S MECHANICAL A ENGINEER Feb 2015
Publication of the South African Institution of Mechanical Engineering, incorporating News of Associate Organisations
Double flow high-pressure pumps for mining application
CNG: FUEL OF THE FUTURE METALS AND ENGINEERING INDABA THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 65 February
2015
1
Here’s a big reason you can save even more energy. Etanorm is a classic that keeps getting more efficient. It meets the energy efficiency requirements of the ErP Directive for 2015 already today – for three good reasons: optimised hydraulic components for pace-setting efficiency, individual impeller trimming, and ideally matching drives and automation components. Etanorm is available really fast, comes in numerous variations, and provides the unique reliability of a globally identical product. For more information, please visit www.etanorm.com / www.ksbpumps.co.za
Pumps Valves Service ■
2
■
THE SOUTH AFRICAN MECHANICAL ENGINEER
VOL 65
February 2015
Chris Reay
Chairman of the Working Committee: Communications (SA Institution of Mechanical Engineering)
A management team that did not have a clue how to run a power utility and which resulted in Eskom running into huge losses for the first time in its history
THE SOUTH AFRICAN MECHANICAL ENGINEER
VOL 65
February 2015
3
4
THE SOUTH AFRICAN MECHANICAL ENGINEER
VOL 65
February 2015
The monthly circulation is 3 947
THE SOUTH AFRICAN MECHANICAL ENGINEER
VOL 65
February 2015
5
6
THE SOUTH AFRICAN MECHANICAL ENGINEER
VOL 65
February 2015
March & April 2015 Workshops Event Code
Event Title
Days
Start Date
End Date
Region
B8615
Machinery Failure Analysis & Prevention
3
03-Mar-15
05-Mar-15
Port Elizabeth
A7715
Value Engineering in Projects
3
10-Mar-15
12-Mar-15
Durban
F8615
Machinery Failure Analysis & Prevention
3
10-Mar-15
12-Mar-15
Secunda
B2815
Running Effective Meetings
1
17 Mar 15
17 Mar 15
Port Elizabeth
D8615
Machinery Failure Analysis & Prevention
3
17-Mar-15
19-Mar-15
Vaal
E6515
Fans & Air Handling
2
18-Mar-15
19-Mar-15
East Rand
A9215
Pressure Safety Valves
3
24-Mar-15
26-Mar-15
Durban
E9215
Pressure Safety Valves
3
31-Mar-15
2-Apr-15
East Rand
C9215
Pressure Safety Valves
3
7-Apr-15
9-Apr-15
Cape Town
B6515
Fans & Air Handling
2
8-Apr-15
9-Apr-15
Port Elizabeth
A4415
Shutdown & Turnaround Management & 3 Planning
14-Apr-15
16-Apr-15
Durban
H7715
Value Engineering in Projects
3
14-Apr-15
16-Apr-15
Rivonia
C2815
Running Effective Meetings
1
15 Apr 15
15 Apr 15
Cape Town
D4415
Shutdown & Turnaround Management & 3 Planning
21-Apr-15
23-Apr-15
Vaal
www.promech.co.za * Easy navigation through the site * Comprehensive archive * Free to users * No registration * Searchability
S MECHANICAL A ENGINEER Jan 2015
RITZ Pumps South Africa (Pty) Ltd Tel: (011) 397-5616 www.ritzpumps.co.za
Publication of the South African Institution of Mechanical Engineering, incorporating News of Associate Organisations
INDABA FOR METALS AND ENGINEERING INDUSTRIES KEEP CURRENT ON WARNING SYMBOLS
www.promech.co.za *
Easy navigation through
THE SOUTH AFRICAN MECHANICAL ENGINEER * Free to users
VOL 65
February 2015
7
8
THE SOUTH AFRICAN MECHANICAL ENGINEER
VOL 65
February 2015
THE SOUTH AFRICAN MECHANICAL ENGINEER
VOL 65
February 2015
9
S MECHANICAL A ENGINEER is proud to be a media partner of
10
THE SOUTH AFRICAN MECHANICAL ENGINEER
VOL 65
February 2015
Academic
Career Path
Projects
Chris Reay
Commentary
Achievements
IT PAYS TO KEEP THE RIGHT COMPANY Find out if you qualify to #JOINOURTABLE at www.pps.co.za
THE SOUTH AFRICAN MECHANICAL ENGINEER
VOL 65
February 2015
11
► EIA Process
► Environmental Risk Assessments
► Geographical Information Systems
► Agricultural Assessment and Advise
► Project Managment
► Wetland and Riparian Services
► Natural Resource Services
► Visual Impact Assessments
► Ecological/Biodiversity Services
► Public Participation Process
► Application Assistance
► Game Ranch Management
► Developement Research, Monitoring and Evaluation
N2 Mnini ECO Duties
Plant rescue
Durban Coal Terminal Site Inspection
Ohlanga Pump station ECO Duties
Freightpak Warehouse Site Audit
Public participation Makhabeleni
Ballito Interchange Botanical survey
Site assessment Sundumbili pipeline
l Tel: (031) 303-2835 l Fax: 086 692 2547 l l Email: info@afzelia.co.za l www.afzelia.co.za l
12
THE SOUTH AFRICAN MECHANICAL ENGINEER
VOL 65
Skills on Site February 2015
Septmeber 2012
1
THE SOUTH AFRICAN MECHANICAL ENGINEER
VOL 65
February 2015
13
Logistics Insurance Solutions that gives you peace of mind Aon has the expertise and extensive knowledge in logistic insurance solutions to make sure your cargo has the right cover. We’ll partner with you throughout the full logistics cycle with decades of experience in freight insurance solutions. Extensive regional Network and the Largest African Footprint. Call 0860 453 672, or SMS* “Freight” to 31762, alternatively visit aon.co.za National office: Cheryl Beurel +27 11 944 7214 | cheryl.beurel@aon.co.za Jeffry Butt +27 11 944 7792 | jeffry.butt@aon.co.za Risk. Reinsurance. Human Resources.
#AskAon * Standard rates apply. Aon South Africa (Pty) Ltd is an Authorised Financial Services Provider (FSP #20555). Aon is a Principal Sponsor of Manchester United.
14
THE SOUTH AFRICAN MECHANICAL ENGINEER
VOL 65
February 2015
THE SOUTH AFRICAN MECHANICAL ENGINEER
VOL 65
February 2015
15
The team from Quality Services
Donaldson delivers Extended filter element life Cost – effectiveness Enhanced productivity and manufacturing efficiency Ÿ Holistic filtration solutions Ÿ Ÿ Ÿ
0860FILTER www.donaldson.co.za
16
THE SOUTH AFRICAN MECHANICAL ENGINEER
VOL 65
February 2015
The boiler needs to be subjected to a complete internal and external inspection, including all safety accessories attached to it
THE SOUTH AFRICAN MECHANICAL ENGINEER
VOL 65
February 2015
17
18
THE SOUTH AFRICAN MECHANICAL ENGINEER
VOL 65
February 2015
Philip Theunissen, HVAC manager at Metraclark
Building managers can set individual timers, modes, temperatures and fan speeds with the click of a mouse via the internet and don’t even have to be in the same building
In VRF systems, one condensing unit can be connected to multiple evaporators, each individually controllable by a user
THE SOUTH AFRICAN MECHANICAL ENGINEER
VOL 65
February 2015
19
20
THE SOUTH AFRICAN MECHANICAL ENGINEER
VOL 65
February 2015
Metraclark has recently installed several of these systems at medical clinic facilities throughout Gauteng
VRF uses energy efficient electronic expansion valves which regulate the precise flow of refrigerant as needed by the system for the various settings of multiple users
THE SOUTH AFRICAN MECHANICAL ENGINEER
VOL 65
February 2015
21
EMERGING OPPORTUNITIES IN THE WORLD’S FASTEST GROWING CONTINENT
EARLY BIRD DELEGATE DISCOUNT SAVE AT LEAST $200 IF YOU REGISTER BEFORE 17 JUNE 2015
Conference & Exhibition 15–17 July 2015 Cape Town International Convention Centre, Cape Town, Republic of South Africa www.powergenafrica.com | www.distributechafrica.com
For booth bookings and sponsorship enquiries, please contact:
Invitation to Participate POWER-GEN Africa and DistribuTECH Africa, will once again provide comprehensive coverage of the power needs, resources, and issues facing the electricity generation and transmission & distribution industries across sub-Saharan Africa.
Leon Stone Exhibition Sales International T: +44 (0) 1992 656 671 E: leons@pennwell.com
The events will feature multi-track conference sessions covering strategic, technical and renewable topics with practical solutions and benchmark case studies and concurrent exhibition floor featuring prime movers showcasing the very latest equipment and technologies. POWER-GEN Africa and DistribuTECH Africa have quickly established themselves as sub-Saharan Africa’s leading events that cover the full power spectrum from supply to delivery, focusing on the current and future trends, as well as the needs and resources within this region of the world.
Andrew Evans Exhibition Sales Africa T: +27 (0) 21 930 9515 E: andrewe@pennwell.com
Nowhere else provides you with the opportunity to reach and meet over 3,000 high-level industry professionals in one place, allowing networking, business and sales opportunities with key industry buyers and influencers from around the continent.
To register and obtain further information, visit www.powergenafrica.com or www.distribtuechafrica.com Owned & Produced by:
22
Host Utility:
Presented by:
THE SOUTH AFRICAN MECHANICAL ENGINEER
0284_PGAF_DTAF15_ITP_Ad_210x297.indd 1
Supported by:
VOL 65
February 2015
Supporting Association:
20/11/2014 09:5
THE SOUTH AFRICAN MECHANICAL ENGINEER
VOL 65
February 2015
23
POWER
GENERATION
24
THE SOUTH AFRICAN MECHANICAL ENGINEER
VOL 65
February 2015
T O D A Y
THE SOUTH AFRICAN MECHANICAL ENGINEER
VOL 65
February 2015
25
26
THE SOUTH AFRICAN MECHANICAL ENGINEER
VOL 65
February 2015
Colin Logan, GIBB Technical Executive of Dams, Hydropower and Tunnelling
THE SOUTH AFRICAN MECHANICAL ENGINEER
VOL 65
February 2015
27
Southern African
28th & 29th May 2015
Metals and Engineering INDABA Engage
EMPERORS PALACE
Contribute
Innovate
Sustain
Introducing the inaugural Southern African Metals and Engineering Indaba, a two-day conference scheduled for 28-29 May 2015 at Emperors Palace, Kempton Park, South Africa. The most inuential and knowledgeable leaders and key policy makers will address the conference and present impressive insights not to be missed. The conference will focus on cutting-edge issues related to our industries and also present numerous opportunities for networking and socialising with Government leaders, opinion formers and business leaders drawn from our various sectors. Exhibitors will get the chance to showcase their products in a high-volume trafďŹ c area offering maximum exposure to key decision makers within the industry.
REGISTER TODAY FOR ONLY R7500 INCL. DINNER (EX VAT)
For ticket bookings, and further opportunities to sponsor or exhibit at the event, visit www.meindaba.co.za
SPONSORED BY
OFFICIAL MEDIA PARTNERS
28
THE SOUTH AFRICAN MECHANICAL ENGINEER
4326 Wetpaint Advertising
POWERED BY
VOL 65
February 2015
hf = f
L V2 D 2g
THE SOUTH AFRICAN MECHANICAL ENGINEER
VOL 65
February 2015
29
Figure 2: The typical life cycle characteristic chart of pumping operations in a municipal environment Suction
Delivery
Water
0.5 to 1.5 m/s
0.9 to 2.2 m/s
Waste Water
0.8 to 1.4 m/s
0.9 to 1.8 m/s
Nominal/ Internal Diameter (mm)
75/68.6
90/82.2
110/100.6
125/114.2
Flow velocity (m/s)
3.25
2.26
1.51
1.17
Friction Loss –Hf (m)
72.9
30.2
11.3
6.1
Static Height – Hs (m)
10
10
10
10
Total Head – Ht (m)
82.9
40.2
21.3
16.1
Table 2: Results of Friction Head when using different pipe sizes
Table 1: Recommended flow velocities in pumping systems
30
THE SOUTH AFRICAN MECHANICAL ENGINEER
VOL 65
February 2015
Figure 3: This shows a pump selection of a certain brand of pumps for the duty point used in the example. The pump shows an efficiency of 78%. For information only, this specific supplier’s motor selection shows a combined pump and motor (pump set) efficiency 68.9% Nominal/ Interna 1 Diameter (mm)
75/68.6 90/82.2
110/100.6 125/114.2
Hydraulic Power (kW)
9.9
4.8
2.55
1.93
Shaft Power (kW)
13.25
6.4
3.4
2.57
Standard Motor Size (kW)
15
7.5
4
4
THE SOUTH AFRICAN MECHANICAL ENGINEER
VOL 65
February 2015
31
Figure 4: This shows a pump selection from a different supplier based on the same duty point carried through the example. This selection shows an efficiency of 71% on the pump only. The motor and overall pump set efficiency is ignored for now
32
THE SOUTH AFRICAN MECHANICAL ENGINEER
VOL 65
February 2015
Electrical Cost Comparison Pump 1 Pump Unit Cost
R 10 000.00
Difference in unit cost
R 0.00
Local Power Costs
R 1.00
Pump 2
Saving/year
R 10 000.00 R 1.00
R 1 445.40
R/KWh Shaft Power P2
R 2 890.80 2.59
2.92
R 4 336.20
KWh
R 5 781.60
Operating hours/Day 12
12
R 7 227.00 R 8 672.40
Operating Years
15
15
R 10 117.80 R 11 563.20
Power usage/day
31.08
35.04
R 13 008.60
KW Power usage/year
R 14 454.00 11344.2
12789.6
R 11 344.20
R 12 789.60
R 15 899.40
KW Electricity Cost/year
R 17 344.80 R 18 790.20 R 20 235.60
Electricity Cost Nr. R 170 163.00 Years
R 191 844.00
R 21 681.00
Table 4: The table shows the respective electrical operating cost comparison between the two pumps, based on R 1-00 per kWH. Note that this table considers kWH running cost only
THE SOUTH AFRICAN MECHANICAL ENGINEER
VOL 65
February 2015
33
Typical
Figure 7: This illustration shows typical load (demand) profiles of the three typical industries
34
THE SOUTH AFRICAN MECHANICAL ENGINEER
VOL 65
February 2015
Figure 9: This illustrates the potential energy that can be saved by removing throttling valves and using a smaller pump
Figure 10: This is a pump manufacturer curve showing the flow and head characteristics on the upper level with the corresponding power requirements on the lower level. However, these curves show corresponding head, flow and power when reducing the pump speed according to the percentages shown. Operating a pump at lower speeds using a Variable Speed Drive when possible, can offer substantial energy savings
THE SOUTH AFRICAN MECHANICAL ENGINEER
VOL 65
February 2015
35
(left to right): Ian Huntly (CEO Rifle-Shot), Ross Hunter, Marinus Ras (MD and MAP Champion at RGR), Paul Abeelen, Michael Epstein, Guy Imbert, Peter van Harten.
MAN ITEMS Y BE OFF CAN ER FROM ED STOCK
36
THE SOUTH AFRICAN MECHANICAL ENGINEER
MULTI_ALLOYS_MECHANICAL_ENG_130x1 1
VOL 65
12/20/12 9:45:24 PM
February 2015
IT PAYS TO KEEP THE RIGHT COMPANY Find out if you qualify to #JOINOURTABLE at www.pps.co.za
THE SOUTH AFRICAN MECHANICAL ENGINEER
VOL 65
February 2015
37
38
THE SOUTH AFRICAN MECHANICAL ENGINEER
VOL 65
February 2015
“understanding friction & wear through materials & lubrication”
South African Institute of Tribology “TRIBOLOGY 2015” 11th International Tribology Conference of the SAIT 10 - 12 March 2015 University of Pretoria Plenary guest speakers are Professor Gwidon Stachowiak, Head of the Tribology Laboratory, School of Civil & Mechanical Engineering, Curtin University in Perth, and Professor Wilfred Tysoe, Distinguished Professor at the University of Wisconsin-Milwaukee. Contact SAIT Secretariat Gill Fuller or Isabel Bradley PO Box 1240 Tel: +27 11 804-3710 Kelvin 2054 Fax: +27 86 719-2261 South Africa Email: secretary@sait.org.za VAT Reg No: 4220144317 Email: admin@ssait.org.za
www.sait.org.za
THE SOUTH AFRICAN MECHANICAL ENGINEER
VOL 65
February 2015
39
MARKET FORUM
Tega Industries SA factory has been built and equipped to produce worldclass mining, rubber and engineered products.
40
THE SOUTH AFRICAN MECHANICAL ENGINEER
VOL 65
February 2015
MARKET FORUM
Richard Inglett and Mohamed Trabelsi of KSB Pumps and Valves
IT PAYS TO KEEP THE RIGHT COMPANY Find out if you qualify to #JOINOURTABLE at www.pps.co.za
THE SOUTH AFRICAN MECHANICAL ENGINEER
VOL 65
February 2015
41
MARKET FORUM
42
THE SOUTH AFRICAN MECHANICAL ENGINEER
VOL 65
February 2015
MARKET FORUM The completely assembled and factory tested system Wortstar aeration unit provides optimum oxygen uptake and consistent hygienic design
Imraan Lambat, Application Engineer at Autodesk South Africa
THE SOUTH AFRICAN MECHANICAL ENGINEER
VOL 65
February 2015
43
MARKET FORUM
Tshwane North Winning team
44
THE SOUTH AFRICAN MECHANICAL ENGINEER
VOL 65
February 2015
MARKET FORUM
The 18 000 litre test tank measures 3.6 m by 2.4 m and is fully automated, with different programs for specific Grindex pumps, which are tested according to the OEM’s pump curve.
A typical large-width banana screen in Joest’s Kempton Park, Johannesburg facility that is destined for a colliery in South Africa.
THE SOUTH AFRICAN MECHANICAL ENGINEER
VOL 65
February 2015
45
MARKET FORUM
Some of the Atex-certified mechanical seals
Rory Schulz
46
Giam Swiegers
Henri Robertson
THE SOUTH AFRICAN MECHANICAL ENGINEER
VOL 65
February 2015
THE SOUTH AFRICAN MECHANICAL ENGINEER
VOL 65
February 2015
47
BMW Original Parts
www.bmw.co.za/ originalparts
Sheer Driving Pleasure
ONE PART CAN CHANGE THE OUTCOME.
This is a simple o-ring. Almost as big as your thumb. Seemingly insignificant. On January 28, 1986, a single faulty o-ring brought down an entire space shuttle, mid takeoff. In a complicated chain, it takes only one part that isn’t as sophisticated and meticulously crafted to compromise the whole machine. Don’t take chances. Insist on BMW Original Parts, because without genuine parts, it’s simply not a BMW anymore. For more information visit www.bmw.co.za/originalparts All BMW Original Parts carry a 2-year unlimited mileage warranty.
48
THE SOUTH AFRICAN MECHANICAL ENGINEER
VOL 65
February 2015
IRELAND/DAVENPORT 76899
BMW ORIGINAL PARTS.