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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

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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 ■

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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

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The monthly circulation is 3 947

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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

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February 2015

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S MECHANICAL A ENGINEER is proud to be a media partner of

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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

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► 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

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Skills on Site February 2015

Septmeber 2012

1

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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.

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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

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February 2015

The boiler needs to be subjected to a complete internal and external inspection, including all safety accessories attached to it

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THE SOUTH AFRICAN MECHANICAL ENGINEER

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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

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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

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February 2015

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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:

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Host Utility:

Presented by:

THE SOUTH AFRICAN MECHANICAL ENGINEER

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Supported by:

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February 2015

Supporting Association:

20/11/2014 09:5

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POWER

GENERATION

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T O D A Y

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THE SOUTH AFRICAN MECHANICAL ENGINEER

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Colin Logan, GIBB Technical Executive of Dams, Hydropower and Tunnelling

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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

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4326 Wetpaint Advertising

POWERED BY

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February 2015

hf = f

L V2 D 2g

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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

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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

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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

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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

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Typical

Figure 7: This illustration shows typical load (demand) profiles of the three typical industries

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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

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(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

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MULTI_ALLOYS_MECHANICAL_ENG_130x1 1

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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

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“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

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MARKET FORUM

Tega Industries SA factory has been built and equipped to produce worldclass mining, rubber and engineered products.

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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

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MARKET FORUM

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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

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MARKET FORUM

Tshwane North Winning team

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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.

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MARKET FORUM

Some of the Atex-certified mechanical seals

Rory Schulz

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Giam Swiegers

Henri Robertson

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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.

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