveyor annual power (Past) savings by introducing a VSD control is the product of the saved power per shift (Pfbs – Pvbs), number of shifts per day (Nsd), number of strike conveyors (Nst) and the number of working days per year (Ndy). Thus
Capacity (t/h)
Belt Speed (m/s)
% Time
Time (% of 8 hours)
Ș VSD
kW
Ș motor
Ș gbox
0
0
38
3.0
0
0
0
0
0
100
1.5
48
3.8
17
0.96
0.93
0.96
75.4
300
1.5
14
1.2
20
0.96
0.94
0.96
27.7
TOTAL P vbs 103.1 Table 4: Strike conveyor absorbed power with variable belt speed
Capacity (t/h)
Belt Speed (m/s)
% Time Time (% of 8 hours)
0
1.5
38
3.0
kW
15
Ș VSD
Ș motor
Ș gbox
1
0.93
0.96
1.5
48
3.8
17
1
0.93
0.96
72.4
1.5
14
1.2
20
1
0.94
0.96
26.6
TOTAL P fbs 149.4 Table 5: Strike conveyor absorbed power for a fixed belt speed
Capacity (t/h)
Hourly Units
% Time
11
10
Low
20 to 199
36
32
Past = (149.9 – 103.1) x 3 x 10 x 252
Medium
200 to 399
38
33
Past = 353,808 kWh
Average
400 to 499
10
9
High
500 to 699
18
16
Thus the annual power money savings at 50 c per kWh is R 176,904.00
Peak
700 to 799
0
0
High Peak
800 to 900
1
<1
Table 6: Conveyor monitored shift capacities
The payback period at present value is 4.2 years.
Technical issues
¨ The introduction of a VSD allows for controlled start-ups with increased belt life and reduced risk of belt tear ¨ The VSD can be used to sense when the strike conveyor is running empty and switch the conveyor off. The signal to restart the conveyor will be provided by the LHD entering the tip area. A VSD fitted with an analogue or profibus system provides the facility to reset the empty belt load limit remotely once the strike conveyor has been extended.
50.4
100
0 to 19
Where the VSDs retrofit cost of units plus installation is R 750,000.00
kWh
300
Empty
Past = (Pfbs – Pvbs) x Nsd x Nst x Ndy
kWh
Absorbed Power Capacity (t/h)
Units
Belt Speed Belt Speed 0.5 m/s 1.5 m/s
Belt Speed 1.88 m/s
Belt Speed 2.5 m/s
Empty belt
kW
12
36
42
60
100 t/h
kW
39
63
72
87
300 t/h
kW
92
117
126
141
450 t/h
kW
133
157
166
182
600 t/h
kW
174
197
206
222
*Note: The minimum operational belt speed is set at 1.5 m/s to match the strike conveyor belt speed to avoid excessive spillage on the decline conveyor system. Table 7: Absorbed power for capacity versus belt speed
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POWER TRANSMISSION
Option 2 The strike conveyors feed an ore pass which feeds the decline conveyor at a controlled rate via a vibrating feeder. It is assumed that each ore pass has sufficient holding capacity so that the decline conveyor can be fed at the minimum rate of 300 t/h to operate the decline conveyors at optimum efficiency.
Operational times
Figure 8: Decline conveyor operational line
Decline conveyor system
Strike conveyors from each of the ten half levels feed the decline conveyors in one of the following ways:
Option 1 Direct strike conveyor feed via a transfer chute onto the decline conveyor requiring â&#x20AC;&#x2122;intelligent conveyingâ&#x20AC;&#x2122; Intelligence is applied to the decline conveyor by detecting the average height of ROM material on the belt and the belt speed. The average material height is measured between each level and the belt speed adjusted accordingly.
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Data taken from a decline conveyor system capacity study is shown in Table 6. The data was collected by taking average belt weigher readings at hourly intervals over a shift. Readings were taken over 19 shifts covering day, afternoon and night shifts. This data can be considered typical for a five level mining operation where strike conveyors feed a decline conveyor system.
Reduced belt speed operation power savings
The installation of a variable speed drive on the decline conveyor system shows that the potential exists for power saving as the power absorbed for a fixed capacity reduces as the belt speed is lowered (Table 7).
POWER TRANSMISSION
The effect of reducing the belt speed for a fixed capacity reduces the belt safety factor and increases the take up load required. The decline conveyor maximum operational line for capacity and belt speed at which the belt safety factor and take up load remains within design limits is shown in Figure 8. This is used to calculate the absorbed power in Table 7.
Capacity (t/h)
Belt Speed (m/s)
% Time*
Time (hours)
Empty Belt
0
10
0.8
100
1.5
32
300
1.5
Reduced belt speed operation power savings
450
1.88
600
2.5
16
The decline conveyor shift absorbed power with VSD control for Option 1 and Option 2 is shown in Table 8 and Table 9. The decline conveyor operating at the design fixed belt speed of 2.5 m/s is shown in Table 10. Theoretical analysis shows that it is possible to save up to 16% in power by introducing Option 1 intelligent conveying over the fixed belt speed operation. Similarly, it is possible to save up to 20% by introducing Option 2 fixed reduced load and belt speed operation over the fixed belt speed operation.
Ș VSD
Ș motor
0
0
0
0
0
2.6
63
0.96
0.92
0.96
193.2
33
2.6
117
0.97
0.95
0.96
343.9
9
0.7
166
0.97
0.96
0.96
129.9
1.3
222
0.97
0.97
0.96
319.5
kW
*See Table 6
Ș gbox
kWh
TOTAL P vbs1 986.5
Table 8: Option 1: Decline conveyor absorbed power with variable belt speed Capacity (t/h)
Belt Speed (m/s)
% Time
Time (hours)
300
1.5
100
7.1
Ș VSD
kW
117
Ș motor
0.97
0.95
Ș gbox
0.96
kWh
939.0
TOTAL P vbs2 939.0 Table 9: Option 2: Decline conveyor absorbed power with variable belt speed Capacity (t/h)
Belt Speed (m/s)
% Time*
Time (hours)
kW
Ș VSD
Ș motor
Ș gbox
1
0.78
0.96
64.1
kWh
It is possible to save up to 5% by switching the fixed belt speed off using a VSD when the belt is running empty.
E m p t y 2.5 Belt
10
0.8
60
100
2.5
32
2.6
87
1
0.92
0.96
256.1
VSD Installation returns
300
2.5
33
2.6
141
1
0.95
0.96
402.0
450
2.5
9
0.7
182
1
0.96
0.96
138.2
600
2.5
16
1.3
222
1
0.97
0.96
309.9
Option 1 The decline conveyor annual power (Past) savings by introducing intelligent conveying of Option 1 is the product of the saved power per shift (Pfbs – Pvbs1), number of shifts per day (Nsd), number of decline conveyors (Nde) and the number of working days per year (Ndy). Thus
Past = (Pfbs – Pvbs1) x Nsd x Nde x Ndy Past = (1,170.3 – 986.5) x 3 x 3 x 252
Past = 416,858 kWh Thus the annual power money savings at 50 c per kWh is R 208,429.00 Where the VSDs retrofit cost of units plus installation is R 880,000.00 The payback period at present value is 4.2 years.
Option 2 The decline conveyor annual power (Past) savings by introducing Option 2 is the product of the saved power per shift (Pfbs – Pvbs2), number of shifts per day (Nsd), number of decline conveyors (Nde) and the number of working days per year (Ndy). Thus Past = (Pfbs – Pvbs2) x Nsd x Nde x Ndy
*See Table 6
TOTAL P fbs 1,170.3
Table 10: Decline conveyor absorbed power with a fixed belt speed
Thus the annual power money savings at 50 c per kWh is R 262,294.00 Where the VSDs retrofit cost of units plus installation is R 880,000.00 The payback period at present value is 3.4 years.
Decline conveyor system switched off when the belt is running empty
The decline conveyor annual power (Past) savings by switching the decline conveyor system off when the belt is running empty is the product of the saved power per shift (Pfbs – Pempty), number of shifts per day (Nsd), number of decline conveyors (Nde) and the number of working days per year (Ndy). Thus Past = (Pfbs – Pempty) x Nsd x Nde x Ndy Past = 64.1 x 3 x 3 x 252 Past = 145,379 kWh Thus the annual power money savings at 50 c per kWh is R 72,689.00
Past = (1,170.3 – 939.0) x 3 x 3 x 252
Where the VSDs retrofit cost of units plus installation is R 880,000.00
Past = 524,588 kWh
The payback period at present value is 12.1 years. BULK HANDLING TODAY
February 2013
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POWER TRANSMISSION
Conclusion
¨ In operating a strike conveyor it is possible to save up to 31% in power by introducing a variable speed drive on the conveyor to switch the belt off when it is running empty
gated as a stand-alone entity to determine what savings are possible.
¨ There is limited opportunity to run strike conveyors at reduced speeds to save power as the belt must be run at full speed to avoid spillage irrespective of the load
Note: This paper has been condensed due to space constraints. The authors are R. Bawden of Read Swatman and Voigt, and J. van Niekerk of Zest Electric Motors and 'ULYHV 7KLV SDSHU ZDV ¿UVW SUHVHQWHG DW %HOWFRQ KHOG in Johannesburg in 2011 and copyright is vested with the IMHC. Enquiries can be made through the website; www. beltcon.org.za
¨ A strike conveyor retrofitted with a VSD can be paid back within 4.2 years in present terms
CONVEYING GUIDE
¨ In a decline conveyor system it is possible to save up to 16% in power by introducing intelligent conveying (Option 1) over the fixed belt speed operation
The CONVEYING GUIDE is aimed at the end-user and will be distributed together with the July 2013 edition of “Bulk Handling Today”. It will also be distributed at Beltcon 2013 and various seminars and conferences throughout the year. We are offering you a golden opportunity to put your product or service on the map.
¨ A decline conveyor intelligent conveying system VSDs can be paid back within 4.2 years in present terms
If you would like your product or service to feature in this definitive conveyor guide, I will be happy to provide you with further information so please do not hesitate to contact me.
¨ In a decline conveyor system it is possible to save up to 20% in power by introducing a reduced fixed load and belt speed operation (Option 2) if sufficient ore pass capacity exists between the levels and the decline. ¨ A decline conveyor fixed load and belt system conveying system VSDs can be paid back within 3.4 years in present terms
Make sure you’re in this comprehensive reference publication! Surita Marx Surita Marx
Bulk Handling Today, Tel: 011 781 1401, 083 281 5761, Email: bulkhandling@promech.co.za
¨ In a decline conveyor system it is possible to save up to 5% in power by introducing a VSD to switch the conveyor off when the belt is running empty ¨ A decline conveyor system VSD which is used to switch off the belt when it is empty can be paid back within 12.1 years in present terms ¨ Power savings achieved in practice will be lower than the theoretical savings calculated in this article as the issues of increasing belt speeds to avoid spillage (Option 1), ore pass change over times, (Option 2), start-up loads and start-up times have not been taken into account ¨ The modifications required to an existing decline conveyor installation to install VSD control to save power may be too onerous to implement ¨ Power saving is possible in new decline conveyor systems where the necessary upfront design has been done to implement VSD control to save power. However, a shift in the industry thinking to consider concepts outside the accepted norm, for instance, single flight steel cord belt, is required. ¨ Power can be saved by introducing VSD control to switch strike and decline conveyors off or run at a reduced belt speed when they are running empty. There is a risk involved in stopping an operational belt as personnel may assume that the live system is locked out. ¨ The savings realised in this article are indicative only. Each installation would have to be investiBULK HANDLING TODAY
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LIFTING
Removing the The traditional method of using pen and paper to manually record and manage safety and inspection procedures is being replaced by automated Inspection and Safety Compliance Management (ISCM) systems. Companies have thousands of pieces of equipment, ranging from rigging to fall protection. While certain equipment requires daily inspection, others need to be inspected on an annual basis and some require recertification.
K
nowing which inspection criteria to apply for each piece of equipment is a process that can easily become unmanageable. To this end, Field ID is a compliance solution that combines electronic identification, inspection and reporting to solve the problems associated with inspection and safety compliance management. Increasing accuracy and safety, it also saves time and money while removing the “guesswork” from compliance management.
Knowing which inspection criteria to apply for each piece of equipment is a process that can easily become unmanageable Crucial to industry
Anchor Testing & Rigging Services (TRS), a subsidiary of the Anchor Group, the sole distributor of Field ID locally, recently introduced the system to the African market. “It is vital for our clients and the rest of the market to realise how critical it is to ensure that the correct health and safety measures are in place. I hope that by making this offering
available, we are able to educate and motivate the industry to replace their outdated security and filing systems,” says Johan Kruger, Anchor TRS MD. In use by Rolls-Royce, Rio Tinto and Goodrich, Field ID has also been implemented at a large internationally-operating engineering company based in Cape Town. Their old paper-based inspection registers and product certificates have been replaced by an internet accessed system allowing safety officers to identify and track all safety critical equipment and to view the scheduling and outcome online. Inspections are completed using handheld devices which indicate the exact standard to apply while guiding the user through the process. Certificates are uploaded directly to the company’s online register for immediate viewing. Simultaneously the software will notify the safety officer when future inspections are due, ensuring compliance with the Occupational Health and Safety Act.
Up-to-date
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and can now be used on iPads and iPhones. Soon we will also provide Field ID on Android smart phones and tablets,” says Jesse Kohl, digital marketing manager at Field ID.
It saves time and money while removing the “guesswork” from compliance management Main features and benefits: No inspection and audit paperwork Chance for human error removed Quick identification and timesaving Web and mobile access to safety reports at any time Daily backups Real-time visibility into safety Automated notifications “All our TRS staff members have undergone Field ID training and are equipped to assist clients with upgrading to, and maintaining electronic ISCM systems,” Johan concludes. Anchor Testing & Rigging Services (TRS), Johan Kruger, Tel: (021) 531-9290, www.anchor-trs.com DRAFTFCB CAPE TOWN 10000341CT/E
Anchor Testing & Rigging Services coordinated a testing and rigging project in Angola aboard the Ocean Confidence, one of the five largest semi-submersible offshore drilling rigs in the world
The technologically-advanced grease range that saves you money in the long haul.
Whatever industry you’re in, you’ll find an Engen guaranteed-quality product to suit your greasing requirements. For more information, don’t hesitate to contact your Engen representative, give us a call on +27 21 403 5090 or visit www.engenoil.com
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Upbeat Crane Industry
The number of cranes owned by the world’s 50 largest crane rental companies (the IC50) has remained almost unchanged over the last four years, despite hostile economic conditions. This finding is just one of numerous conclusions drawn from the new World Crane Report, an Executive Report published by KHL Group.
T Chris Sleight
his World Crane Report is the most comprehensive study ever prepared into the global crane sector. It is broadly split into two sections, one focussing on crane manufacturers, which examines their financial performance, stock market performance and standing within the wider construction equipment industry. This draws on unique studies by International Cranes & Specialized Transport, such as the ICM 20 league table of crane manufacturers and the IC Share Index.
The second section looks at crane owners worldwide, drawing on ten years of data from International Cranes & Specialized Transport’s IC50 ranking.
Companies in the IC50 have adopted a policy of replacing smaller cranes with higher capacity units Since 2008, numbers have ranged from 21 467 to 22 002 cranes. Prior to that there was a period of steep growth in the global fleet, from a low point of 15 540 units in 2004.
The world’s 50 largest crane owning companies had a fleet of 21 896 cranes in 2012, with a total lifting capacity of some 4.98 million tonnes. The fleet is dominated by mobile wheeled cranes, with a split of 78:22, mobiles to crawlers in unit terms. Although crane numbers have remained flat since 2008, the total lifting capacity of the fleet has continued to climb. At 4.98 million tonnes in 2012, it was 47% higher than 2008 and more than 200% greater than the level seen in 2003. The growth in capacity over the last four years taken with flat crane numbers implies that companies in the IC50 have adopted a policy of replacing smaller cranes with higher capacity units. The average lifting capacity of an IC50 crane was 227 tonnes in 2012, compared with 158 tonnes in 2008 and 93 tonnes in 2003. World Crane Report author, Chris Sleight says, “It is striking that in the most difficult economic conditions experienced for the last 60 years or more, the world’s largest crane owners have not only maintained their fleet sizes, but also invested heavily in increasing lifting capacity. This indicates a robust health at the top end of the global crane rental industry.” KHL Group, Chris Sleight, Tel: (018) 927-86205 Email: chris.sleight@khl.com, www.khl.com
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Controlling Service Records The De Hoop Dam crane can lift 15 tonne 72 metres
Keeping record of the services, inspections and load tests of each and every crane as required by law, can be a nuisance. Imagine you no longer have to worry about missing an inspection or a load test because the supplier not only notifies you in good time, but undertakes all the necessary work for you on site?
T
his unique service is now offered to all FB Crane Builder’s clients, director Matthew Best tells “Bulk Handling Today”. “Having founded the company twenty years ago on a service and maintenance base, we certainly know the importance of providing a professional service in terms of maintenance, inspections and load
On the system, each entry for each item is accompanied by a digital photograph, details about type, model and make accompanied by the full maintenance history to date testing, aspects which are often neglected by the end users,” he says. “To differentiate ourselves in this respect we embarked on a project a year ago to systematically capture all our customer’s crane data on a database in order to keep track of their lifting equipment, in our book a critical aspect to keep their business going.
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Database
“On the system, each entry for each item is accompanied by a digital photograph, details about type, model and make accompanied by the full maintenance history to date. Now, when we get a call from a customer regarding a broken rope on crane X, for example, we immediately know what make crane it is, that it takes a 16 mm thick rope and is fitted with 16 metres of rope. Turn-around time for the right replacement rope, or any other part for that matter, is thus dramatically reduced because our technician will arrive on site with the right stuff in the first place.” Matthew admits that capturing all the data was no easy task, but the time and expense has been justified with customers exceedingly happy with FB’s prompt and efficient service. “We now have no fewer than 2 800 cranes from customers across South Africa and as far afield as the Congo on our database,” he adds. “These are serviced by eleven
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service teams constantly on the road. Our technicians are trained in-house, not only for general maintenance and servicing, but also special tasks such as removing and hoisting down large motors from high beams without causing damage, things not normally taught at training institutions.”
We’ve just commissioned a customdesigned mobile test rig which is operated electrically and hydraulically for all on-site testing in order to issue the certificate there and then
Variable speed control for crane drives
Alerts
Another function of the database programme is the built-in alerts for all equipment which requires a three-monthly inspection and an annual load test. “The programme alerts us on a daily basis allowing us to prompt the customer in good time that crane X, for instance, is due for an inspection or a load test,” explains Mathew. This gives the customer time to plan around such an interruption and more importantly, makes sure he doesn’t miss an inspection due to a busy production schedule. “For the convenience of our customers we’ve just commissioned a custom-designed mobile test rig which is operated electrically and hydraulically for all on-site testing in order to issue the certificate there and then,” he adds. “The whole rig fits onto its own trailer so that any service technician can simply hook it up to his service vehicle when carrying out testing. It has a capacity to test up to thirty tonnes on a pull and a push up to twenty tonnes while rope lengths up to 15 metres can be tested on it.” Mobile test rig
A gantry leaving the workshop
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The hoist for the dam application under construction in the workshop
Manufacturing
Although FB Crane Builders originated as a repair, maintenance and service specialist, the company has since made its mark in the local lifting industry as a reputable manufacturer offering a large range of cranes branded in their own name. “The mining industry makes up a large percentage of our customer base, but we’ve built custom cranes for all sorts of applications in all industries,” Mathew explains. “We’ve just doubled our manufacturing facility to about 5 000 square metres under roof so that we can go bigger as demand dictates. All our cranes are built in the factory and fully tested before they go on site for installation where they are put through a final test.”
The company has since made its mark in the local lifting industry The company has a particularly strong design capability allowing custom solutions to be created for unusual applications. “We’ve just done a custom built crane application for an automotive manufacturer where an 80 tonne overhead crane forms part of the automated production line which runs 24 hours a day,” Mathew says. “Like most of the cranes we build today this one is also driven by a variable speed drive, reducing power requirements for the crane significantly compared with the double speed motors we used in the past.
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Projects
“Another unusual project was a crane we’ve just commissioned for the De Hoop dam,” adds Mathew. “This custom-made crane is installed on the dam wall which is 80 metres high. The height was our biggest challenge in this design, but we’ve come up with a solid design to do 15 tonnes on a 72 metre lift.”
The company has a particularly strong design capability allowing custom solutions to be created for unusual applications Matthew is not one to shy away from work and often gets involved in assisting customers with civil and structural work around a crane installation. “We can very often save customers money if they involve us early in the design of new factories and workshops,” he says in conclusion. “We know the specifications governing crane installations and combining these requirements with our up-to-date knowledge of new materials available on the market, means we can come up with an optimised design which does not require less steel and comes in at a reasonable price.”
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Mathew Best, FB Crane Builders, Tel: (011) 902-3271, Email: mathewb@fbcranes.co.za
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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Overhead crane under test in Condra’s Johannesburg factory
International quality certification and lower overall lifetime costs are helping Condra drive export sales to central Europe, North and South America, and the Middle East. During 2012, the crane manufacturer achieved GOST certification, the quality standard recognised throughout the Russian Federation and surrounding states. Compliance with these standards, together with the introduction of innova-
tive production methods to reduce overall lifetime costs, have helped secure two noteworthy Russian orders worth several million Euros during the past year. The orders, for overhead travelling cranes of up to 70-tons in capacity, were met by manufacture shared between two continents. Condra’s parent factory in South Africa tackled high technology components, while girders and several sub-assemblies were made by the Eu-
ropean subsidiary. From Canada came multiple orders for hoists up to 60 tons and overhead cranes up to 40 tons. Condra entered the Canadian market at the beginning of 2011 through an agency, the same method of sales and distribution in effect in South America and the Middle East. Condra, Marc Kleiner, Tel: (011) 776-6000, Email: sales@condra.co.za
Explosion Proof Becker Mining South Africa’s range of lifting equipment includes explosionproof type Kito electric chain hoists, designed for optimum efficiency and enhanced safety in materials handling applications in explosive atmospheres where there are various ignitable gases and vapours present. “These explosion-proof hoists are recommended to be used as authorised with the type approval by JIS C0903 for ‘electrical apparatus for explosive atmospheres in general industry’ and C0905-d2G4 which conform with ‘supplementary requirements for the construction of electrical apparatus for explosive atmospheres in general industry’,” says Rick Jacobs, Becker Mining South Africa. “Electric components of these hoists have sufficient
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strength to withstand the internal pressure indicated in JIS C0903. Other detailed specifications like gap, depth of gap and locking construction also meet required standards.” A chart in the Kito brochure makes it easy to determine the ignitability and explosion grade in each application. This is identified by establishing the dimension of the gap with the depth of 25 mm through which the internal flame is able to escape, the type of gases and vapours present and the temperature range in which the equipment has to operate. Becker Mining, George McMaster, Tel: (011) 617 6320 Email: info@za.becker-mining.com www.za-becker-mining.com
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Capturing the African Market Showing massive success with its Integrated Project Management Control System (iPMCS) in the United States and now managing more than US $50-billion in capital projects, TPG America has joined forces with TPG Africa to promote TPG iPMCS throughout Africa. iPMCS was built to manage the financials, schedules and project controls for some of the world’s largest capital programmes. As an enterprise-wide system with a single point of entry, iPMCS can maximise project control and visibility and integrates core internal systems such as SAP, Oracle and Primavera. “We plan to expand TPG America’s success to South Africa where mining and construction industries can capitalise on these system offerings. We are excited by the prospects of iPMCS after several successful meetings with leading mining companies in South Africa. TPG America will certainly be returning to meet with several other large South African companies,” says TPG Africa Ceo, Pieter Meyer. TPG Africa has also developed a unique and practical Project, Program and Project Portfolio maturity and organisational readiness assessment tool. These services
and tools are based on OPM3 and are integrated with Strategic Throughput Principles and Project Portfolio Management best practices. It assists and advises organisations on the findings of these assessments and helps determine what PPPM tools will suit them best. As part of its practical
assessment services, TPG Africa also performs project audits on mega, capital, large and medium size projects, using its own developed tools and highly qualified assessors. UMT Consulting SA, Pieter Meyer Tel: (012) 345-2521 Email: PieterM@theprojectgroup.co.za
Unique Functionality Vodacom is launching a Global Data Service Platform (GDSP) to help companies deploy and manage large, wireless Machine to Machine (M2M) projects. The new platform will be supported by an expert local team backed by Vodafone's global M2M business unit. The launch of the Vodacom GDSP is one of the ways that the company is looking to bring its scale and expertise to this fast-growing market, which is seeing an increasing number of customers using wireless M2M to enable new business opportunities and enhance customer service. This is particularly evident in areas such as smart metering, vehicle tracking, point of sales (POS) and the remote monitoring of equipment. The Vodacom GDSP platform, with its unique functionality, will provide
customers with managed connectivity for M2M smart service deployments. By using the GDSP platform, companies will be able to centrally manage and control the process of rolling out M2M devices across many countries, increasing the speed of implementation and reducing the cost, complexity and risk traditionally associated with deploying such projects. "We understand that deploying and managing large numbers of SIM cards can be very resource intensive and hence costly. The GDSP addresses this by putting the control back into the hands of our M2M customers so that they can focus on other areas of their business," says Ilze-Mari Kriek of Vodacom Business Services. Vodacom, Ilze-Mari Kriek, Tel: (011) 653-5000, www.vodacom.co.za/business
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Night Vision Tractor Three New Holland TD95D tractors have been modified by Gaborone Hoses and Fittings according to exact specifications prescribed by a mining operation in Botswana. “These robust cab tractors have been identified by the mining sector as perfectly suited for modification to efficiently handle demanding tasks on the mines,” says Peter Askew, MD of New Holland Agriculture. “These tractors have been designed by New Holland for optimum safety and reduced CO2 emissions, ensuring minimal impact on the environment.” Typical tasks of these modified tractors - predominantly acting as towing work horses on mines - include pulling trailers, skid washing bays, cable towers and high voltage connectors in the pits and around the mining lease areas. These tractors will also be used to tow telcon and reel trailers, as well as various mine plant. Gaborone Hoses and Fittings, a key New Holland Agriculture dealer in Botswana, has adapted these 4-wheel drive trac-
tors to meet exact requirements of the mine, where optimum safety standards and care for the environment are critical. Special adaptations encompass a fire protection system, night vision and anti collision sensors, a pre-programmed greasing system and a keyless start and anti-theft lock-out devices. For enhanced safety during night operation, a night vision camera and anticollision sensors have been installed. The infrared camera operates at all times giving the operator a clear rear view. The anti-collision sensor, which is enhanced by a distance indictor and close proximity warning buzzer, automatically activates when the reverse gear is engaged. When backing up the vehicle, the system clearly indicates objects on the left, right or centre of the tractor’s path. An audible alarm is easily activated or de-activated. New Holland Agriculture, Peter Askew Tel: (011) 922 2300 Email: petera@nhsa.co.za, www.nhsa.co.za
No Moving Parts Durban-based SEM has been a manufacturer of concrete pumps since 1968, and was officially acquired by Pan Mixers South Africa (PMSA) – the leading supplier of concrete brick, block and paving-making machinery and technology in Africa, in October 2011. SEM specialises in the manufacture of versatile and user-friendly concrete placer pumps that are predominantly used in underground mining applications, however SEM general manager Sarika Lutchman highlights the fact that the company's pumps have recently been commissioned at a number of dam building projects in Coffee Bay in the Eastern Cape and in Maseru, Lesotho. Due to the fact that there are no moving parts in the SEM concrete placer pump range, Sarika points out that the danger of mechanical breakdown and subsequent downtime is almost entirely eliminated. “This simple, yet robust design ensures that SEM concrete placer pumps are able to operate at maximum efficiency, even in the most challenging site conditions.” Lutchman believes that SEM sets itself
Up-close Inspection An open day was recently hosted by Osborn, to promote the addition of the KPI-JCI Vertical Shaft Impact Crusher (VSI) to its product range. Two new VSIs were on display at the company’s Elandsfontein premises, enabling customers to have an up-close inspection of these versatile 1500 and 2500 machines. Osborn has already had remarkable success with the VSI, with both machines sold before they landed in SA, reports Shane Beattie, product sales manager. They will be used at quarry sites for sand production. “Manufactured in the USA by sister company KPI-JCI, the VSI is highly efficient, has unmatched precision and proven flexibility,” he explains.
Left to right: Gaone Kgomotso (Bank Gaborone – Customer relation assistant), Elize Utting (Bank Gaborone – HOD business banking), Moshe Modiakgotlhe (Section Engineer) and Luis Santana (GHF – MD)
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KPI-JCI (which was formed by the amalgamation of long-time industry leaders Kolberg-Pioneer Inc. and Johnson Crushers International Inc), Osborn Engineered Products, Telsmith, Breaker Technology (BTi) and Astec Mobile Screens are members of the Astec Aggregate and Mining Group of companies (AAMG). Osborn Engineered Products, Shane Beattie Tel: (011) 820-7600, www.osborn.co.za
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Preventing Downtime NewElec’s OLR 8 and UCR 80 motor protection relays are single-purpose relays designed to monitor overcurrent and undercurrent respectively. These relays measure one phase of the main circuit to provide running stall and load loss protection for selected applications.
Sem 250 concrete placer pump in operation on a dam wall project in Umtata
apart from the competition due to the fact that most other manufacturers supply piston pumps, which are considerably larger and more expensive than the SEM range. "The capital cost of the SEM range of air-operated concrete placer pumps is up to 90 percent less than that of a
similar piston-driven pump, thereby proving the user with significant overhead savings,” she concludes. PMSA, Quintin Booysen, Tel: 086 100 7672 Email: quintin@panmixers.co.za Web: www.pmsa.com
Local Flavour With over 60 years of operational expertise and experience, Veyance Technologies Africa is driving the development of innovative belting products by producing belting solutions that are based on local customers’ needs and expectations. The exclusive manufacturer and marketer of Goodyear Engineered Products, Veyance Technologies’ production plant in Uitenhage is one of a few belt manufacturing facilities that uses an automated Dynamic Individual Steel Cord Tensioning system. This facility utilises Lean methodologies to produce Steel Cord (Flexsteel), Fabric (Plylon and Conquest) and PVC (Coal-Flo) conveyor belting products. “The Lean production practice focusses on increasing productivity, decreasing
waste, and reducing total manufacturing costs, without compromising on quality, to produce products based on the customers’ requirements,” says Paul van Zyl, marketing manager, Veyance Technologies Africa. One of Veyance’s innovations is the adhesion levels of its Flexsteel belts, manufactured in Uitenhage and used in the production of overland and long incline conveyor belting products in the South African mining industry. This unique product leads to extended belt and splice life, which ultimately reduces the cost of the belt in the long run. Goodyear Engineered Products, Paul van Zyl Tel: (011) 248-9337 Email: paul_vanzyl@veyance.co.za www.goodyearep.co.za
The OLR 8 Series prevents costly downtime due to impact torque conditions that result in broken conveyor belts, snapped chains, coupling failures, or even broken gearboxes. In some instances and with careful adjustments, the relay has been used to prevent crane overloading. The relay is equipped with one main trip changeover contact and one instantaneous conditional changeover contact. It can be used in conjunction with any current range as an alarm / trip or current regulating unit. NewElec, Luc Dutrieux, Tel: (012) 327-1729 Email: sales@newelec.co.za, www.newelec.co.za
Book now for April 2013
Power Transmission Lifting equipment Underground mining equipment Earthmoving and plant hire
Contact Surita Marx Tel (011) 781-1401, Fax: (011) 781-1403 or E-mail: bulkhandling@promech.co.za to book your advertising space
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Virtual Training The first Cat simulator introduced locally by Barloworld Equipment’s Operator Training Academy was a dedicated Version I unit designed for the new M-Series motor grader line-up launched some three years ago. At the time, the M-Series marked a new technological breakthrough as the first grader models in industry to be wholly operated by joystick controls, setting a new standard for ergonomic performance.
Following favourable industry response to this initial virtual trainer, the Operator Training Academy is now introducing five additional simulator models, which will cater for a much broader machine spectrum. Including M-Series graders, this latest generation Version II simulator product line will cover small wheel loaders; large wheel loaders; large mining trucks; track-type tractors (based on the Cat D8 model, but applicable up to and including the top of the range Cat D11T, covering both construction and mining applications); and medium sized hydraulic excavators (based on the Cat 330 model). Featuring the very latest technology, they are designed to make the training experience as realistic as possible. Examples include a ‘motion’ sensor tracking device, which is worn on the operator’s head. Barloworld Equipment, Alastair Currie Tel: 011-929-0000 Email: acurrie@barloworld-equipment.com
The Cat M-Series grader simulator
Arresting Damage A safety product designed and manufactured in South Africa has prevented costly structural damage after two conveyor belt breakages at Potash Corporation of Saskatchewan (PCS) in Canada. When the breaks occurred, the potentially damaging fall of gravity take-up (GTU) conveyor counterweights was successfully halted by Technogrid counterweight arrestors installed for this eventuality.
Technogrid is a strain energy absorption device which absorbs the kinetic or potential energy of a moving object by deforming a metal grid of known design and characteristics through a stroke deformation of predicted value.
The product is particularly cost effective in arresting the fall of GTU conveyor counterweights, simple mechanical devices comprising suspended counterweights that maintain tension in the PCS decided to install the belts by moving up or down Technogrids on its raw according to load. potash conveyor belts Horne Group, André du Preez when expansion of its op- Tel: (011) 974-1004 erations in Saskatchewan Email: andre@horne-group.com and New Brunswick began more than ten years ago. Close-up of yellow Technogrids and catch-frame, viewed from below the installation
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More Cranes Konecranes Southern Africa has secured a R13m contract for a variety of different cranes, ranging from 10 to 100 tons, from Sonils Oil & Gas in Angola. This brings to a total of 122 cranes that have been supplied by Konecranes to Sonils Luanda’s port facility so far. As one of Konecranes major clients in southern Africa, the most recent additions will be ten overhead cranes, including a 100 ton overhead crane, twenty 5 ton
Industrial Reservoirs Rainbow Reservoirs, the Polokwane-based distributor of steel panel water storage vessels, has extended its product offering to include very high volume tanks. Designs for dry bulk storage are included in the extended product offering, made possible by an agreement with CST Industries, a United States-based manufacturer of coated tanks and aluminium
overhead cranes and Jib cranes. Delivery of the cranes is set for early 2013. Late last year Konecranes also delivered ten Konecranes rubber-tired gantry (RTG) cranes to Ports and Cargo Handling Services (PCHS) Ltd in Lagos, Nigeria. PCHS, the port operations arm of Nigerian Sifax Group, is a major player in port operations and related services on the West African coast. Delivered to the company’s terminal
tank covers. Rainbow’s current range of panel reservoirs has a maximum storage volume of 1,3 million litres. By contrast, CST Industries routinely installs tanks with storage volumes in excess of 20 million litres. Markets served include potable water, wastewater, industrial liquids, bioenergy, dry bulk, petroleum, power generation, fire protection and agriculture. The CST product is differentiated by the type of panel used to build the reservoir. There are two variations: Vitrium, which is a fusion of glass
in Tin Can Island Port on schedule, the RTG cranes are equipped with the new Konecranes cabin offering improved ergonomics and visibility. “With the delivery of 10 RTGs to Sifax, Konecranes now has 32 RTGs in operation in West Africa”, says John Macdonald, sales & marketing director of Konecranes Southern Africa. Konecranes Tel: (011) 864-2800 Web: www.konecranes.co.za
and steel, and OptiBond, a steel panel powder-coated with epoxy. The agreement with CST will enable Rainbow Reservoirs to move for the first time beyond its traditional cylindrical vessels into the rectangular tank format. This will allow tenders on reservoirs limited by space constraints, such as construction projects requiring the accommodation of support columns. Rainbow Reservoirs, Wayne Thompson Tel: (015) 297-7640 E-mail: skywater@mweb.co.za
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Complete Coal Processing
The FLSmidth circular stacker reclaimer at Mafube
As a single source supplier with a full value proposition aimed at the African coal mining sector, FLSmidth is able to offer custom engineered solutions that will facilitate lower cost per ton on process plants. Recent acquisitions have seen the company close the gaps in its product suite with the result that it no longer needs to outsource requirements to external vendors. “This ability to cover the complete coal processing flow sheet allows FLSmidth to participate more fully in what is a key focus industry for us,"
Peter Lohrman, managing director of FLSmidth South Africa says. The company’s technology capability extends from bulk materials handling to coal beneficiation and covers not only the supply of capital equipment solutions, but also a comprehensive technical support through its field service teams. Theo Winterbach, engineering manager at FLSmidth Roymec, says this ability to manage equipment engineering in-house has a massive benefit for the customer as it allows the company to adapt its products to offer workable solutions.
“Servicing and maintenance of a broad range of coal equipment is vital to ensure the high levels of reliability needed in this hard-pressed sector, and our technical personnel are always available to ensure a rapid response to technical queries. In addition, our Delmas-based Supercentre will also carry a comprehensive spare parts stockholding and is on the coal sector’s doorstep,” Theo adds. Flsmidth, Terence Osborn Tel: (010) 210-4820 (PDLO PDULQGD NHUU#ÀVPLGWK FRP ZZZ ÀVPLGWK FRP
Continuous Miner South Africa’s first MC430 continuous miner was purchased from Sandvik Mining by STA Coal Mining at the Electra Mining Africa 2012 show and is already in operation underground in the Wonderfontein area of Mpumalanga. Sandvik Mining and STA Coal Mining crew ready to cut the first roadway into the high wall
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A no ther Success Tenova Takraf has replaced the Bradford crusher at Anglo American Thermal Coal's Kromdraai opencast operations north west of Witbank in Mpumalanga. Tenova Takraf’s Paul Davies says that the increased demand for rock-free coal is leading more and more companies to re-examine their production processes, with particular emphasis on the rockremoval and crushing operations. "The need to have efficient rock removal processes has led major companies to revisit the effectiveness of existing plants, to ensure that they are operating at maximum efficiency," he explains. Bradford crushers, or Bradford Breakers, are used for crushing, sizing, and de-stoning ROM feed. They are used to produce a product that is relatively coarse, with minimum fines, and 100% to size. "A Bradford Breaker is an extremely efficient machine, and is the best combined crusher/ de-stoning machine on the market" Paul adds.
installed the Bradford Breaker in a structure that had not originally been supplied by the company. This meant that expert engineering was needed to ensure that the new machine would fit. Numerous modifications had to be made during the fabrication phase and on site in order to ensure a successful replacement. The client, during the refurbishment, made repairs to the structure that supports the Bradford, and the two teams worked together closely. Despite the slight delay that the modifications entailed, the project was still completed on schedule. Tenova Mining & Minerals Tel: (011) 201-2300, Email: enquiries@bateman.com
Tenova Takraf, in record time, built and delivered the Bradford, which has an enhanced interior design unique to Tenova The new Bradford being lowered into the structure making use of Takraf. They then a heavy lift crane
Ermelo-based STA Coal Mining, an underground contract coal mining company employing more than 600 people, was established in 2006 and currently mines an average of 300 000 tons of coal per month. Sandvik Mining’s senior account manager, John Pinheiro comments that because it is heavier and more robust than other continuous miners in this category, the MC430 is a more stable machine and as with its 3.3 kV MC470 sister unit (the heaviest machine of its kind on the South African market) with which it shares 70% of its major components, its total cost of ownership is very low. “We’ve established an excellent relationship with STA Coal Mining and as part
of the full service contract supplied with the MC430, we have included a product line manager, commissioning team, contract manager and shift technicians on site,” John comments. “The new machine was exposed to some very tough conditions when it was put to work cutting the floor outside the high wall for a sump and is now cutting underground. The extremely tough conditions experienced with the stone bands and floating stone in the face are really putting the machine through its paces and demonstrating that its design and capabilities are more than equal to the task.” Sandvik Mining, Alice Ward Tel: (011) 929-5400, alice.ward@sandvik.com www.sandvik.com
Quick Delivery Times
Johannesburg-based Sizemech specialises in the manufacture of grizzly and vibrating feeders, inclined or horizontal screens, banana screens and probability sizing screens that are used by a number of internationally-recognised mining companies in numerous applications across Africa. Sizemech managing director Stephanie Steytler points out that the company's entire range of equipment is powered by external vibrators that are manufactured by OLI South Africa, which forms part of the Wamgroup , an internationallyrecognised specialist in the manufacture of screw conveyors and various other bulk material handling and processing equipment."OLI has been supplying Sizemech with external vibrators for the past eight years, and we are extremely satisfied with the quality of the motors and the related services provided by the company." She believes that the company sets itself apart from its competitors, thanks to its fast turnaround times. "Sizemech prides itself on the high standards of quality and competitive pricing of its machinery, however our delivery time is definitely what sets us apart from our competitors, as we are able to deliver a newly-built machine within four to six weeks of manufacture, compared to the industry standard of between 12 to 14 weeks. What's more, we are able to supply customers with comprehensive general assignment drawings that indicate all of the dynamic loads and sizes, within two days." Stephanie highlights the fact that all Sizemech machinery is built in-house at the company's 2 000 m² manufacturing facility in Wadeville, Germiston, which boasts two 10-ton overhead cranes and a 10 ton A-frame. "This facility enables us to carry out all types of fabrication, including; steel tanks, steel structures and steel work of up to 100 tons per month. Due to the fact that all components are assembled in-house, we are able to completely build a separation machine within two weeks." OLI South Africa, Emilie Marchand, Tel: (011) 822-2623, Email: emilie.marchand@olivibra.com www.olisouthafrica.co.za
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MARKET FORUM
Hot Commission Weba Chute Systems has installed more than 300 transfer points at various sections of Assmang’s Iron Ore Mine in the Northern Cape and the most recent 19 chutes are poised for hot commissioning as part of the WHIMS Expansion Project by the end of February 2013. The Weba Chute Systems order forms part of the greater Khumani Wet High Intensity Magnetic Separation (WHIMS) Project (KWP) that will incorporate a new WHIMS super fines beneficiation circuit and related infrastructure into the existing Parsons processing plant. The Weba Chute team was tasked with engineering chutes capable of reducing production losses related to blockages, eliminating spillage and achieving an 80% maintenance-free transfer point.
“The major application requirement on the latest Expansion Project (WHIMS) was to cater for the extreme stickiness of the material, which is prone to choking and blocking in transfer points,” Weba Chute Systems’ managing director, Mark Baller, says. “Although we have extensive experience with the type of material being handled at this operation, the application in itself presented certain challenges owing to the super fines being transferred from conveyor to conveyor. “These particle sizes range downwards from 2 mm to micron proportions and the material is very abrasive and sticky. Our design has, therefore, incorporated 20 mm high alumina ceramic engineered tiles to facilitate the necessary level of
abrasion resistance and the free flow of the sticky material.” Mark adds that one of the primary objectives during the design phase was to ensure that the angle of flow within the chute was such that it would not choke or block during material transfer. In total, 19 chutes were custom designed, each ceramic lined and taking specific installation and application factors into account. The tonnage throughput rate varies from 120 tph to 900 tph, feeding onto the receiving conveyor. Conveyor widths vary from 750 mm to 900 mm, with belt speeds between 2.24 metres/ second and 1.85 metres/second. M & J Engineering, Mark Baller Tel: (011) 827-9372, www.mjeng.co.za
Index to advertisers Afzelia
30
APC
12
Bearings International
10
Bibby Turboflex
39
BMG
Outside Front Cover
Bonfiglioli
Inside Back Cover
Conveyor & Industrial Supplies Outside Back Cover ELB Energy Cybernatics
24
Engen
32
Engineer Placements
36
Eskom
28
FAW
Weba Chute Systems has installed more than 300 transfer points at various sections of Assmang’s Iron Ore Mine in the Northern Cape
46
BULK HANDLING TODAY
February 2013
8
Inside Front Cover
Horne SA
25
IEE
22
ILS
16
Johnson Taylor
26
Linde
14
Oriole Consultants
29
Transmission Components
20
Voith
37
BULK HANDLING TODAY
February 2013
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48
BULK HANDLING TODAY
February 2013