SA Mechanical Engineer Jan/Feb 2019

S MECHANICAL A ENGINEER Jan/Feb 2019

Publication of the SA Institution of Mechanical Engineering, incorporating News of Associate Organisations

from

2

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69

January/February 2019

AN ENGINEER’S VIEW

Amazing New Shoots

T

his past year has shown me, in many ways, just how amazing people can be, but I have been particularly amazed by the enthusiasm, discipline and resulting activity happening at the youthful end of the SAIMechE membership pipeline.

At the November 2018 Council meeting, we heard about the activities of the various SAIMechE Student Chapters, and the Council was very impressed.

In the three-month reporting period, the Student Chapters arranged and hosted sixteen events involving seven tertiary education institutions and eight companies. The activities included speedmentoring, site visits, technical talks, conferences and recruitment drives. There was some social interaction as well, and one chapter arranged and hosted a sold-out dinner dance at an up-market venue, which included sponsorship from a major bank which they secured themselves.

Shortly after the Council meeting, I attended an industry advisory committee meeting at a tertiary institution, and rather than having to find my own way around the typically complex campus, I was pleasantly surprised to be greeted just inside the main gate by a group of SAIMechE Student Chapter committee members. I could hardly miss them in their matching branded golf shirts, each holding a clear sign for those attending the meeting. They guided me to a special parking space and then to the venue. I felt like the most important person on the campus!

The Student Chapter AGMs and meetings that I have been to have been professionally run and focused on the interests of the member.

Meeting protocol is generally well understood and meeting minutes Vaughan Rimbault, CEO, are concise and well prepared. I SaiMechE don’t think that anyone is teaching the Student Chapters about the finer points of professional conduct - they are figuring it out by themselves, and learning important life lessons in the process.

Standing out from the crowd

In all cases of student activity, there have been individuals who have responded to the call for service to others. A handful of students arrange all the activities and put in the hours necessary to get the job done. This is not unusual and we see this in all sorts of organisations relying on the voluntary service of members. The individuals who serve will naturally stand out from the crowd because of their commitment, dedication and effort. They may not realise it, but they are being recognised, and the effort they put in now will produce some greater benefit in the future.

Serving means meeting other people, interacting with them and doing things collectively to serve the greater good.

Getting on with the job

What a fantastic advertisement for SAIMechE from those who have only recently become members.

They were so proud to be identified with SAIMechE and to play a role in hosting guests on their campus.

They are also so keen to play a productive role in the profession, and are looking to their SAIMechE membership to help them achieve their goals.

My overall impression of the Student Chapters is that, in the main, they have been getting on with the job by themselves. They have helped each other to form and manage the chapters. They have drafted their own guidelines and procedures to be more effective in arranging their activities. They have been careful with their expenditure and have managed their budgets effectively.

I am very grateful to our Students Chapters for reminding me of one of the cornerstones of voluntary professional associations like SAIMechE. That professional and personal growth comes through service to others, with many opportunities and platforms from which to serve. Serving means meeting other people, interacting with them and doing things collectively to serve the greater good.

Serving means not feeling alone, but feeling part of a group. Thank you for reminding me of all the good reasons for being a member of SAIMechE. Vaughan Rimbault, CEO SaiMechE

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69

January/February 2019

3

S MECHANICAL A ENGINEER Jan/Feb 2019

Publication of the SA Institution of Mechanical Engineering, incorporating News of Associate Organisations

S MECHANICAL A ENGINEER January/February 2019

VOLUME 69

Contents from

On the Cover Carl Hamm Pipes Pumps Solutions Chris Munnick 072 256 0926 Email: chris@carl-hamm.co.za www.carl-hamm.co.za

Cover Story

Industry 4

8

28 Research Hub brings SA into Industry 4

A Pump Designed for Harsh Mine Conditions

Marking & Tracing

Drive Systems

11 Barcode Readers for Tobacco Company

31 Addressing White Structure Flaking

Dust Control

Training

15 Putting Ash to Good Use

32 Share the Knowlege-it’s free

Pumps & Valves

Pumps

16 Flywheel Pump Prevents Damage to Infrastructure

34 Pontoon Solution Reduces mine Downtime

Repairs

Reunion

18 Technology Makes Light Work of Sewage Pipe Replacement

37 Commemorating a Half-Century

Ports

SA Institute of Tribology

21 Emergency Helicopter Service at Cape Town

38 Improving a Turning Insert’s Lifespan

Design 22 Open Day Showcases mechanical Students Innovations

Maintenance 26 Mobilising Maintenance Trough Digitisation

Regulars 3 6 39 46

An Engineer’s View Institution News Market Forum On the Move

Copyright

All rights reserved. No editorial matter published in “SA Mechanical Engineer” 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.

Produced by: PROMECH PUBLISHING, P O Box 373, Pinegowrie, 2123, Republic of South Africa Tel: (011) 781-1401, Fax: (011) 781-1403 Email: samecheng@promech.co.za, www.promech.co.za Managing Editor Susan Custers Editorial Contributors Liesl Venter/Patricia Holburn Advertising Sales: Louise Cresswell Cell: 071 886 1263 DTP: Sanette Badenhorst Circulation: Belinda Siegruhn Subscriptions Please email us at accounts@promech.co.za if you wish to subscribe to “SA Mechanical Engineer” at R550,00 (excl postage and VAT) per year; R1 380,00 per year for Africa/ Overseas.

Disclaimer

Official Publication of THE SA INSTITUTION OF MECHANICAL ENGINEERING and endorsed by:   

      

PROMECH Publishing and The South African Institution of Mechanical Engineering as well as any other body do not take responsibility for the opinions expressed by individuals.

Printed by: Typo Colour Printing, Tel: (011) 402-3468/9 FSC (Forestry Stewardship Accreditation)

 



CONSULTING ENGINEERS OF SA CORROSION INSTITUTE OF SA INSTITUTE FOR CERTIFICATED MECHANICAL AND ELECTRICAL ENGINEERS NATIONAL SOCIETY OF BLACK ENGINEERS NUCLEAR INSTITUTE SA ASSOCIATION FOR ENERGY EFFICIENCY SA CAPITAL EQUIPMENT EXPORT COUNCIL SA INSTITUTE FOR NON-DESTRUCTIVE TESTING SA INSTITUTE OF TRIBOLOGY SA PLASTIC PIPE MANUFACTURERS ASSOCIATION SA PUMP MANUFACTURERS ASSOCIATION SA VALVE AND ACTUATORS MANUFACTURERS ASSOCIATION VALVE & ACTUATOR MANUFACTURERS CLUSTER OF South Africa

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69

January/February 2019

5

SA INSTITUTION OF MECHANICAL ENGINEERING

Council 2018 - 2020

Company Affiliates

Office Bearers President......................................................Prof D Blaine (Debby) Vice President....................................... H Makwarela (Hangwani) National Treasurer.............................Prof JL van Niekerk (Wikus)

Branch Chairpersons

Central ............................................................... A Celliers (Alicia) Eastern Cape........................................... G van den Berg (Gideon) KwaZulu-Natal ........................................ Dr J Padayachee (Jared) Mpumalanga Highveld .....................................N Lecordier (Noel) Vaal.............................................................. N Swanepoel (Niekie) Western Cape ............................................... Dr M Venter (Martin)

Portfolios:

Collaboration

Procedures.......................................................... SZ Hrabar (Steve) Communications and Marketing..................G Bartholomew (Bart) TBC...........................................................MAE Black (Malcolm) TBC..............................................................HG Bosman (Tertius) TBC.................................................C Molomo-Mphephu (Cillia) TBC..............................................................R Tshitahe (Rudzani) Chief Executive Officer..................... Vaughan Rimbault National Office Manager................ Anisa Nanabhay PO Box 511, Bruma, 2026 Tel: (011) 615-5660 Email: info@saimeche.org.za Website: www.saimeche.org.za Membership Email: membership@saimeche.org.za

E

MBE Minerals (SA) (Pty) Ltd

Autodesk as represented by Worldsview Technologies

Megchem

Ainsworth Engineering (Pty) Ltd

Osborn Engineered Products SA (Pty) Ltd

Alstom Power Service SA (Pty) Ltd Babcock Ntuthuko Engineering Pty Ltd Bosch Projects Pty Ltd Eskom Rotek Industries SOC Ltd Esteq Group (Pty) Ltd Exxaro Resources (Pty) Ltd Festo (Pty) Ltd Fluor SA (Pty) Ltd Kelvion Systems (Pty) Ltd Green Plan Consultants (Pty) Ltd Hatch Africa (Pty) Ltd Howden Power (a div of Howden Africa) Howden Projects (a div of James Howden)

Mod-U-Flow CC

Plant Design & Project Services (Pty) Limited (PDPS) PPS Insurance Co Limited Proconics wwRedheads Engineering Services (Pty Ltd) S.A.M.E Water (Pty) Ltd SA Power Services (Pty) Ltd Sasol Technology (Pty) Ltd Siemens (Pty) Ltd Simera Technology (Pty) Ltd Spirax Sarco (Pty) Ltd Tenova Mining and Minerals SA Thyssenkrupp Engineering (Pty) Ltd Vital Engineering (Pty) Ltd Weir Minerals Africa

and specialisations. And we are not limited to engineering.

“We will find ourselves increasingly collaborating with social sciences and humanities as machines take over more mundane functions (AI, Industry 4.0).”

Making a difference

Collaboration will also be key to the success of ECSA’s regional presence. Says ECSA CEO, Sipho Madonsela, “It’s one thing to open an office and another to ensure it makes an impact.

In this light, key performance indicators have been put in place including monitoring the number of registrations, keeping track of training programmes and CPD, with the purpose of providing real value to the engineers in each region.”

Vaughan Rimbault

CSA (Engineering Council of SA) has recognised that it needs better representation across the regions and also with institutes of learning. Thus it is rolling out satellite offices in DBN (KZN), East London (E Cape), Cape Town (W Cape) and Bloemfontein (Free State).

SAIMechE CEO Vaughan Rimbault, National Office Manager Anisa Nanabhay and Susan Custers, editor of “The SA Mechanical Engineer” joined an impressive group of engineers in November last year to hear about progress being made at ECSA’s Free State satellite office.

Housed at the Central University of Technology on the Bloemfontein campus, a large group representing CESA (consulting), SAICE (civils), IMIESA (municipal) and SAIEE (electricals), as well as agricultural engineers, academics, students and Gerhard Slabbert of Merseta, attended the event.

With Alf Ngowi of CUT as programme director, this get-together is proof positive that traditional ‘silos’ across the disciplines are rapidly becoming blurred. As Vaughan told delegates, “Problems encountered by each profession bear a striking resemblance to those being addressed across other disciplines

6

Amoricom

THE SOUTH AFRICAN MECHANICAL ENGINEER

Another drive for ECSA is opening up the field for a wider panel of assessors, tasked with awarding Pr Eng certification.

Previously undertaken by the VA’s (Voluntary Associations), ECSA has swollen the numbers with 25 new reviewers/ moderators recruited and trained in July 2018. Another 30 will be trained up early this year.

On-line

Although satellite offices will make it easier for engineers to earn CPD points on local ground, Sipho is of the opinion that on-line courses will take off exponentially. Having recently returned from Australia, he is a keen proponent of on-line training which he sees as taking root especially where there are no current vested interests in place. He cites the Sol Plaatjie University in N Cape (Kimberley) as an example.

They have aspirations to add engineering to their curriculum which may be feasible given the opportunities presented by on-line education.

“I also support the idea of accrediting service providers as a group rather than the more cumbersome method of accrediting each course individually.”

The floor

When questions were invited from the floor, two main topics came up. The first was that of mandatory registration with

VOL 69

January/February 2019

SA INSTITUTION OF MECHANICAL ENGINEERING

ECSA CEO Sipho Madonsela

Alfred Ngowi of CUT

ECSA. All were of the view that when it comes to public safety, the involvement of a PREng is non-negotiable.

However, Sipho did point out that compulsory registration can be divisive among engineers, and sometimes even evoke resistance. The Competition Commission may rear its head but, again, all agreed that it’s essential to uphold high standards and norms.

In addition, government and recruitment agencies need to be sent a clear message that dealing with qualified and competent engineers, technicians and technologists is vital.

Sipho reports incidences of ‘fronting’ whereby a Pr Eng allows his/her certificate to be used by a ‘pal’ to land a contract when they, in fact, play no role in the contract execution.

Millenials

The second topic under discussion was that of the Identification of Work (IDOW). Some felt it was simple to implement citing that the Dept of Public Works already has IDOW in place, others felt it would involve a ‘huge’ complicated matrix and would be unwieldy from the start.

However, everybody was on the same page and heartily supported Gerhard Slabbert of Merseta who is encouraging engineers to sign up for their candidacy programme. “We have funding in place and would like more engineers to be enrolled particularly as we’re going to need millennials to help us navigate an increasingly digital future.”

Gerhard Slabbert, Merseta

Susan Custers, Managing Editor

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69

January/February 2019

7

COVER STORY

A Pump Designed for Harsh Mine Conditions Carl Hamm Pipes Pumps Solutions specialises in the turnkey abstraction of water. “Whether it is a virgin mine planning strategy or a flooded or closed mine, we can offer turnkey solutions.” Chris Munnick, CEO of Carl Hamm PPS South Africa, is going the extra mile in looking for cost-effective solutions to deliver the goods – or water, in this case. “SA Mechanical Engineer” found out how.

C

arl Hamm PPS South Africa, a subsidiary of the privately-owned fourth generation family business in Germany, recently added and began distributing Düchting pumps.

An exciting development for Chris and the team, Düchting pumps offer solutions many southern African mining companies are looking for – they can pump

We can eliminate one of the biggest problems - we can handle ‘run of mine water’

‘run of mine’ underground water at high pressures with less downtime and maintenance than normally associated with this type of multistage pump.

Multistage

“At first glance, the Düchting HPX pump range appears the same as many other pumps on the market, but they can do so much more,” Chris says.

The difference is in the rotational speed, clearances and robust design.

The HPXL, HPXM and HPXU pumps have a nominal pressure of up to 160 bars and flow of up to 3 500m3 per hour. The maximum density is up to 1 400 g/l and the PH value 0-14. They operate at a low speed so there is low wear and they are available in almost any metal from cast iron to Super Duplex stainless steel.

8

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69

January/February 2019

COVER STORY

• • • •

4-pole pump for liquids with abrasive content Maximum Density up to 1,400 g/l (e.g. brine) Typical mining applications up to 5 % by weight (approx. 50.000 ppm) low speed = low wear

More than 2 000 units have been sold across the globe from the USA and Canada to China, the Philippines, Germany and Poland There’s a wide range of Düchting pumps, but Chris is particularly excited about the multistage centrifugal HPXL, HPXU and HPXM pumps with their high efficiency and low life cycle costs – at an average MTBS of 25 000 working hours.

The ring-section design includes axial thrust compensation, achieved by the use of balancing disc and balancing counter disc, shaft sealing by stuffing box or mechanical seals, and flanges positionable in 90° steps. The pumps are manufactured according to DIN/ASME standards.

Tailor made solutions are available such as one or two connective shaft ends, single or double inlet suction and intermediate flanges at stage casing.

A high pressure type HPXM 50X3 pumping 720m3 per hour at 30 bar was supplied to a coal mine at Ibbenburen, Germany in 1988 and is still in operation. An HPXU 200X13 high pressure type pump was adapted to the needs of a coal mine in China and pumps 500m3 per hour at 93 bar. An HPXM 250X6 pump installed in a copper mine in Lubin, Poland was in use for 49 000 hours without a service.

The pumps have a guaranteed efficiency of over 80%, and vastly reduce maintenance and downtime The answer

“The pumps have a guaranteed efficiency of over 80%, and vastly reduce maintenance and downtime,” Chris says. Making them ideal for any mine.

He explains, “Mines cannot stop pumping water, even when they close, because of the flooding risk.

“The market has asked for this product for a long time,” Chris concludes. “And now we can deliver it.”

The pumps can handle contaminated, chemically neutral or aggressive liquids with up to 10% solids.

Problem solved

“We can eliminate one of the biggest problems - we can handle ‘run of mine water’, Chris emphasises.

More than 2 000 units have been sold across the globe from the USA and Canada to China, the Philippines, Germany and Poland. The experience of some of these users highlights the impressive performance of the pumps.

Carl Hamm Pipes Pumps Solutions Chris Munnick 072 256 0926 Email: chris@carl-hamm.co.za www.carl-hamm.co.za

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69

January/February 2019

9

Invincible Valves (Pty) Ltd was established in 1982 and since has grown to a medium sized enterprise located in Knights, Germiston Invincible Valves prides itself on service excellent and flexibility by striving to enhance our customer’s bottom line.

Our 6,500m² facility in Knights is made up of 4,500m² under roof being our stores and workshop. The facility is fully equipped to offer a one-stop resource for valves and ancillary equipment which we transport globally.

As an approved BBBEE Level 4 supplier to all major industries within South Africa, we maintain expertise and experience across a broad spectrum of industries and applications with a wide range of products. We offer a comprehensive range of local and imported valves and accessories for the mining, petro-chemical, power generation, water, sewerage and general industries. We have agents in all major centres around the country and service all four corners of the globe.

We offer an in-house rubber lining service for valves, pipes, fittings and vessels which is utilized by many of the country’s major valve manufacturers. In addition we offer complete service, repair and valve reconditioning services for all types of valves.

Our Core Values: We believe in treating our customers with respect. We grow through creativity, invention and innovation. We integrate honesty, integrity and business ethics into all aspects of our business functioning.

Our Mission Statement: Build long term relationships with our customers and clients, to provide exceptional customer services by pursuing business through innovation and advanced technology.

Our Purpose: To be a leader in the Valve Industry by providing enhanced services, customer service and profitability.

Our Vision: To provide a quality service that exceeds the expectations of our esteemed customers.

Invincible Valves is a proud supplier of quality valve products and ancillary equipment backed by service excellence around the globe. It is the combination of these values that allows us to form lasting business relationships.

Invincible Valves (Pty) Ltd 10

THE SOUTH AFRICAN MECHANICAL ENGINEER

If it's not INVAL®, it's not Invincible 33 Shaft Road, Knights, Germiston TEL: +27 (0) 11 822 1777 | FAX: +27 (0) 11 822 3666 EMAIL: enquiries@invalve.co.za | WEB: www.invalve.co.za

VOL 69

January/February 2019

MARKING & TRACING

Barcode Readers for Tobacco Company 120 image-based 2D barcode readers were recently installed across multiple scanning stations in a South African-based tobacco manufacturing plant.

T

he cigarette manufacturer was looking for a solution to move from its manually intensive marking and tracing system, which often led to human error and lacked a satisfactory verification process, to a modern technological one.

The client’s objective was to ensure the plant retained its ability to produce world-class products.

The Lector 620 range includes a fail-safe micro SD card in case of device failure, which automatically loads all required device settings when inserted into a new device This would be achieved through increased product traceability and improved quality control. Sick recommended its Lector 620 Professional image-based barcode readers, part of its Lector 62x product family, specifically designed for improved product and process traceability.

Across-the-board traceability

The installation of these barcode readers has ensured that the plant has technologically up-to-date unit level traceability on all product elements. This incorporates from the container-stored tobacco blends through the entire production process, ending with cartonised cigarette boxes contained in palletised containers for distribution. The 620 range includes a fail-safe micro SD card in case of device failure, which automatically loads all required device settings when inserted into a new device.

“Product traceability allows for safe products to be manufactured while protecting the production process,” points out Mark Madeley, Marketing Manager, Sick South Africa. He adds that among the benefits of the Lector 620 Professional is their automatic parameter switching ability.

“This allows the barcode reader to change its settings between four different modes, thereby accommodating variances in lighting conditions.”

The software used can also artificially enhance the

barcode to ensure the highest possible read rates and its additional image capturing ability is another advantage. No-read images are saved, providing our client with the ability to diagnostically ascertain the cause of the fault,” Mark concludes.

le

The Lector 620 Professional image-based barcode reader ensures the plant has technologically up-to-date unit level traceability on all product elements.

THE SOUTH AFRICAN MECHANICAL ENGINEER

Sick Automation South Africa Mark Madeley, Tel: (010) 060-0550

VOL 69

January/February 2019

11

TRANSFORMING FREIGHT LOGISTICS

12

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69

January/February 2019

TRANSNET FREIGHT RAIL

www.transnet.net www.transnetfreightrail-tfr.net

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69

January/February 2019

13

14

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69

January/February 2019

DUST CONTROL

Putting Ash to Good Use With a little innovation and a sound business plan, any South African stands to make a fortune out of the millions of tons of coal ash produced by our generators annually.

W

ith mountains of ash available at all of South Africa’s coal-fired power stations, there is no shortage of supply to anyone wishing to make use of the ‘Grey Gold’. Those wanting the product are likely to get it at low or no cost, provided they can prove that they have a viable usage and that the operation will generate revenue and jobs.

Already 10% of the total 50-million tons of ash produced per year is used in the manufacture of cement powder and concrete bricks. It is also being used to treat acid mine drainage and to remediate soil for agriculture and other land uses. However, this is just the tip-of-the-iceberg and experts have already identified a range of other uses including alternative building products, volumisers for plastics manufacture, contouring for road, rail and landscaping infrastructure and many other uses.

10% of the total 50-million tons of ash produced per year is used in the manufacture of cement powder and concrete bricks Entrepreneurs wanted

Now, with Government’s assistance, the South African Coal Ash Association (SACAA) has been given a target to increase ash usage to 20% of offtake and to create 26 000 new jobs in the process within the next five years. In addition, start-up ash operations can expect some kind of assistance from Government, generators, SACAA and academics to extract the maximum potential out of ideas that are deemed to be viable.

SACAA general manager, Mark Hunter, says the association is looking for industrial entrepreneurs to assist in identifying and developing viable business opportunities for the use of waste ash generated by producers via their boilers. As the second biggest waste stream (after organic waste that is sent to landfill), coal ash is becoming a headache for the country as space is running out to dump the ash.

Mark proclaims that reaching the 20% target is not only possible, but probable if some viable alternatives can be found to dumping. This will require close cooperation between role players and speedy facilitation between Gov-

Mark Hunter of the SACAA ernment and other role-players who also fully understand the urgency of the matter and will likely pull-together to make it happen.

Team effort

“First and foremost, we need ash to be excluded from the classification of hazardous waste. There is a plethora of research which has been completed which shows that there are many applications of ash which are not harmful to the environment or health.

It is only when ash is stored for extended periods that it may have an impact on the environment.

Next, we will need to continue working with formal industries, such as mining, construction and the cement industries to find all possible avenues to utilise ash.

“Simultaneously, we will engage with scientists and entrepreneurs to identify areas where ash can be used as additives in manufacturing processes and as an end product in other instances. Then the race will be on to industrialise these and we will facilitate and assist in every way to make sure it is successful.

“As a part of the Department of Environmental Affairs’ Phakisa programme to reduce waste to landfill/ash dump/dam, as well as create sustainable employment in the process, we are confident that we have the full backing of Government and that we will make a success of the project. We therefore call on creative and technical people, as well as business people and entrepreneurs, to come forward and be a part of the solution,” says Mark.

Different types

Coal ash ranges in consistency from ultra-fine fly ash, through courser grades to hard stone-like granules.

Its unique properties include round molecules that make fine particles flow into microscopic spaces.

When combined with liquids, different sized molecules also provide good adhesion in cement pastes and plastics, while course materials are used elsewhere in the world for landfilling applications.

It is fireproof and provides high levels of insulation.

Environmentally, the material is considered carbon neutral, is inert and can be vegetated over.

South African Coal Ash Association (SACAA) Mark Hunter Tel: (083) 631 0793 Email: mehunter22@icloud.com Web: www.coalash.co.za

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69

January/February 2019

15

A unique flywheel water pump system that is able to continue pumping long enough to mitigate the possible effects of water hammer in the event of power failures

Flywheel Pump Prevents Damage to Infrastructure KSB Pumps and Valves was called upon to develop a unique flywheel water pump system able to continue pump long enough to mitigate the possible effects of water hammer in the event of power failures

R

uan Nel, KSB Pumps and Valves project engineer, explains that the pump was developed for the rural Tsomo District Municipality where it is required for critical high lift pumping of potable water to supply water transfer requirements. Due to unstable electricity supply, the municipality however, required a solution to prevent the potentially catastrophic backward rush of water in the event of a power failure that could lead to water hammer and the destruction of its water infrastructure.

A failsafe method of maintaining water pressure long enough to reconnect power was needed in the event of a power failure This required the technical team to develop a reliable and failsafe method of maintaining water pressure

16

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69

long enough to reconnect power, or in the event of no power, to (gradually) slow down and arrest the flow without air bubble-causing cavitation. Due to the rural location of the pump station, the team also needed to develop a reliable solution with minimal maintenance requirements.

High RPM

“The requirement for a flow of 380 cubic metres of water per hour, at differential height of 261 metres with an efficiency of 80.8%, called for a powerful pump and motor combination with the addition of a heavy flywheel. “Weighing 681 kg each, the flywheels spin up to 3 000 RPM and provide enough momentum to pump water for at least four minutes after power is interrupted. With a flywheel central to the design chosen, the pump selection was based on our high-efficiency Multitec multistage pumps which we configured in an inline orientation with the

January/February 2019

PUMPS AND VALVES

high revolutions has been made and paves the way to apply a smart solution to an old problem,” says Ruan.

Well balanced

Incorporating the flywheel was particularly challenging, requiring them to be specially designed and manufactured to high standards with balancing to G2.5 at 3 000 RPM, which is a particularly close tolerance to ensure near perfect balance. Mating to the pump also required careful engineering requiring self-centring ball bearings able to withstand high pressure, as well as a special grease to allow for the high RPM. Operational bearing temperatures were tested to remain at 19-21°C during extended operation.

Weighing 681 kg each, the flywheels spin up to 3 000 RPM and provide enough momentum to pump water for at least four minutes after power is interrupted

Ruan Nel, KSB Pumps and Valves project engineer

suction side on the left front side of the pump and discharge on the right front side to make room for the flywheels.

“Considering the critical application in which the pump is to be used, we also elected to manufacture all internals from bronze for corrosion resistance and low maintenance as well as added durability.

In the end, this is one of the only times that a flywheel pump of this size and spinning at such

The system also uses a variable speed drive (VSD) to synchronise the motor, pump and flywheel speeds and makes use of specialised couplings to ensure the transfer of energy between the motor and flywheel remains seamless at all times including start-up, power outages and restart while the flywheels are still turning.

In addition, the system required a heavy-duty base plate made from channel type steel and reinforced around the flywheel plumber block pedestal, similar to large industrial baseplates, to ensure the system remains perfectly balanced at all times.

KSB Pumps and Valves Annett Kriel Tel: (011) 876-5600 Email: Annett.Kriel@ksb.com www.ksbpumps.co.za

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69

January/February 2019

17

REPAIRS

Technology Makes Light Work of Sewage Pipe Replacement REPAIRS

A small piece of equipment is making a big difference in the City of Johannesburg’s bid to replace aging sewage infrastructure with its ability to work faster than a large team of men working in its place.

D

rill Power Tech Engineering recently put its newly-acquired HammerHead Portaburst PB30 into service throughout the suburbs of Weltevreden Park and Roodekrans where it is able to burst and replace aging cement and clay sewage pipelines with long-lasting HDPE pipes in a fraction of the time it usually takes.

Can be operated by a small team operating out of the back of a bakkie Purchased from ELB Equipment, the sole supplier of Hammerhead equipment in South Africa, the small and simple-to-operate pipe bursting machine has even surprised veteran pipe replacement specialist, Fernando Barbosa, the owner of Drill Power Tech Engineering.

Long distances

“So far the longest run that we have done is 120m

of standard 160mm piping which we completed in just two hours. In just over three months since entering the operation, our HammerHead Portaburst PB30 has racked up an incredible 2km of pipe replacements in all sorts of terrain.

“What makes it even more useful is the fact that it is lightweight with a small, narrow footprint about a metre long and roughly the same height which means it requires much smaller entry and exit pits. This makes it ideal to use in confined areas or mid-block between two properties (usually in the backyards).

“Even in the tightest of situations the HammerHead Portaburst PB30 proves its worth as it can be disassembled and rebuilt in tight confines, especially complexes and dense urban areas. Its small entry and exit pits also minimises disruption and due to its fast operation it considerably shortens downtime of the sewers,” says Fernando.

Portable solution

The HammerHead PortaBurst PB30 is a portable lateral pipe bursting system with a massive 30 tons

The Drill Power team on site

18

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69

January/February 2019

REPAIRS

of pulling force. This enables it to burst and pull pipes of up to 355mm over long lengths. Its modular four component design, with each component weighing less than 32kg, allows it to be passed over walls or into hard-to-reach spaces where it can be quickly reassembled in the pit if necessary.

Once set up, the operators can quickly push the

Racked up an incredible 2km of pipe replacements in all sorts of terrain in just over three months main cable through the existing pipeline, attach the burst head with new HDPE pipe attached and thread it to the machine’s jaws to begin bursting.

The Quick Grip burst heads use snap-fit fixtures and don’t require any hand tools. Its rugged design

also gives it the unique ability to negotiate bends of up to 45 degrees.

The system operates at low hydraulic pressures which allows contractors to use a small powerpack setup. It can also be run from a backhoe or compact excavator or any other hydraulic supply capable of 3 000psi with a flow of at least 60Lpm. Another impressive feature of the unit is its constant tension which gives a firm grip on the cable and allows it to pull at nearly 2 metres per minute.

World-class contractor

ELB Equipment product manager, Phillip McCallum, says the HammerHead PortaBurst PB30 is the ideal system for replacing pipes in South Africa’s suburbs and townships due to its compact size, simplicity and power. It does not require expensive supporting infrastructure and can effectively be operated by a small team operating out of the back of a bakkie.

The small pit that it requires can be quickly and easily dug by hand which makes it a labour-friendly solution either for emerging contractors or an additional solution for established professionals. With an affordable price tag, and a massive, and growing amount of work required in almost all cities and towns throughout the country, sales of the equipment are expected to climb.

ELB Equipment Phillip McCallum Tel: (011) 306 0700 phillipm@elbquip. co.za www.elbequipment.co.za

Fernando Barbosa, owner of Drill Power Tech Engineering

Leading Expertise. Delivered.

COLLIERY TRAINING COLLEGE (PTY)LTD

Colliery Training College: Artisan training for all employers in any industry.

Ask yourself the following question about artisan training: •

Does your training provider share your passion for safety?

Open Day for employers - 26 June 2019 Email: info@ctctraining.co.za

www.ctctraining.org

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69

January/February 2019

19

The Local Manufacturing Expo Aims to:

21 – 23 MAY 2019

Promote local manufacturing

EXPO CENTRE, NASREC,

Demonstrate Southern Africa’s export potential

JOHANNESBURG, SOUTH AFRICA

Provide access to global markets

A Showcase of Southern Africa’s Manufacturing Capabilities Who Will Exhibit?

Networking opportunities Develop public / private partnerships Public / private sector collaborations Identify industry challenges and opportunities for growth

Manufacturers across a variety of sectors, including:

Agriprocessing

Automotive

Business Process Outsourcing

Capital Equipment

Chemicals

Construction

Engineering

Food and Beverage

Furniture

ICT and Electronics

Metals

Mining

Plastics

Textiles/ Clothing/ Footwear

Transport

www.localmanufacturingexpo.co.za In association with:

20

Endorsed by:

THE SOUTH AFRICAN MECHANICAL ENGINEER

Implemented by:

VOL 69

Brought to you by:

January/February 2019

PORTS

Emergency Helicopter Service at Cape Town Transnet National Ports Authority (TNPA) is exploring options to introduce a helicopter service at its Port of Cape Town to assist with operations during major swells and to increase the availability of service during stormy conditions.

C

ape Town is often plagued by bad weather and high swell conditions. This has at times impacted port operations and the use of pilot boats to transfer marine pilots to and from vessels.

Physical testing of the marine helicopter operation took place between 28 September and 5 October last year at the port using a helicopter that services the Port of Durban.

Richards Bay and Durban are the only ports in TNPA’s port system which use helicopters to transfer marine pilots Port of Cape Town Harbour Master, Captain Alex Miya, who recently transferred from the Port of Durban, says, “Richards Bay and Durban are the only

ports in TNPA’s port system which use helicopters to transfer marine pilots. Our recent successful test exercise indicates that this is a viable service to offer at the Port of Cape Town.”

TNPA Chief Operating Officer Nozipho Mdawe adds,“The process includes engaging with major customers to establish their level of interest and to test whether the service cost would be acceptable.

We are also debating whether the service should be shared between the Western Cape ports or dedicated to one port.”

Exploring the options

Nozipho says two options are being explored. The first involves stationing one of the existing TNPA helicopters in Cape Town to service the Western Cape ports, while the second entails partnering with a private helicopter company to render the service as and when swell conditions dictate or when there are insufficient pilot boats to meet the number of vessel calls.

TNPA has an existing fleet of three AgustaWestland (AW 109) helicopters to service the Ports of Durban and Richards Bay and through its fleet replacement programme has procured two new helicopters valued at around R250 million from Italian global high-tech company Leonardo S.p.A. The two new aircraft are expected to be delivered by June this year.

th

The Port of Cape Town is also striving to replace two of its workboats and a request has been made to bring forward the replacement of two tugs and two launches to 2019/20 instead of 2020/21 in order to meet industry needs.

Port of Cape Town Transnet National Ports Authority Mpumi Dweba-Kwetana Tel: (021) 449-261

TNPA tested a helicopter service to transfer marine pilots at the Port of Cape Town recently, with aircraft making use of the grass and parking area in front of TNPA’s Cape Town administration building

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69

January/February 2019

21

DESIGN

Open Day Showcases Mechanical Students’ Innovations Late last year, final-year Mechanical Engineering students unveiled their engineering projects to the public at the University of KwaZulu-Natal’s (UKZN) annual Mechanical Engineering Open Day.

T

he projects, which are part of the degree requirements of the final-year Design and Research Project modules were designed for the agricultural, sanitation, construction, airline, search and rescue, manufacturing and transport sectors.

Assessment of the projects was structured in accordance with the Engineering outcomes required by the Engineering Council of South Africa (ECSA).

Academic Leader for Mechanical Engineering at uKZN Professor Glen Bright says the focus of the Open Day is to highlight the technical achievements of the final-year students. “We want the public to experience and interact with these engineering projects,” says Glen.

In addition, some previous-year design projects were on display, with staff and students on hand to take the public for rides on the UKZN pedal bus, electric trikes and the rally car simulator. There were also technology demonstrations throughout the day, including the unmanned aerial vehicle (UAV) and a mobile robotic display.

Design project that were on display:

• Quadriplegic Unassisted Archery Device (QUAD) Currently there is no quadriplegic division within Para-archery. Students were hopeful that the creation of this device will lead to the development of a new Para-archery division in the Paralympics.

The device allows a person of quadriplegic disability to draw, aim and fire a compound bow; while

The vintage off-road rally vehicle on display

22

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69

January/February 2019

DESIGN mimicking and simulating the experience of an able-bodied archer as closely as possible.

• Play (Creating the illusion of fruit growing on trees) The aim of this project was to replicate the faraway tree through means of modern engineering, on an existing tree in the Durban Botanic Gardens. This project demonstrated how engineering and technology are able to interact with nature in order to enhance the aesthetic value of the environment and the lives of Durban citizens.

The students had produced a semi-autonomous 3D printing and distributing system that can be mounted within a weather proof housing onto a tree. The device printed fruit made from Poly Lactic Acid (PLA). At a certain point during printing, a metal ball was inserted in the fruit from a ball release mechanism positioned on the printer.

A hanging conveyor system comprising of fishing line, support pulleys and magnets then collected the fruit and rotated it around the tree, giving the illusion that the tree is growing fruit.

• ITS Intergrated Urban Electric Transporter This urban electric transporter, aligned with UKZN’s vision of the “African City of the Future” presented a “smart vehicle” concept of an Intelligent Transport System equipped with vehicle-to-vehicle technology

(providing drivers with safety information regarding possible road accidents, traffic congestion, and defective traffic lights). A newly designed solar powered station charged the electric transporter with energy that is off the grid.

• Autonomous Mobile Security Robot A low-cost autonomous mobile security robot has been designed and manufactured to be used in a factory floor or warehouse setting with the focus being on surveillance. The robot comprises an autonomous navigation system, wireless communication network and visual intruder detection.

Research project modules were designed for the agricultural, sanitation, construction, airline, search and rescue, manufacturing and transport sectors.

• Flying Hovercraft The purpose of this research and development project was to design a multipurpose hovercraft with the ability to fly over obstacles. The concept featured a hovercraft with small aspect ratio wings which took advantage of the ground effect phenomenon for efficient low altitude flight. The hovercraft also included a remote-controlled steering system.

• Vintage Off-Road Rally Vehicle The aim of this project was to explore the conversion of an old 1968 VW Beetle to an off-road rally vehicle. The vehicle was intended to be an economical version of an All-Terrain Vehicle (ATV) that repurposed old, roadunworthy vehicles that are in a ‘scrap’ condition.

.

The flying hover craft on display for the public

Trike Electric Commuter

The main objective of this project was to design and construct a three-wheeled, electrically powered vehicle that could be used for daily commutes and which also matches up to South African roadworthiness standards. The two seater vehicle has minimal environmental impact and is capable of reaching speeds of over 100km/h.

.

Forced Convection Solar Dryer with a Preheater Students designed and manufactured a solar dryer proposed to dry synthetic faecal sludge. The aim of the project was to develop a solution to address the challenges involving water and sanitation that many rural communities face.

.

Solar Energy Desalination Plant

Students were tasked to design and manufacture a prototype of a small-scale solar desalination plant that produces 5 litres of water a day for domestic use.

Staff and students were on hand to the public for rides

University of KwaZulu-Natal Sejal Desai Tel: (031) 260-7829 Email: desaisej@ukzn.ac.za

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69

January/February 2019

23

TRACE Inte is a globa anti-br or leading pr party risk

TRACE due diligence solutions are based on internationally accepted best practices and our experience and familiarity with the compliance needs of multinational companies. Services range from a denied parties screening to enhanced due diligence, including TRACE Certified Due Diligence.

International, Inc. globally recognized ti-bribery business organization and g provider of third risk management solutions.

Mobilising Maintenance Through Digitisation A few years ago the word maintenance immediately evoked an image of a man wearing blue overalls. Today however, it is increasingly characterised by digital services and mobile devices such as tablets and data glasses. Exhibitors will be presenting examples of these at EMO Hannover 2019, being held in September.

"

Today, maintenance staff are no longer called in only when there is a mechanical, hydraulic or pneumatic problem that has brought a machine to a standstill," explains Peter Strohm, Global Service Project Manager at Emag Systems.

"Nowadays it's crucial for maintenance technicians to be fully familiar with the hardware and software of their machines in order to plan repairs in advance and procure any required materials. They increasingly have to use digital services to help them monitor the condition of the machines.

Today it’s crucial for maintenance technicians to be fully familiar with the hardware and software of their machines in order to plan repairs in advance “Before purchasing a machine, companies should make sure that the manufacturer offers service solutions that are tailored to their individual requirements.

We offer customers maintenance provided by our own specialists, but we also support customers who want to carry out their own maintenance. However, it is important for every solution to be future-proof with regards to digitisation," says Peter.

Predicting axis and spindle failure

"At Emag, we have been working for some time on a product that facilitates wear analysis of the machine axes and spindles using a vibration sensor.

Based on a defined dry run of the machine, we will soon be able to use an algorithm to evaluate which machine components are likely to fail.

“This gives the maintenance engineer optimum support for his repair and maintenance planning," says Peter. The aim of such preventive and predictive maintenance is to eliminate downtime in the future.

Another example is a service app from Emag. "This makes it easy for maintenance staff to get in touch with our service department. The app scans a QR code on new Emag machines and recognises the machine type and location.

“This then allows the appropriate service staff member to be contacted. Old machines are retrofitted free of charge – and there is no age limit," explains Peter. Customers can then choose to contact the specialists by telephone, e-mail or live video chat.

Companies must train up their employees

Today's experts not only have to maintain and

EU standard DIN EN 17007:2017 Structuring plant maintenance

in the development. One of the leading figures in the project is Prof. Dr. Lennart Brumby, head of the Service Engineering Department at the Baden-Wuerttemberg Cooperative State University in Mannheim.

These processes serve as a reference for companies coordinating their own processes with the use of service providers or for comparing themselves with other companies. The standard also suggests suitable key figures for measuring the individual maintenance processes.

Reference processes for key maintenance tasks

A new EU standard provides a useful management tool: DIN EN 17007:2017 which structures and describes the typical maintenance processes of a company in a universally applicable form.

DIN EN 17007:2017 is based on a French standard and its scope has been considerably expanded in cooperation with various other European countries.

In Germany, maintenance managers from various manufacturing and process industries were involved

26

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69

“In the networked world of work in Industry 4.0, it will be important not only to co-ordinate the information systems, but also to mesh the respective business processes with one another.

As a leader for Industry 4.0, maintenance needs reference processes for the key tasks, both for the core processes of reactive and corrective maintenance as well as for the wide range of support processes. Only then can networking succeed,”

January/February 2019

optimise machines and automation systems, they must also ensure that the different systems communicate with each other. Furthermore, they must ensure that is possible to conduct data analyses across different interfaces. This should ultimately help identify further potential for the selection of suitable efficiency measures.

The interface between IT and maintenance in particular is an important corner-stone of modern maintenance. "This is also a major challenge for the companies because they have to ensure that their employees are appropriately qualified in this complex environment," says Dr. Jens Reichel, Head of Technical Services & Energy at thyssenkrupp Steel Europe AG in Duisburg. This is sometimes difficult, particularly in view of the shortage of good IT specialists on the labour market.

Ensuring data security for all parties

For Jens, data security is another important issue in digitised, mobile maintenance. Smart services today often involve production companies feeding production data into the cloud via an interface.

Appropriate background analyses are then carried out in the cloud: these provide an insight into what is happening in the plant, but can also be used to issue alerts of possible failures.

"Many production companies are reluctant to give third parties access to their data. For one thing, it allows conclusions to be drawn about process parameters which could reveal company knowhow. And it also opens up access channels to the production processes, which could lead to abuse," Jens explains.

To counteract this, dedicated firewalls are created for the open channels. Companies use these to

make intrusion as difficult as possible. A second way is to open up data access only to the extent required by the case at hand. This means filtering available data in advance to reduce it to the appropriate level for the intended analysis.

In this case, employees must know which security procedures need to be installed at the appropriate interfaces.

"Basically, it's important to realise that maintenance is an area of corporate expertise which is worth protecting," he says.

Precisely-tailored condition monitoring

Prof. Dr. Lennart Brumby, head of the Service Engineering Department at the Baden-Wuerttemberg Cooperative State University in Mannheim

At thyssenkrupp Steel, experts are currently refining condition monitoring systems which will then allow them to be coupled with data from process control, process automation systems and quality management. "The aim is to be able to draw conclusions regarding optimum operation of the system, ie, optimised either for maximum service life or, depending on the parts involved, for the maximum throughput or the best possible quality,”Jeus concludes

Baden-Wuerttemberg Cooperative State University Mannheim, Prof. Dr. Lennart Brumby Email: lennart.brumby@dhbw-mannheim.de www.dhbw-mannheim.de

says Prof Brumby.

“Like all standards, this one is not mandatory.

However, it is advisable for all companies to adapt their own maintenance processes to the DIN EN 17007:2017 processes. Only then will they be ready for the world of Industry 4.0.”

Regarding the scope of the standard, he adds, “DIN EN 17007:2017 not only describes the classic core maintenance processes, such as repair and preventive maintenance, but also includes the many supporting processes without which maintenance would not function. The multitude of links and information flows between these processes are also covered. Because, generally, it is the coordination and networking of processes that offers the greatest potential for optimisation.”

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69

January/February 2019

27

INDUSTRY 4

Research Hub brings SA into Industry 4 The University of Pretoria’s Faculty of Engineering, Built Environment and Information Technology, the SA National Roads Agency Limited (SANRAL) and the Council for Scientific and Industrial Research (CSIR) have embarked on a partnership to establish an Integrated Education, National Certification, National Reference and Research Laboratories Facility to the value of R280 million in the area of transportation. The partnership is part of UP’s Future Transportation and Smart Cities research focus to lead South Africa into the Fourth Industrial Revolution (4IR).

“

This is going to be a unique project, in the sense CSIR will benefit from the body of research that that for the first time in Africa, UP will have will be pursued at UP and gain postgraduate rean accredited national reference laboratory, search skills, Sanral and the rest of the road sector stand to benefit from the material testing, quality accredited in terms of meeting international assurance and research output for road apstandards, and the reference laboratory plication purposes. to reference for testing purposes for the industry at large. Our The space planning and designs With engineers in the industry that have been produced for the will benefit a lot from this facility promise a vibrant Fourth Industrial this project,” says Prof interactive and state-of-theRevolution upon us, and Sunil Maharaj, Dean art facility that will hold its the importance of smart of Engineering, Built own among the best in the Environment and Ininfrastructure and big data world, while exposing both formation Technology students and the industry science in driving job creation at UP. to cutting-edge research, and economic growth, South training and material testThe future transportation Africa needs to prepare its ing,” says Skhumbuzo Mahub will be housed in the graduates for the future cozoma, CEO of Sanral. new Engineering 4.0 facility on the Hillcrest campus, on the doorstep of the N1/N4 Proefplaas Interchange.

world of work

The completion of the facility is planned for November of this year.

This facility will consist of the accredited Sanral National Roads Materials Reference Laboratory, training laboratory, an Accelerated Pavement Testing facility, an active traffic track for real traffic testing, and an upgraded concrete research laboratory. The facility also provides future expansion of the laboratory, and experimental and testing facilities related to interdisciplinary and transdisciplinary research.

The vision is to have a research hub where industry, academia, government and research students across the world can develop future innovations to make South Africa and Africa a smart country and continent.

Aligning individual priorities

“This three-way partnership demonstrates the ability to align individual priorities to create a bigger impact. While the university stands to gain futuristic engineering and research facilities, the

28

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69

“The significance of this project is that this is truly a partnership.

We have UP, CSIR and Sanral working together and being responsible for the roads in our country. Three institutions will come together to discuss priorities and specifically how each, with our own distinctive mandates, can pull our expertise and our resources to make an impact that will shape the future of transportation in South Africa, and beyond our borders in Southern Africa,” says Prof Cheryl de la Rey, Vice chancellor and Principal of UP.

Facility aims to address training of engineers

According to the Infrastructure Report Card, South Africa needs to address current challenges in the transportation-engineering sector, and there is a need to train the required number of engineers, technologists, technicians and artisans in order to address the current skills gap.

In the long run the facility is expected to provide, among other things, top-of-the-range laboratories to provide a platform for quality training, reference testing and research in transportation engineering;

January/February 2019

INDUSTRY 4

The vision is to have a research hub where industry, academia, government and research students across the world can develop future innovations to make South Africa and Africa a smart country and continent

Prof Wynand Steyn (UP), Prof Sunil Maharaj (UP), Mr Kenny Kistan (CSIR), Mr Skhumbuzo Macozoma (SANRAL), Prof Cheryl de la Rey UP), Mr Louw

a unified effort to train engineers, technologists, technicians and materials testers for the skills needed in future transport engineering—as well as postgraduate research output; and a pipeline of transport engineers who have been exposed to the latest technologies and methods.

With the Fourth Industrial Revolution upon us, and the importance of smart infrastructure and big data science in driving job creation and economic growth, South Africa needs to prepare its graduates for the future world of work. The Future Transportation Hub and Smart Cities Hub is the vehicle that UP is using.

University of Pretoria Liesel Swart Tel: (012) 420-3650 Cell: 082 672 0067 Email: liesel@roundtree.co.za

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69

January/February 2019

29

30

THE SOUTH AFRICAN MECHANICAL ENGINEER

12192 - PROPAK AFRICA 2019 FP VISPROM AD 210X297 (WHERE TO PRINT)_V3.indd 1

VOL 69

January/February 2019

2018/10/15 08:30

DRIVE SYSTEMS

Addressing White Structure Flaking The symptoms of bearing damage known as White Structure Flaking, which occurs in wind turbines as well as other drive systems, typically become noticeable very early, well before the end of the bearing’s expected service life. The causes have long remained unknown, but now, new findings are being made available by bearing specialist, NSK.

D

rive components for wind turbines have to meet tough requirements in terms of durability and resistance, and these requirements are becoming increasingly stringent. Onshore turbines traditionally require bearings that are designed to last for a service life of 175 000 hours, which is equivalent to 20 years.

One issue that still afflicts the bearings in turbines is White Structure Flaking (WSF) or White Etching Cracks (WEC) However, in the market for offshore wind farms, where high levels of investment and difficult location access is common, a lifespan of 25 years is required.

Longer lifespan, higher dynamic loads

With extreme dynamic loads acting on the drivetrain of a wind turbine, this requirement presents a real challenge. In onshore wind turbines, the main bearings undergo loads of approximately 1MN. At sea, however, due to very high wind speeds, even

stronger static and dynamic loads act on the rotor and, consequently, on the entire drivetrain.

Researching the causes

One issue that still afflicts the bearings in turbines is White Structure Flaking (WSF) or White Etching Cracks (WEC). In the case of both failure modes, certain areas of the material under the bearing’s raceway show local embrittlement. The brittle structure cannot withstand the loading thus forming the basis of cracks. Eventually, these cracks grow up to the raceway and finally the bearing fails.

After conducting a picral etching, these entities show a white appearance and are thus called white structures. Various rolling contact fatigue tests have demonstrated that white structures are caused by hydrogen penetration. This hydrogen penetration is most likely affected by several factors and their combination, including axial or circumferential slippage between rollers and raceways, electricity and certain types of lubrication.

Hydrogen subsequently penetrates the raceway and forms the white etching structures that lead to crack formations and eventually result in flaking. These cracks can be several millimetres long and spread from the interior out to the surface. Destructive tests of used bearings that showed no visible signs of surface damage demonstrated that white etching areas can even be present here.

When the damage is examined in more detail, it can be observed that under the influence of hydrogen, the originally martensitic microstructure degrades into a very fine-grained, brittle ferrite.

This mechanism can be explained by the Hydrogen Enhanced Localised Plasticity (HELP) theory. One of its characteristics is that plasticity only occurs locally and that the global fatigue of the bearing is slight, so it is not one of the classic types of fatigue damage which originate either below the raceway (due to the inclusion of non-metallic particles) or in the raceway (due to severe contamination).

A new bearing material

Based on the white structure findings, NSK has introduced its AWS-TF (AWS), which combines an optimised chemical composition with optimised heat treatment.

Tests have shown that while bearings made of AWS-TF do not totally eliminate the risk of WEC, the delay before damage appears is seven times longer compared with conventional bearing steels.

NSK South Africa Geraldene Govender Tel: (011) 458-3600 Email: nsk-sa@nsk.com

THE SOUTH AFRICAN MECHANICAL ENGINEER

08:30

VOL 69

January/February 2019

31

Invincible Valves MD, Pam du Plessis

Invincible Valves Training Centre

Share the Knowledge – it’s free

“Create an opportunity when there is a challenge.” That’s Invincible Valves MD Pam du Plessis’s take on the current tough business environment. “If you sit in the office and say it’s terrible, nothing will happen. This doesn’t motivate you to go out to the coalface. Right now we are motivated to see clients and business opportunities are opening up.”

“

SA Mechanical Engineer” caught up with Pam at the company’s premises in Germiston and found that a marketing plan and focus on training continues to benefit this business.

And if you’re not a fan of marketing plans, Invincible Valves’ success may change your mind. They rarely show an immediate tangible return on investment, so it’s difficult to see the value in terms of time and money. Pam has seen the value of a marketing plan first-hand.

If you don’t have a structure that forces you to take action, you put it off and say next month, and next month. Next month never comes.

“The last three years have been phenomenal. I couldn’t put my finger on it initially but now I know - it’s marketing.”

Pam explains that marketing can take time, but the benefits are worthwhile. “Relationships start small, you work on them, and then you start seeing growth.

We’ve signed up a lot of new business, picking up new clients across the country.

“Marketing is telling people about yourself, your company and what you can do. That’s really important, because even if you are the best in the industry, your services and products won’t sell if no one knows about you.”

Taking action

When we visited Pam a year ago she told us how the company’s focus on governance had helped grow the business. They have a five year plan, including a marketing strategy, and the plan is continuously updated.

32

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69

She attributes the focus on planning and follow through to the company’s board structures. “Our corporate governance says we have to do things such as our marketing strategy, and so we do it. If you don’t have a structure that forces you to take action, you put it off and say next month, and next month. Next month never comes.

“Marketing is not seen as essential, it hurts the pocket and sometimes it is mind-bending, we are not marketing experts. So a lot of companies overlook it. Today I can attest to the fact that what has made a significant difference in the business, is our marketing plans,” Pam says.

Developing people

Another focus of the business which is equally important, but sometimes difficult to measure benefits, is training. Pam is passionate about everything she does in life, but she is particularly passionate about training, mentoring and developing people.

“Development for me is the biggest thing and it starts at the front door. You develop your staff to build the industry, ensuring a supply of skilled technicians and artisans, and more.”

Training and development builds the morale and reputation of the industry because when an industry looks after its people, it becomes what people want to work in, and stay working in.

“Look at the automotive sector. Once a person works in that industry they stay there,” Pam points out.

“We have to have the same culture where people want to stay in our industry. We need to create resources so people can move within the industry,

January/February 2019

TRAINING ensuring our sector doesn’t hurt when they leave.

When you uplift someone, they seldom walk out.”

Invincible Valves has their own training centre located in the factory, where everyone can see it.

The centre is used for training as varied as valve training, self-defence, what to do in a hijacking and telephone etiquette.

“We have a lack of qualified people in the industry who can add value, so a training facility means we can skill people for our industry and for life,” Pam highlights.

“Our training centre seats up to 30 people and has wireless connectivity, projectors and a library with books, phonic books and resources that teach how to read, as well as technical books and training material.”

The library area has an entertainment area where staff can read at lunchtime.

Long-term programme

“We have a long-term industry training programme that starts with basic hand tools, moves onto surface grinding and then welding, and fitting and turning.

You can also study for your learners and drivers licences and there are story books for age seven and up. I’m also trying to get newspapers delivered daily so we can stay up to date while keeping people involved and encouraging them to read,” Pam tells us.

“There is a cost involved, but put this through SETA and in addition to the SETA returns, you get two hands in the business who can assist. They might not be able to do the high profile jobs but they can do things such as filing, and you are teaching them value systems and creating someone who is employable.”

A two-way trade

There’s an added benefit Pam has discovered, young people teach us about their world.

“We need to do some social media, which is quite daunting. I’ll speak to our interns and they are familiar with the platforms such as Twitter and Facebook and know how to use them effectively. A social media expert could cost a fortune to explain the ins and outs, but I’ve got just as good an education from my interns. And it’s instant. That is their skills transfer to me.”

She concludes: “You’ll never understand the value they add in your business until they are there.”

When you uplift someone, they seldom walk out

Invincible Valves Pam du Plessis Tel: (011) 822-1777 www.invalve.co.za

“The centre used to be a dark dingy hole, where everyone threw their rubbish. I didn’t take any photos of it. Now I wish I had so I could show before and after pics. The training centre has made my world complete.”

Around 40 man hours a week are dedicated to training. “Our programmes are not limited to staff. For some courses such as telephone etiquette, we invite some members of the community to participate.”

Two things you need to commit to for a successful training programme are time and money. “You can never say you don’t have time for training. Plan a few months ahead and if you need to move the schedule around in busy times, do it,” Pam emphasises.

And when it comes to finances you have to bite the bullet and spend the money. “But it doesn’t have to cost a fortune,” she notes.

Knowledge transfer

“You can do things like sharing knowledge.

It costs nothing to spread knowledge around.

It’s a matter of inviting people round and sharing. One of the biggest problems in our industry is knowledge transfer. We are sometimes scared to do it, but we must help the next person.”

“Skills transfer costs you nothing in your own business. Teach the next person.”

Invincible Valves also has an intern programme and Pam says they have interns in this business who are 19 years old, and some who have no idea what they’d like to do.

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69

January/February 2019

33

Pontoon Solution Reduces Mine Downtime Regular engagement with Rio Tinto’s QIT Madagascar Minerals (QMM) operation and a good understanding of local conditions allowed Weir Minerals Africa to provide the optimal solution to the customer’s recurring challenge on a process pond.

A

ccording to Weir Minerals Africa’s Dewatering Product Specialist, Neil Matthews, the mine was experiencing a continual collapse of the 20 metre suction hose to the Warman AH 12/10 pump mounted on a skid at the back of the pond. This resulted in the need to keep priming the pump and was causing regular downtime.

The design of the handrails and other structures needed to prevent crocodiles from gaining access to the deck space

“Unpacking the issues facing the customer was the first part of upgrading the mine’s process water utilisation,” says Neil. “We discussed several options with the customer after which our dewatering and engineering teams collaborated to design a solution.

It was vital to carefully consider the problem in the context of the geographic and site conditions, as well as the local fauna and flora.”

Finding a suitable solution

To provide the most suitable products and solutions, the team specified a Warman AH 10/8 pump mounted

Having the slurry pump mounted onto the skid solves the customers problem with continually collapsing suction hose

PUMPS

on a Multiflo pontoon with the pump coupled to a variable frequency drive (VFD) facilitating greater flexibility in dealing with varying site conditions. A second pontoon was fitted with a Warman AH 6/4 pump with a motor and fixed speed drive as design conditions should remain constant throughout the life of the mine.

Both pontoons are connected to a floating docking station which is connected to a 20 metre walkway fixed to the bank-side landing.

“It is standard practice in most of our pontoon designs to mount the pump sets at 30 degrees to submerge the suction eye of the impeller, thereby ensuring consistent priming,” Neil explains.

One of the most important factors affecting the solution was Madagascar’s weather conditions, which include regular tropical storms and high wind speeds. These have the effect of creating wave action and wind loading on the pond during storms which the pontoon solution has to accommodate.

To address the wave action and minimise possible structural damage, the fixed walkway was designed to incorporate a pivot system on the bank landing structure. This allows the entire assembly, including the docking station, to rotate 90 degrees and still be tied down to the shore during these storms.

One of the most important factors affecting the solution was Madagascar’s weather conditions, which include regular tropical storms and high wind speeds Crocodile-proof

“Madagascar is also known for its varied wildlife, including crocodiles,” says Neil, “so the design of

Neil Matthews, product specialist at Weir Minerals Africa

the handrails and other structures needed to prevent crocodiles from gaining access to the deck space.”

These creatures would tend to climb onto the deck to bask in the sun, making it almost impossible for staff to conduct routine maintenance. Restricting this access was achieved by closing all the gaps between the handrails and the separate structures.

“Our design took all the site conditions into account, making for better and more predictable operational reliability,” Neil concludes. “Both the pontoons and the pumps can now be moved for servicing or for securing during bad weather.”

Weir Minerals Africa Rajen Govender, Tel : (011) 929-2701 Email: rajen.govender@mail.weir www.minerals.weir

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69

January/February 2019

35

36

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69

January/February 2019

REUNION

Commemorating a Half-Century It was fifty years ago that the first class of students graduated in Mechanical Engineering from Wits. All those classmates are now in their 70s and they recently met for a celebratory reunion.

A

series of events was organised for this occasion. It included lectures, guided tours, luncheons and the obligatory visit to the Alma Mater where they spent four or more years of their life as students.

Changing times creates different graduates

Although every individual has a unique personality, each era creates its own brand of graduate depending on the culture of the time, the technology, the environment, the interactions with others and the role models. The technological culture and focus in the 1960s was very different from the present.

It was a time when the ‘Cold War’ and the ‘Arms Race’ threatened nuclear Armageddon; and it was a time that saw the beginning of the Space Age. It was also the era when new materials, like plastics, made many products more affordable and when improvements in transportation was becoming faster and more accessible to the public. Such significant technological public events stirred the public imagination and promoted interest in technology and engineering.

In South Africa, the Professional Engineers’ Act was passed in 1968. It was the first legislation regulating the engineering profession.

Adapting

Then a new technological era emerged that would radically change all their lives. Engineers had to adapt quickly to the Digital Era: it made tedious calculations easier and faster while minimising errors; it enabled the development of new techniques

of analysis and the modelling of more complex problems; it created new industries and accelerated progress. The first scientific pocket calculator, the HP-9100A, was commercially released in 1968 by Hewlett-Packard, but was too expensive for students of the time, who still made use of the slide-rule (or ‘slipstick’) for their calculations.

Using a slide ruler was one issue that the students quickly forgot about with the visit to the SA Breweries plant in Isando. The programme was a guided tour of the ‘World of Beer”, which also allowed for a good measure of socialising.

Memories were also brought back with a visit to the ‘Mech Eng Building’, and the Laboratory housed across the The road in the North Digital Era West Engineermade calculations ing Building, easier and minimised ably guided errors.

It enabled the by lecturer, Michael Atdevelopment of new kins, who intechniques of analysis troduced and and the modelling explained some of more complex of the projects problems and experiments being conducted.

The group recognised some of the old test rigs and machinery in the ‘Lab’, which is now filled to capacity and has a large Wind Tunnel and an actual Mirage jet fighter plane taking a prominent position.

School of Mechanical, Industrial and Aeronautical Engineering, University of the Witwatersrand

50 Years ago the first class of students gratuated in Mechanical Engeneering from Wits, last year they met for a celebratory reunion

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69

January/February 2019

37

SA INSTITUTE OF TRIBOLOGY

Improving a Turning Insert’s Lifespan Cemented tungsten carbide turning inserts are employed industrially to machine a specific work piece to a desired shape or profile using a lathe under continuous cutting conditions. A coating is typically applied to the inserts, to further improve their machining performance, and to prevent failure due to aspects, such as diffusion from the heat generated during the machining process.

I

n industrial operations, the insert coating experiences adhesion and abrasive wear which has been shown to compromise its performance and life span. Thus the aim of this research was to investigate ways of potentially improving a turning insert’s lifespan and performance, by creating a better final surface finish of the insert’s coating.

This was achieved by conducting in-depth investigations into three existing polishing processes which may be used to produce the required surface finish, and possibly lead to a reduction in the coating wear rates. Fluid jet, hand-held, and submerged bowlfeed polishing techniques were employed, with a prototype bowl-feed machine being designed and manufactured during this project. Different grades of alumina and diamond slurries were used as the polishing mediums.

During polishing, parameters such as slurry flow rate, abrasive grain size, applied pressure and slurry viscosity, were varied to determine their effect on the final coating surface finish Different parameters applied

Fig. 1. (A) Shear stress and (B) total pressure experienced on the surface of the submerged insert [Pa] when polishing with 800 grit alumina.

During polishing, parameters such as slurry flow rate, abrasive grain size, applied pressure and slurry viscosity, were varied to determine their effect on the final coating surface finish. Fluid simulations were done (eg, refer Fig 1), and collision dynamics and shear stresses between the insert and the slurry were calculated and evaluated to provide an improved understanding of the surface finish of the inserts.

The effect of the polishing techniques on the wear resistance of the coatings were assessed by conducting industrial turning tests of bright mild steel shafts in accordance with ISO3685 and measuring the manufacturing output of each insert. Wear scars were examined using optical and electron microscopy to identify the wear mechanisms (eg, refer to Fig. 2).

An unpolished insert was included in the machining tests to provide a base-line comparison between the polishing methods. From the results, it was concluded that all three polishing methods had a positive impact on the performance and lifespan of the inserts. Fluid jet polishing generated the lowest Ra-values and best surface finish of the steel workpiece, and also provided a better aesthetic finish of the coating.

Fig. 2. Examples of wear mechanisms identified on the cutting edge of an insert.

38

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69

Dominic Smit and Natasha Sacks SAIT, Tel: (011) 804-3710 Email: secretary@sait.co.za, www.sait.org.za

January/February 2019

MARKET FORUM

Long-term rentals –the clever alternative Mines require a range of hire equipment from time to time. Precisely what equipment is needed depends on the type of mine, explains Rand-Air’s Business Development Manager for Long Term Rental, Henry Fourie. For instance, on an open-pit mine, generators and lighting plant are most frequently hired.

On the surface during shaft sinking, the mines use electric or diesel 1500 cfm machines. Once the mine is established, then Rand-Air is capable of supplying air from surface for the underground mining operations to power rock drills of various types.

Rand-Air has also specially modified electric units for use underground. A major deep-level gold mine, for example, will have a two kilometre deep shaft down to a certain mine level. And then from the shaft, it can be as far as a kilometre or more to the rock face where drilling is actually happening.

Asked what hire period constitutes a long-term rental, Henry explains that there is no given period - although the minimum is usually 12 months, which

can be extended to some years. With longer rental periods, Rand-Air will give the mine an option to renew the rental contract if it so wishes. “We have one mining company on our books who has had long-term rental equipment from us for 12 years,” explains Henry.

Long-term rentals come with the benefit of a lower rate to the mine and the mine does not have to employ skilled people to service and maintain compressors or generators.

In terms of any responsibility the mines have for Rand-Air’s hire equipment on a long-term rental, Henry explains that, apart from not intentionally damaging the machines, they have none. “Rand-Air takes full responsibility for maintenance, response times and knowledge of our equipment,” he explains.

Ultimately, by looking to a third party to provide ancillary services, mining operations can conserve operational cash flow as well as capital. In the longer term, this promises the mining company a viable sustainable future with increased profitability,” he concludes.

Depending on the number of machines on site. “There are many benefits to mines hiring equipment on a long-term basis.

Rand-Air, Henry Fourie Tel: (011) 345-0700, www.randair.co.za

much more than just a pump in a

BOX

complete pumping solutions Email. info@pumptechnology.co.za THE SOUTH AFRICAN MECHANICAL ENGINEER

www.pumptechnology.co.za VOL 69

January/February 2019

39

MARKET FORUM

Company strengthens hygienic position

facilitate a stronger position for Verder in the Asian market,” says Andries Verder, CEO of the Verder Group.

consumer markets in the world and linked to this, consumables – particularly food and beverage and pharmacare – are some of the fastest growing industries on the continent too.

However, manufacturers in these industries are some of the most highly regulated, and penalised businesses globally, as impeccable standards of process and product quality and safety must be maintained to protect consumers and end-users. To this end, the global acquisition of JEC enables us to provide our clients with access to further options of high quality and niche market pump solutions that will perform at optimum production levels while meeting all hygienic requirements.”

Darryl Macdougall, Managing Director, Verder Pumps South Africa, says: “Africa currently has one of the fastest growing

Verder Pumps South Africa Kirstin Adam, Tel: (011) 704-7500 Email: kirstin.adam@verder.co.za

The Verder Group, a company specializing in advance industrial and niche market pump solutions and laboratory equipment has acquired JEC, a manufacturer of hygienic rotary lobe, centrifugal and twin-screw pumps.

This acquisition will strengthen Verder’s hygienic position in the pharmaceutical and food and beverage market, offering a full portfolio of high end products.

“We feel that the integration of JEC into the Verder sales and distribution organisation worldwide, will enable JEC to continue its high growth trajectory. The acquisition of JEC with their high quality rotary lobe, circumferential piston and twin-screw pumps will also

APE pumps

Pumps at the heart of Africa

Power Generation

APE Pumps manufacturing pumps for over

H

66 Years!

F

Mining

Leaders in pump innovation

Waste Water processing

26 Nagington Road, Wadeville Germiston 1400, South Africa T: +27 11 824 4810 | F: +27 11 824 2770

B V1

X1

G VIEW SIDE A

A1

Manufacturers of:

I

B1

A

SUCTION VIEW

A

Split casing pumps End suction pumps

Petrochemicals

S

Vertical industrial turbine pumps

G

G

N E

H

J

C

I

S H M

J K L MD

Multi-stage high pressure pumps Vertical sump pumps

ISO VIEW

API 610 pumps

PO Box 14733, Wadeville 1422, South Africa E: apepumps@mweb.co.za W: www.apepumps.co.za

APE ad 148x210.indd 1

40

THE SOUTH AFRICAN MECHANICAL ENGINEER

ISO VIEW

VOL 69

January/February 2019

2018/07/10 10:32 AM

K

L

:32 AM

Pumps to handle dirty water with ease home transferring anything from clean water to slimes, sewage, sludge and liquids laden with solids. “In addition to the robust design of the internals, the pumps can run dry for extended periods without damage.”

“As fluid levels fluctuate, the pump will ‘snore’ until there is enough liquid for it to fully re-prime itself automatically,” he says. “This means that they can run mainly operator free, as the diesel powered units come standard with a minimum of 27 hours of fuel supply – much longer than the usual refill intervals of about 12 hours.”

The Sykes auto-prime pumps have hardened stainless steel internal components which ensure high performance and low maintenance.

Water transfer applications in many industries across Africa must often deal with unpredictable water quality, so it is important to specify a pump built for African conditions - tough, reliable and robust.

Rentals, the hardened stainless steel internal components on its range of Sykes auto-prime pumps is a key factor in ensuring their high performance and low maintenance needs.

Henru says the tough 316 stainless steel impeller and wear plate construction in the pump range from Sykes are at

According to Henru Strydom, Sykes product specialist at Integrated Pump

Efficiency is also a strong point for Sykes, with an average efficiency across the range of about 78%, while handling larger solids than most other autopriming units on the market, he says, highlighting the higher shaft stiffness ratios due to an over-designed shaft and bearing housing.

Integrated Pump Rental, Lee Vine Tel : (072) 627-6350 E-mail: lee@pumprental.co.za www.pumprental.co.za

Big project clenched for roller conveyors Profinet communications for seamless interfacing. Other major advantages are precise positioning and ramp-up and ramp-down, and the ability to vary the conveyor speed accordingly, which makes for a highly customisable system.

SEW-Eurodrive South Africa has clinched its largest project to date for its ECDriveS drive system for light-load conveyor technology. The project is for seven conveyors and 40 accumulation zones at a major automotive manufacturer in Gauteng.

Sensor input and output is provided for easy monitoring, with an alarm triggered in the event of any problem. The drive system has an IP 54 protection rating, in addition to an IP 66 version for more demanding applications. The

DRIVE SIDE VIEW

I

C D The latest order follows a demonstration S project involving two small conveyors, DRIVE END VIEW U Twith one over a production line, to move W T small components around the assembly A area, explainsX SEW Sales RepresentaW A tive, Willem Strydom. The automotive E manufacturer was so impressed with this Q T U V it has now embarked initial foray that N A on a massive seven conveyor, 40 accuR mulation zone project, which is where SUCTION the ECDriveS drive system really came G O P K Q R intoO itsL own, says Willem.

O 1

1

1

K

L

C1

E1

temperature range is –10°C to 40°C, while the roller speed is up to 5m/s.

Gearbox speeds range from 8.5 rpm to 645 rpm for added flexibility.

Set-up is either by dual in-line package (DIP) switches, or the drive system can be programmed using proprietary SEW software.

SEW-Eurodrive Tel: (011) 248-7000 www.sew-eurodrive.co.za

F

B

DISCHARGE 4 - ''X'' DIA HOLES

P The ECDriveS driveA-Asystem has 40 W V U continuous power and up to 100 W A-A ( 1:1 ) dynamic power, optimised for the typical power ranges ofwroller conveyors used in light-duty materials-handling technology.

The name is an acronym for Electronically SHAFT VIEW Commutated Drive System, a brushless D DC gearmotor.

1

SHAFT VIEW

It is easily integrated into existing solutions, as it features both Ethernet and THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69

January/February 2019

41

MARKET FORUM

Level 1 BBBEE rating awarded The Zest WEG Group recently achieved Level 1 status in terms of Broad-based Black Economic Empowerment (BBBEE) ratings.

A subsidiary of the Brazil-based multinational WEG, the Zest WEG Group is over 51.6% black-owned, including a 32.1% stake by black women, and was ranked as Level 2 last year.

Reaching this BBBEE rating has been the culmination of various efforts, according to Zest WEG Group operations director Juliano Vargas, and is just one indication of the investment that the group is making in the country’s economy and society.

Putting waste to good use

From its position as an ISO 9001-listed business, Zest WEG Group was recently one of the first to upgrade to ISO 9001-2015, making it one of only 112 companies out of 2 200 South African

The focus on continuous improvement has been accompanied by developing its skills base in industrial manufacturing and engineering, well beyond the legal requirements of BBBEE. Juliano highlights that leading technology from WEG’s plants in Brazil is also being shared with South African operations, whose facilities will benefit considerably from the skills transfer; this will allow the local engineering operations to become more independent in terms of knowledge and skills.

Zest WEG Group Africa, Louis Meiring Tel : (011) 723-6000 Email: marketing@zestweg.com www.zestweg.com

“Some cities may soon need to transport waste to the other provinces, which can increase waste disposal because of added transportation costs,” says Surendra Krishnaswamy, Engineering Manager at Black & Veatch.

Cities like Johannesburg are taking proactive steps it was mandated last year that residents implement source separation of waste in a phased approach. The mandate specifies that dry recyclables like plastic, paper, glass, and metal are disposed into a separate receptacle from municipal waste, and organic materials into another.

He points out that landfill sites in the United States are also fast approaching capacity. As a result, the government has placed higher tariffs for dumping at landfill sites and has introduced a number of waste-toenergy (WtE) plants to better utilise waste streams, by converting it to generate electricity. Across the United States and Europe in particular, WtE plants have been in operation for several decades.

“The economics of WtE plants are a bit more challenging without some sort of tariff, or tipping fee, structure in place to support it. The economics will continue

www.pumprental.co.za

42

firms with ISO 9001 certification to reach this next level.

Louis Meiring, Zest WEG Group CEO, and Juliano Saldanha Vargas, group logistics and operations director with the certificate Zest WEG Electric received for its Level 1 BBBEE rating.

to evolve, and the long-term benefits of better waste management that come from WtE are undeniable.”

Surendra explains that there are a number of strategies that could be deployed for different waste streams. For example, combustion plants use boilers to capture and convert released heat into steam, which then powers turbines to create electricity. These plants use municipal solid waste and commercial and industrial waste as their feedstocks.

Anaerobic digestors operate at low temperatures to allow micro-organisms to digest feedstock, which is subsequently converted into a mixture of carbon dioxide and methane known as biogas. These plants are typically much smaller than combustion plants and ideally suited for wet organic wastes, such as food waste, sewage sludge, and some types of agricultural residues.

Neither of these systems are able to accept dry and wet waste as feedstocks, meaning that a greater amount of waste separation is required, which increases the operating cost of WtE plants.

Black & Veatch, Surendra Krishnaswamy Tel: (011) 013-3500, www.bv.com

dewatering k c o l c e h t d roun

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69

January/February 2019

tel: +27 11 894 2906 email: admin@pumprental.co.za

MARKET FORUM

Guzzling up spillages in bulk Having taken delivery of the very first Guzzler vacuum truck in the country some five years ago, a coal export terminal has purchased the second unit from Goscor Cleaning Equipment, the supplier of the Guzzler brand in South Africa.

Gregory Venter, MD of GCE, explains that the unit will be deployed to remove spillages from coal chutes and around the facility, as well as for sludge removal from the pits. “The client has an existing unit and, having had a great experience running it for the past five years, requested for the exact same unit to match the performance of the existing one,” says Gregory. “The pits where they vacuum spillages from are about 10m deep, and the vacuum performance of the Guzzler ensures that they are able to clear up the spillages timeously and efficiently.”

would be vacuuming from the deep pits,” he adds.

In line with the client’s requirements, GCE had to ensure that the supplied unit was corrosive-proof due to the environment and the corrosive nature of the product recovered on site. “We also had to reinforce the boom to be able to handle the weight and volume the client

Guzzler vac trucks are designed to vacuum a full spectrum of materials – from solids and dry bulk powders, to liquids, slurries and thick sludge – across industrial areas such as coal terminals, cement plants, steel mills, railroads, oil refineries, chemical plants, foundries and power

stations, among others. One of the key talking points on the supplied unit is the effective dust control capability offered by the 4-cyclone system.

Goscor, Debby Marx Tel: (011) 230-2600 Email: dmarx@goscor.co.za www.goscor.co.za

Process technology provider turns 125 GEA, a provider of process technology components recently turned 125. Oelde is GEA’s largest single site worldwide with a production area of around 37 000 square meters.

Around 1 900 employees, 180 of whom are trainees, are currently working in the areas of design, production and administration. “We had and still have the clear ambition not simply to swim in the global competition, but to increasing efficiency,” says Steffen Bersch, member of the GEA Executive Board. For example, the new building in Oelde, which was built in 2013, was essentially based on the idea of sustainability: its own combined heat and power plant with an electrical output of 1.2 MW reduces the CO2 footprint and generates enough electricity to supply more than 2 000 average sized households.

The company’s own Process Test Centre (PTC), which opened in 2014 and provides specialist support for customers’ investment projects, enables greater customer orientation. Starting with the specification of product properties through the determination and design of machine types to pilot tests at GEA and on site at the customer’s premises.

In cooperation with the customer, GEA Product Managers and GEA Process Development, the PTC also develops and tests completely new processes.

“Finding the right answers with digital products and services are crucial for tomorrow’s competitive advantage,” explains Steffen.

GEA sees digitisation above all as an opportunity and a pioneer for new growth and development potential, both in the new machine sector and with regard to the growing range of service solutions.

In most cases it is applications ‘behind the scenes’, i.e. not visible at first glance, in which GEA technologies are installed.

For example, the GEA PerformancePlus monitoring service is an ideal complement to an industry 4.0 strategy. This uncovers optimisation potentials that enables sustainable plant operation. Modern technologies for condition monitoring combined with the know-how of GEA employees provide the customer with meaningful condition analyses and information for decision making.

For example, in Dubai, The Palm’s underground sewage treatment plant is run with GEA decanters. The plant runs at a capacity of up to 15 cubic metres per hour.

GEA Dr. Michael Golek Email: michael.golek@gea.com, www.gea.com

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69

January/February 2019

43

MARKET FORUM

Company goes green WearCheck is going green by implementing earth-friendly best practices in many facets of their business model.

A key element of MD Neil Robinson’s management philosophy is ardent support for moves that reduce the company’s pollution footprint. “I tasked my team to seek out recycling alternatives, as an extension of WearCheck’s ISO 14001 certification for environmental consideration.

“Some of the earth-friendly initiatives include redirecting our waste from the landfill sites and recycling items wherever possible.

“We meticulously ensure that none of our process waste ends up in a rubbish dump. Instead, all our plastic oil sample bottles, caps and cores are recycled. They are melted down into pellets, which are used to manufacture industrial products such as drain grids.”

The oil from the oil samples is not simply discarded but is also recycled. After the oil and water is separated, the oil is processed and then re-used in other applications. The oily tissue is converted to refuse-derived fuel and is used, for example, as a fuel for cement kilns.

A 2 500 litre JoJo tank was installed at the company’s Pinetown laboratory, which harvests rainwater from the roof.

Another eco-friendly practice is that the company’s plastic courier packets and office paper are given to a recycling company.

WearCheck South Africa Tel: (011) 392-6322 www.wearcheck.co.za

Every drop counts: WearCheck’s Wellington Ndlovu prepares a drum of used oil for delivery to a company which recycles the oil as fuel for cement kilns.

RELIABLE PRODUCTS & SOLUTIONS for the entire industry.

Motor Control Centres, Panels & Distribution Boards

Overhead Lines

Standby/Emergency Generator Sets Motor Protective LV Switchgear

Electrical Construction

Direct Online Starters (DOL)

Motor Scan Power & Distribution Transformers LV Motors, Drives, Softstarters & Switchgear MV Drives, Softstarters and Switchgear

Steam Turbo Generation Set Solutions

MV Motors

Invicta Vibrator Motors Mini Substations

Zest WEG Group is able to offer a range of standard off-the-shelf products as well as end-to-end energy solutions by leveraging best practice engineering and manufacturing capabilities.

All products are engineered to facilitate a safe and reliable environment with operational stability and the highest possible production levels as an objective. Reduced maintenance and ease of serviceability assist in lowering the total cost of ownership.

1 44ZWG_general_130mmx180mm.indd THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69

Tel: 0861 009378

January/February 2019

www.zestweg.com

2018/12/04 10:28

MARKET FORUM

Washing coal with less water The coal preparation process is normally water-based and uses substantial amounts of water, so optimising its performance will impact positively not only the environment but also the bottom line.

One response to this pressure has been the move from the traditional technology of bath washers to centrifugal washers like cyclones as this allows for a higher tonnage per footprint while maintaining optimal separation efficiency.

The effectiveness of cyclones is determined by the nature of the feed, by the cyclone’s dimensions and maintenance and by the circuit’s influences on the equipment.

An additional process that is incorporated into modern designs to reduce water loss is the use of coal centrifuges which can reduce the surface moisture content of the dense medium circuit product from 8 to 15% to 5 to 12% depending of the size of particles being processed.

The performance of screens is also becoming an important point of focus in coal washing. Factors such as bed depth, spray water addition and the open area on screen panels all affect the performance of desliming screens. Here, it is vital to understand screening principles, so that optimal screen performance is ensured.

With drain and rinse screens, it is crucial to drain higher volumes of medium associated with ever increasing tonnages being processed, to minimise medium losses. While it may

TeePee panels provide significantly increased drainage capacity compared to conventional flat panels.

not be practical to replace the screen with a larger version, alternative screen panel designs may be an option to improve drainage capability.

When drain sections perform optimally, they reduce the need to add more spray water on the rinse section of the screen, saving water.

The fine coal circuit is also an area deserving focus, especially with increasing feed tonnages being fed to coal preparation plants. Not only can this circuit become a bottleneck if it is unable to process the full fine fraction stream but as the separation process is mostly water-based this is where much of the water is used. The objective here would be to minimise excessive water use without sacrificing separation efficiencies.

Multotec Group, Vivienne Marray, Tel : (011) 923-6000 Email: marketing@multotec.com, www.multotec.com

Digital capture of plant conditions Emerson’s AMS Inspection Rounds is a new application for the AMS Trex Device Communicator that makes it easier for operations teams to capture, report, and respond to abnormal plant conditions that pose risks to reliability, safety, and performance. The new application allows personnel to accurately record field condition data and automatically deliver that data to other plant systems where decision makers can take action.

With clear dashboards of routes, status, alerts, and action items, users can identify, schedule, and coordinate steps for resolving issues more quickly. Electronic recording of route data saves hours of time typically lost in transcribing paper notes to electronic media and simplifies the generation of audit trails - freeing

personnel to focus on more important tasks. Operations and maintenance teams can also access historical data to identify and eliminate root causes of recurring problems.

Emerson www.Emerson.com/AMSInspectionRounds

With AMS Inspection Rounds, operators on rounds can electronically record any hazardous conditions immediately, such as unusual equipment noise, spills, smells, excessive corrosion, or safety hazards. Condition data can be entered on the ruggedized AMS Trex in real-time - timestamped for compliance and audit requirements.

AMS Inspection Rounds delivers condition data to other plant systems via a wired or secure Wi-Fi connection, eliminating the need for manual entry.

It also provides automated workflows to operations and maintenance personnel while they are in the field, ensuring complete, consistent, and repeatable collection of condition data.

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69

January/February 2019

45

On the Move

Creating 178 jobs The 21 young entrepreneurs selected as finalists in SAB’s youth entrepreneurship development programme, SAB KickStart Boost, have created a total of 178 jobs in their respective communities as a result of the support provided by the programme last year.

Entrepreneurship is one of SAB’s top sustainability goals with a target of helping to create 10 000 jobs in South Africa over the following 5 years.

Laurance Fineberg

Victor Strobel

Laurance Fineberg has been appointed Product Manager for ContiTech’s range of Industrial Fluid Hose.

Bearings International (BI) has appointed Victor Strobel as Customer Offer Marketing Manager, reporting directly to BI Business Unit Head Ross Trevelyan at the Parkhaven head office.

The 21 finalists operate largely in sectors identified at a national level as being high impact job creators, including manufacturing, agriculture, transport, information technology and renewable energy.

Support offered to the entrepreneurs came in the form of “Supply Chain Readiness” themed business development guided by their individual business strategy, one-on-one mentorship, understanding of industry trends, as well as business pitches to SAB depots & partnering organisations.

Top 5 SAB KickStart 2018 businesses: Most Impressive Business Award (R150 000 grant): Profecia IT Sustainability Award (R75 000 grant): KCM Environmental Services

Shaun Combrinck

Neville Alberts

Bearings International has appointed Shaun Combrinck as product manager for its FAG, KOYO, INA, and FSQ bearing ranges, reporting directly to BI Business Unit Head Ross Trevelyan at the Parkhaven head office.

Neville Alberts has been appointed as Branch Manager for Hydraulic and Automation Warehouse (HAW), Johannesburg, a Bosch Rexroth South Africa Group Company.

Lubricants reduce gearbox cost

customer’s requirements and applications, and then suggest an optimal solution, BI Product Manager, Richard Lundgren comments.

Bearings International (BI) has been distributing Rocol lubrication solutions for 25 years, allowing its industrial customers to reduce gearbox power consumption and thereby slashing costs and reducing downtime.

These solutions range from gearboxes to bearings, chains, compressor and hydraulic oils, anti-seize and corrosion lubricants, industrial cleaners, and multi-purpose maintenance, wire rope, specialist maintenance and oxygen system lubricants, among others.

Lubrication experts from Rocol can be called upon to assess a particular

46

In addition to the ROCOL lubricant range itself, BI is also able to supply

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69

Perseverance Award (R50 000 grant): Chumile Transport Up and Coming Business Award (R15 000 grant): Excserpro Innovative Business Award (R10 000 grant): Samac Engineering Solutions SAB Phumzile Chifunyise Tel: (011) 881-8111 Email: SABentrep@za.ab-inbev.com www.sab.co.za

complete solution packages consisting of belting, bearings, and seals, which is a major value-added service that assists its customers in reducing their total cost of ownership. Industrial sectors covered range from food-andbeverage to mining and automotive.

Bearings International Richard Lundgren Tel: (011) 899-0000 info@bearings.co.za

January/February 2019

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69

January/February 2019

47