SA Mechanical Engineer Feb 12 by Promech Publishing

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

February 2012

The Power to Create

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THE SOUTH AFRICAN MECHANICAL ENGINEER

www.objet.com info@objet.com VOL 62

February 2012

AN ENGINEER’S VIEW

Lowest Common Denominator? Chris Reay

Chairman of the Working Committee: Communications (SA Institution of Mechanical Engineering)

It has been interesting, if nothing else, to read the various news reports on the recent matriculation results. What they convey is that the Education Ministry itself is not exactly a star performer in matters of mathematical interpretation or statistical determination. Celebrations have taken place to highlight certain socalled achievements that, when the numbers are studied in cold, hard reality, leave a seriously sub-standard and effectively deteriorating situation overall.

ne can only conclude that it is politically driven distortion, nothing we do not now expect from the ANC government that has earned itself a dominant fail mark in handling the country’s education system. Here’s the celebratory bit, ably enthused about by our Minister of Education. “The overall matric pass rate for 2011 was 70%, up from 61% two years previously”. Compared with the previous year, there was a 40 % higher number of dropouts who did not write matric, thus enabling a higher percentage pass rate.

Beyond reason that the acceptable pass rate for maths and science is 30% “The average mark for the maths paper was 29%, for physical science 32% and for life sciences 38% (after being adjusted up from 34.9%).” To obtain a final mark, Minister Umalusi adjusts some of the marks either up or down based on various statistical factors. Umalusi refuses to explain how this is done, claiming it is a highly complex, technical and qualitative process, and presumably, they conclude, is beyond the comprehension of the public to understand.

How low can you go?

Unofficially, insider comment is that it is done because learners could lose bursaries, universities would scoff at the unadjusted grades, it could jeopardise those intending to study abroad, and it could prejudice those with good marks whose figures were not adjusted. Overall, it is beyond reason that the acceptable pass rate for maths and science is 30%.One wonders if we can envisage how such low levels can produce candidates capable of mastering simple, daily numeracy let alone designing structures, undertaking complex medical operations and carrying out actuarial evaluations. Such pass levels, however, are clearly sufficient to qualify to become politicians. For it was they who disbanded the Teachers Training Colleges which had historically provided a standard of teacher required

to understand the subjects they had to teach. It was they who decided after many expensive overseas trips and conferences to introduce the OBE system against the advice of many countries and academics who had experience of it, if not for the simple reason that it only works in highly cognitively advanced environments. It was they who have now got the teachers’ trade unions into such a state of self protection and poor work ethic that is pervasive at public schools. All I can say is thank goodness for private institutions and parental involvement that are producing a high grade of students, albeit very small in real numbers. It is imperative to address this alarming state of affairs by getting to the root cause of the problem: surely teacher quality and work ethic. Fudging numbers to give the veneer of success achieves nothing and in fact hides the reality that results in our current skills, unemployment and service delivery crises.

Get real

Insofar as the feedstock to the engineering profession is concerned, I was amazed at some recent edicts that we must draw on our rural communities (many serviced by under-provided schools) for our future engineering resources, clearly motivated by a strong dose of political correctness. When will this level of thinking which should know better about the challenges facing the professions that require a high standard of maths and science get real? It is imperative to draw their feedstock now from the top schools that produce the distinctions to keep the numbers flowing to the tertiary institutions. The real issue is that SA is being steadily duped by a government that has evolved some sort of DNA that controls a process that achieves the lowest common denominator, not the highest common factor. Certainly this is not a formula for a competitive country.

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

February 2012

Atlas Copco Compressor Technique P O Box 14110, Witfield 1467 Tel: (011) 821 9000, Fax: (011) 821 9106/7 E-Mail: air.compressors@za.atlascopco.com www.atlascopco.com / www.atlascopco.co.za

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

February 2012

February 2012 VOLUME 62 NUMBER 2

On the cover: Your partner for energy efficiency and environmental technologies. Managing effective solutions, achieving targeted results for sustainable industries and environments. Clyde Bergemann Tel: (011) 704-0580 Fax: 086 734 0135 Email: enquiry@cbz.co.za www.cbz.co.za

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.

Contents Monthly Column 9 Prominent Professionals

HVAC

Letter to the Editor 30 Under-utilised

11 Hard-earned Experience

Compressors, Air Motors, Vacuum Pumps

Pipes, Pumps & Valves

31 Streamlining Service Delivery 33 Friction Free

13 Maintenance is Crucial 15 Linking Design and Manufacturing

POWER GENERATION TODAY 17 Mobile Traffic Control 21 South African Ingenuity 25 Power Generation News

Materials & Machine Tools 27 Hard Work Pays Off

Regulars 3 An Engineer’s View 6 Institution News 8 SAINT 29 SAIT 36 Market Forum

The monthly circulation is 4 242

Produced by:

Official Publication of THE SA INSTITUTION OF MECHANICAL ENGINEERING

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 Website: www.promech.co.za Managing Editor Susan Custers Editor Kowie Hamman Advertising Mark Bennett Circulation Catherine Macdiva DTP Zinobia Docrat/Donovan Vadivalu

and endorsed by:

Disclaimer

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

 CORROSION INSTITUTE OF SA  SA PUMP MANUFACTURERS ASSOCIATION  SA VALVE AND ACTUATORS MANUFACTURERS ASSOCIATION  THE SA INSTITUTE OF TRIBOLOGY  NUCLEAR INSTITUTE  SA INSTITUTE FOR NON-DESTRUCTIVE TESTING  NATIONAL SOCIETY OF BLACK ENGINEERS  INSTITUTE FOR CERTIFICATED MECHANICAL AND ELECTRICAL ENGINEERS  SOUTH AFRICAN ASSOCIATION OF CONSULTING ENGINEERS  ASSOCIATION OF SOCIETIES FOR OCCUPATIONAL SAFETY AND HEALTH

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

February 2012

THE SA INSTITUTION OF MECHANICAL ENGINEERING

Council 2011/2012 Office Bearers

President .................................................. G Barbic (George) Vice President .............................................. D Findeis (Dirk) National Treasurer ............................... KK Nyangoni (Kudzai)

Branch Chairpersons

Central ...................................................... M Cramer (Mike) Eastern Cape ................................................ W Rall (William) KwaZulu/Natal ................................................. J Moto (John) Mpumalanga Highveld.............................. L Odendaal (Louis) Western Cape ........................................... Dr D Blaine (Debbie)

Portfolios:

Communications/Strategic Planning/ Specialist Group..................................................CD Reay (Chris) Young Engineers Forum................Prof B Collier-Reed (Brandon) Education: Universities of Technology............... E Zawilska (Ewa) Membership .................................................... E Zawilska (Ewa) Professional Development Programme..........M Black (Malcolm) Technology Programme ................................. SZ Hrabar (Steve) To be confirmed....................................................A Roos (Andre) To be confirmed.........................................G Bartholomew (Bart)

Chief Executive Officer: Vaughan Rimbault National Office Manager: Anisa Nanabhay

PO Box 511, Bruma, 2026 Tel: (011) 615-5660, Fax: (011) 388-5356 Email: info@saimeche.org.za Website: www.saimeche.org.za Membership: Central, Eastern Cape, Mpumalanga & KZN: membership@saimeche.org.za Membership: Western Cape: saimeche.wc@vodamail.co.za

Company Affiliates Alstom Power Service SA Babcock Africa Limited Bateman Engineered Technologies Bosch Projects Fluor SA GEA Air-cooled Systems Hansen Transmissions SA Hatch Africa Howden Power Howden Projects Industrial Water Cooling

Osborn Engineered Products SA Rotek Engineering RSD a division of DCD-Dorbyl S.A.M.E Water Sasol Technologies SEW Eurodrive

SNC-Lavalin SA Spicer Axle SA Spirax Sarco SA Thyssenkrupp Engineering Transvaal Pressed Nuts & Bolts

Winder Controls

THE SOUTH AFRICAN MECHANICAL ENGINEER

Compliments of the season to you all. I trust you have survived another silly season, and by now you are probably back in the swing of things and looking forward to the year ahead. That’s where I find myself and so I thought I would share my wish list with you concerning some of the bigger SAIMechE issues which I hope will see some action in 2012.

t the top of my wish list is to see more SAIMechE members using the SAIMechE web platform for their own benefit. I hope to see members finding employment through the site’s career section, and for other members to earn placement and referral fees. Vaughan Rimbault I hope to see members selling their intellectual property through the site, in electronic formats such as PDFs, spreadsheets, videos, audio files. I hope to see members launching successful newsletters for paying subscribers. All these good things are available to all members at no charge - just some effort on their part. I hope SAIMechE will launch the Professional Development Programme (PDP) in 2012, aimed at providing a structured framework within which Candidates can develop towards professional registration. I wish for some meaningful progress in the identification of engineering work, and that those who have been trying to get this issue resolved for the past decade will step aside and make way for others to have a try.

Siemens

Ultra-Flow Engineering Services MBE Minerals (SA) (Pty) Ltd (previously KHD Humboldt Vital Engineering Wedag SA) Weir Minerals Africa Megchem Eng & Drafting Services

Message from the CEO

Finally, I wish for a significant South African company to become the Patron of SAIMechE, and to support our efforts at developing the Mechanical Engineering profession in South Africa. Oh yes, I am also wishing for a 4-week surfing holiday in Hawaii. Until then, it’s shoulder to the wheel. Have fun. Vaughan Rimbault, SAIMechE CEO

VOL 62

February 2012

THE SA INSTITUTION OF MECHANICAL ENGINEERING

Why SAIMechE should be your company’s preferred training partner

South African industry and the engineering fraternity are experiencing advertising overload of technical training offered by local and international conference organisers. Catchy layouts and fancy graphics are employed to attract customers. So why choose SAIMechE as your preferred mechanical engineering training partner? Well, the reasons why are: • We strive for development and presentation consistency, whereby tried and tested training methods are used. (We’ve set a transfer of information standard to which our workshop material developers are required to adhere). • Our prices are competitive against those of many commercial conference organisations. • SAIMechE members may claim a 20% delegate fee reduction on all training events.

• SAIMechE members may apply to develop and present workshops for which they are fairly remunerated. • All workshops are available to be held In-House at a discount rate. • We endeavour to present a tailor made workshop that best suits the client’s needs. • We use concise, no-frills promotional information of events offered. • The efficiency of our administration is consistent, friendly and reliable. Now, you know why using SAIMechE, your 120 year old mechanical engineering custodian body, as your short course training supplier is a great choice! You can view a comprehensive list of available workshops by following ‘Training Events’ on www.saimeche.org.za.

2012 Scheduled Workshops – March to September National Events Department - Tel. (031) 764-7136 Enquiries, Registration & Accounts: Carey Evans, National Events Administrator, E-mail - carey@saimeche.org.za In-House Workshop Bookings/ Event Planning & Speaker Recruitment: Linda Robinson, National Events Manager, Email - linda@saimeche.org.za Event Code Title

Date - Start

A2212

Lean Manufacturing

28-February 2012

Date - End

Region

1 Mar 12

Durban

B2312

Emergency Planning for Evacuation

7 March 2012

E2312

Emergency Planning for Evacuation

14 March 2012

14 March 2012 East Rand

A6112

Leadership and Management Principles & Practice

14 March 2012

15 March 2012 Durban

E2212

Lean Manufacturing

27 March 2012

29 March 2012 East Rand

K2312

Emergency Planning for Evacuation

28 March 2012

28 March 2012 Free State

B6112

Leadership and Management Principles & Practice

11 April 2012

12 April 2012

Port Elizabeth

C2212

Lean Manufacturing

1 May 2012

3 May 2012

Cape Town

F6112

Leadership and Management Principles & Practice

2 May 2012

3 May 2012

Secunda

A2412

Predictive & Preventive Maintenance Best Practice

8 May 2012

Durban

F2412

Predictive & Preventive Maintenance Best Practice

15 May 2012

Secunda

C6112

Leadership and Management Principles & Practice

23 May 2012

24 May 2012

Cape Town

B2212

Lean Manufacturing

29 May 2012

31 May 2012

Port Elizabeth

KHY12

Hydraulics Seminar Seminar

30 May 2012

Free State

Port Elizabeth

C2412

Predictive & Preventive Maintenance Best Practice Workshop

5 Jun 2012

Cape Town

AWF12

Welding & Fabrication Seminar

6 Jun 2012

7 Jun 2012

Durban

B2412

Predictive & Preventive Maintenance Best Practice Workshop

12 Jun 2012

Port Elizabeth

E2512

Effective Management Roles Workshop

13 Jun 2012

12 Jun 2012

East Rand

K2412

Predictive & Preventive Maintenance Best Practice Workshop

19 Jun 2012

Bloemfontein

CWF12

Welding & Fabrication Seminar

20 Jun 2012

21 Jun 2012

Cape Town

E2412

Predictive & Preventive Maintenance Best Practice Workshop

21 Jun 2012

East Rand

FWF12

Welding & Fabrication Seminar

27 Jun 2012

28 Jun 2012

Secunda

A2512

Effective Management Roles Workshop

4 Jul 2012

Durban

BWF12

Welding & Fabrication Seminar

11 Jul 2012

12 Jul 2012

Port Elizabeth

EWF12

Welding & Fabrication Seminar

18 Jul 2012

19 Jul 2012

East Rand

KWF12

Welding & Fabrication Seminar

25 Jul 2012

26 Jul 2012

Bloemfontein

B2512

Effective Management Roles Workshop

1 Aug 2012

Port Elizabeth

F2512

Effective Management Roles Workshop

15 Aug 2012

Secunda

C2512

Effective Management Roles Workshop

12 Sep 2012

Cape Town

THE SOUTH AFRICAN MECHANICAL ENGINEER

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February 2012

SAINT

All Systems Go All systems go for the 18th World Conference on Non-Destructive Testing (WCNDT) in Durban during April this year.

uring 2011, SAINT mentioned the staging of the 18th WCNDT in Durban from 16 to 20 April 2012 in 4 issues of this magazine. Now that 2012 has arrived, SAINT would like to give the final figures to the engineering industry thereby whetting their appetite and encouraging them to attend. The facts for the event are as follows: • 120 companies involved in the NDT field, either as equipment or service providers have purchased exhibition space. The exhibition covers a surface area of around 9500 m2, which is approximately the size of a rugby field. In this exhibition the NDT industry is showcasing the state-of-the-art NDT technology to the world. What an opportunity to have such an exhibition in our country; what a privilege to be able to communicate with the major players in the field of NDT on our doorsteps. Please make use of this opportunity by attending the conference.

• 5 plenary speakers and 25 overview speakers have accepted the invitation to present the state-of-the-technology to the international NDT community. These lectures will have as a purpose the outlining of the NDT industry in the various technologies. Everyone will learn from these papers. • 520 papers will be read in 8 parallel sessions, or will be presented in the form of posters, which will give the opportunity for one-on-one discussions. Here the industry communicates regarding developments which are on the go. Please make use of this unique opportunity to become aware of the latest developments. • A number of discussion sessions and podium discussions have been scheduled on topics of interest to various sectors in the industry. • The programme has been submitted to SAIMechE for the awarding of CPD points for attendees, who need to gain the points for 2012. Please make this the event to gain at least 3 of the CPD points for 2012. As can be seen this will be a world class event. Please make use of the opportunity to become conversant in NDT and to be part of this prestigious event. Such an opportunity will not come to South Africa again in our lifetime. All information is available on www.wcndt2012.org.za. Dr. Manfred Johannes President SAINT

THE SOUTH AFRICAN MECHANICAL ENGINEER

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February 2012

MONTHLY COLUMN

Prominent Professionals Mathau Botsane Pr.Eng, Senior Engineer

just integrate them so that the mines of the future are fully automated. The wealth of Africa is underground, but we must exploit this cost effectively.

Academic School

High School in Virginia in the Free State

Projects

Graduate studies

Mechanical Engineering at Wits University

Most challenging and rewarding

Post-Graduate

MBL through Unisa; Post-graduate diploma in Mining Engineering at Unisa

Although designing a new mine provides an opportunity to implement new technologies and improve on old ones, the challenge lies in getting it all right at the design stage. It requires diligence, experience and good judgement to integrate the various elements of mechanical engineering to make it feasible and workable. It’s basically a complex problem-solving exercise.

Professional Bodies

South African Institution of Mechanical Engineering; ECSA registered; serve on ECSA QEC committee member; Member of the accreditation committee for Mathau Botsane Universities.

Career Path - First employer

Anglo Coal at open cast mine in Vereeniging

Growth path

Anglo Coal; Sasol Mining, from foreman to section engineer; Goldfields Mine; Exxaro as engineering manager; Anglo Platinum as engineering manager; Murray & Roberts.

Commentary Are there shortcomings in the Mechanical Engineering Industry in South Africa?

One major shortcoming in terms of mechanical engineering is that the public only hears about us when failures of significant multitude happen. The perception is we’re only there to fix failures because we’re responsible for them anyway. We as mechanical engineers should be more proactive and do much more marketing of the profession in the eyes of society and the general public.

Present employer & position

Murray & Roberts – senior engineer

Achievements A project

To develop a multi-billion rand mine right from the Greenfield stage through to an operating concern requires a broad knowledge of all the various engineering technologies and is a very satisfying achievement. Using engineering methodologies, you have to design an entire mine into a workable solution which has to be constructible.

Future – a concept, a dream or a wish

It’s been a passion for quite a long time to play a role in the development of fully automated mining. Traditionally, and even today, the mining industry does not portray a technology-rich model which attracts intelligent young people. This is a mindset which should change. There are so many opportunities to employ advanced technologies to optimise the mining processes. The technologies are there, we must

How would you mend this?

Mechanical engineers should start getting out there to market the things we do. Take the Gautrain and World Cup projects, for instance. The engineers never came forward and boasted, this is what we’ve done to bring these great projects to realisation. Had it not gone well, the engineers would have had to explain why.

Message to young engineers

Looking at the African continent in terms of engineering, there is a lot of room for improvement. The young engineers of today will have to take it to the high end. They’re flexible, dynamic, think fast and are much more daring. It is dependent on them to take it further, create a balance and shape the future of the engineering profession.

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

February 2012

Passion Through Our People

Coralynne & Associates +27 (011) 422 1949

0861 00 ZEST |

www.zest.co.za

CAPE MECHANICAL ENGINEER THE SOUTH AFRICAN

VOL 62

February 2012

ZEST Electric Ghana Limited

HVAC

Hard-earned Experience An industrial blower could range from a straightforward roots blower through to highly-sophisticated turbo compressors, each with its own technology suitable for specific applications.

A Mechanical Engineer” speaks to Brian Volk of PHC Projects in Midrand, a company specialising in the design and manufacture of process air, vacuum, refrigeration and industrial cooling & heating solutions. “When business tapered down a bit on the industrial cooling side we started getting more involved in waste water treatment in terms of aeration blower system design and manufacture,” he says. “This machinery being very similar to gas recovery systems naturally led to us getting involved in this aspect of blower technology and applications.

The standard, simplest roots blower we manufacture is a low pressure machine usually with pressures below one bar Roots blowers

“The standard, simplest roots blower we manufacture is a low pressure machine usually with pressures below one bar used in the aeration of sewerage or mine flotation cell applications,” Brian explains. “Although the principles are simple, each application has to be treated individually and the system designed accordingly to achieve optimum efficiency.”

Blowers built into accoustic enclosures

Brian Volk of PHC Projects

The basic blower is imported and then custombuilt to each application in terms of duty, frame structure, acoustic requirements and control systems. “Our most recent large order was seven roots blower units for a waste water treatment plant in Namibia,” Brian elaborates. “The client wanted the units built into acoustic enclosures so we had to change the configuration to fit into space available. Instead of the silencers being fitted vertically as is usually the case, we configured them horizontally. Additional cooling fans were then mounted into the enclosure structure. “Prior to fulfilling this order we had manufactured similar units in acoustic enclosures, but on a much larger scale, for a mining flotation cell application” Brian adds. “Driven by 200 kW motors they are the biggest we’ve built, in fact, we had to do the final fitting into the enclosures outside our workshop due to their sheer size.”

Gas recovery

Based on the same basic principle, but with additional components such as heat exchangers and a cooling tower making up part of the gas and air flow circuit, Brian recently designed and built a skid mounted gas recovery system. “The client wanted to take the gas off a diesel powered furnace, compress it, cool it and use it in other processes in order to save on certain chemicals,” explains Brian. “The CO2 recovered from the outlet gas is then used to complement one of the chemical processes on their production line. “From the gas discharge of the furnace, the gas enters the unit through a finned coil heat exchanger which is cooled from a dedicated cooling tower, then flows through a liquid ring blower and into a separator vessel from where it goes to the point of use,” explains Brian. “This is a system we designed from scratch, specific for this application, complete with flow meter and control system. It was a steep learning curve, but now we have yet another solution

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February 2012

HVAC

came up with a more affordable turbo compressor for this industry. “In essence we now have a simpler, more affordable machine. Several similar machines are in operation at various sites around the country.” Brian adds. “It’s a highly-efficient machine which allows us to offer a comprehensive range of solutions to all sizes of water treatment plants in the sewerage and mining industries.” At the heart of this range of single stage turbo compressors is the impeller design. “The integration of an overhung high efficiency impeller, precision gears and high stability bearings results in smooth, minimum power loss transmission,” explains Brian. “It is fitted with a pressurised oil lubrication system with high integrity protection which ensures maximum reliability and hence availability of the equipment.

Applications

The standard, simplest roots blower manufactured is a low pressure machine usually with pressures below one bar

A comprehensive range of solutions to all sized water treatment plants in the sewerage and mining industries to offer the South African industry.”

Turbo blowers

On an even bigger scale, for large waste water treatment plants, PHC is now an agent in South Africa for the more sophisticated, higher capacity blowers made by HWT, Howden Water Technology, a joint venture company of Howden International formed specifically to serve the water treatment industry internationally. “Originally this turbo blower was built by Howden for the petrochemical industry, but it proved to be too costly for the water treatment industry,” explains Brian. “HWT took the basic machine, removed all the sophistication not needed for water treatment applications and

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Apart from providing aeration for the treatment of industrial effluent, these blowers can be used in the petrochemical industry as air blowers for sulphur recovery, providing reaction air for the catalytic recovery of sulphur, in sulphuric acid plants as combustion air blowers and in the flue gas desulphurisation process as oxidation air blowers associated with the cleaning of flue gases produced within power and heavy industry. They’re also used as air suppliers in furnaces, smelters and reactors, as process gas and fuel gas blowers as well as air blowers associated with biochemical fermentation in the pharmaceutical and the yeast production industries. “We’ve been in this market for the past five years and now have the right products to offer a comprehensive service to a wide range of industries in South Africa,” Brian concludes. “Apart from our wide range of standard machinery, we’re able to design and build specialised solutions while continuously striving for optimum efficiency.” Brian Volk, PHC Projects, Tel: (011) 805-5221, Email: brian@phcprojects.co.za

February 2012

PIPES, PUMPS & VALVES

Maintenance is Crucial They say that after electricity, the next crisis looming is our water supply. Much of the problem seems to stem from a dire lack of engineering skills in our municipalities exacerbated by a distinct lack of maintenance.

A Mechanical Engineer” visits WPS (Waterpump Services) in Pretoria north, a company which, among many other pump applications, specialises in waste water treatment pump repairs and installation.

Before - An incoming pump at WPS

Riaan Seegers of Water Pump Services

Aged equipment

“The company has been around since 1980, focussing mainly on sewerage works at municipalities, fresh water plants and waste water treatment plants at mines right across South Africa,” says manager Riaan Seegers. “Across the board, the main problem which leads to waste water plants bursting at the seams can be ascribed to aged piping and pump equipment which has not been maintained properly for extended periods of time.

It’s not really a case of increased capacity, but rather pumps which are sometimes over sixty year old “At many of the pump houses we get called out to inspect, we find that it’s not really a case of increased capacity causing overflow, but rather pumps which are sometimes over sixty year old,” Riaan adds. “First off, there are no longer any spares available for these old pumps and secondly, they’re in a poor state having been neglected for years resulting in seals starting to leak all over the place while pipe work simply collapses due to severe corrosion.”

Theft

Another major problem which is not only affecting pump stations in the water treatment industry, but also farmers and other pump stations located in remote areas, is theft. “Many pump installations out in the bundu, away from any activity, are frequented by thieves even though they’re often housed in a pump house structure,” says Riaan. “The culprits break in and take everything, from the pump to the wiring and control panels. Not necessarily to sell as pumps, but purely to sell as scrap metal. “Borehole pump installations are plagued with the same problem,” he adds. “Just in our immediate area around Pretoria North, and we’re not the only suppliers here, we’re doing around 10 to 15 borehole pump replacements a month due to theft. Sometimes thieves vandalise pump installations only to steal a piece of electric cable half a metre long.”

Products & Services

Walking through the product display area at the THE SOUTH AFRICAN MECHANICAL ENGINEER

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February 2012

PIPES, PUMPS & VALVES

After - A pump after its overhauled

all types of pumps and bio-filters for purification plant,” explains Riaan. “Apart from servicing a large client base of private borehole customers, numerous high rise buildings in Pretoria call on us for the maintenance and repair of their booster pumps and subterranean drainage pumps, including chiller pumps on air conditioning units. We also service pool pump units, filters, chlorine dosing units and water purification systems.”

New problems

Problems with sufficient water pressure in highrise buildings seem to be on the increase at some municipalities. “Lately we’ve had several cases where the fresh water pressure is insufficient for the proper flow of water throughout the building,” explains Riaan. “We go out to investigate each case, but generally, installing a water storage tank fed by the municipal feed followed by taking it through a booster pump into the building, solves this problem. “In some areas in Johannesburg, for instance, there are regular water cut-offs as old rusty pipes from the main supply burst. Buildings and factories are without water for several days while they repair the pipes,” adds Riaan. “Our custom-designed storage and booster system ensures enough water under pressure, a critical factor particularly when factories depend on constant water flow. One of our bigger installations is the provision of an 80 000 litre water storage solution to a shopping centre. Booster pumps supply all the tenants while keeping the fire extinguishing system under constant pressure.”

A complete pump system built by WPS

Pump selection

In Riaan’s book, the key factor lies in selecting the right pump for an application. “You have to start off the selection process with as much information as possible about the application and what the customer expects from the pump system,” he says in conclusion.

Problems with sufficient water pressure in highrise buildings seem to be on the increase at several municipalities company’s premises in Hermanstad it becomes clear that WPS supplies just about any type of pump from all the major pump manufacturers around the world for all industry sectors. “Our scope of work includes the erection of sectional water tanks and tank stands, as well as repairs to

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“Selecting a pump which will run off its curve leads to cavitations, impeller damage and the overheating of the motor and bearings which in turn results in premature failure. Also, once the system is installed, the most critical factor for long pump life is regular preventative maintenance, something grossly neglected in many pump stations.” Riaan Seegers, WPS, Tel: (012) 377-0668/0407, Email: wpscc@netactive.co.za

February 2012

PIPES, PUMPS & VALVES

Linking Design and Manufacturing Engineering designers can push the envelope but, at the end of the day, it’s no use to anyone if it’s impractical to manufacture.

New pump range

This is essentially what happened in the development of a new range of VersaFlo vertical spindle pumps manufactured by Walter Meano Engineering (WME) in Germiston. “SA Mechanical Engineer” speaks to managing director of WME, Detlev Börner, about the new features of this popular mine dewatering pump. “The new design of the VSE series addresses the most common failures users have been experiencing in vertical spindle pumps,” he says.

We started the development of our own design, specifically to increase reliability and reduce maintenance costs

s new developments in CNC machining come to the fore, so engineers can push the design frontier not only for new products but also by tweaking existing designs. Refinements and even subtle changes can result in dramatic improvements in efficiencies.

“A while back, we were doing training at a workshop that was flooded with repairs on these pumps, we reviewed the basic design and realised there’s plenty of room to make improvements” Detlev adds. “That’s when we started the development of our own design, specifically to increase reliability and reduce maintenance costs. With better machining technology at our disposal today we’re able to make design changes which simply weren’t possible or cost-effective in the past.”

Features

The new range is represented by three main models, the VSE 50, VSE 80 and VSE 100, with the numbers indicating the diameter of the outlet of each model. “The VersaFlo VSE vertical spindle pump design was complemented strongly by our design experience over the past 30 years, gained with the well-known Pompie pump used on mines for decades. The same applies to the VPM air driven pump as well as the VPM electric vertical spindle pump,” Detlev says.

Detlev Börner of Walter Meano Engineering at his design station

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PIPES, PUMPS & VALVES

ing stock, built up when the engineering side of the business is quiet,” adds Detlev. “In addition to manufacturing submersible pumps, we also provide machining services in the light engineering field to OEMs in the mining, motor and defence industries.” Although the new pumps look a lot like older designs and other makes on the market at face value, the changes have brought about a pump design with improved performance. “Although we have had to keep in mind that the basic components of the new range of pumps need to be interchangeable with existing designs in the market, we’ve been able to bring in unique features in our design,” explains Detlev. “For example, the way we manufacture the spindle on a machining centre is unique. The fact that not many companies have this facility is probably the main reason it hasn’t been copied yet. Our competitive advantage lies in our human resource skills, CAD (computer-aided design) and computer-aided machining (CAM) software which allow us to utilise the full capability of our machines to produce highquality products at competitive prices.”

Savings

The VSE series of electric spindle pumps

resulting in lower loads and a much longer life span. It also has a separate wear plate and inlet screen, resulting not only in reduced maintenance cost, but also easier maintenance.”

New tricks

Normally on a vertical spindle pump the shaft would be contained in a protective housing. This is split halfway along the shaft to mount the bearing because the original designers of the shaft system did not want the lower bearing to be submerged with the volute of the pump.

The first VPM-E vertical spindle pump design from WME was well received in the market a couple of years ago, but before long the mines started asking for bigger pumps which prompted Detlev to extend the range while simultaneously improving the design. “The more electricity rates increase, the more viable it becomes to gain just 5 to 10 % on the actual efficiency on a pump and if you can simplify maintenance at the same time, it all adds up in the long run,” he says. Detlev does all the design work himself, using SolidWorks 3D CAD software. “To exploit the full potential of modern CNC machining we’ve now invested in a flow analysis package from SolidWorks called Flow,” Detlev remarks in conclusion. “This will allow us to explore further improvements of our pump designs, particularly in terms of the efficiency of pump performance.” Detlev Börner, Walter Meano Engineering, Tel: (011) 8738620, Email: wme@mweb.co.za

Although the new pumps look a lot like older designs, the changes have brought about a pump design with improved performance

Engineer Placements

“With new bearing and seal technology that allows for the submersion of this bearing, we could remove the flange arrangement halfway along the housing and put the bearing right down the bottom of the shaft,” says Detlev. “This not only provides more stability in the long shaft, but it’s easier to manufacture the housing and it will be easier to carry out maintenance on the bearing.

Engineering

“Having a full engineering facility in-house provides us with the competitive advantage of always hav-

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Are you looking for engineering resources?

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February 2012

POWER GENERATION

PROMECH PUBLISHING Tel: (011) 781-1401 Fax: (011) 781-1403 Email: editorial@promech.co.za Website: www.promech.co.za Managing Editor: Susan Custers Editorial: Kowie Hamman, Eleanor Seggie Advertising: Mark Bennett Circulation: Catherine Macdiva DTP: Zinobia Docrat/ DonovanVadivalu Disclaimer PROMECH Publishing does not take responsibility for the opinions expressed by individuals.

TICKER TAPE

All rights reserved. No editorial matter published in “Power Generation Today” 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.

Mobile Traffic Control Pierre Sanan is a thinker, not in a philosophical way, but rather in a mechanical way. He invents a thing, patents it and then produces it as a South African product. Not too long ago he visited China and while sipping his first morning cuppa in a shop overlooking a busy intersection, he spotted Chinese traffic cops one after the other zipping through the congested intersection on an electric bicycle to get to work.

y first thought was what a great thing to take back to South Africa,” Pierre says excitedly. “Toying with the idea really got me thinking which is when the idea of a mobile traffic light sprang to mind. These would be very handy when traffic lights go out, much better than a pointsman,” he adds. “I made some sketches there and then, thought a lot more about it and when I got back to South Africa I had the drawings made up of how this battery-powered traffic light would be fitted onto the Chinese bicycle. The next step

I had the drawings made up of how this battery-powered traffic light would be fitted onto the Chinese bicycle

An umbrella body, provisionally called the SA Renewable Energy Council, will be launched by four industry-related associations to act as a voice for the renewable energy industry in South Africa The volume of electricity consumed in SA grew by 0.2% (48 Gigawatt-hours) year on year (y/y) in November, and electricity for the first eleven months of 2011 rose by 0.9% y/y, says Statistics SA.

was to patent the invention, a procedure which special patent attorneys in Pretoria formalised and carried out for us.” Pierre is one of those fortunate people who not only invent new things, but can also make them himself in his workshop in Turffontein, south of downtown Johannesburg. “While waiting for the patent to be registered, we started building the first mobile traffic light onto the electric bicycle, now known as the Motralite,” he explains. “This one we painted in the colours and logo of EMPD (Ekurhuleni Metro Police Department) while the second one became JMPD for the Johannesburg police department.

How it works

“We built the box housing the traffic lights, battery and control electronics, adapted a tripod to fit onto the side of the bicycle so The Department of Energy plans to centralise the regulation of the entire energy sector, including fuel and liquefied petroleum gas, under Nersa. South Africa’s future energy mix envisioned in the IRP2 is putting the competitiveness of the coal industry in danger and is too ambitious for the local, vastly coal-dependent economy, says XMP Consulting senior coal analyst, Xavier Prevost.

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Pierre Sanan in his workshop with his patented mobile traffic control solution

A solar panel fitted on top of the light box, not only to charge the light’s battery, but also the bicycle’s battery

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that it can either operate in situ on the bike, or be taken off and placed in an intersection to control traffic as any normal traffic light would do,” explains Pierre. “The traffic cop simply drives the bike into an intersection, lifts it onto its stand, raises the light up on the tripod and switches it on with a remote control. At first the lights in all directions flash red for a couple of seconds and then automatically switch into a normal sequence with the right-turning arrow being last.”

Now that the mobile traffic light is patented, Pierre has already come up with more features such as a solar panel fitted on top of the light box, not only to charge the light’s battery, but also the bicycle’s battery. “At a recent traffic convention held in KwaZulu Natal we exhibited the bicycles and everyone, even a local traffic light manufacturer, loved the concept,” Pierre says. “Back in Joburg the municipality invited us over to demonstrate the bikes in their yard to a gathering of all their

Eskom's generation division says that while it agrees with moves towards cleaner forms of energy, it will not do away with coal. Meanwhile, Numsa is calling for a socially-owned energy renewable sector to boost job creation.

Last year, the world market for wind turbines reached a total size of 41 GW, after 37,6 GW in 2010. Preliminary data by WWEA shows that total capacity worldwide has come close to 239 GW.

Energy Minister Dipuo Peters said that foreign investors are welcome to invest in South Africa's energy sector but they must bring their technology with them so local firms can adopt it.

Irish developer Mainstream Renewable Power, that plans to spend R9.9-billion building 18 wind farms in South Africa over five years, is on track to build its first facility at Jeffreys Bay next year.

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POWER GENERATION

The four-directional traffic light is powered by a battery, charged by a solar panel on top of the box

The electric motor for the bicyle is built onto the hub of the rear wheel. Pierre’s tripod holder allows in situ operation or thelight can stand on its own

traffic officers. So far reactions have been favourable and hopefully some orders will follow soon.”

South Africans simply aren’t built like the Chinese and this little electric bike could very well take some strain Comfy seating

One problem we envisage is that South Africans simply aren’t built like the Chinese and this little electric bike could very well take some strain or become quite uncomfortable under the weight of some of our traffic officers, so we asked Pierre about this. “The standard saddle is spring-loaded and quite comfortable, but if it becomes a problem, we’ll simply fit a bigger saddle,” he says with a chuckle. “However, we’re already negotiating with a Chinese manufacturer to also bring in an electric scooter which is a little bigger, has more power and has a wider seat than the bicycle.”

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Pierre Sanan, Tel: (011) 683-8383, Email: psanan8@gmail.com

California-based BrightSource and its partner Alstom will partner with Sasol to conduct a FEED study for a solar thermal power plant. Sasol will use the study to determine how best to deploy BrightSource's technology in the markets it serves. Suzlon Energy, a global wind-power company based in India, is considering two possible manufacturing sites in SA. It has also been awarded a contract to supply 2,1MW turbines in the Eastern Cape.

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February 2012

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February 2012

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ENERGY EFFICIENCY

South African Ingenuity “Architect & Specificator” was delighted to attend annual Eskom’s eta Awards which, as usual, spawned some novel ideas.

Industrial Category

Colgate Palmolive — a ten-year lighting programme has reduced energy consumption by 45% while increasing production by 100%. Anglogold Ashanti — compressor and pipe optimisation project leading to a saving of 5.2MW per year.

Residential Category

Solek — reduced demand from the grid by 450MW per year through solar water heating and photovoltaic project at Kleinmond low-cost housing project.

Colgate Palmolive, Roy Mwanzia

Commercial Category

Power Optimisa — optimising fluctuating and excess voltages led to savings of R105 523 per year at Woolworths Bridge store in Tyger Valley, Cape Town. Woolworths — an automatic load transfer system switches off non-essential appliances such as geysers, lighting and airconditioning resulting in an annual saving of R8.366 million. First National Bank — hailed as a green building

AngloGold Ashanti, Jean Greyling

Power Optimisa, Alan Palmer

Solek, Adriaan Rootman

Anton Killian (left) of Woolworths and Craig Webb of UGU Engineering Solutions

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ENERGY EFFICIENCY

in its day, the First Rand Office Park in Fairlands, Johannesburg underwent further interventions in lighting, water heating etc, to arrive at an annual saving of R7.5 million per annum.

Efficiency Champion: Community Category

Deborah Schuiling â&#x20AC;&#x201D; Ekanah House School started with 100 pupils in 1997 growing to 1 300 pupils today all of whom are educated in green principles, recycling litter from the community, while being schooled in a building with an indigenous garden, natural ventilation, water-less urinals etc. Funisile Zothe â&#x20AC;&#x201D; the driving force at Three Crowns Junior Secondary School in Lady Frere, Kavali village, eastern Cape, Funisile has introduced a worm farm, solar cooking,

Deborah Schuiling

James Cruickshank

First National Bank, left to right: Rajen Reddy, Willam Cass, and Riaan van Wyngaardt

Simon Grier

Funisile Zothe

Marlene Snowdon

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ENERGY EFFICIENCY

Utillabs, Themba Gama and Paroshen Naidoo

Iweathar, Russell Witthuhn

Meinhard Fourie

Nicholas Nouwens

waste-water treatment, biogas facility and a wind/solar hybrid system at the school.

Efficiency Champion: Industry Category

Simon Grier — covered three roofs of their wine estate, Villiera Wines in the Stellenbosch with 539 solar modules capable of providing more than 132Kw of power per day. James Cruickshank — champions energy-saving water heating at the Mediclinic private hospital group across the country saving R1.8 million per year. Marlene Snowdon — as CEO and Trevor McLachlan of Pick n Pay and Manie de Waal of Energy Partners founder of Inti Solar, Marlene is rolling out solar water heaters to RDP homes a typical low-income home. across the country Meinhard Fourie — designed a prototype of a pool Innovation Category pump achieving a saving of around 3Kw per day. Iweathar — creator of an efficient vertical wind turbine for coastal regions producing around Utillabs — manufacturer of plug-and-play devices 500Kw of electricity per month, enough to power that fit into any three-pin plug socket and monitor/ THE SOUTH AFRICAN MECHANICAL ENGINEER

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ENERGY EFFICIENCY

display a household’s energy consumption in real time. Nicholas Nouwens — designed a multiple cavity water heater system that subdivides a geyser into two cavities whereby the outside cavity insulates the interior one. Reduces heat losses by 30 to 40% and delivers up to 70% more hot water.

Energy Efficiency Awareness Category

Pick n Pay — an energy ‘dashboard’ is sent daily to store managers to enable active energy management and improvements to be tracked. Keegan Cordeiro

Laura Andreas Teacher Susan McDonald with some of the learners from Greenwood Independent School

Young Designers Category

Keegan Cordeiro (16 years old) — built a solar system that can charge a cellphone and run various small appliances. Laura Andreas (16 years old) — has built a solar furnace that desalinates salt water and generates electricity. Gr eenwood Independent School (Plettenburg Bay) — researched ways to improve RDP houses through better building orientation and insulation. They presented their findings to their local mayor. Shri Vishnu Primary (Pietermaritzburg) — devised a solar cooker using an old satellite dish and CD’s which can boil two litres of water in 25 minutes. Annamarie Murray, Tel: (011) 800-2847, Email: MurrayA@eskom.co.za

Shri Vishnu Primary

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POWER GENERATION NEWS Energy Project of the Year Powertech IST Otokon was awarded the Energy Project of the Year at the Southern African Association for Energy Efficiency (SAEE) Awards. As the largest industrial Eskom DSM peak clipping project, Powertech IST Otokon’s compressed air project at Goldfields Driefontein had a peak clipping target of 12MW, but it has over-performed by 40% and resulted in avoiding 33t of CO2 emssions. These are only the contracted savings reported through the required Measurement and Verification (M&V), and Richard du Preez, programme manager receives Powertech IST Otokon’s Energy Project of the Year Award for 2011 from the Southern African Assonot the savings in their ciation for Energy Efficiency (SAEE) Board Member, Dr Tsakani Mthombeni entirety. The project encompasses an open architecture SCADA system controlling

50 underground valves, instruments, PLC systems, compressor efficiency,

compressor controls, all part of an inclusive design process that was followed with the client’s involvement to ensure the successful performance of the system. Goldfields are not only saving energy and the environment but due to the proper design, implementation, measurement and verification of the project installation, the energy savings will be sustained and not diluted over time. Prof LJ Grobler, President of the SAEE comments, “It is not uncommon for energy efficiency projects to over-perform, especially if standards and M&V are applied to ensure that savings aren’t only a one-off occurrence, but sustainable. The successful integration of various technologies at Driefontein highlights the fact that successful energy efficiency is a holistic approach that delivers performance figures as Powertech IST Otokon has proven here.”

SAEE, Tel: (041) 367-1041, Email: info@saee. org.za, www.saee.org.za

ish company Gantrail, will secure rail lines for the stockyard’s coal stacking and reclaiming machines. Horne is the authorised distributor in South Africa for Gantrail fastening systems. The multi-million rand order is the single biggest yet placed for Gantrail products in South Africa. For Kusile’s stockyard, Gantrail will supply rail fasteners from the manufacturing facility in Gloucester, England. Supporting sole plates in four different sizes will be manufactured locally by Horne SA.

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Rail fasteners Horne SA has secured the order for all soft-mounted rail fasteners to be installed in the Kusile power station coal

stockyard, currently under construction near Delmas, Mpumalanga. The fasteners, to be supplied by Brit-

Horne’s group managing director, André du Preez, says he is delighted with the large portion of the order that will be manufactured locally at the Spartan works. “The local manufacturing portion of the contract is important, and will supply useful work for our factory through to the May 2012 delivery date,” said du Preez. Horne Group, André du Preez, Tel: (011) 9741004, Fax: (011) 392-5650, E-mail: andre@ horne-group.com

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POWER GENERATION NEWS Ground-air heat exchanger The largest Awadukt Thermo ground-air heat exchanger system has been installed in Scotland at the newly refurbished and extended Banff and Buchan College in Fraserburgh. The Rehau system draws air from outside at a rate of 16000m³/hr through a 42m x 30m grid of Awadukt Thermo polypropylene pipework, 1.5m below the playing fields of the college. This

allows optimal heat transfer to take place between the ground and the air, resulting in the air being warmed by up to 9ºC in winter and cooled by as much as 14ºC in summer by the time it reaches the air handling unit (AHU). This will have a significant impact on the energy loading of the AHU and will eliminate the requirement for refrigerantbased mechanical cooling to counter the heat gain in the building generated by high occupancy levels and large amounts of glazing, particularly in the atrium. Senior Mechanical Engineer, Alan Gibb from KJ Tait Engineers says: “On a sunny summer day when the external ambient temperature could be as high as 25ºC, the system will deliver air to cool the atrium which has been precooled by the groundair heat exchanger to around 10-11ºC using

Awadukt thermo pipe system

minimal amounts of energy and with almost zero running costs. For a building which has no mechanical cooling, this will be hugely rewarding. KJ Tait will be monitoring the temperature of the air entering the air handling unit via BMS readings as it evaluates the performance and payback of the Rehau Awadukt Thermo system over its first year in operation. Rehau, Tel: (011) 201-1300, Sharecall: 0860 0REHAU, E-Mail: johannesburg@rehau.com, www.rehau.co.za

Book NOW for 2012 April • • • • •

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June • • • • •

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Contact Mark Bennett on Tel: (011) 781-1401 or E-mail: samecheng@promech.co.za for further details

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February 2012

MATERIALS & MACHINE TOOLS

Hard Work Pays Off The Toolmaking Association of SA’s (TASA) partnership with the Department of Trade and Industry (dti) into improving the sector’s future competitiveness position is gaining momentum. Two important milestones have been accomplished in recent months.

ver 550 students (foundation level and 1st year apprentices) have been deployed at over 189 participating companies across six provinces, for their on-the-job training (workplace training) phase.

Also, a national benchmarking exercise has been completed where 36 local companies were identified to be benchmarked against international competitiveness standards by the Fraunhofer Institute of the University of Aachen in Germany. Twenty two of these companies were successfully benchmarked by end of September 2011. This is a clear demonstration of industry’s commitment to be part of the solution in making an investment in their future. The benchmark methodology focused on key enabling factors within companies such as business processes, resources, organisation, strategy and leadership and key company results such as financial results, customer service results and product results.

Key facts

The benchmarking results confirmed some key facts about the status of the South African TDM sector: • Local tooling companies have very little diversification into foreign markets Hands on training at the NTIP's pre-apprenticeship programme

• Local tooling companies are less than 50% as profitable (sales per employee) as the best in class (international) • Cash-flow on average per employee is only 17% of that of best in class • Net income is on average 41% of best in class • Value add per employee is on average only 32% of best in class • Reinvestment rate (in new technology and equipment) is on average 33% of best in class • Labour costs are less than half of best in class in Europe, but companies are failing to turn this to an advantage • Top of class European tool rooms have 0% unskilled labour where local companies have on average 28% unskilled labour • Local tooling companies spend only 30% of that spent by international companies on design

Students learn from experience and each other

• The SA market mainly has the ca-

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MATERIALS & MACHINE TOOLS

• On time delivery is managed in less than 50% of the time, where best in class achieves 80% • Many SA tooling companies have no marketing materials or websites • Machine utilisation (eg, milling) less than 43% of best in class, creates the opportunity that SA tooling companies can drop their machine rates if they increase utilisation, ie, second shift operation Students work on one of the lathes at the South West Gauteng College

pacity to produce smaller less complex tools for which there is higher competition from Far East suppliers

• Under quoting is frequently done in local business to stay busy

• Process and tool simulation technology usage is only 30% against best in class As a next stage to the benchmarking, the NTI with its regional and international partners, will develop interventions with the benchmarked companies to develop: • Focus • Supply management systems • Technology and know-how deployment • Employee skills sets, and • Strategic management capacity.

Turnaround

This is part of the interventions towards demonstrating the turnaround capabilities of the local tooling industry towards competitiveness. A specific pilot partnership with the Gauteng Economic Propeller (GEP) will lead to the application of the above interventions in 10 Gauteng benchmarked companies to develop a "franchise" type model for SA tool room restructuring. GEP is investing R 1,6 million into this project through the Gauteng Tooling Initiative (GTI) and will be followed by similar partnerships in the other provinces.

Developing the sector

TASA is hereby demonstrating that the National Tooling Initiative (NTI), as a successful partnership between industry and government, has the key ingredients and capacity to develop the sector towards increased competitiveness in the medium to long term. Robert Williamson, Tel: (021) 531-3138, Fax: (021) 5315074, Email: Bob.Williamson@Quad.co.za

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SAIT

Lubrication of Mechanical Chains Steel chains are widely used in all types of industries because of the real advantages of this type of transmission system, which eliminate sliding, are flexible, are compact and have high transmission capacities. A chain well maintained, will give efficiency around 98% due to the inherent low friction losses.

here are a number of different types of chains, all of which require lubrication in some way. It is known that 60% of chain failures are due to the lubricant or lubrication system. It is therefore essential to use the right product for the right application in order to optimise chain life. Wear occurs mainly along the shaft - sleeve - roller contact points, which causes the chain to stretch. If stretching is excessive, gear meshing will be downgraded and increase stretching further. Stretching is acceptable when it is in the order of 1 to 3%. The role of the lubricant is to decrease wear on the chain but also to protect the chain from corrosion; reduce transmission noise and improve transmission efficiency.

The lubricant acts on the chain in the friction areas of the rotating parts, in the gaps between the main shafts, sleeves, rollers and links. It is in these gaps that the oil has to reduce the contact between the different moving parts. It is important for the lubricant to be able to penetrate between the links in order to lubricate the sleeve and the shaft. There are a number of different types of wear mechanisms that occur, namely: • Friction wear: Due to micro-welding caused by metal-to-metal contact and shear arising from friction.

• Abrasive wear: Due to friction of abrasive foreign particles which penetrate the chain moving parts. • Fretting: When running over a gear wheel, vibration causes wear on the metal and micro-cracking if there is insufficient lubrication. • Corrosive wear: Due to the corrosive effect of the environment followed by removal of this corrosion due to friction. It is important to lubricate the chain components in the minimum chain load area, to allow the lubricant to penetrate.

Critical

Several types of products can be used for chain lubrication, depending on the type of chain and operating conditions. The oil should have sufficient fluidity to penetrate the internal surfaces of the link, sufficient thickness to maintain the oil film under a heavy load, sufficient adherence of greases to stick to the chain, good anti-corrosion properties and in some cases good temperature resistance. In all instances, reducing friction reduces wear and minimises wasted energy lost in transmission. It is critical that the chain is sufficiently lubricated on a regular basis, with the correct lubricant to ensure that the high power transfer is maintained and energy consumption is reduced. The question is when last did you look at your chain lubrication strategy? Thomas Surmon & John Fitton, SAIT Committee Members Gill Fuller, Tel: (011) 802-5145, secretary@sait.org.za

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LETTER TO THE EDITOR

Dear Chris Under-utilised

We have met, many years ago, most likely during my time with Mondi in Richards Bay, but I have also worked with Goldfields, SA Breweries, CG Smith Sugar, Richards Bay Minerals and finally Pöyry Southern Africa. I read the September issue of ‘An Engineers View’ about ‘older’ engineers with interest and found it particularly pertinent to my situation. At 56 years of age I am probably in what you describe as the ‘ centre of gravity of the (engineering) skills’ yet I am for all intents and purposes, unemployed since my retrenchment at the end of 2008. Since my first job at Goldfields I gravitated towards Project Management and have managed major investments in the pulp & paper industry both locally and in Poland. My last job was in the position of MD of the South African office of one of the worlds largest engineering consulting companies. I was retrenched when Executives in Helsinki decided to close the South African office due to

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diminished investments in the local pulp and paper industry. I have applied for countless jobs and no-one can (or cares to take the trouble) to explain to me why I appear to be unemployable. I have an excellent track record, excellent references and feel so young and fit I could work effectively until I am at least 70. Be assured that I am not only applying for top level positions, but all Project Manager jobs. I have sometimes wondered if coming from a position of MD, somehow works to my disadvantage and I am sure that 56 is considered over the top. Last year I started my own company, and have also done a little part-time consulting on project management, but all this activity falls way short of my aspirations and income requirements. Your comment that “we are failing to utilise the experiential skills in a mentoring role for younger resources” is very true. Kind regards Derrick

February 2012

COMPRESSORS, AIR MOTORS, VACUUM PUMPS

Streamlining Service Delivery One of the most tedious tasks of any service crew is filling out job cards. This report is essential not only for invoicing purposes, but also to provide a record, for both the service provider and the customer, of what’s been done. service data in the office just minutes after a job has been completed anywhere in South Africa,” Allen adds. “The service teams collect their job sheets for the day off the internet with complete details of the address, contact number and map of where the job is, ensuring there are now no excuses of getting lost between jobs.”

Instant reporting

Once the job is completed, the technician can take

Allen Cockfield of Artic Dryers

illing out the job card is usually done in a hurry so the technician can get back on the road to the next job, resulting in a piece of paper which even the technician himself can’t read afterwards. Now the service manager, usually days later, has to create an invoice and service record from an indecipherable job card.

Resulting in a piece of paper which even the technician himself can’t read afterwards Illegible reports

Allen Cockfield, MD of Artic Dryers decided to do something about it. He tells “SA Mechanical Engineer”: “We recently did a survey with our customers to find out how we can improve our services,” he explains. “A major issue across the board was the fact that customers could not read the handwriting of our technicians. So, over the past six months we’ve introduced a new system whereby our technicians are each issued with an internet-connected iPad tablet computer containing all the templates to complete service reports which are then sent back to our office immediately. “We appointed an IT specialist who developed and implemented the system which not only benefits the customers, but our service manager can update

Artic supplies the full spectrum of compressed air drying requirements

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COMPRESSORS, AIR MOTORS, VACUUM PUMPS

quicker, but technicians can also solve problems on site timeously because they can communicate ‘live’ with the service manager when encountering problems on site. “For example, if the technician isn’t sure about what filter to use when replacing an old one, all he does is take a photo of the system, send it to the service manager via the internet and the problem is resolved within minutes. Aside from making our life easier, the customers’ major benefit is that they receive a comprehensive, legible report in electronic form which they can utilise for their own records. An added assurance is that the system is designed to automatically add any new capital equipment to a database we’ve built up for each one of our clients on our side.”

Clean air

pictures, or even 3 dimensional composite photos of the plant with the iPad to accompany the job sheet which is signed off on the tablet by the client. Says Allen, “The technician then simply hits the ‘send’ button and we have a complete report back in the office within seconds. The data is processed here to produce an invoice, a complete 3-page report with pictures and a signature to send back to the client within the hour.”

Ensuring there are now no excuses of getting lost between jobs Artic offer multi-brand servicing, “As a result, our service teams are extremely busy and out on the road for several days at a time, which means we were getting the job cards days afterwards in some cases,” says Allen. “Now we not only invoice

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Artic supplies the full spectrum of compressed air drying requirements, from low to high quality drying and filtration to ultra dry air demands with desiccant rich low dew point chemical dryers. “In among this wide range of options we now also have a catalytic converter for compressed air systems where any oil contamination in the compressed air is converted into water,” says Allen. “This is very new on the market, used to attain 100% guaranteed pure oil-free air from an oil lubricated compressor. It can be installed at the compressor house, or as a de-centralised function closer to the point of use. “Although filtration systems do remove most of the oil in a compressed air network, the catalytic converter will clean up the rest,” adds Allen. “The waste from filtration and dryers, all contain oily waste water which has to be managed to avoid environmental contamination. To solve this problem we offer the Sepura range of separators for the management of oily condensates drained from air systems. “Condensate must be purified to strict legal levels before the water content from the condensate may be discharged into a drain,” concludes Allen. “Discharging of contaminated condensates not only damages the environment, but is now illegal and leaves operators and CEO’s open to substantial fines.” Allen Cockfield, Artic Dryers International, Tel: (011) 4253484, Email: allen@articdriers.co.za

February 2012

COMPRESSORS, AIR MOTORS, VACUUM PUMPS

Friction Free The less friction between the moving parts of machinery, the less energy required to move those parts. If the moving parts don’t touch each other at all, there is no friction and so no energy usage.

reducing the energy requirements which would be needed for the same duty in other types of vacuum pumps and low pressure compressors, quite dramatically. Apart from energy savings, maintenance costs are reduced significantly as well. He adds, “We’ve just replaced old carbon vane-type, watercooled vacuum pumps with these units. The blades on the old units, for example, used to break on a regular basis, adding to maintenance costs with vane replacements taking place about every six to eight months.”

he claw technology used in the working chamber of the new vacuum pump from Elmo Rietschle is based on this principle where two claw-shaped rotors roll together very closely but without actually touching, forming the compression chamber which causes the vacuum.

These claw pumps are oil-free and frictionless reducing the energy requirements which would be needed for the same duty in other types of vacuum pumps “SA Mechanical Engineer” visits the South African distributor of this equipment, Air & Vacuum Technologies (A&VT) in Midrand, to speak to product specialist, Mark Burn, about the principle of these vacuum pumps now catching on widely locally. “Elmo Rietschle is a Gardner Denver company and the only manufacturer which makes a claw vacuum pump with a capacity of 1 000 cubic metres an hour,” he says. “We’ve now installed a number of these units with great success locally.”

Claw technology

These claw pumps are oil-free and frictionless

From left: Ross Sinclair and Mark Burn of AV&T

To achieve the capacity of 1 000 cubic metres per hour for his operation, an A&VT client previously had to have two vane machines. These have now been replaced with one claw-type machine. “With the claw units there is no friction whatsoever, reducing this client’s running costs in terms of spare parts for regular blade replacements,” says Mark. “There are also no costs in oil or water because the claw pump runs completely dry and is air-cooled. Environmentally the air released from the system is cleaner and contains no carbon dust or oil vapour to contaminate the working environment.”

The principle

The dry running Elmo-Rietschle C-Series generates contact-free vacuum or compressed air efficiently and economically due to the principle of internal compression. Ross Sinclair, product manager at A&VT explains, “This results in considerable energy savings compared with the traditional rotary vane design.” The claws of the C-Series pump are an optimised, high precision shape which roll together without making contact, made possible through the synchronisation of the rotors by a precision gear set. Special seals separate the compression chamber and the gearbox to ensure there’s no oil in the chamber. The claw rotors control the transportation of the medium by opening and closing the inlet and outlet channels and, therefore, no sealing fluid is needed in the compression chamber. THE SOUTH AFRICAN MECHANICAL ENGINEER

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A claw pump consists of two rotors (1 and 2). They turn in opposite directions in a compressor housing (7) without contact observing very tight clearances. They are synchronised via a precision gear. As the claw moves over the suction connection (3) and the axial suction channel inlet (4) the gas is sucked into the compression chamber. As the rotors revolve, the gas moves from the suction side to the pressure side. Then it is compressed by the reduction of the volume between the rotors until the lower rotor uncovers the discharge channel (5). This “internal compression” leads to high differential pressures at efficiencies of more than 60 %. Afterwards the pre-compressed gas is discharged via the pressure connection (6). To remove the heat generated by the compression process, cooling air is sucked in between the compression housing (7) and a silencing cover (8) before it leaves the pump.

the gas is sucked into the compression chamber. As the rotors revolve, the gas moves from the suction side to the pressure side where it is then compressed by the reduction of the volume between the rotors until the lower rotor uncovers the discharge channel. This ‘internal compression’ leads to high differential pressures at efficiencies of more than 60 %. Afterwards the pre-compressed gas is discharged via a pressure connection. To remove the heat generated by the compression process, cooling air is sucked in between the compression housing and a silencing cover before it leaves the pump.

Wide selection choice

“The C-VLR ZEPHYR Claw vacuum pump range come in capacities ranging from 60 to 1000 m³/h and maximum continuous vacuum up to 50 mbar,” Ross elaborates. “Our pump has a steady performance curve over the entire operating range. The integrated air cooling principle has proved to be

A claw pump consists of two rotors which turn in opposite directions in compressor housing without making contact How it works

Much like rotary vane and rotary lobe pumps, the claw compressors and vacuum pumps of the C-Series are based on a static compression system but unlike rotary lobes, compression happens internally by volume contraction. A claw pump consists of two rotors which turn in opposite directions in a compressor housing without making contact by observing very tight clearances. They are synchronised via a set of precision gear so that as the claw moves over the suction connection and the axial suction channel inlet, The dry running Elmo-Rietschle C-Series generates contact free vacuum or compressed air efficiently and economically

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highly effective and no additional cooling is necessary. This range is also available with optional variable speed drive while Atex compliant versions are also available.” The C-KLR claw combination (vacuum/pressure) pumps are also available up to 140m³/h. This version has been well received in the printing industry and the C-DLR low pressure compressors also have a wide scope of uses. “This technology has been around for a couple of years, is thoroughly proven in many installations across all industries in Europe, but is only now catching on locally,” says Mark in conclusion. “Anyone considering upgrading old plant, be it vane technology or liquid ring vacuum technology, should take a serious look at switching to claw technology altogether. Besides the small footprint of a high capacity vacuum machine, there are so many advantages over the old technology which all translate into direct savings and consistent machine availability.” Ross Sinclair, A&VT, Tel: (011) 318-3241/5, Email: vacuumsales@vactech.co.za, Website: www.vactech.co.za

Several type of vacuum pumps for various applications

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Going green Engen’s pursuit of a ‘greener’ bulk transport fleet and operation was boosted recently with the purchase of two environmentally-friendly vehicles from Scania. According to Engen Transport operations manager, Llewellyn Snyman, the bulk transport vehicles both contain Euro 4 spec engines, which run on ADO 50 ppm diesel. They also sport exhaust gas recirculation and particulate filter technology which translates into fuel consumption savings. “These are the first vehicles with reduced emissions technology to be owned by Engen. Not only do they offer great fuel consumption and advanced technology but they also have safety features such as driver airbags and pre-tension seat belts, which are unique in the market,” says Llewellyn. These vehicles will be operating out of Engen’s Cape Town and Langlaagte terminals. Additional ‘green’ vehicles’ will be purchased in accordance with the company’s fleet replacement programme and roll-out of ADO 50ppm nationally. “The Engen Transport Department will be monitoring the performance of these two vehicles and, pending their efficiency and sustainability, will pursue further roll-out,” says Llewellyn. With ADO 50ppm diesel being the future, investing in a ‘greener’ fleet is definitely a step in the right direction for the company and surety to sustainability. Gavin Smith, Engen Petroleum Limited, Tel: (021) 4034312, Email: gavin.smith@engenoil.com

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Pump Leader

On site at Barloworld Power’s facility in Boksburg, Gauteng are (from left to right) Graeme de Villiers, assistant general manager, Barloworld Power; and AllightSykes’ executive general manager for Africa, Peter Breen

An exclusive distribution agreement concluded with Australian manufacturer, AllightSykes, allows Barloworld Power to sell, rent and support the Sykes-branded pump range within its southern Africa territories. From its production facilities in Australia and Dubai, Sykes has helped shape the world’s construction and mine de-watering market for more than 40 years. Core products in the Sykes line comprise the Contractors, HIMAX, and the Xtra pump ranges. Much of Sykes’ success has stemmed from its priming systems, which improve fluid handling efficiencies and greatly reduce maintenance requirements. A

‘snore’ facility built into its groundbreaking auto-priming pumps means they can run dry without damage for extended periods. Comments Barloworld Power assistant general manager, Graeme de Villiers, “AllightSykes’ diesel driven pump products are powered by Cat engines and so the strategic alliance leverages off our clear synergies. “For customers in South Africa and our other key territories, such as Zambia, Botswana, Namibia, Mozambique and Angola, it means Barloworld Power can provide a seamless after-sales support strategy alongside our allied Cat power solutions.”

AllightSykes sales and marketing director, Paul Sowerby, explains, “Most pumps in this corner of the de-watering market are imported and then retrofitted with various technologies in a bid to help them cope with southern Africa’s notoriously tough operating environments,” he expands. “Having all the crucial components designed, engineered and then factory-fitted in Australia means the new Sykes MH300i reaches Barloworld Power ’s target markets tailor-made to make projects more efficient and productive.” Theo Jooste, Barloworld Power, Tel: (011) 8980450, E-mail: tjooste@barloworldpower.com

Wider context ABB has signed a five-year, ABB Full Service contract with Nampak Corrugated, to manage maintenance and improve overall efficiency at the company’s Rosslyn Paper Mill in Pretoria. Under the agreement, ABB will manage all maintenance operations at the paper mill to improve equipment efficiency and increase production output while reducing operating costs. 62 Nampak maintenance employees transferred to ABB when the contract took effect on 1 December 2011. The Rosslyn mill manufactures recycled

based paper for a variety of corrugated packaging products, supplied by Nampak’s Corrugated operations. Under the agreement, ABB will manage all maintenance to improve productivity and equipment reliability at the mill, and retain and develop all existing maintenance staff and management. ABB will train the staff in pulp and paper industry-specific predictive maintenance and management practices. In addition, ABB will provide process optimisation, energy consulting, equipment lifecycle services at the site, as well as manage all

third-party subcontractors and suppliers. “We are not only looking forward to improved maintenance processes and practices, but the performance guarantees will ensure the relationship is a true partnership with the parties working closely together to improve operations, and value is added in a much wider context than pure maintenance services”, says Christiaan Burmeister, managing director of Nampak Corrugated. ABB, Tamara Chetty, Tel: (010) 202-5093, Email: tamara.chetty@za.abb.com, www. abb.com

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Bundled Package

A single stage SAG mill with Krebs cyclones at a mine in Africa

DRC-based Boss Mining SPRL has awarded FLSmidth four different orders for equipment at its copper operation in Kakanda in the Katanga Province of the Democratic Republic of Congo (DRC). The bundled package comprises a mill contract and a gyratory crusher contract, both awarded in June 2011, and two contracts — for thickeners and flotation equipment respectively — signed in September 2011. Most of the equipment is scheduled to be on site at Kakanda by the third quarter of 2012 with installation starting before the end of this year leading into commissioning in 2013. FLSmidth’s Terence Osborn says, “Our 22 foot diameter ball mill at Tenke Fungurume in the DRC copper belt is very similar to that required at Kakanda and a similar flow sheet comprising a gyratory crusher, grinding mills, flotation cells and thickeners is in operation at Lumwama. “The mill required at Kakanda is specified for 11 000 kW of installed power, which requires a dual pinion drive. FLSmidth is the leader in this technology in the southern African market. We understand copper belt operations and have two fulltime agents based in Northern Zambia

to support our customers in the region.” Terence says apart from the obvious financial benefits, there are many other advantages to bundled packages. These include leveraging economies of scale and optimising project execution and on site resources. “This means that we need deploy only two project managers to oversee the entire project package and only one multi-disciplinary crew will be on site for installation and commissioning,” he explains. Marinda Kerr, FLSmidth, Tel: (010) 210-4820, Email: marinda.kerr@flsmidth.com www.flsmidth.com

More Exposure First Cut has been awarded the sole distributorship rights in Southern Africa by Bystronic’s, says area and sales manager (South Africa), Phillip Burgener. Bystronic has maintained a presence in South Africa since its inception in the late 1980’s but has increasingly felt that its potential for growth and market penetration was not being fully realised through its existing channels.

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“We had received a number of calls and emails from customers in South Africa recommending First Cut as a possible distributor of choice for our products. Based on the enthusiasm and feedback we received from these customer companies, we were motivated to contact First Cut to discuss the opportunities for both organisations,” says Phillip.

Phillip Burgener

“Within a short space of time we decided to cement our relationship. Bystronic has an extensive range of laser and waterjet cutting solutions developed for a range of customers, from small job shops up to large engineering conglomerates. While the laser cutting equipment is already proving popular with a number of local customers, waterjet cutting technology has not been given the exposure it needs in the market. We have already implemented plans to increase customer awareness,” says Phillip. Andrew Poole, First Cut, Tel: (011) 614-1112, Email: andrewp@firstcut.co.za

MARKET FORUM

Hydraulics Systems Hytec has broadened its range of mobile hydraulic components suitable for application in the mid-tier mobile and industrial market segments. “The new range includes hand pumps, cartridge valves, hand control valves, selector valves, and DC power packs,” says Freddie Kühn, regional manager, Hytec. “What excites us is that all new technologies offered are very competitively priced and provide trusted European engineering excellence.” This extensive hydraulics product range is brought to the market through the Hytec Group network of 25 branches and distributors throughout southern Africa. The company has also invested in continuous staff training, aiming to ensure all customers get the best possible service from these branches.

Hytec’s new DC Power Pack features pressure ratings of up to 250 bars, and is available in 12 and 24 volt variations

Willem Gijzelaar, Hytec Holdings, Tel: (011) 979 4630, Fax: (011) 979 4635, E-mail: willemg@hyhold.co.za

Topping Its Own Record

eir Minerals Africa has just dispatched the biggest hose bend manufactured on the African continent — a 1 000 nominal bore (NB) hose weighing 1.4 ton and a mandrel weighing 1.4 ton — to a customer in Australia and is currently working on an enquiry for an even bigger unit of 1 100 NB. These orders follow the successful completion in 2010 of what was then the biggest hose bend to be produced on the continent, an 855 NB unit. “Before we entered this market segment, there were only three suppliers in the world capable of manufacturing hose bends of this magnitude,” Weir Minerals Africa’s Grant Ramsden, says. “We

recognised that demand was greater than supply and took a strategic decision to develop the capacity to produce these units as an additional specialised product line. “Tooling design has been carried out inhouse by our engineering department in Isando and we’ve been fortunate enough to find an engineering company based in KwaZulu-Natal to manufacture the hose mandrel and the bend former for us.”

Weir Minerals Africa has just dispatched the biggest hose bend manufactured on the African continent — a 1 000 nominal bore (NB) hose weighing 1.4 ton and a mandrel weighing 1.4 ton — to a customer in Australia

Grant adds that other challenges included the physical handling of the massively heavy hose bends and the manner of extracting the large mandrel from the cured product.

in a very short time frame,” he says. “In fact, manufacturing the 1 000 NB unit went very smoothly, because we had trialled and debugged the system while expediting the order for the 855 NB unit last year.”

“In the end we devised a highly innovative solution for extracting the mandrel

Rene Calitz, Weir Minerals Africa (Pty) Ltd, Tel: (011) 929-2622, www.weirminerals.com

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Going Global Multotec is expanding extensively into other parts of the African continent — and beyond. The company recently established branches in Mozambique, Zambia and Ghana, with an agent in Zimbabwe, and Thomas Holtz, Multotec chief executive officer says business is “flourishing” in all these areas. “Our growing branch infrastructure is helping us transition from pure equipment sales into the field service maintenance arena,” he says. “Today we’re in the business of delivering peace of mind — work- Thomas Holtz, Multotec ing closely with Chief Executive Officer our customers to provide condition monitoring and process optimisation services for the lifetime of the equipment we supply. We stand by our product and staying with it in the field, ensures it provides a maximum return on investment to our customers. Multotec is also playing on an increasingly global platform, focusing on benchmarking its product offering against international leaders. “For example, in an African context, several Australian companies are operating very successfully in our part of the world,” Thomas says. “We want to establish ourselves just as successfully in Australia in order to be able to provide a reference base that proves our capabilities in the international arena.

Maintaining The Seal “The demands of modern engineering make the choice of the right sealing product an important consideration, both in the design of new equipment and in selecting products to replace those that are no longer suitable,” says Deidre le Roux, BMG’s seals division. “BMG’s range of gaskets, which is manufactured according to stringent quality controls, is designed for product conformance to specifications and uniformity that results in unvarying performance, even in demanding environments. “The definition of a seal has changed dramatically over the years Included in BMG’s extensive range of sealing products are quality and leakage measure- branded gaskets, designed for reliability, chemical and corrosion resistance, extended service life and easy installation ments have advanced from drops per minute, to parts per million (1mg/kg = 1 part tion, media and pressure. Variables, per million. This is the commonly used like the flange metallurgy, bolt thread term to describe very small amounts of embedment, flange rotation, bolt stretch, contaminants in the environment. additives to the media and the flange surface finish, now determine how well “The selection of the correct gasket for a gasket performs.” a specific sealing application involves consideration of variables present in a flanged connection. Traditionally, these factors include temperature, applica-

High Spec Range

“Although research and product development keeps our products state-of-theart and able to hold their own against international competition, having local specialists takes time and money. This process has to be nurtured and built up from scratch to establish a local track record,” Thomas says.

Actom Electrical Machines has launched a new range of cast-iron medium voltage motors into the market that incorporates state-of-the-art technology, as well as world class electrical steel and insulation systems.

“We’ve realised, however, that we need to operate very selectively in certain foreign markets, initially establishing critical mass. We can’t be all things in all markets, but we’re moving forward in a steady and promising fashion by leveraging the local model that is working so well for us.”

Developed by the company over the past few years, the new high specification range – dubbed the MS4 series – comprises totally-enclosed fan cooled (TEFC) motors in the 300 kW to 800 kW power range, with frame sizes of between 355 and 500 and voltages of 3,3 kV, 6,6 kV and 11 kV.

Bernadette Wilson, Multotec Group, Tel: (011) 923-6193, www.multotec.com

“The MS4 series represents a significant advance over the TEFC range of motors

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Deidre le Roux, BMG, Tel: (031) 576-6254, Fax: 086 242 5973, www.bmgworld.net

MARKET FORUM

National Footprint

hrough the recent establishment of the four new SKF authorised distributors in Kwazulu Natal, Bearing Services Africa has acquired SKF’s Durban, Pietermaritzburg, Mandini and Richards Bay branches. This is part of SKF’s ongoing commitment to deliver complete product and service solutions to the customer’s doorstep. Discussing the objectives behind the distributor programme, SKF South Africa managing director, Barry Dailly, says that it is in line with the company’s 2008 strategic decision to restructure its South African branches and establish an authorised SKF distributor network. “SKF has over 100 years experience in bearing and rotating technology. We aim

to provide customers with added value across the board by delivering SKF’s core technologies - bearings and units, seals, lubrication systems, power transmission, mechatronics, and mechanical and reliability engineering services. “However, because it is impossible for us to be everywhere, our authorised independent industrial distributors, who are an extension of our product and service delivery, give us the best route to market and enable us to place SKF appropriate resources and skills where they are required, in other words, equip our customers with SKF knowledge”. SKF South Africa (Pty) Ltd, Samantha Joubert, Tel: 011 821 3500 / Fax: 011 821 3501, samantha.joubert@skf.com, www.skf.co.za

From left to right: Robin Briggs - distributor development manager - SKF, Barry Everitt managing director - Bearing Services and Barry Dailly, managing director, SKF South Africa

we previously produced and supplied,” says Paul Lepora, Actom Electrical Machines’ commercial & marketing manager. “The MS4’s, which are fully interchangeable with our previous 1LA1 range, incorporate sound proofing systems that greatly reduce full load running noise levels, and new large format terminal boxes that facilitate ease of installation and reduce the risk of flashovers during operation. Actom formerly traded under the name Alstom South Africa and re-branded to Actom in September 2009. Paul Lepora, Actom Electrical Machines Tel (011) 899-1114 Fax (011) 899-1371 E-mail paul.lepora@actom.co.za

Lifting 65 ton boiler Johnson Crane Hire (JCH) recently carried out two lifts to install a new coal fired boiler at Impala Platinum’s platinum refinery and production facility in Springs, on the East Rand, during a plant shutdown. “Safety during this kind of operation is of optimum importance,” says JCH’s Malcolm McNicholas. “That’s why at least 50% of the effort on a project like this goes into planning, taking in account factors such as the dimensions and details of the unit to be lifted, lift information, the geological conditions on site and any existing obstructions.” The new boiler weighed in at 65 ton and the only possible position in the plant for the crane to be located was in the coal bunker area. As a result, Impala Platinum personnel had to move hundreds of tons of coal out of the area to a temporary storage site to clear the necessary space. “The boiler arrived by road from Cape Town and, in order to enter the site, had to be lifted over a pipe bridge near the site entrance,” says Malcolm. At 5.3 metre high, the boiler would not pass underneath the bridge. “We were aware that this would be a requirement and we set up our crane in the first lift position near the pipe bridge. The boiler was lifted off the transport vehicle, over the top of the bridge and replaced back onto the vehicle to proceed closer to the final lift position. The crane then had to be dismantled and moved to the second lifting position.” Johnson Crane Hire, Alison Dickson, Tel: (011) 455-9258, www.jch.co.za

Actom Electrical Machines’ Projects Manager Brian Lindsay with two of the new high specification MS4 series medium voltage motors now being produced by the company

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Water Transfer The submersible pump MS-T from Ritz Pumps does not have a continuous shafts and is therefore easily adapted to changing water levels and is extremely easy to maintain. The single suction submersible pumps they manufacture

range from 30 m³/h up to 900 m³/h for heads up to 550 m, and are manufactured in materials suitable for mine dewatering and acid mine dewatering. The submersible MC-T mining motors are customised for the individual application and therefore last extremely long. The motors are available from 30 kW up to 6 500 kW in voltages from 380 V up to 14 000 V. The company also offers models for off-shore and

Increased loads Companies will find it more and more challenging to cool increasing loads in their data centres, says Perpetual Power Systems CEO, Mark van Heerden. “Maintaining effective precision cooling for increased loads of nearly 10 times the current load, in high density server racks is becoming more difficult, especially within traditional data centre environments which are not suitable for these applications. “In essence, companies will be dealing with legacy systems, while still main-

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subsea applications. The double suction axial thrust free dewatering pump, HDM, for capacities between 200 m³/h to 6500 m³/h and heads up to 1500 metres with motors up to 6.5 MW is the company’s speciality for mine and acid mine dewatering. Ritz Pumps, Tel: (0) 87 805 7267, Email: chris@ritzpumps.co.za, jeanette@ritzpumps. co.za, molefi@ritzpumps.co.za

MARKET FORUM

New valve factory in China On 1 November 2011, the pump and valve manufacturer, KSB, inaugurated a new factory for globe and gate valves in Changzhou, China. The production halls as well as a logistics and storage centre which span an area of 45 000 square metres were constructed over a period of ten months.

“By opening this new production site we have reached another milestone on our way to expanding our activities in the local Chinese market as well as in valve business worldwide,” states Dr. Peter Buthmann, representing the Board of Management at the opening ceremony in Changzhou.

taining current business continuity and trying to rebuild, introduce and manage a new way of cooling IT equipment in their data centres,” he explains.

air from the hot return air, thereby improving the efficiency of data centre cooling.

However, there are a number of new technological advances in cooling, racking, data centre management and power supply and generation that can help companies deal with the challenges they face as a result of growing IT equipment loads. New technology in data centre cooling is able to contain hot and cold aisles, separating the cold

For KSB, China is one of the strategically most important markets. Today, the manufacturer of pumps and valves has five production sites, seven sales offices, four agencies and two service centres in this country. More than 1 300 employees work there for KSB. Website: www.ksbpumps.co.za

“Instead of producing nearly four times the cooling capacity that was needed previously, we can now optimise our capacity and produce only what is needed, resulting in electricity savings,” explains Mark. Perpetual Power Systems, Mark van Heerden, Tel: 0861 777 877, www.perpetualpower.co.za

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Bushing Benefits Local pump manufacturing and repair companies are set to benefit from a new, high quality PFR throat bushing recently launched by Aesseal. The bushing has been developed over several years for pump stuffing boxes, where it allows softer wearing packing to be used. This reduces gland packing costs and delivers a more effective sealing arrangement. Spiral grooves and special flow geometry are the main features of the new bushing. These work together to reduce flush water usage and prevent solids from entering the stuffing box, resulting in less wear on the shaft and packing surfaces. Aesseal's PFR-throat bushing harnesses the displacement and orien-

Aesseal’s new PFR-throat bushing

tation of the flow medium around the rotating shaft, using the spiral grooves to collect any solids between the shaft and the bushing, and expelling them by means of the induced flush stream. A narrow gap to the shaft allows the

Safe and Sound The Omsa Group has supplied over 100 Praher PVC butterfly valves to U’Shaka Marine World in Durban which is the largest aquarium in the Southern Hemisphere. One of the major considerations for Omsa was the internal and external corrosion risk of underground piping in such a water-filled environment thus contaminating the water, a possibility with metal or steel valves. This made the Praher PVC butterfly valve the preferred choice due to its on-site economic and environmental benefits.

lasting solution to U’Shaka Marine’s valve problems. Reliability was a key factor for the aquarium. We have supplied over 100 valves to the U’Shaka project, all are functioning well and sizes range from 80-600 mm diameter.The majority are butterfly type, but there are also some ball and diaphragm valves which are purpose-specific. The Praher valves are used from the seawater intake, throughout the entire aquarium plant including the quarantine area which houses the more vulnerable animals. The contract is ongoing.

Roger Kuch Omsa’s business Lizelle Nel, OMSA, Tel: (011) 793development manager says, 5562 or email: lizelle@Omsa.co.za “The quality of the Praher PVC www.Omsa.co.za butterfly valve provides a long

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bushing to control flushing water volume, minimising leakage and reducing the water requirement by up to 80 percent. Aesseal (Pty) Ltd, Rob Waites, Tel: (011) 4666500, E-mail: rwaites@aesseal.co.za

MARKET FORUM

On the Move

Vilashika de la Guerre

Michael Gibbon

Gerard Derbesy

Mohammed Sali-Ameen

Brett Kimber

Amec Minproc has appointed a new commercial manager Vilashika de la Guerre. Bosch has appointed a new chief executive, Michael Gibbon. Gerard Derbesy, CEO of BP Southern Africa (BPSA) has been elected chairperson of the South African Petroleum Industry Association as of January 2012.

Des Pearson

Johan van der

Chris le Roux

African Oxygen Limited (Afrox) has announced that Westhuizen South African Brett Kimber, currently chief executive of industrial gases company Linde Korea, is to become the new managing director of industrial gases, welding and safety products group, Afrox. Mohammed Sali-Ameen is the strategic market leader for South and Sub-Saharan Africa for Honeywell. Des Pearson has joined Metso as general manager projects and sales support. Chris le Roux has been appointed production manager, SEW Johannesburg. Quadrant Engineering Plastic Products has divested of its filtration products business through a management buy-out process, and put its two fully-owned South African units, Quadrant PHS and Quadrant Chemplast, under the common leadership of Johan van der Westhuizen, who has served as Managing Director of the Chemplast business since 2007.

Pipe reclamation “One of the ways in which Mining Pressure Systems (MPS) established commitment to mining is through a unique process known as pipe reclamation,” says Fred Crabbia, managing director of MPS. “During this process, MPS takes piping already utilised by the mine and exposes these pipes to rigorous testing, checking thickness, quality and whether the pipes are reclaimable. If the pipes are suitable they are cleaned and HDPE lined.”

enables HDPE liners to be easily and permanently installed conforming to old and new steel piping regulations. The HDPE pipe is drawn into the steel pipe by a mandrill through a converging throat and inlet ring and sealing mechanism, which introduces water at high pressure into the annular space between the inner wall of the steel pipe and the outer wall of the plastic (HDPE) pipe. This has the effect of reducing the outside diameter of the liner (HDPE pipe) and facilitating easy insertion into the host (steel outer pipe).

The company has perfected a unique patented process of lining large bore steel piping using high density polyethylene (HDPE) liners. Using its unique ‘Tight Lining’ process, they developed a system which

“This simple but effective process means that old pipes can be reclaimed at a fraction of the cost of replacing the entire pipe, and even extends the life of the pipe by 20 to 25 years,” says Fred. “Many old pipes would have become

redundant” says Glen Anderson, Plant Engineer at AngloGold Ashanti. “After the pressurisation tests were performed by MPS, the pipes were lined with HDPE. This resulted in a significant cost-saving for AngloGold Ashanti. Due to the high wear resistance of the HDPE, these lined pipes shouldn’t need replacement. “ “MPS is currently testing a new system which utilises a large diameter refrigeration pipe column, which will enhance and improve working conditions in the mine, thereby optimising efficiency,” concludes Fred. Fred Crabbia, Mining Pressure Systems (MPS), Tel: (011) 660-8058 Email: fred@miningppressure.co.za www.miningppressure.co.za

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

February 2012

MARKET FORUM

Strip curtains in battery breaker plant

Multiple legal actions In an important case, a South African malpractice law firm is pursuing one of the largest medical appliance firms in the world for damages caused by their hip implants. Pretoria-based Law firm CP can Zyl Attorneys Inc. will be assisting clients in their claims against DePuy, part of the Johnson & Johnson “Family of Companies” representing seven patients who had received the hip implants. One of the patients who is pursuing DePuy is Petro Pretorius whose hip bone eroded to the point where she had to have bone from a calf implanted prior to the fitting of the second replacement hip joint. Petro had a left sided hip replacement using ASR Cup of DePuy on 23 September 2006. CP van Zyl Attorneys Inc. are seeking compensation damages from DePuy on behalf of Pretorius and six other patients who had received the prosthesis. Sunelle van Heerden a professional consultant with CP van Zyl Attorneys Inc. said the prosthesis, manufactured by DePuy failed about two years ago and in addition to releasing heavy metals eroded Pretorius’ hip bone. Information provided by DePuy shows that, based on data from the UK, one in eight of the surgeries done with the implant used on Pretorius had to have second hip replacement operations (revision surgery). The DePuy documentation states that the company had decided to recall the ASR XL Acetabular and the DePuy Hip Resurfacing System. Sunelle van Heerden, CP van Zyl Attorneys, Tel: (012) 460-7050

Fry’s Metal, involved in the secondary smelting and refining of lead, antimony and tin alloys and the production of lead and lead alloys in ingot form, has installed Apex Strip Curtains in its newly commissioned battery breaker plant. Apex Strip Curtains feature a patented Balledge design which ensures a positive thermal seal. This means that the strip curtain effectively prevents the ingress of dust into cordoned-off areas. This is especially important in production applications where a dust-free environment is required. The actual strips overlap in a way that allows easy access for personnel and equipment, but still ensures a positive closure. The company’s Rod Hedley says the order was placed with Apex Strip Curtains based on its “always immediate and excellent service”.

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Index to Advertisers Airconduct 12 Altas Copco

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Ceccato 8 Chemsystems 8 Clyde Bergemann Africa Outside Front Cover Dermaplastech

Inside Front Cover

The patented Balledge design on Apex Strip Curtains ensures a positive thermal seal

Engineer Placements

The curtains are suitable for small, medium and large openings where it is necessary to prevent the ingress of hot or cold air, dust, insects and any other contaminants. This system is suitable for areas where both people and vehicular traffic pass through and the strips are transparent, which promotes both visibility and safety. The specially formulated PVC material does not become brittle with age and can be used in areas where temperatures go down to minus 400C.

Horne 14

Wim Dessing, Apex Strip Curtains, Tel: (011) 452 8723, Email: www.apexstrip.co.za

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

February 2012

Gemü 19 Kira Engineering

Multi-Alloys 30 Power Africa

PPS 9 Pump & Seal Services

SAISC 28 Schaeffler 34 Spectra Carbide Tooling

Inside Back Cover

Verder 32 Weir Minerals

Outside Back Cover

Zest 10

www.kraas-lachmann.com

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THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

February 2012

Excellent Minerals Solutions

ISOGATE® Slurry Valves Lower your operational costs with the Weir Minerals Solution

Expertise where it counts

Weir Minerals is committed to delivering market leading products and services which meet the technical and commercial challenges across the full spectrum of mineral processing and power & industrial applications. Robust design and rugged heavy-duty construction, the Isogate® slurry knife gate valve ensures long life and high reliability. Isogate® valves now also include Autoball™ 3 way check valves, swing check valves, and a diverse range of mechanical and pneumatic pinch valves. For more information contact us on: +27 (0)11 9292600 www.weirminerals.com

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

February 2012