S MECHANICAL A ENGINEER June 2015
Submersible 2X Suction 0 Thrust Deep well pump
Publication of the South African Institution of Mechanical Engineering, incorporating News of Associate Organisations
Submersible Single Suction Modular Borehole pump
Submersible Induction Motor
Submersible Permanent Magnet Motor
TRENDING TECHNOLOGY ENERGY EFFICIENT REFRIGERATORS
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Chris Reay
Chairman of the Working Committee: Communications (SA Institution of Mechanical Engineering)
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Stephen Murefu
The monthly circulation is 3 947
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Proudly SAIMechE – Proudly South African SAIMechE is proud of the extensive attention to detail featured in many of its training activities, most particularly the following technical workshops which it encourages corporations to book as In-House events: 07
Pressure Equipment Regulations
44
Shutdown and Turnaround Management and Planning
48 – 50 Mechanical Seals (I, 2 & 3) 65
Fans and Air Handling
53
Understanding the Refrigeration Installation Design Process
54
Understanding the Air Conditioning Installation Design Process
72
Mechatronic Motion and Control
85
Fault Current Calculations and Application for Mechanical Engineers
86
Machinery Failure Analysis and Prevention
88
Fundamentals of Industrial Sound Propagation and Industrial Noise
90
Pump Design, Operation, Maintenance and Trouble Shooting
92
Pressure Safety Valves
In-house bookings and enquiries for our many available workshops: Linda Robinson, Tel. 031 764 7136 or Email: linda@saimeche.org.za
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Forthcoming Workshops : July – August 2015 Programmes and Registration Forms obtainable from Carey Evans, Tel. 031 764 7136 or Email: carey@saimeche.org.za Event Code
Event Title
Start Date End Date
Region
Booking Closure Date
E2915
Lubrication & Lubricants
01-Jul-15
East Rand
19-Jun-15
E6915
Lubricants & Oil Monitoring
02-Jul-15
02-Jul-15
East Rand
22-Jun-15
B0815
How Technology Evolution Enables Inventive 07-Jul-15 Engineering Designs
08-Jul-15
Port Elizabeth
26-Jun-15
01-Jul-15
E9215
Pressure Safety Valves
07-Jul-15
09-Jul-15
Vaal
26-Jun-15
H2815
Running Effective Meetings
14-Jul-15
14-Jul-15
Rivonia
02-Jul-15
C7715
Value Engineering in Projects
14-Jul-15
16-Jul-15
Cape Town
03-Jul-15
E4415
Shutdown & Turnaround Management & Planning 14-Jul-15
16-Jul-15
East Rand
03-Jul-15
A0815
How Technology Evolution Enables Inventive 21-Jul-15 Engineering Designs
22-Jul-15
Durban
10-Jul-15
F9015
Pump Design, Operation, Maintenance and 21-Jul-15 Troubleshooting
23-Jul-15
Mpumalanga
10-Jul-15
E9015
Pump Design, Operation, Maintenance and 28-Jul-15 Troubleshooting
30-Jul-15
East Rand
17-Jul-15
B2915
Lubrication & Lubricants
29-Jul-15
29-Jul-15
Port Elizabeth
17-Jul-15
B6915
Lubricants & Oil Monitoring
30-Jul-15
B4415
Shutdown & Turnaround Management & Planning 04-Aug-15
30-Jul-15
Port Elizabeth
20-Jul-15
06-Aug-15
Port Elizabeth
24-Jul-15
D4615
Value Engineering; Value Management
05-Aug-15
05-Aug-15
Vaal
24-Jul-15
A7415
Forestalling Problems Through Root Cause and 11-Aug-15 Failure Mode
12-Aug-15
Durban
31-Jul-15
C4415
Shutdown & Turnaround Management & Planning 11-Aug-15
13-Aug-15
Cape Town
31-Jul-15
D9315
Coaching Skills for Managers in Engineering
12-Aug-15
12-Aug-15
Vaal
31-Jul-15
B9015
Pump Design, Operation, Maintenance and 18-Aug-15 Troubleshooting
20-Aug-15
Port Elizabeth
07-Aug-15
H9315
Coaching Skills for Managers in Engineering
19-Aug-15
19-Aug-15
Rivonia
07-Aug-15
D6515
Fans and Air Handling
19-Aug-15
20-Aug-15
Vaal
07-Aug-15
E7415
Forestalling Problems Through Root Cause and 25-Aug-15 Failure Mode
26-Aug-15
East Rand
14-Aug-15
C9015
Pump Design, Operation, Maintenance and 25-Aug-15 Troubleshooting
27-Aug-15
Cape Town
14-Aug-15
124th SAIMechE National Annual General Meeting To be held on Wednesday, 5 August 2015. Venue: Johannesburg (details to be advised).
After the Annual General Meeting all guests are invited to join the President, Office Bearers and Council for a light supper and drinks whilst networking with like‐minded individuals. The AGM notice including full details will be sent to members shortly or visit the SAIMechE website at www.saimeche.org.za.
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MS-T modular cooling technology
MS-T modular shaft technology
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Will revolutionise pump technology, especially where costs are concerned
IPM interior permanent magnet motor
HDM heavy duty mining
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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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June 2015 Skills on Site
Septmeber 2012
1
Imraan Lambat, an applications engineer for Worldsview
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Dr. Michal Hubรกlek
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MAN ITEMS Y BE OFF CAN ER FROM ED STOCK
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June 2015
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Achievements
Academic
Projects
Stephen Murefu
Career Path
Commentary
INVEST ONCE WITH TWICE THE OPPORTUNIT Y
Visit ppsinvestments.co.za Email clientservices@ppsinvestments.co.za Call on 0860 INV PPS (0860 468 777).
Professional Provident Society Investments Proprietary Limited (“PPS Investments”) (39270), Professional Provident Society Multi-Managers Proprietary Limited (“PPS Multi-Managers”) (28733) and Professional Provident Society Insurance (“PPS Insurance”) (1044) are licensed Financial Services Providers.
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1. 2. 3.
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Figure2. Schematic view of boundary lubricating regime
E:\!BMG\#Jobs\Adverts\2015\062015\BMG-BMG-BEA04062015-ME.cdr 08 June 2015 02:35:09 PM Color profile: Disabled Composite Default screen
Bearing Brands That Deliver. BMG does more than just supply a vast range of superior quality bearings and engineering components to all sectors of industry. We also provide the technical resources needed to keep your bearings and machinery operating at an optimal level. Proud contributors to your success. Part of the process.
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BMG-BEA04062015
BRANCHES NATIONWIDE. 24hr Distribution & Service
Figure3. Process of adhesive wear
Figure 4. Typical example of fretting corrosion The gearbox has been standing for a prolonged period of time at vibrating conditions (ie, next to a running machine)
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Figure 5. The typical effect of fretting corrosion
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Figure 6. The tension determines the torque not the other way around
Figure 7. Bolts act as heavy coil springs; they must be stretched to be effective
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POWER GENERATION
POWER
GENERATION
Greg Leventis
T O D A Y
Virginie Letschert
MARKET ASSESSMENT
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POWER GENERATION
Theo Covary
PROGRAM ANALYSIS
Paul Waide
ENERGY PERFORMANCE ANALYSIS
Nihar Shah
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POWER GENERATION
Refrigerator ( 1-6)
Domestic
Imported Overall
0%
9%
9%
Refrigerator/Freezer (EU category 7&10)
68%
23%
91%
Total Refrigerator/Freezers
68%
32%
100%
Table 1: Import VS. Local production for each product class
Scenario 1:
Scenario 2:
Option #
Change from previous option
Annual Energy Retail Price Manufacturing Consumption (kWh) (Rand) Cost (Rand)
EEI*
Base case Fresh-food cabinet insulation (22mm door, 25mm sides, 746.8 niche and top, 50mm mullion, 35mm back), freezer cabinet insulation of 30mm, compressor = Zanussi GL80AA90, R134a
3,448
1,586
128
1
As base case with fresh-food evaporator height = 0.33m, 547.1 condenser height increased to 1.5m, application of thermal paste to improve evaporator conductivity, and re-optimised thermostat/controls and capillary tube
3,631
1,678
94
2
As Option 1 with fresh-food evaporator height = 0.38m, 409.9 freezer evaporator width = 0.45m , use of higher-efficiency compressor (Danfoss NLX15, R600a), and re-optimised control
4,205
1,944
70
3
As Option 2 with 10mm extra insulation in fridge, freezer 203.7 back/niche, and fridge door, and 20mm extra in freezer; fridge evaporator to 0.48m; and re-optimised control
4,345
2,036
35
4
As Option 3 with extra 10mm insulation on freezer back and 131.8 niche, fridge evaporator to 0.41, freezer evaporator = 0.42m, and re-optimised control
4,375
2,051
23
7,474
3,504
19
Design option with less certain impact 5
Application of maximum vacuum-insulated panel coverage 111.1 and reduction of evaporator cooling capacities to attain design temperatures
* Energy Efficiency Index (EEI) are set out in the European Energy Labelling Directive but essentially an EEI value of 100 is the efficiency of the average product on the EU market in 1993 Table 2: Energy-Efficiency Design Options
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POWER GENERATION
Scenario 1 Results: UPSTREAM PROGRAM
Figure 1:.Refrigerator ownership by Living Standards Measure (LSM)
Scenario 2 Results: DOWNSTREAM PROGRAM
Figure 2: Upstream scenario 1 results
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POWER GENERATION
Administrator
Beneficiary
Form
Ghana
Government
Utility customers
Rebate/replacement
Mexico
Government-owned utility
Utility customers
Rebate/replacement Rebate/replacement
Brazil
Investor-owned utilities (IOU)
Low-income utility customers
United States4
Federal government and Utilities
Manufacturers and Consumers Tax credit and Rebate/replacement
China
Government
Manufacturers and retailers
Rebate
Table 3: International examples of refrigerator incentive programs. The term “administrator” refers to the body that carries out the incentive program. The table shows examples in which the administrator is the government (Ghana, US, China), a government-owned utility (Mexico), or investor-owned utilities (Brazil, US). The term “Beneficiary” denotes the recipient of the incentive. 4 Two types of refrigerator program exist in the US: a manufacturer tax incentive administrated by the federal government and rebate and replacement programs administrated by Utilities or State third party agency.
www.promech.co.za
Test
Benefits
TRC
Utility avoided supply costs • Program administrator costs • Incremental cost
Costs
PAC
Utility avoided supply costs • Program administrator costs • Incremental cost covered by incentive
Table 4: Cost-benefit tests
* Easy navigation through the site Assumptions * Comprehensive archive Discount rate 7.65% Avoided cost users - rand/kWh 0.7146 * generation Free to Administrative cost 18% of total incentive cost * No registration Baseline B (hypothetical new standard) Refrigerator lifetime 10 years * Searchability
Table 5: Incentive analysis assumptions
RITZ Pumps South Africa (Pty) Ltd Tel: (011) 397-5616 www.ritzpumps.co.za
www.promech.co.za * * * * *
S MECHANICAL A ENGINEER
Easy navigation through the site Comprehensive archive Free to users No registration Searchability
May 2015
Publication of the South African Institution of Mechanical Engineering, incorporating News of Associate Organisations
CFD IN BOILER DESIGN RITZ Pumps South Africa (Pty) Ltd Tel: (011) 397-5616 www.ritzpumps.co.za
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Our Technology, Your Success Pumps. Valves. Service.
COOLING DATA CENTRES
1 384 photovoltaic panels were installed across the north-facing roof spaces of the facility. The panels provide a low-maintenance solution rated to last 25 years
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Welcome to HBC‐radiomatic SA (PTY) Ltd From the competent consultation up to sales and services. We will find a radio Solution for you.
Unit 7 The Stewards Industrial Park C/o Main Reef & Beryl Street The Stewards Benoni Phone : +27 11 421‐0004/25 +27 10 020‐0607,0608,0609
QUADRIX
MICRON 5
Fax : +27 11 422‐2571 www.hbc‐radiomatic.co.za
HBC radiomatic SA
MICRON 7
HBC data logger
Useful information at your disposal • The HBC data logger stores different operational data of machine utilization, for example the usage time of drive functions. • HBC user identification. Data is collected for individually users.
• Determins how long the crane was used and by which user. • The collected data can be helpful in various situations, for example in service cases. • The data is read out via Bluetooth® interface and visualized with HBC developed software. 32
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DATA LOGGER
ECO
SPECTRUM
SPECTRUM E
Safe working with camera assistance radiomatic® photon enables safe and precise working in demanding situations where visibility is restrictd.
SPECTRUM B
CARD REMOTE
The intelligent card for more safety and information
TECHNOS User identification is based on a handy login‐card (HBC Smart Card). With its key function it protects the control from unauthorized use. THE SOUTH AFRICAN MECHANICAL ENGINEER
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FUNCTIONS
MEANS Base oils
Additives
• Reduce friction losses
⇒⇒ Lessen viscosity
⇒⇒ Oiliness and friction reducing agents
• Combat wear
⇒⇒ Increase viscosity at high temperature ⇒⇒ Anti wear and E.P. property
• Dissipate and control heat in critical areas ⇒⇒ Lessen viscosity
⇒⇒ Anti oxidant
• Protect equipment from rust and corrosion,
⇒⇒ Anti rust and anti corrosion
• Prevent formation of deposits that settle ⇒⇒ Filterability down and clog filters & pipes.
⇒⇒ Dispersants - Detergents Demulsifier
⇒⇒ Increase viscosity (grease)
• Act as a seal
⇒⇒ Slight swelling seals (compatibility) • Retain their properties for a long time • Perform under widely changing pressure ⇒⇒ Type of base oil and temperature conditions. • Transmit power (hydraulic oils)
INVEST ONCE WITH TWICE THE OPPORTUNIT Y
⇒⇒ VI improvers ⇒⇒ Pour point depressant
⇒⇒ Incompressibility - aeration - resistance ⇒⇒ Antifoamants
Visit ppsinvestments.co.za Email clientservices@ppsinvestments.co.za Call on 0860 INV PPS (0860 468 777).
Professional Provident Society Investments Proprietary Limited (“PPS Investments”) (39270), Professional Provident Society Multi-Managers Proprietary Limited (“PPS Multi-Managers”) (28733) and Professional Provident Society Insurance (“PPS Insurance”) (1044) are licensed Financial Services Providers.
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MARKET FORUM
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MARKET FORUM
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MARKET FORUM
KSB Pumps and Valves factory in Germiston
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MARKET FORUM
From left to right: Oliver Ackermann, Sourcing Unit Director Indonsa; Bruno Witvoet, President: Africa; Paul Polman, Unilever CEO; Piet Joubert, Ingede Project Lead
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MARKET FORUM
Sydney Bruckner
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MARKET FORUM
One of WearCheck’s new ICPs (Inductively Coupled Plasma spectrometers) that has been installed at their Middelburg laboratory is pictured here.
A single stage rotary vane vacuum pump from Oerlikon Leybold Vacuum
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MARKET FORUM Mondi’s Richards Bay mill
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MARKET FORUM
Centac C400 centrifugal air compressor
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On the Move! Adrian Buddingh
Johan Bester
Brian Abbott
Ian Nicholls
Greg Maruszewski
Sean Blake (left) and Jim Guild (right)
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Ernst Smith
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