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SAMHYDRAULIK, which is one of the leaders in the field of hydraulic transmission, has been operating for over 25 years in the international market, offering a complete range of orbital hydraulic motors and power steering units, axial pumps and motors for medium and high pressure ranges, all characterised by excellent performances. SAMHYDRAULIK employs 120 people who operate inside a very modern and efficient plant that spans over 6 000 square metres to assure a high standard and flexible production capacity. The latest computer technology is used for both design and production, combined with strict quality control procedures during all production phases, which translates into innovative, reliable and functional products that meet the various needs of the market. Its ISO 9001 certification, held since 1994, is the result of a qualityorientated philosophy on which SAMHYDRAULIK has always based its operation.
A H 214
AXIOM HYDRAULICS (PTY) LTD Tel: (011) 334-3068 / 334-3086 Fax: (011) 334-4543 E-mail: axiomjhb@mweb.co.za
THE THESOUTH SOUTHAFRICAN AFRICANMECHANICAL MECHANICALENGINEER ENGINEER
17 Heidelberg Road, Village Main, Johannesburg, 2000 P O Box 260248, Excom, South Africa, 2023
VOL 2012 VOL6262 August May 2012
Chris Reay
Chairman of the Working Committee: Communications (SA Institution of Mechanical Engineering)
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Geared Motors \ Drive Electronics \ Drive Automation \ Industrial Gears \ Services
We drive the mining industry
SEW-EURODRIVE, a BEE company, leaders in the field of geared motors are now able to supply an Industrial Gear Unit that offers more efficiency for mixing and agitating applications with their MC range of Extended Bearing Distance (EBD) Industrial Gear Units.
1Thread_4565_SAM
In process plants, large axial and radial forces occur at the agitator shaft during agitating processes. Traditional designs solve this problem with separate, external bearings that take on the function of the agitator shaft bearings, a solution that very often proves cost intensive. Our new EBD concept extends the bearing span across the low speed shaft and offers stronger bearings within the gear unit itself, which means that in many cases separate bearings are no longer required in the agitator or an over sizing of the gear unit can be avoided. These high torque MC Industrial Gear Units can be used for the reliable operation of mixers, mounting flanges, agitators and surface aerators.
Tel: +27 11 248-7000 Web: www.sew.co.za
SEW-EURODRIVE - Driving the world.
Come and visit us at Electra Mining. Live in Hall 6, Stand J20 at the Nasrec Expo Centre in Johannesburg on 10th - 14th September 2012. We look forward to seeing you there! 4
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Forthcoming Training Events Programmes, fees and registration forms may be obtained from Carey Evans on E-mail carey@saimeche. org.za or Tel. 031-764-7136. Also, detailed individual event programmes are available from Carey. Code
Abbreviated Title
Date – Start
Date – End
Region
C0212
Boiler House; Safety Valves
5 Sep 12
7 Sep 12
Cape Town
C2512
Effective Management Roles
26 Sep 12
26 Sep 12
Cape Town
E0212
Boiler House; Safety Valves
3 Oct 12
5 Oct 12
East Rand
A0212
Boiler House; Safety Valves
10 Oct 12
12 Oct 12
Durban
E2912
Lubrication & Lubricants
17 Oct 12
17 Oct 12
East Rand
E61A2
Leadership & Management Roles
17 Oct 12
18 Oct 12
East Rand
E2912
Lubrication & Lubricants
17 Oct 12
17 Oct 12
East Rand
C5612
Problem Solving for Engineers
24 Oct 12
24 Oct 12
Cape Town
E5612
Problem Solving for Engineers
14 Nov 12
14 Nov 12
East Rand
A5612
Problem Solving for Engineers
21-Nov-12
21-Nov-12
Durban
In-House Workshops To obtain a comprehensive list of workshops that may be held In-House or to discuss your corporate training needs, kindly contact National Events Manager, Linda Robinson on E-mail linda@saimeche.org.za or Tel: 031 764 7136.
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Fritz Fourie, managing director of Hansen Transmissions SA
“The launch of the system at a school in the north-western province
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The teacher can schedule a programme on a specific subject matter at a time when they’re actually dealing with the subject in class
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Academic
Adrie Conradie
Career Path
Projects
Commentary
Achievements
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Excellent Minerals Solutions
WARMAN® Centrifugal Slurry Pumps ENVIROTECH® Centrifugal Slurry Pumps ISOGATE® Slurry Valves Lower your operational costs with the Weir Minerals Solution In slurry and dewatering pumping, processing and control applications where the cost of ownership often outweighs capital cost as a priority, we help our customers address such issues as longevity, capacity, efficiency of operation and maintenance. Warman® slurry and Envirotech® dewatering pumps are among the world’s most comprehensive range of pumps for use in mining, chemical and industrial applications. These pumps are designed for ultra heavy duty applications such as mill discharge, process plant and tailings, high pressure pipelines, as well as other speciality applications.
Expertise where it counts
Robust design and rugged heavy-duty construction, the Isogate® slurry knife gate valve is designed for long life and high reliability. The Isogate® valve range now also includes Autoball™ 3 way check valves, swing check valves, and a diverse range of mechanical and pneumatic pinch valves. Copyright ©2012, Weir Minerals Africa (Pty) Ltd. All rights reserved. WARMAN is a registered trademark of Weir Minerals Australia Ltd and Weir Group African IP Ltd; ISOGATE is a registered trademark of Weir do Brasil Ltda; AUTOBALL is a trademark of Weir Minerals Australia Ltd.
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For more information contact us on: +27 (0)11 9292600 www.weirminerals.com
Gavin Halse MD, ApplyIT
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BLUE IS THE NEW GREEN
Coralynne & Associates +27 (011) 422 1949
0861 00 ZEST (9378)
|
www.zest.co.za
To find out more scan the code or visit: zest.co.za/sustainability
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Member: Mr W Swaffield Cell: +27 (0) 82 553 0717 E-mail: wayne@spragcomponents.co.za Address: 57 Eva Road, Fairleads, Benoni, Gauteng, South Africa Postal Address: P.O. Box 16355, Atlasville, Gauteng, South Africa, 1465 Tel: +27 (0) 11 742 9600 / +27 (0) 11 965 0394 Fax: +27 (0) 11 965 0330 / +27 (0) 86 647 4299 E-mail: sales@spragcomponents.co.za/sprag@lantic.net/sales-sprag@lantic.net Reg No: 1991/017881/23 Vat No: 474 013 2149
One-way Rotation Control
Sprag Components cc, agent of Stieber Clutch for Africa. We are proud to announce the launch of the newly developed and tested products of Stieber Clutch.
Applications: • Anti Rollback
• Drive Units (One Way)
• Roller Ramp Clutches
• Back Stops
• Electric Motor Back Stops
• Semi High Speed Clutches
• Back Stopping Clutches
• Engaging Clutches (One Way)
• Special Purpose Couplings
• Cam Clutches
• Fan Clutches (Back Stops)
• Sprag Clutches
• Centrifugal Lift Off Clutches
• Freewheels
• Test Bench Drive Couplings
• Compressor Drive Clutches
• Gearbox Back Stops
• Torque Arms
• Concrete Mixer Clutches
• Holdbacks
• Torque Limiting Clutches
• Conveyor Back Stops
• Low Speed Back Stops
• Torque Limiter Couplings
• Conveyor Idler Brakes
• Over Running Clutches
• Underground Haulage Back Stops
• Conveyor Indexing Clutches
• Press Clutches
• Winch Back Stops
• Crusher One Way Clutches
• Repair Service Back Stops
• Winch Clutches
• Drawn Cup Needle Roller Bearings
• Repair Service Holdbacks
• Wrap Spring Clutches
• Drive Couplings (One Way)
• Repair Service Torque Arms
• Drive Pulleys (One Way)
• Roller Drive Couplings (One Way)
Stieber Clutch, Germany has been designing and manufacturing high speed freewheels/ backstops for over thirty years, particularly in the mining sector. One of the latest designs is to accommodate an application with several drives, a load-sharing backstop and an optional feature which provides a release function. This is aimed at more safety under-load and two types of release functions are available. Overloads on a conveyor or belt jams are the problem areas where the release function will provide the safety of a controlled release of tension. All heavy industry and mining sites operate with incline conveyors and rotary machines, kilns, fans, crushers, etc. The gear drives will have a high speed backstop or backstops mounted either on the high speed or medium speed shafts. When in use, reduction in power loss is experienced because of the contact-free components of the backstop at high speed. Multiple drives on large conveyors are the sector for which the load sharing backstop is designed. A smaller size backstop can be selected based on the actual load and not the E-motor stall torque, as the case would be when using a standard rigid backstop. This also contributes to savings in power and cost. The backstop with the release function is suitable for any conveyor. Should there be a belt jam or problem, employees can safely work on the conveyor or in the environment of the conveyor, confident that, even though the power be off, the belt would no longer be under tension. A very important safety aspect. A backstop would be selected for safety. The backstop is expected to run continuously for any number of years and if and when a problem occurs, such as a power cut, overload, or belt jam, the backstop is relied upon to provide the safety according to the design specifications. The assurance of the Stieber load-sharing backstop performing when needed comes from the friction linings which are oil impregnated throughout. This means that throughout years of extended use or stand times, the slipping torque remains constant because the contacts between linings and pressure plates are not affected by constant corrosion or contamination from oil. Stieber provides a load-sharing backstop with a release function through an internal hydraulic system. This allows a rapid controlled release of tension when a belt is jammed. The release function can be stopped at any time by the operator which offers more safety and aids productivity. It is easily understandable and can be locally actuated with a hand pump connection. Another option would be a remote or centralized operation. Stieber are prepared to meet customized applications for specific requirements in performance and the Stieber RS Series of load-sharing backstops are specifically for durability and high reliability. Standard models are available in considerable variety up to 300,000 Nm hold torque.
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Overrunning clutches and backstops Types RSRV, RSRT and RSCI–LK Load sharing and releasable backstops
Introduction Types RSRV (load sharing) and RSRT/RSCI-LK (releasable) are centrifugal lift off sprag type backstops with an integral torque limiter. The inner race overruns. Please refer to the RSCI/RSXM catalogue pages for basic information that apply also for the above mentioned models. These backstops are primarily intended for installation on the high speed or intermediate shaft of the driving machines in multiple drive arrangements, where two or more backstops share the reverse load, such as on large inclined conveyors. This design allows the selection of smaller backstops than an arrangement without a load sharing device. The same principle offers a backstop protection when a temporary overload occurs. Please contact Stieber for any further usage of this model. The slipping torque is factory set to the customer's requirement. The high quality friction linings ensure a consistent and reliable friction coefficient even when lubricant has reached the friction faces or after a long time without slippage. Maximum set values are shown in the data sheet.
RSRV
Type RSRV is the basic model. It operates as load sharing device when several backstops are working together on the same machine and needs no attention when installed. The function is automatic and no maintenance is requested.
RSRT (RSCI-LK)
These models include a release facility which, in the event of a blockage or stalked belt condition, allows the stored energy to be released in a safe and controlled manner. The RSRT features a mechanical release. The operator must tight progressively 3 big screws that release the spring forces on the pressure plate. When the screws are loosen again the backstop is automatically re-set to the original slipping torque. The RSCI-LK features a hydraulic release. An integrated hydraulic cylinder actuated by a simple hand pump, progressively releases the backstop. When the oil pressure is released the backstop is safely and automatically re-set to the original slipping torque.
Other Design characteristics 1. Friction linings (RSRV, RSRT, RSCI-LK)
The friction linings control the slip torque. When the backstop is released, some lubricant may get to the friction linings surface. In order to keep a constant friction coefficient and then a constant slip torque to the unit, Stieber has chosen and tested oil impregnated linings. This solution also insures that the latter will also not be submitted to contact corrosion.
2. Bearing support of the outer race. (RSCI-LK)
In order to allow the unit to be released under torque, the complete backstop assembly must rotate backwards from a fraction of to several complete rotations. The bearing allows this rotation without interfering on the slip torque and without damage to the centring device like it would happen with the classical centring spigot that is generally used for the other units.
3. Hydraulic operation (RSCI-LK)
The hydraulic device used to release the backstop insures a rapid, progressive and controlled backstop release. The operation can be interrupted at any time. In case of a multiple backstop system, it is possible to link these, in order to operate them simultaneously from a centralised location. The hydraulic integral system is protected against temperature fluctuations. The optional hydraulic hand pump is set to the maximum working pressure of the unit.
Note: It is possible to make such designs for low speed shafts using a roller or conventional sprag type backstops.
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POWER GENERATION NEWS
ROMECH PUB p - T, O, G 2/20/11 9:54 PM Page 2
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POWER GENERATION NEWS
BLAZING A TRAIL THROUGH CHANGE The CMG name has changed to Regal. As a global player, we offer cutting-edge technology to enhance product quality and service excellence for which we are already renowned. We boast a 2 year warranty on our new Marathon motor - an industry first! We combine global and local expertise to deliver efficient, cost effective solutions for lowest cost of ownership. Choose the right partner when running your Marathon.
Visit us at the finish line
Electra Mining Stand E6 Hall 6
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Pumps Valves Systems
Knockout Unexpected Outages MDX pumps are designed to match the life cycle of your mills. At a major copper mine in Chile, GIW’s patented hydraulic design and advanced materials have almost tripled parts life. The result was a reduction in costs and increased production at the mine site. Got a hard rock slurry problem? GIW offers expert slurry pumping solutions around the globe. Minerals are everywhere. So is GIW. KSB Pumps and Valves (Pty) Ltd www.ksbpumps.co.za
A KSB Company
MDX 750 Pump
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(5)
Figure 1: L 10 bearing life with percentage axial load
(6)
Bearing
L 10h life
1
174,248
2
165,598
3
125,120
4
61,166
5
131,731
6
111,276
7
993,794
8
26,713,820
Table 1: Individual L10h bearing life for a typical conveyor gear unit
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Figure 2: Typical conveyor gear unit layout
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Figure 3: Minimum required viscosity, v
Figure 4: Actual operating viscosity, v
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Figure 5: a23 Life adjustment factor graph
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Daan Louw of Verder Pumps SA
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A peristaltic pump in a slurry application
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Marius Heyns, CEO of Basil Read
David Vaughan, sales director at Babcock
Representing one of the most significant innovations in the past 80 years, the patented, Volvo pipelayer represents a major step forward�
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On par with your needs
Technical Expertise - Service - Quality - Training • Bearings • Couplings • Chains • Sprockets • Pulleys • V-Belts • Gearboxes • Geared Motors • Electric Motors • Oil seals • Lubricants and cleaners • Many other allied products
Not just a bearing shop After Hours National Hotline: 083 250 9191 BBBEE Level 3
For your FREE GIFT, scan
or visit www.bearings.co.za
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PRE-REGISTER AND BE PART OF THE IN-CROWD INTERNATIONAL MINING, INDUSTRIAL, CONSTRUCTION AND POWER GENERATION EXHIBITION SHOWCASES NEW INNOVATIONS, PRODUCTS, SERVICES AND TECHNOLOGIES Pre-registration is now open for Electra Mining Africa, the ultimate market place for all stakeholders involved in the mining, construction, industrial and power generation industries. Visitors can expect to see leading local and international industry players in the packed halls and outside precincts. It’s the ideal place to view the latest in technology and equipment, innovative products and new supplies and services. Experts will be on hand to give advice, live demonstrations will be happening daily and co-located conferences and workshops will add even greater value. Electra Mining Africa is recognized as the second largest mining show in the world and the biggest trade exhibition in southern Africa with global recognition for its broad reach across mining, construction, industrial and power generation industries. Electra Mining Africa and co-located Elenex Africa, Machine Tools Africa and Transport Expo runs from 10-14 September 2012 at the Expo Centre, Nasrec, Johannesburg, South Africa.
PRE-REGISTER FOR FREE ENTRY It’s simple – just complete the registration form at www.electramining.co.za R15 per vehicle, per day for secure parking
Contact the Marketing Director at Specialised Exhibitions Leatitia van Straten leatitiavs@specialised.com +27 (0) 11 835 1565 www.electramining.co.za
MINING • INDUSTRIAL • CONSTRUCTION • POWER
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Eco- friendly solutions
Water jet-cutting and profiling expert AquaJet Profiles supplies highlyspecialised precision-cutting services for complex applications within various industries in South Africa, ranging from aerospace and petrochemical, to architecture and mineral processing. Johannesburg-based AquaJet uses the powerful cutting force of water and garnet sand to create a unique cutting tool known as a jet, explains company director Preeshan Naidoo. “The AquaJet cutting process involves the use of ultra high-pressure water at 3 500 bar, which is pumped through a diamond jewel with a 0,2 mm diameter hole – accelerating the water to Mach 2,5. The abrasive garnet sand is then introduced into the stream of water, and is also accelerated to Mach 2,5.” Preeshan notes that the greatest advantage of aqua-jetting is that it is able to cut material with pinpoint accuracy, without interfering with the material’s inherent structure. “Unlike plasma cutting, aqua-jetting entirely eliminates the heat affected zones (HAZ) during the cutting process; thereby, enabling metals to be cut without harming or changing intrinsic properties. The process is essentially the same as water erosion found in nature, but greatly accelerated and concentrated.” Aqua-jetting can be applied to almost any manufacturing material. “Aquajetting is particularly-beneficial in applications where expensive alloys such as copper, aluminium and titanium need to be cut with complete accuracy, and minimal waste. The precision of our cutting is based on our proximate settings and fine tuning, holding tolerances between 0,09 mm to 0,35 mm, and only 75 percent loss per millimetre.” AquaJet Profiles Preeshan Naidoo, Tel: (011) 908-5550, Email: info@aquajetprofiles.co.za, Web: www.aquajetprofiles.co.za
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The Mobicon mobile container handling system from BLT SA is designed for efficient, safe and versatile container and product handling, in and around automotive assembly plants.
Meclift variable reach trucks are also suitable for use in automotive plants. These units have a 16 ton lifting capacity and at full reach of 2.5 metres, they can safely lift 7 tons. Meclift reach trucks are able to go into a container for efficient, swift and safe container stuffing, de-stuffing and are also designed for handling all types, sizes and shapes of goods. These 16 ton units are able to stack empty, 6 metre containers, three high.
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MARKET FORUM
Pump protection unit The SkidRat pump protection unit is attracting attention in the industry as an ideal way to prevent pumps from being damaged by sediment at the bottom of ponds. This innovative unit was developed by UAT in Australia and is exclusively distributed throughout sub-Saharan Africa by Xylem (formerly known as ITT Water & Wastewater South Africa). Harnessing a pontoon approach, the SkidRat features modular floats that lend this unit to unlimited configurations to suit each pump and application. The tough and durable unit is chemical resistant and can be handled by cranes, excavators, dozers, trucks and trailers. The Australian developed SkidRat is now available from Xylem and offers an ideal way to prevent pumps from being damaged by sediment at the bottom of ponds.
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Xylem, Lee Vine, Tel: (011) 966-9300, Web: www.xylemwatersolutions.com
MARKET FORUM
MARKET FORUM
Two prestigious contracts
The first of the 12 purpose-built 1,2 MW main pump motors for NamWater’s Von Bach-Windhoek Transfer Capacity Project is shown here ready for dispatch from ACTOM Electrical Machines’ Benoni plant.
Actom Electrical Machines recently won export contracts worth a total of R14,5million from two prominent customers – an international pump manufacturer based in Italy, and Namibia’s water supply authority NamWater.
the 1LA1 series previously on offer, comprises totally-enclosed fan cooled (TEFC) motors in the 200 kW to 1100 kW power range, with frame sizes of between 355 and 500 and voltages of 3,3 kV, 6,6 kV and 11 kV.
The pump manufacturer is KSB Pumps, which placed an order with Actom Electrical Machines in January this year for a total of 44 medium and low voltage motors – all destined for use in the water treatment plant currently under construction at Eskom’s new Kusile coalfired power station near Delmas in Mpumalanga.
The contract for NamWater is for the manufacture and supply of 12 customised high efficiency main pump motors which are to be installed at the Von Bach-Windhoek Transfer Capacity Project, which is aimed at expanding the water supply system for Windhoek.
A noteworthy aspect of the medium voltage motors portion of the order is that it represents Alstom’s first large contract for motors in their new MS4 series of high-spec medium voltage cast-iron motors, which were launched into the market early this year. The MS4 series, which have replaced
The motors, which will be purpose-built to NamWater’s stringent specifications, are 1,2 MW 4-pole 690 V Unibox units designed for variable speed drive applications. Actom Electrical Machines, Paul Lepora, Tel (011) 899-1114, Fax (011) 899-1371 E-mail paul.lepora@actom.co.za, Web: www.actom.co.za
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MARKET FORUM
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EXPERIENCE THE POWER OF TURNING VISION INTO REALITY. Engineer what you envision.
Spectra Carbide Tooling Technology (PTY) Ltd. 24 Desmond Street, Korsten, Port Elizabeth PO Box 2631, North End, 6056 Tel: 0860 23 23 23 Fax: 0860 33 22 33 spectra@spectra-sa.co.za www.spectra-sa.co.za
www.walter-tools.com THE SOUTH AFRICAN MECHANICAL ENGINEER
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Reliability. Made by Schaeffler Schaeffler is the bearing specialist in the field of mining. For excavating, conveying and processing, our service accompanies the bearings throughout their entire life cycle. Both our standard range and special bearing designs are tried and tested in the toughest of environments and offer ideal solutions to the most challenging applications. Three examples: For time-saving bearing replacement in hard to reach locations, our FAG split spherical rolling bearings minimize downtime saving you time and money. In conveyors, our new FAG Black Series is interchangeable according to JIS and has Durotect® B coated bearing rings for improved corrosion resistance. And the FAG SmartCheck, an innovative sensor for real time monitoring, provides greater safety for machines and plants.
936 011
For more information please contact: Schaeffler South Africa – Industrial 1 End Street Ext. · 2000 Johannesburg · South Africa Phone +27 11 225 3000 · Fax +27 11 225 3092 tlhalefang.mtombeni@schaeffler.com
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