SA Mechanical Engineer Jan/Feb 2020 by Promech Publishing

S MECHANICAL A ENGINEER Jan/Feb 2020

Publication of the SA Institution of Mechanical Engineering, incorporating News of Associate Organisations

BUILDING A LARGE BOILER SOLUTION

AIR-GAPPING: CLEAR SEPARATION TO SECURE NETWORKS

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THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 70 Jan/Feb 2020

S MECHANICAL A ENGINEER Jan/Feb 2020

Publication of the SA Institution of Mechanical Engineering, incorporating News of Associate Organisations

S MECHANICAL A ENGINEER Jan/Feb 2020 VOLUME 70

Contents BUILDING A LARGE BOILER SOLUTION

AIR-GAPPING: CLEAR SEPARATION TO SECURE NETWORKS

Machine Tools Africa Tel: (011) 835-1565 Email: nadineb@specialised.com www.machinetoolsafrica.co.za

On the Cover

Supply Chain

Machine Tools Africa 12-15 May Expo Centre Nasrec

25 MRO Solutions Contract

Strip Curtains

26 The Factory of Tomorrow

9 Enhancing Safety in Manufacturing

Global Manufacturing

Humans and machines

Steam, Turbines and Boilers 10 Building a Large Boiler Solution

Air-Gapping 12 Minding the Gaps to Protect Industrial PLC’s from Cyber Threats

29 Three Key Movements

Pumping Slurry 30 Where Others Fall Short

Minerals 31 New Manganese and Iron Removal Device

SA Institute of Tribology 14 Sliding Your Way to Rehydration

Feminine Touch

Regulars 4

An Engineer’s View

National Productivity Award

Institution News

19 Emerging Business Sector Category

32 Market Forum

16 Bridging the Gender Gap

Real-Time Operations Intelligence

38 On the Move

22 Digital, Direct and On the Go

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. Produced by: 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, www.promech.co.za Managing Editor Susan Custers Editorial Contributors Liesl Venter/Patricia Holburn Advertising Sales: Louise Cresswell Cell: 071 886 1263 DTP: Sanette Badenhorst Circulation: Netta Janse van Rensburg Subscriptions Please email us at accounts@promech.co.za if you wish to subscribe to “SA Mechanical Engineer” at R550,00 (excl postage and VAT) per year; R1 380,00 per year for Africa/ Overseas. 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 FSC (Forestry Stewardship Accreditation)

Official Publication of THE SA INSTITUTION OF MECHANICAL ENGINEERING and endorsed by:             

CONSULTING ENGINEERS OF SA CORROSION INSTITUTE OF SA INSTITUTE FOR CERTIFICATED MECHANICAL AND ELECTRICAL ENGINEERS NATIONAL SOCIETY OF BLACK ENGINEERS NUCLEAR INSTITUTE SA ASSOCIATION FOR ENERGY EFFICIENCY SA CAPITAL EQUIPMENT EXPORT COUNCIL SA INSTITUTE FOR NON-DESTRUCTIVE TESTING SA INSTITUTE OF TRIBOLOGY SA PLASTIC PIPE MANUFACTURERS ASSOCIATION SA PUMP MANUFACTURERS ASSOCIATION SA VALVE AND ACTUATORS MANUFACTURERS ASSOCIATION VALVE & ACTUATOR MANUFACTURERS CLUSTER OF South Africa

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AN ENGINEER’S VIEW

Value Proposition for Your Membership

hat is value for your membership? Well, before we get to that, maybe it’s worthwhile to ask who are we. The South African Institution of Mechanical Cillia Molomo-Mphephu Engineering is the senior body representing the discipline of Mechanical Engineering in South Africa (SAIMechE). We remain steadfast in the view that “By Knowledge We Advance”. That brings us to the significance of the engineering opinion, particularly, related to the Mechanical Engineering discipline. To understand the importance of our opinion, perhaps a good place to start will be where that opinion is going to be applied and ultimately its impact on the economy. Think infrastructure for aviation, rail, road, marine and their corresponding systems including their different modes of transport; infrastructure for utilities; medical equipment, mining infrastructure and other such significant assets. Where does one go for an opinion on the above? It should be undisputed that the home of such opinion is, predominantly, SAIMechE.

Home of the Mechanical Engineering opinion

Lest we forget that the screw pump at a wastewater treatment plant, massive as it is, is useless without an electric motor.

What organisation can ever have a conclusive position on what constitutes value proposition for its members without their involvement On the other hand, both these pieces of equipment are controlled by a Programmable Logic Controller (PLC) which is electronic. Need I say more! Well, of course we will still defend the Mechanical Engineering opinion with appreciation of the equally significant roles played by other disciplines. But I said “home” of the Mechanical Engineering opinion. I want to make an assumption that each time one refers to a place as home, a sense of belonging, of pride, of security and of freedom, among others, quickly takes over. Now, open the door of

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that home, walk in and only find one member sitting there. Surely you will have doubts in as far as one person’s opinion versus the scope of what is expected from a regular home. On the other hand, the consolidation of many authors’ views is that engineering is the application of science and mathematics to solve humanity’s problems. Given the wide variety of problems in this regard, it makes sense that the logical and structured approach might not be adequate to assist in finding such solutions.

The home owner

Of course the home-owner’s role cannot get easier than keeping family members happy and engaged to maximise and sustain their sense of belonging. But simply saying “keeping members happy” does not provide much. The organisation will have to, together with its community, unpack that to the satisfaction of all members. Many sources I have consulted on organisational membership suggest that the organisation must ensure provision of continuous value for its members. While that might be correct to some extent, I’ll still go ahead and rephrase that to suggest that the organisation must ensure provision of platforms for creation of continuous value, because what organisation can ever have a conclusive position on what constitutes value proposition for its members without their involvement? Notwithstanding the fact that members involvement provides more clarity on what they see as value for their membership, it is also expected that their involvement will give them a sense of owning that part of the organisation to which they have contributed. I suppose it’s a safe assumption, again, to suggest that members who are having a sense of belonging will stay and, further, automatically continue to engage meaningfully for knowledge creation and sharing. And what better place for the Mechanical Engineering stakeholders than in SAIMechE. Fortunately, SAIMechE already has many platforms to enable easy value exchange for its members. To count but a few, the website and its many features; and also a number of contact sessions. Although those platforms are very important, they should not be confused with real value for membership, which I will attempt to get to soon.

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The role-players

are invited to come and contribute meaningfully.

Why do we want to congregate? Is it because we want to achieve shared goals/outputs? I’d say yes… The importance of achieving results together cannot be underestimated. Out of that comes member confidence and a sense of fulfilment for those who played a role. Arguably, people who achieve together are likely to stick around together.

And on a biased note, given the slow uptake by females in this profession, I particularly urge all eligible female persons to rise up and make a difference in this profession. Their colourfulness is sorely missed!

The question however remains whether the SAIMechE membership numbers are adequate enough to provide for a representative opinion. According to our records, females in particular make up a heartbreaking 8.9% of the total number of SAIMechE members. According to the Engineering Council of South Africa (ECSA), South Africa has one engineer per 2 600 people compared with international norms, where one engineer serves 40 people.

According to our records, females in particular make up a heart-breaking 8.9% of the total number of SAIMechE members

Considering that we’ve already seen here that the engineering scope can never be perfectly designed to allow for the engineer to follow a logical and structured approach given the wider scope of the problems to be solved, the more innovative and progressive opinions from the members the better! The organisation provides for a wide variety of categories to enable a wide range of role-players: Company Affiliates, Associates, Honorary Fellow, Fellow, Graduates, Students and open category members where all qualifying stakeholders of this profession

The value proposition

Is it incentives, rewards, and the likes that will make you proud each time the name SAIMechE is mentioned; or is it SAIMechE’s credible engineering opinion that cannot be ignored by society that will make you proud to belong? I choose a credible engineering opinion. Whichever one you choose, please still come and advance the organisation with us! With more members involvement, we can be certain of a more accurately defined value proposition, and therefore a better output for SAIMechE. Cillia Molomo-Mphephu (MSAIMechE) SAIMechE Council Member

SA INSTITUTION OF MECHANICAL ENGINEERING Council 2018 - 2020 Office Bearers President........................................................ Prof D Blaine (Debby) Vice President..........................................H Makwarela (Hangwani) National Treasurer............................... Prof JL van Niekerk (Wikus)

Company Affiliates Autodesk as represented by Wordsview Technologies

Plant Design & Project Services (Pty) Ltd (PDPS)

Branch Chairpersons Central ................................................................. P Motleka (Portia) Eastern Cape.............................................. G van den Berg (Gideon) KwaZulu-Natal ........................................... Dr J Padayachee (Jared) Mpumalanga Highveld .................................... M Mashele (Mishael) Vaal................................................................. N Swanepoel (Niekie) Western Cape ....................................................Dr G Erfort (Gareth)

Babcock Nththuko Engineering Pty Ltd

PPS Insurance Co Limited

Eskom Rotek Industries SOC Ltd

Redheads Engineering Services (Pty) Ltd

Exxaro Resources (Pty) Ltd

S.A.M.E Water (Pty) Ltd

Festo (Pty)

SA Power Services (Pty) Ltd

Portfolios: Procedures..............................................................SZ Hrabar (Steve) Communications and Marketing.....................G Bartholomew (Bart) Professional Development Programme (PDP)................................. ......................................................................MAE Black (Malcolm) Projects and Systems Awards........................HG Bosman (Tertius) Membership .................................C Molomo-Mphephu (Cillia) Diversity and Transformation ..................R Tshitahe (Rudzani)

Fluor SA (Pty) Ltd

Sasol Technology (Pty) Ltd

Kelvion Systemes (Pty)

Siemens (Pty) Ltd

Hatch Africa (Pty) Ltd

Spirax Sarco (Pty) Ltd

Howden Power (a Division of Howden Africa)

Tenova Mining and Minerals SA

Chief Executive Officer............................... Vaughan Rimbault National Office Co-ordinator………...........… Carey Evans PO Box 511, Bruma, 2026 Tel: (011) 615-5660 Email: info@saimeche.org.za Website: www.saimeche.org.za Membership Email: membership@saimeche.org.za

MBE Minerals (SA) (Pty) Ltd

Weir Warman Africa

Megchem

Thysssenkrupp Engineering (Pty) Ltd

Howden Projects (a Division of James Howden)

Mod-U-Flow cc Osborn Engineered Products SA (Pty) Ltd

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Proconics

Thyssenkrupp Engineering (Pty) Ltd Vital Engineering (Pty) Ltd

Vital Engineering (Pty) Ltd Weir Warman Africa

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“THE LINK FOR AFRICAN TRADING”

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TRANSNET FREIGHT RAIL

www.transnetfreightrail-tfr.net

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STRIP CURTAINS

Enhancing Safety in Manufacturing Facilities According to statistics, a significant number of forklift fatalities occur within manufacturing facilities. While driver education on the correct operation of forklift trucks is a primary goal in reducing this risk, other elements also come into play.

im Dessing, sales executive of Apex Strip Curtains & Doors, says that accidents can occur at internal entry and exit points as well as at points of transition between various sections in a manufacturing or storage facility. By ensuring that visibility is maximised, the risks associated with the movement of vehicular traffic can be substantially reduced.

Thermal seal

Wim proposes the use of strip curtains in doorways. “We pioneered the use of flexible PVC strips in in-

Strip curtains are also becoming increasingly popular as a means of temporarily partitioning areas within larger facilities

dustrial applications more than 35 years ago and the use of these transparent strips to cordon off doorways and sections of a plant ensure optimised safety in the workplace” he says. The curtains are produced using specially formulated PVC material which is transparent for increased visibility and will not discolour, crack or tear over time. The individual strips incorporate the company’s patented Balledge feature which, while ensuring an effective thermal seal at all times, allows the strips to part easily allowing unimpeded movement of personnel or vehicular traffic. The Balledge design comprises a reinforced edge on the border of each strip that also provides extended life of the strips irrespective of the application in which they are used.

Food preparation

Another benefit provided through the use of Apex General Purpose Strip Curtains accrues in the food and beverage manufacturing and packaging sectors in the form of enhanced hygiene. Sensitive areas such as food preparation are governed by the Hazard Analysis and Critical Control Point (HACCP), an internationally recognised food safety system that assists with the manufacture of safe food products. The curtains are HACCP compliant and play a vital role in the food and beverage industry by preventing the ingress of unwanted elements. This requirement is critical in the light of issues such as crosscontamination. Wim says that production facilities as well as retail outlets have come to depend on strip curtains to minimise the entrance of dust and heat while at the same time facilitating easy access for personnel and vehicular traffic. The curtains are commonly attached to an overhead hanging rail and provide a cost effective and highly efficient way of separating atmospherically critical areas from temperature extremes and environmental pollutants. In addition to their obvious use at entrance and exit points, these industrial PVC strip curtains are also becoming increasingly popular as a means of temporarily partitioning areas within larger facilities. “With an in-depth knowledge of the requirements under HACCP, our team is able to customise solutions that consider all design and regulatory elements within an operation,” Wim concludes. Strip Curtains are HACCP compliant and play a vital role in the food and beverage industry by preventing the ingress of unwanted elements

Apex Strip Curtains & Doors Tel: (011) 452-8723 Email: apexstri@global.co.za. www.apexstrip.co.za

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STEAM, TURBINES AND BOILERS

Building a Large Boiler Solution Regardless of the application, the priority of any steam operation is cost effectiveness. Finding the most cost-effective solution is a matter of achieving the optimal level of reliability, energy efficiency and asset preservation. As projects get bigger, running at peak efficiency becomes exponentially more important, and energy-related cost becomes a much bigger component of total lifecycle cost over 70% in many cases. This is something that Energy Partners can attest to, having recently completed one of its largest boiler installations to date.

ohan Kritzinger, Divisional Head at Energy Partners Steam – a division of Energy Partners and part of the PSG group – provides some insight into the installation of this large steam plant at the Nokeng fluorspar mine. “The mine is a R1.7 billion open-pit project, which will produce 180 000 tons of acid grade fluorspar and 30 000 tons of metallurgical grade fluorspar per year, once it is operational. The processing plant for this operation requires coal-fired boilers that can handle the production volumes.” Johan explains that while the equipment used for this project was stock standard, there was nothing ordinary about the project scope. “Based on

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Johan Kritzinger

the client’s requirements, we installed four Cochrane Mk7 10 ton per hour coal-fired boiler units, supplied to us by Cochrane Engineering in Zimbabwe. In addition, Energy Partners selected, manufactured and supplied the associated infrastructure, which includes grit collectors, chimneys, a deaerator, and coal feed and ash extraction systems. Lastly, we had to design the boiler house where the system would be contained.” Aside from the scope of the installation, Johan notes that the other unique feature of this project is the boiler control system developed by Energy Partners. “There are very few service providers

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in our sector who can design, manufacture and install a system of this complexity, so the client’s decision to award the contract to us can largely be attributed to the fact that our control system has the ability to seamlessly integrate into the mine’s control and monitoring systems.”

Transparent systems

He explains that while most suppliers do not share control system information with third parties because they have to protect their intellectual property, Energy Partners has been developing ways of creating transparent systems that can more easily be integrated into clients’ existing control systems. Lastly, the client was also presented with the option to outsource the operation and maintenance of the system to Energy Partners. “Initially, the client was reluctant to extend the contract to include outsourcing. However, on a project of this scale, being able to get the best possible output and efficiency is crucial. In the case of a boiler rated for 10 tons per hour, efficiency losses of one or two percent add up to significant additional fuel costs. In order to mitigate this, an operation needs a dedicated team with extensive technical expertise.”

“This was the largest project that our company had ever taken on, and it was a learning curve in some respects. With that said, by the time we completed the initial contract, our in-house capabilities had also grown significantly, and we look forward to taking on more builds of this scope in future,” Johan concludes. Energy Partners Johan Kritzinger Tel: (021) 941-5140 Email: info@energypartners.co.za

Largely be attributed to the fact that our control system has the ability to seamlessly integrate into the mine’s control and monitoring systems

Johan says that by the end of the initial contract, which ran from July 2017 until November 2018, the client also agreed with this point of view. It was ultimately decided to extend the scope of the contract to include steam outsourcing. He adds that, going forward, Energy Partners will be tasked with the operation and maintenance of the boilers for the production of steam.

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AIR-GAPPING

Minding the Gaps to Protect Industrial PLCs from Cyber Threats Times have changed dramatically since the first programmable logic controllers (PLCs) found their way onto factory floors to control and automate manufacturing and industrial processes. One of the biggest changes is the advent of the internet that changed available communication technologies from Profibus, a protocol gateway that directly connects PLCs to the machinery they control, to Profinet, an Ethernet-based industrial communication system that provides faster real-time communication and can interconnect network devices to the internet.

LCs, designed to control machinery and specific processes, were never built with cybersecurity threats in mind and protecting PLCs against these threats requires healthy isolation from the World Wide Web. With the change in how industrial machines communicate within a network came new risks. Systems that were isolated in the past are now visible on the internet.

When OT networks run unsegmented alongside Information Technology (IT) networks, which also uses Ethernet connections, disparate systems like Payroll systems and PLC systems can be accessed from the same network Operational Technology (OT) networks have always been designed and configured in a flat and unsegmented configuration where all the OT devices are connected on the same network. When OT networks run unsegmented alongside Information Technology (IT) networks, which also uses Ethernet connections, disparate systems like payroll systems and PLC systems can be accessed from the same network. If an IT network is infected with malware, the manufacturing operationâ&#x20AC;&#x2122;s OT network is exposed to the same malware. OT networks should, therefore, be isolated from IT networks in the fundamental

planning of an organisationâ&#x20AC;&#x2122;s Operational Technology infrastructure. This is where air-gapping comes in. Air-gapping is part of the actual set-up of a network where a secure network is physically separated from an unsecured one. Clear separation between critical and non-critical systems can limit the impact of a breach and makes it possible to apply appropriate security controls. For example, non-critical systems can have access to view information on critical systems, but not necessarily make changes. Air-gapping within OT networks, where you isolate your PLC environment from the rest of your systems, is the modern way of doing it. When done effectively, air-gapping makes it possible to allow interplay between systems, but there are healthy boundaries to keep your PLC environment safe from the types of cyber threats that afflict IT. For instance, industrial control systems, including those that many PLCs integrate with, use Microsoft Windows, which opens up the same risks to the PLC system as those affecting PCs. Yet traditional software security tools are not effective enough in protecting PLCs.

Case study The Stuxnet case study was a wakeup call for the industry and made role players in the industry realise there are risks of additional threats when exposing production processes to the internet and that small changes can have a big impact. Other malware is designed specifically to target PLCs. The malicious Stuxnet worm, for example, was designed to target industrial PLCs, ultimately modifying the codes and giving unexpected commands to the control system with far-reaching consequences. It can cost money, downtime, reputational damage, and even lives. In a water plant, if a PLC goes haywire because of being compromised, water quality can be impacted and as a result, affect thousands of lives. In Iran, the Stuxnet virus made a small modification to a PLC environment and forced a complete shutdown of this uranium enrichment plant.

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By implementing an effective PLC security strategy, which includes air-gapping in the correct areas, identity and access management, and asset discovery, the user can mitigate these risks and avoid setbacks and costly downtime.

Proprietary protocols

In the old days, companies had proprietary protocols in terms of how they ran productions. Those were well-networked protocols, and they were isolated from IT-based cyber environments. To create efficiencies, enhance Just-In-Time manufacturing, eliminate waste, reduce working capital and provide instant information, it became necessary to get PLCs connected via Ethernet, which means there is a high level of connectivity between cyber systems and PLCs nowadays.

Slapped together

The problem lies in the way in which communication channels have been opened up between OT networks, IT networks and the Internet. There is a lack of proper segregation, adequate VLANs aren’t created, and often a firewall or two is slapped into the mix. This means that there are rivers of information rushing together and they really should run separately so that one cannot infect the other. Complete isolation is not the solution. That would be like having all the doors to a shopping centre locked, stopping everyone from entering, including customers. Instead, you want to control access, allowing customers in and unwanted ‘guests’ out.” Similarly, you want to be able to inspect and control the nature of traffic going in to and out of OT environments, as well as between different PLCs so that the business still benefits from connectivity between them without exposing systems to unwanted risk. When it comes to identity and access control, the user should define exactly who is allowed into the environment, what timeframes they are permitted

access, and what they can work on while they are there. This is most certainly one of the highestranking priorities in the PLC security plan.

Assessment

The first step, however, should be a cybersecurity vulnerability assessment. Modern manufacturers need to understand where all their PLC data resides and how people connect to that data. In a manufacturing environment, there will typically be different PLCs in different parts of the organisation, factory or mine, and these are interlinked. It is essential to know how they are exposed to other computers that have connectivity to the Internet as these create open gateways for industrial cyber threats. This includes all internet-connected devices, even smartphones that employees might be plugging into their computers to charge during their day at work.

Air-gapping makes it possible to allow interplay between systems, but there are healthy boundaries to keep your PLC environment safe from the types of cyber threats that afflict IT Once companies have a comprehensive understanding of the environment and how the different network areas are connected, it becomes necessary to call on technology to assist with controlling access to the environment’s systems, which includes physical and digital assets, as well as putting processes in place to protect data. Ongoing monitoring solutions are also needed to maintain visibility of the data flowing between and in and out of the various environments. Not all threats and attacks occur from the outside, which is why companies need to put their employees through security awareness and training. AVeS Cyber Security, Tel: (011) 475-2407 Email: info@aves.co.za

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SA INSTITUTE OF TRIBOLOGY

Sliding your Way to Rehydration Articular cartilage loses fluid when compressed, but how does it recover so quickly?

s soon as we put any load on our articular joints (eg, knees and hips when we stand), fluid is squeezed out of the cartilage, which comprises the sliding surfaces in our joints and consists of about 80% water. This process, which can cause as much as a 50% compression, is one of the mechanisms by which cartilage sustains load and protects itself from damage. It is less clear how the cartilage recovers after loading, which it does at a rate of a few percent per hour, total recovery taking place overnight. STLE-member David Burris and colleagues Brian Graham, Chris Price and Lucas Ramsey from the Figure 1. Cartilage samples were extracted from the central region of bovine femoral condyles (a), machined to size (b) and tested in a bath of buffer solution, with or without added hyaluronic acid on a rotary pinon-disk tribometer (c). (Figure courtesy of Ref. 1.)

University of Delaware, in collaboration with Axel Moore from Imperial College, UK, recently reported results that offer a convincing explanation as to how this recovery may be occurring. Previously they had carried out experiments on real cartilage in a reciprocating tribometer and observed that the sliding itself appeared to induce rehydration. They suggested a possible mechanism for the “tribological rehydration” that was based on the idea that hydrodynamic forces generated in the sliding contact pushed the fluid back into the cartilage.

Showed that increased sliding speed above 10mm/s led to a dramatic reduction in both deformation and friction However, an alternative explanation could be the influence of “reciprocal wedging,” which involves the fluid “wedge” that is produced during sliding becoming compressed upon direction reversal in the reciprocating test rig. The induced squeeze-film effect from this wedge compression also could be a potential rehydration mechanism.

Setting the issue

In order to settle the issue, Burris et al. changed their measuring setup to a unidirectional sliding configuration (see Figure 1), thereby eliminating any possibility of reciprocal wedging. The experiment involved measuring the steady-state values of both friction coefficient and vertical deformation (once the initial elastic effects at a given load had been subtracted) as a function of sliding speed, load, fluid composition and cartilage-pin size. The deformation-versus-speed and μ-versus-speed graphs reproduced the results from the reciprocating study—a clear indication that hydrodynamic effects dominate over any wedge effect (which had been eliminated here)—and also showed that increased

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sliding speed above 10mm/s led to a dramatic reduction in both deformation and friction. As expected, higher loads led to greater compression, but higher loads also required higher speeds for fluid recovery, reflecting the competition between the hydrodynamic pressure induced by sliding and the interstitial pressure in the cartilage resulting from loading. Increasing the pin diameter appeared to facilitate the recovery of both deformation and the drop in friction coefficient consistent with a hydrodynamic mechanism.

Low speeds

The addition of a large polysaccharide, hyaluronic acid (HA), to the tribometer bath, led to a reduction in friction, especially at low speeds, suggesting that it also may interact with the cartilage surface and act as a boundary lubricant. The HA also led to a reduction in the speed at which both deformation and friction began to drop. In other words, the HA, surprisingly, appeared to facilitate the rehydration process. While the increase in viscosity due to HA addition might be expected to reduce the rate of cartilage rehydration by hindering flow into the tissue, the increased hydrodynamic pressure caused by the presence of HA appeared to more than compensate for this effect. This work moves us a little closer to understanding the mechanism by which cartilage functions so effectively and over such a long time in our joints and hopefully toward approaches to both repairing and imitating this extraordinary tissue at some point in the future. Eddy Tysoe is a distinguished professor of physical chemistry at the University of Wisconsin-Milwaukee. You can reach him at wtt@uwm.edu. Nic Spencer is professor of surface science and technology at the ETH Zurich, Switzerland, and editor-in-chief of STLE-affiliated Tribology Letters journal. You can reach him at nspencer@ethz.ch. Republished with permission from the August 2019 issue of TLT magazine, published by the Society of Tribologists and Lubrication Engineers, an international non-profit technical society headquartered in Park Ridge, Illinois

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FEMININE TOUCH

Bridging the Gender Gap A packaging company has appointed its first female engineer and she’s already reshaping the company’s operations for the better.

vette Mabelane, PackSolve’s industrial engineer was appointed a year ago at this multidisciplinary industrial packaging solutions provider.

“The company is on an amazing growth journey, but it recognised that it needs to formalise more of its operations if it wants to sustain that growth,” says Yvette, explaining her role. “My focus is on improving our processes and introducing new ones, setting standards and supporting the continuous improvement culture we’re establishing.”

Her bubbly and warm manner seemed like a good fit for labour relations. But the course soon bored her at university. Yvette is a key player in the company’s strategic execution. She is one of several individuals representing ‘super services’ in the business. The group reports directly to the CEO to ensure a coherent application of Packsolve’s vision. These roles are new and respond to the changes the company is undergoing as it grows.

People’s touch

Adjusting procedures and standards towards those goals is Yvette’s responsibility. It may seem like a typical engineering pursuit, chasing arcane measures and indicators hidden inside operations. But her job is actually very people-centric, which is a boon for this outgoing and personable engineer. “Dealing with people is key,” she explains. “Industrial engineering has the theory, but it’s difficult to implement. You need buy-in from people to make things happen. You need to communicate with them

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in ways they understand and can contextualise to their roles. You have to be very hands-on. That requires the right personality.” Yvette certainly has the people touch, and nearly didn’t end up in engineering as a result. Her bubbly and warm manner seemed like a good fit for labour relations. But the course soon bored her at university. “It’s so much reading and theory ‘cut and paste’. I discovered I prefer to calculate things, to create solutions out of the elements in front of me. After considering my options, I changed to industrial engineering and loved it from the first week. I have a real passion for it.” Hailing from the Vaal, she completed her degree and then interned at a mining business. After several promotions resulting from her incredible drive, she had established her pedigree as a top engineer. But staying in one place was not a long-term option. Yvette knew that her career requires wider exposure to different industries, hence the shift to PackSolve.

Everything happens

Industrial packaging seems like an unlikely place for the rising star but Yvette could see the opportunities. The company is a fast-growing business that encompasses a variety of solutions, ranging from mining equipment to train wrapping to drums for the food industry. It provides exposure to a wide range of clients and scenarios, encapsulated in tightly-run operations that also pursue R&D and staff development. Joining the company provided an opportunity for Yvette to shift her training and experience into the next gear. “The company is much larger and more

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complex than it was a few years ago, so there is a lot for me to work with. These include minor changes through to looking at line balancing and changing the layout of certain lines. I also look at how we keep our stakeholders in the loop, including suppliers and customers. Do we communicate with them enough? How can those engagements be more systematic?” PackSolve’s solutions cater to the B2B market and its operations have a direct impact on customers meeting their own delivery schedules. Yvette works to enhance those relationships through several improvements, including the deployment of a business-wide ERP platform.

Challenges

Her ambitions aim high, but Yvette is not someone who settles for second-best. She almost can’t afford to in the male-dominated world of engineering. As a black female industrial engineer, she’s met more than her share of opposition and attitude. But these don’t slow her down.

Barriers to engagement “I can admit that being a female engineer is a challenge. There can be barriers to engagement and being taken seriously. But I push through those challenges because I’m here for the job. We have things to accomplish at the company and those who can’t move with the change will be left behind.” She adds that coming in left-of-field as a female engineer can be useful as it prompts people to think outside of the box. Lineworkers also look up to her status as a successful black professional, considering her an example of what can be accomplished in today’s workplace. PackSolve Gugu Mthimkhulu Tel: (011) 864-7323 / 078 117 3940 Email: sales@packsolve.co.za

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Your boutique business destination Surrounded by lush gardens in the hub of Johannesburgâ&#x20AC;&#x2122;s northern suburbs, The Peartree in Craighall Park caters for groups of fifteen through to 100 guests in three well-appointed and equipped business suites. Breakfast meetings, working lunches, indoor or outdoor dining, half-day and full-day packages including all welcome refreshments, teas and lunches are offered in Standard, Gold and Platinum packages. Secure parking, Wi-fi, lockable space, all underpinned by highly qualified and helpful staff dedicated to ensuring your event is a success, make The Peartree a destination of choice.

www.thepeartree.co.za e-mail: info@thepeartree.co.za Tel: 011 781 1401 41 St. Albans Ave, Craighall Park

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NATIONAL PRODUCTIVITY AWARD

Emerging Business Sector Category Wagner Systems, a Cape Town-based producer of fine mechanics components and assemblies, was recently awarded Productivity SA’s prestigious National Productivity Award in the Emerging Business Sector category.

“

The aim of the competition is to recognise South African companies that represent the highest qualities and attributes of productivity, and reward their efforts to improve efficiency, competitiveness and sustainability.” says Wagner Systems managing director, Lasni Millar. “We feel honoured having received this significant acknowledgement, especially as it gives recognition to our hard work and dedication to improve productivity and the efficiency of our business.”

Customer satisfaction, for example, improved from 60% to 90%, while the improvement in the number of items shipped on average per month came to 117% All segments

The company embarked on a productivity improvement initiative in 2016, with Productivity SA becoming involved a year later. The objective was to advance Wagner Systems’ competitiveness, profitability and sustainability. The programme extended across all segments of the business with the aim of increasing efficiency of production and enhancing the utilisation of resources by, among others, minimising wastage. In practical terms this meant the improvement of manufacturing processes and the reduction of variables to increase production output, still using the same workforce and equipment. “The programme was decidedly successful and the

impact of the productivity improvement far-reaching,” says Lasni. “We quantified the results in eight functional areas: production efficiency, production quality, customer satisfaction, staff component, resource utilisation, use of capital employed, sales, and profitability, and recorded extensive improvements in all of them. Customer satisfaction, for example, improved from 60% to 90%, while the improvement in the number of items shipped on average per month came to 117%.

Increased production capacity

Lasni has no doubt that the successful outcome of the programme has placed the company in a favourable position when it comes to proficiency and output. “It especially makes a difference where it matters most, with our customers. With improved operational efficiency and increased production capacity, we’re now able to respond to customer orders and requirements with enhanced flexibility, and deliver within shorter lead times – competitive benefits that favour the end-user.” Lasni concludes, “Productivity SA’s hands-on guidance provided us with simple and easy-to-understand techniques that helped us gain momentum. Without them we would not have been as successful.” Wagner Systems Lasni Millar Tel: (021) 715-8713 Email: jnmillar@wagnersystems.co.za www.wagnersystems.co.za

With the award (f.l.t.r.) Albert Brink, Regional Manager: Cape, Productivity SA. From Wagner Systems: Wilna Harmse, Quality Manager; Alex van Rooijen, Production Manager; Nizaam Manuel, Foreman; Giuseppe Geldenhuys, Technical Manager.

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TRACE In is a glo antio leading party ri

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nternational, Inc. obally recognized bribery business organization and provider of third isk management solutions.

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REAL-TIME OPERATIONS INTELLIGENCE

Digital, Direct and On the Go A new generation of site management information systems has been launched for cement and mining. Customers can access a suite of mobile and web apps that bring performance data out of the control room and direct to their laptop and smartphone.

LSmidth is bringing the digital revolution to the cement and mining industries with a new generation of products focused on delivering real-time data on the go. These latest products form part of the FLSmidth Enablr portfolio of digital solutions that connect, monitor, and optimise asset performance and enable customers to simplify operations and improve productivity. Mobile insights: This is an intuitive-to-use and simple-to-navigate mobile app, delivering insights

on the go with on-demand equipment and plant performance and health data. Data signals, known as tags in the app, can be easily found and monitored. Tags can be grouped into collections to offer snapshot summary reports of critical indicators, such as production, equipment performance or equipment health. A favourites list enables users to recall key data instantly. Email alerts and push notifications inform users when pre-defined events occur, eg unplanned downtime or production shortages, allowing prompt resolution of issues. Plant Data Management: A comprehensive management information system is designed

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for the cement and minerals industries. The latest browser-based system integrates all process and quality information islands, making critical real-time plant data available to operational, management and executive personnel. ECS/PlantDataManagement can cover one process area, a complete plant or several facilities, following an enterprise architecture. Dashboards, process analysis and process/production reports have never been more easily available. UptimeGo: This downtime analysis solution helps plant staff to identify the issues that interrupt operations and prevent unwanted future downtime. ECS/UptimeGo is now fully integrated into a single platform with ECS/PlantDataManagement, allowing simultaneous analysis of process, production, health and downtime data via a unified user interface. The solution calculates the economic value of downtime, allowing plant staff to focus on finding the root causes of the problems that impact plant productivity. “With on-demand and remote access to key data points, we are putting users in control of optimis-

ing their plant and equipment performance health,” says Ole Knudsen, Head of Digitalization Product Management.

Give users a better night’s sleep, safe in the knowledge that their plant and equipment are operating as they should be, and that they have the ability to respond quickly and effectively if the unexpected happens “We live in an interconnected, data-rich world. Our suite of products helps make sense of this data, bringing insight and transparency to plant and equipment operations. Ultimately, we want to give users a better night’s sleep, safe in the knowledge that their plant and equipment are operating as they should be, and that they have the ability to respond quickly and effectively if the unexpected happens.” FLSmidth Ole Knudsen Tel: +45 30 93 13 45 okn@flsmidth.com

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SUPPLY CHAIN

MRO Solutions Contract Dries Van Tonder

A successful contract extension with automotive and industrial product manufacturer Bosal Afrika is testament to the significant cost-savings that Bramhope Group’s Maintenance, Repair and Operations (MRO) solutions can add to a company’s bottom line.

pecialising in product sourcing and procurement, MRO and inventory management, specialised retail services, consulting, and software solutions, the Bramhope Group has been active in the supply chain industry since 2002. “Our comprehensive service offering covers the entire business cycle, from marketing to distribution, importing, selling, and procurement, and even encompasses packing,” MD Dries Van Tonder explains. The group secured the initial contract with Bosal Afrika three years ago when it sought to outsource its MRO function. That contract has just been extended, with the manufacturer set to take up

The difference that we can bring to a manufacturer is that we assume total control of their MRO system, allowing the company to concentrate on its core business

additional services in the near future, including assistance in setting up a new facility in early 2020. “Our extensive relationship with Bosal Afrika to date, in conjunction with the significant optimisation and cost-savings we have managed to achieve, has resulted in a very happy client,” Dries confirms. The Bramhope Group’s offering has extended from pure MRO to its current involvement with the bill of materials for the actual manufacturing process itself.

Valuable partnerships

“Over that time we have not only become an integral part of our customer’s operations, but it has transformed into a valuable partnership,” he highlights. As the Bramhope Group has evolved its own service offering, so it has been able to pass on these advances and benefits to its client as well. “The difference that we can bring to a manufacturer like Bosal Afrika is that we assume total control of their MRO system, allowing the company to concentrate on its core business. We also provide daily reports that give insight into all of the items available to the production process,” Dries notes. The automotive component and aftermarket segments present significant growth opportunities for the Bramhope Group. Due to rising input costs and constrained economic conditions, any appreciable cost-saving has an exponential impact on productivity and profit.

Exemplary feedback

Apart from leveraging its own supply chain to the benefit of its customer base, the fact that the Bramhope Group is Level 2 accredited means its customers benefit from its accreditation as well. “We are a fully-accredited, single source of supply offering the highest quality products and services,” Dries stresses. The client feedback to date has been exemplary, with Bosal Afrika confident enough to add even more services as it continues to streamline its own supply chain and thereby reduce its total cost of ownership. “This is an excellent example of our strategy of growing ourselves at the same time as our client develops further. Such synergy allows us to refine our own service offering as technology advances, especially in terms of automation and data analytics,” Dries concludes. Bramhope Group, Isak Marais Tel: (011) 397 5075 Ext 114 Email: sales@bramhope.co.za www.bramhope.co.za

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HUMANS AND MACHINES

The Factory of Tomorrow In view of the progress made in automation and artificial intelligence, a well-established and improved interaction between man and machine could help to ensure high economic standards and productivity. A promising model for the new harmony on the factory floor is based on the intelligent, integrated and interactive design of tomorrowâ&#x20AC;&#x2122;s manufacturing processes.

any still believe that man and robots can only work against each other or, if need be, side by side; moreover, there is still a fear that machines will replace human workers. However, the coexistence of human workers and automated machine solutions and robots has become commonplace in more and more companies.

It offers an innovative solution for the simple automation of applications that have traditionally been carried out by humans and where automation has so far been very difficult But thatâ&#x20AC;&#x2122;s not all: digitalization provides companies in the manufacturing industry with an enormous inventory of technological options for implementing

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the factory of the future. Smart networking using artificial intelligence offers the opportunity to convert manufacturing data into strategic information. It also enables the smooth integration of highprecision robotics technologies that work at high speed, supplemented by methodically safe and simple interaction between man and machine.

Interactive production

An impressive example of the potential of a technology that can revolutionise the factory floor of the future, while promoting harmony between human and machine, is a new collaborative robot that emerged from the partnership between Omron and Techman. It offers an innovative solution for the simple automation of applications that have traditionally been carried out by humans and where automation has

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Changing consumer behaviours are forcing manufacturers to flexibly produce smaller quantities in a larger number of variants, saving as much time as possible. The factory of the future must therefore become more flexible and be able to convert production more quickly and produce smaller runs. The ultimate goal is to be able to deliver personalised products from an agile and networked production line. In an automation model that meets this requirement, all devices, machines and solutions should operate in an integrated manner.

so far been very difficult. The robot can be seamlessly integrated into an autonomous mobile robot and also enables the automation of complex tasks using a 3D camera. One example of a futuristic solution is bin picking. The robot quickly and precisely sorts different articles and deposits them where they are needed. The 3D camera locates the items and sends their coordinates to the robot, while the software, supported by AI algorithms, performs the advanced calculations required for optimised goods picking, for example for customized orders. Meanwhile, a mobile robot is responsible for the subsequent transportation of the goods. In this respect, the efficient combination of different production processes forms the basis for particularly flexible and reliable production and material handling. It also gives a foretaste of what will be possible in the future with â&#x20AC;&#x153;Factory Harmonyâ&#x20AC;?, where integrated, mobile and collaborative robots work in harmony with humans, to ensure flexible manufacturing and customization.

Malfunctions and breakdowns

Operational excellence is an important basis for investment security, especially in view of the current changes in the industrial production organisation.

Effective quality control is essential in all production and packaging lines. Those who can identify defective products before they leave the factory, or even before they are produced, benefit from considerable time and cost savings and avoid costly product recalls, loss of production and possible damage to brand reputation.

Faulty products

Equally important is the quality control of packaging for products such as food or medicines. An illegible barcode or a wrong expiration date can lead to the need to dispose of faulty products. In addition, there is a trend towards stricter legislation, which gives top priority to unambiguous labelling for all types of products. For example, the EU has introduced new regulations in 2019, requiring production lines to meet even higher quality control standards.

The line layout can be quickly redesigned and the recognition pattern for quality control can be easily updated in the software As a result of the increasing degree of automation in production lines, the need for automated processes in quality control has also been amplified. Among other things, it pays off if the machines are able to collect data in order to optimise predictive maintenance. The more data collected and processed, the more intelligent the machine becomes in helping to extend production line life, reduce downtime, and increase productivity. For example, Omronâ&#x20AC;&#x2122;s Sysmac AI controller includes a predictive maintenance library based on AI and collects, analyses and uses data on Edge devices to extend their life, detect anomalies and prevent failures. No internet connection is required: users are no longer dependent on cloud computing and can leverage the AI potential for their business advantage.

Error detection

An increasingly important factor in quality control on production lines is smart image processing, technically implemented either as a completely new solution or by partially retrofitting an existing system. Very compact image processing systems monitor production in real time and react immediately to any error. The data transmitted by an image processing system is processed on site and THE SOUTH AFRICAN MECHANICAL ENGINEER

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HUMANS AND MACHINES

made available centrally via the cloud for detailed analyses so that suitable measures can be taken. In order for an inspection system to make intelligent decisions, data must be captured by a sensor such as a camera, for image processing. These cameras can be set up to monitor various aspects of a product, such as detecting defects or checking labels for printing errors or missing information. The data is then analysed with high computing power to compare the process with the actual and target results.

The ultimate goal is to be able to deliver personalised products from an agile and networked production line When problems are detected, the system responds according to programmed rules. Sometimes it can automatically correct the errors, but even then, the operator is always informed to ensure correct processes are implemented and in case additional action is required. Since this system is fully networked, it provides a better link between the machines on a production line, resulting in both more precise quality control and greater efficiency. When an error is detected, the system can often automatically compensate for it and production is not affected. Intelligent automation solutions of the latest generation work fast, offer high computing power, are easy to operate and thus ensure transparent quality control in the factory of tomorrow.

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Flexibility is key

Since customer and business requirements are constantly changing, the factory floor must also be more flexible in the future. Flexibility in the organisation and arrangement of production resources is one of the key success factors for efficient production. This includes on one hand the mobility of the robots used and, on the other hand, their adaptability to perform requirements practically. This is another advantage of an effective quality control and process management system. By combining image processing, motion, control, functional safety and robotics in a single management system, production lines can be more easily adapted to short production runs and changing market requirements. The line layout can be quickly redesigned and the recognition pattern for quality control can be easily updated in the software. This ensures that different product variants or even different products are produced and packaged flawlessly. In addition, such a system brings the benefits of future-proof orientation, because it can easily be adapted to new regulations. As a result, manufacturers do not have to worry about changing their production lines but can simply initiate a firmware update for the existing solution if necessary. Omron Electronics (Pty) Ltd Tel: (011) 579-2600 Email: info.sa@eu.omron.com Website: www.industrial.omron.co.za

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GLOBAL MANUFACTURING

Three Key Movements Despite the uncertainties ahead, many manufacturers are discovering new reasons to innovate, driven by macroeconomic pressures, competition, supply chain shifts, sustainability efforts, and, of course, customer demands.

ere are three key movements that will shape global manufacturing in 2020.

Sustainability comes to the fore

Consensus is growing that there is far too much waste and pollution in the world. Many consumers in the upper LSM bands are consciously using less plastic, demanding brands to reduce unnecessary packaging, and becoming more ‘energy smart’ in their everyday lives. Generation Z consumers are becoming less materialistic. They recycle clothes, hire bikes, and share car rides. This behaviour is altering the global consumer’s expectations on the products they receive. People are no longer looking for fast churn to create more goods. Instead, they want better quality and longevity on the product lifecycle so goods can be reused or recycled. In 2020, the shift from a linear economy (take, make, dispose) to a circular economy (reuse, repair and recycle) will take precedence in the industry. While not a new concept, the circular economy will soon hit its potential.

Food compliance – a global concern

From food production to processing, distribution to consumption, every stage is integrated and has the ability to enhance – or damage – the environmental, economic, social and nutritional health of the ecosystem. At the centre of all this is food traceability. It covers every stage of the ecosystem from producers to manufacturers, all the way through the supply chain to the retailer or caterer. Food traceability has been a top priority for food manufacturers and retailers for decades, yet consumers continue to be plagued by inconsistency in food quality standards. Consumers deserve to know where the food comes from and how it is prepared. Demand for greater

transparency and quality control has reached new heights. The growing popularity for plant-based food only adds to the complexity. South African food producers and exporters in particular, need to take extra steps to ensure their production processes are of the highest quality to meet the latest food standards. Enhanced compliance and quality controls, together with tougher regulations, will place a renewed focus on food standards in 2020.

Create your own applications playlist

Gartner predicts that by 2023, 40% of professional workers will orchestrate their business applications like they do their music streaming services. Until now, many businesses offered IT services as a ‘one size fits all’ approach. They expected employees to fit their job around what is available, and as a result, we have seen a rise in shadow IT where employees bring their own devices and applications to the workplace. It may also be a reason for the weak productivity levels we have been talking about for so long. In addition, this model has had the unintended consequence of putting increasing risk to the organisation’s data security. The knock-on effect is disruption to the business workflow. Instead of restricting users from choosing their own way of working, businesses need to find new ways to provide effective IT services to employees. At the same time, they need to enhance security and accessibility. Enterprise Resource Planning (ERP) technologies offer businesses the ability to consolidate their data and business applications and give IT the capability to deliver their services in building block form. As a result, users can create their own individual ‘playlists’ of applications customised to their needs, empowering them to work more productively. Sage Tel: (011) 304-3000 www.sage.com/africa

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PUMPING SLURRY

Where Others Fall Short… Pumping fluids with high solids concentrations is far more complicated than just pumping water. To avoid sedimentation in the system, the correct pump size with appropriately dimensioned hoses and pipes must be selected.

dding to the complexity of selecting pumps for slurry pumping applications is that the concentration of solids, together with particle size and shape, can affect pump performance as well as power requirements. Settled solids might require external agitators, water jets or mixers to get them back in suspension and allow them to be pumped.

Ownership costs

All these factors need to be considered when selecting the correct slurry pump for an application, and local Grindex pump distributor, Integrated Pump Technology has issued a caution against making this purchase decision based on capital cost alone.

Coping with the high levels of wear caused by this abrasion requires a pump with hydraulic parts manufactured from a very hard metal alloy “Slurry pumps need to handle abrasive solids in suspension, including sand, gravel and waste prod-

ucts in high concentration,” Colin Adams, managing director of Integrated Pump Technology says. “Coping with the high levels of wear caused by this abrasion requires a pump with hydraulic parts manufactured from a very hard metal alloy. Selecting anything less will result in high maintenance and repair costs translating into unnecessarily high total cost of ownership.”

Hardest materials available

Grindex Bravo submersible slurry pumps are engineered to cope with the toughest pumping conditions, and the hydraulic components are made from Hard Iron, one of the hardest materials available. “Countering excessive wear is important in slurry pumps and the robust construction of the Bravo pump, coupled with its low shaft speed, ensures high wear resistance even in the most demanding slurry applications,” Colin explains The Bravo pump range can operate over the complete pump curve, not just on a specific duty and can handle from 30 litres per second up to 130 litres per second at a maximum head of 45 metres. The large throughlet means that the pump can handle solids of varying sizes. The pumps are equipped with a leakage sensor that facilitates early detection of any problems, allowing action to be taken as soon as possible.

Coarser material

Colin explains that with its single adjustment screw it is simple to tweak the pump impeller ensuring optimal performance. Pumps in the Bravo series range from the 400 upwards and are equipped with an agitator designed specifically for coarser slurries. This enables the pump to stir up and pump sand, sludge and solids in suspension. “Our team of experienced and skills pumps specialists can advise customers on the most appropriate pump for a particular slurry application, assuring that the pump installation will operate at low total cost of ownership,” Colin concludes. Integrated Pump Technology Tel: (011) 894-2906 Email: info@pumptechnology. co.za www.pump-technology.com The Grindex Bravo pump is proving its worth in slurry pumping applications

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MINERALS

New Manganese and Iron Removal Device For the first time in South Africa, making available a Runxin device (F107) specifically designed to remove manganese and iron from water, is available locally.

llmech is a South African manufacturer of boilers and supplier of water treatment components, and is bringing in the valve for a pilot project in the agricultural food processing industry. Lionel Maasdorp, General Manager, explains that iron and manganese can be effectively removed from water using a number of treatment processes, depending on both the form and concentration of the metals. “We are not the first to use these Point-of-Entry (POE) treatment devices, but this is the first time that this specific device is being made available in South Africa and we believe it will help solve the challenges of our customers across several sectors,” says Lionel.

Resin in a softener should last up to 10 years, but with this client we were making replacements every three to six months “Manganese tends to be difficult to remove from water because removal depends on its state of oxidation, the pH of the water, the presence of other minerals, and the TDS (total dissolved solids) of the water being treated.”

Damaging the resin

Another complication is that manganese often appears alongside iron and hydrogen sulphide. While conventional water softeners are sometimes effective for removing iron and small amounts of manganese, Lioneel says high concentrations of manganese can damage the resin in the softener. “Resin in a softener should last up to 10 years, but with this client we were making replacements every three to six months,” he explains. “Borehole water is often very high in manganese and iron, which has major cost implications for businesses if they have to constantly replace the resin in their softeners. “We have suggested the Runxin iron and manganese removal device to our clients as an alternative solution. It’s essentially a pre-treatment device that removes the substances from the water before it reaches the industrial softening system or demineralisation system.” The Runxin F107 iron and manganese removal control valve uses a special design that offers a high aeration method. This assures the dissolved oxygen required for manganese removal is present. It has an automatic air release valve which constantly drains the air and carbon dioxide that is formed in the water.

Simple design

The valve has a simple design and is made from corrosion resistant material, which ensures reliable sealing. When the water is properly pre-treated with air, any good filter medium will remove the manganese. The device is suitable for water pressure of between 0.25MPa and 0.6MPa, temperatures of 5 to 25oC (and environmental temperatures of 5 to 50oC), and electrical supply of AC 100 to 240V (or 50 to 60Hz). It will be effective for water supply containing ≤25mg/litre of iron, or ≤3mg/L of manganese and water turbidity <15NTU. Allmech Lionel Maasdorp, Tel: (011) 849-2731 Email: lionel@allmech.co.za www.allmech.co.za

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MARKET FORUM

Flow measurement solution Emerson’s Rosemount MS slurry sensor with the Rosemount 8782 slurry transmitter is a slurry magnetic flow meter specifically designed for high noise and slurry applications for use in the oil and gas, mining, and pulp and paper industries. Featuring robust coils and advanced signal processing, a responsive yet stable flow signal is possible even in high noise applications.

It uses advanced signal processing with real-time diagnostics to deliver flow measurement confidence and the ability to automatically control the loop. Southern Africa, Emerson Automation Solutions Devesh Roopnarain Email: Devesh.Roopnarain@Emerson.com

With over 25 years of experience delivering products for these challenging applications, the new slurry magnetic flow meter helps improve product quality, reduce raw material cost, and minimise waste and re-work. Slurry Mag provides a flow measurement solution for customers with fluids that contain large solids, mining ore, pulp or sand, or that experience high process noise or signal instability. Featuring the latest advanced signal processing that is the first to adapt to changing process conditions in real time, the Slurry Mag eliminates noise from the flow signal without using excessive damping, giving operators confidence in their measurement calculations.

100% locally manufactured Werner Pumps, a manufacturer of high-pressure jetting equipment in South Africa, is now ISO 2009:2015 accredited. This certification is in recognition of the company’s compliance to the ISO standard that specifies requirements for implementing a quality management system (QMS). “The ISO 9001:2015 accreditation will enable Werner Pumps to demonstrate to clients that we are recognised in our provision of products and services that consistently meet

regulatory and customer requirements,” says Sebastian Werner, Managing Director. “Our ISO 9001:2015 certificate for quality management encompasses the design, manufacture and refurbishment of our high-pressure jetting and pump equipment. This certification sets us apart from local competitors and shows how serious we are about the level of quality we produce.” Sebastian believes that in a challenging economy, the need to remain competitive is paramount. The company’s investment in advanced machinery and technology enables it to supply 100% locally manufactured high-pressure jetting products that can compete at a global standard. “We are growing despite the tough economic environment, and we believe this is because we continue to reinvest in our business and to source advanced manufacturing equipment to ensure our products offer a superior quality and value,” Sebastian concludes. Werner pumps Sebastian Werner Tel: (011) 362-6280 Email: sebastian@wernerpumps.com

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MARKET FORUM

Dutch origin The Verder Group has reinforced its top position after being named the number one brand in the Maakindustrie100 (Manufacturing Industry100) in 2019, and for the second consecutive year. The Maakindustrie100 is an annual list of the best performing manufacturing companies in the Netherlands, compiled by CFI and Management Team. Led by CEO Andries Verder, the family group produces hightech laboratory equipment and a very wide range of pumps and mixers for industrial applications The completely independent family business serves customers from all over the world. In 2018, revenue amounted to more than 302 million Euros, with revenue and profit growth over the last four years of 16 and 15 percent, respectively. The company has 1 850 employees worldwide. The Maakindustrie100 is published annually and consists of the 100 best-presenting SMEs in the Netherlands. The list is compiled by MT in collaboration with CFI (formerly MBCF Corporate Finance). “We look at manufacturing companies with a Dutch mother and a turnover of up to 500 million euros,” says Kevin Driesen of CFI. “We want to pay attention to the hidden champions of the Dutch economy.” Publicly available information is used in the composition of the list. The criteria are revenue, revenue growth, EBITDA and return on invested capital. This leads to four rankings, where each ranking amounts to a certain number of points. By adding up all those points, you get a total score. Just as in 2018, Verder Group tops the list.”

“We are delighted to represent the Verder brand and its wide range of products and solutions in Africa and remain grateful for the continued support of our clients, partners and peers which contributes to the growth of the local and international business,” Darryl Macdougall, Managing Director, Verder Pumps South Africa concludes. Verder Pumps South Africa Kirstin Adam Email: kirstin.adam@verder.co.za

From 3 months to one year After experiencing ongoing problems with the bearings on a vital milling machine at a steel plant in Europe, the management team turned to NSK for a solution. This decision proved to be extremely lucrative, with the steel mill now enjoying annual savings of i35,600. The mill produces rails for lift equipment that require the machining of two flat areas at the ends, which assist the fitting of the rails during assembly. While the time required to mill these rough surfaces is short, the stiffness of the machine´s spindle is critical due to the length of the rails. However, using the milling machine´s original bearings, the steel plant noticed that spindle stiffness reduced after just three months, making it necessary to change the spindle assembly, including motors. Faced with a recurring and expensive situation, NSK was asked to find a solution. Engineers visited the plant and analysed the spindle design as part of its AIP Added Value Programme. Calculations were made based on the use of tooling expected to deliver high cutting capacity and withstand high loads. Engineers

also inspected the failed bearings and checked the wear bands of the raceways. Following their analysis, NSK´s engineers recommended that the spindle be redesigned with a four row bearing set, instead of three, thus increasing the radial load capacity and radial stiffness. The contact angle was also changed from 15° to 25°, to increase the bending stiffness of the shaft. NSK´s high precision angular contact ball bearings (ACBB) were selected from its range of standard products. After the steel mill had implemented the change, the bearings continued working in the milling machine for more than a year, with no failures experienced in the motor or transmission. Indeed, a full report was produced by NSK to verify the improved characteristics, detailing the enhanced bending stiffness of the shaft and extended operating life from three months to over a year. NSK South Africa (Pty) Ltd Geraldene Govender Tel: (011) 458-3600 Email: nsk-sa@nsk.com

NSK´s high precision ACBB series of angular contact ball bearings

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MARKET FORUM

Empowering women in engineering Working to embrace the spirit of transformation and development, Metric Automotive Engineering has affirmed its Level 4 status in terms of Broad-Based Black Economic Empowerment (B-BBEE) requirements. In an exciting recent deal, the Intombazane Development Trust has invested in the Germistonbased specialist in diesel and gas engine component remanufacture. The involvement of the trust will further enhance Metric’s work, in supporting the entry of black women into engineering fields through study bursaries. “It is gratifying to see our interventions uplifting previously disadvantaged candidates, focusing on learners at tertiary level,” Andrew Yorke, operations director at Metric Automotive Engineering, says. “The Metric Automotive Engineering operates a comprehensively equipped facility and is committed to empowering skills development skills they are learning are vital to the South African economy, and exist in fields like the local remanufacturing of large engine will certainly transform their lives for the better.” components. He emphasises that the beneficiaries of the recent deal are previously disadvantaged women. Through the company’s Metric Automotive Engineering, Tel: (011) 873-2350 training initiatives, it is furthering the opportunities that Email: marketing@metricauto.co.za, www.metricauto.co.za

much more than just a pump in a

BOX

complete pumping solutions Email. info@pumptechnology.co.za 34

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www.pumptechnology.co.za VOL 70 Jan/Feb 2020

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Boosting coal plant performance Yoctolux Collieries in Mpumalanga has achieved improved yields and production throughput with the installation of a Cavex 500CVXT20 DM hydrocyclone from Weir Minerals Africa. Part of the Tala Group, the opencast coal mine was looking to improve the performance of its dense media separation (DMS) circuit in its Wash Plant 1. The existing 610mm cyclone, installed during the mine’s initial design phase, had an operational life of only six months between refurbishments. Members of the Weir Minerals Middelburg branch and hydrocyclone product team conducted a site audit, revealing that the incumbent cyclone was operating inefficiently. A wash-ability analysis showed that an improved yield could be achieved using the Cavex hydrocyclone technology on the DMS circuit. The customer specified that the product would have to offer improved separation efficiency, increase wear life and match the existing cyclone footprint. Following a proposal that included dense media (DM) hydrocyclone simulations, a Cavex 500CVXT20 DM hydrocyclone was installed in August 2017. Manufactured from mild steel, it is lined with 25mm slip-casted radius ceramic tiles manufactured 92% alumina content. To date, the hydrocyclone has achieved higher separation efficiency through an average 15% yield increase. It has achieved an overall average of 75% yield for both of the mine’s

Sheldon Gabriel, product manager - hydrocyclones at Weir Minerals Africa

coal types – grains and peas. This compares favourably with the 65% achieved previously by the competitor’s cyclone. There has been a 49% throughput increase in production tonnage, from 78 tonnes per hour to 116 tonnes per hour as a result of the reduced turbulence in the hydrocyclone’s design. The mine has also seen significant wear life improvement, with the Cavex DM hydrocyclone requiring only a spigot replacement after nine months. Weir Minerals Africa Tel: (011) 929-2600 Email: Africa.minerals@mail.weir www.minerals.weir

Setting the benchmark With the advent of Industry 4.0 set to change the face of industry and production, SEW-Eurodrive (Pty) Ltd. has a range of solutions for its concept of the Lean Sm@rt Factory. This is based on the paradigm shift introduced by new technologies such as big data, embedded computing, the Internet of Things (IoT), and cloud computing in the production environment. The Movigear mechatronic drive system from SEWEurodrive (Pty) Ltd. is designed for flexible use across various communication infrastructures. It is ideal for decentralised field applications. Features include a compact design and optimal integration of components with permanent-field synchronous motor, gear unit, and integrated electronics. Movigear is especially tailored for efficient use in the general materials-handling sector. It is available in two sizes and three electrical performance classes for a total of four communication variants. Energy savings of up to 50% are possible due to the seamless interplay between the IE4-rated motor, efficient gear unit, and integrated electronics. “Perfectly-matched components, combined with the energy optimisation of the overall system, facilitate high system efficiency. These features make the Movigear mechatronic drive solution a cost-effective, power-optimised, total solution,” SEW-Eurodrive (Pty) Ltd. MD Raymond Obermeyer concludes. SEW-Eurodrive (Pty) Ltd Tel: (011) 248-7000 Email: sewjhb@sew.co.za www.sew-eurodrive.co.za

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Quality fasteners Almost every bearing or power transmission application requires fasteners. In order to be able to offer a complete solution to its customers, Bearings International (BI) now stocks and supplies a comprehensive range of quality fasteners, including blind rivets, self-drilling screws, hexagonal nuts, bolts, and washers from FTS Boltworld. Ancillary products include anchors, grease nipples and roof sheeting fasteners, as well as specialised fasteners such as hook and straining eye bolts, u-bolts and gutter bolts, BI Offer Marketing Manager Victor Strobel explains. “The main benefit for our customers is point-of-sale convenience. BI can now offer them the full basket of products required for all their construction and maintenance needs, making us a favourable one-stop shop,” he highlights. Due to it being a popular consumable product used in most customer applications, across all industries and markets, the FTS Boltworld offering will be available across BI’s 48-branch network countrywide. “Our market research indicated a gap at our point-of-sale, where we can grow revenue sustainably and innovatively, as well as satisfy customers’ needs more holistically,” Victor concludes. BI, Victor Strobel Tel: (011) 899-0000 Email: info@bearings.co.za www.bearings.co.za

Victor Strobel

Dump reclamation Rand-Air, a local provider of portable air, is involved in the reclamation of four historical mine dumps at the site of the former Zincor zinc refinery just to the south of Springs.

The refinery was constructed from a former uranium plant belonging to the defunct Vogelstruisbult gold mine. These dumps include a high-hazard certified waste tailings dam, two gold tailings dams and an iron/lead/zinc residue dump. The initial phase of the project entails hydro-mining the neutral leach dump, which comprises 2.5-million tons of zinc material that will be processed over an eight- to nine-year period. The neutral leach dump was formed between 2000 and 2010 as a result of zinc/copper ore treatment from the effluent plant. The zinc tailings will be treated with acid leach filtration followed by hydroxide precipitation and filtration. This metals reclamation project is being carried out by EBM Projects, a subsidiary of Vele Private Equity which is, in turn, a subsidiary of Vele Investments. The project has a net present value in excess of R1-billion and the estimated value of the property’s remaining in-situ lead, silver, gold and iron-ore resources is estimated at about R22-billion. By removing potentially hazardous metals from these defunct dumps, EBM Projects is eliminating a potential environmental risk, while at the same time creating direct and indirect work opportunities for some 700 individuals. This initiative is welcome in a region where job opportunities are relatively scarce. “We are hiring out three of our top-of-the-range compressors, two GA315FF and a GA160VSDFF. The compressed air is being used to operate the filter presses which remove water from the mineral products,” explains Rand-Air’s Business Development Manager Henry Fourie. The rental contract commenced in February this year and will continue for a five-year period. Rand-Air, Tel: (011) 345-0700 Email: info@randair.com

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Food grade belts Ammeraal Beltech’s Rapplon folder gluer belts, which meet FDA and EC standards for contact with dry foodstuffs, form part of BMG’s extensive range of food grade belts used in pristine hygiene applications. “Rapplon folder gluer belts, which have been re-engineered for the carton box industry, are now fitted with abrasion-resistant, non-glazing food grade covers for safe use in food, liquid and pharmaceutical packaging industries,” explains Ryan Forsyth, Business Unit Manager, BMG’s light materials handling division. “There are many applications in the food processing sector, where standard process or conveyor belts Ammeraal Beltech’s Rapplon folder gluer belts, which meet FDA and EC standards for cannot be used. It is critical in contact with dry foodstuffs, form part of BMG’s extensive range of Food Grade belts used in modern food processes that only pristine hygiene applications high-quality coating materials, suitable for direct contact with The belts, which are available in 3mm, 4mm and 5,5mm foodstuffs, as well as for packed food conveying, are used to thicknesses to fit most folder gluer machines, provide a firm ensure hygienic and safe processing and efficient logistics.” grip on all types of board for accurate carton blank movement The new construction of these folder gluer belts ensures re- during folding, gluing and packing production. duced energy consumption and also offers extended service life and fewer maintenance stops.

BMG, Ryan Forsyth, Tel: (011) 620-7422 Email: ryanf@bmgworld.net, www.bmgworld.net

Doing the job right The Colliery Training College (CTC) in Emalahleni (Witbank), has awarded Industri Tools & Equipment the 2020 contract to supply tool kits, which are used during mining and engineering related skills training. “The CTC, which was established in 1964 specifically for the mining sector, has since diversified and artisan skills training is now available for many different trades. Students are offered training for various sectors, including electrical, auto electrical and instrumentation, or as riggers, diesel mechanics, plater welders, millwrights and fitters,” says Kriban

Govender, Managing Director, Industri Tools & Equipment, part of the Engineering Solutions Group (ESG) of Invicta Holdings Limited. “Our team is proud to be part of this skills upliftment initiative, which plays an increasingly critical role in South Africa. The 2020 CTC tool kit contract encompasses the supply of quality-branded hand tools, that are used by hundreds of students every day in the engineering workshops and during practical skills training.” The CTC, which is accredited by the Mining Qualifications Authority (MQA) and the Quality Council for Trades and Occupations (QCTO) also has certification from relevant SETAs. In line with the commitment to meeting the highest standards in every aspect of the training programme, all tools are carefully selected by our specialists, in terms of quality, suitability for the task, safe use and long service-life.” The company’s extensive product offering is available from seven specialist divisions: tools and equipment, cutting tools, welding products, lifting equipment, PPE products, locks and machine tools. The manufacturing division offers workshop repairs and services, as well as the production of a wide range of custom-made industrial materials, including welding screens, strip curtains, fire blankets, spill mats, tarpaulins and dam liners.

JS Spies, Witbank Branch Manager, Industri Tools & Equipment and Johan Venter, Managing Director, Colliery Training College

Industri Tools & Equipment Kriban Govender Tel: (011) 386-5801 Email: info@industri.co.za, www.industri.co.za

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On the Move Mikko Keto

Graham Forte

Mikko Keto will join FLSmidth as President, Mining Industry and member of Group Executive Management. The appointment comes following Manfred Schafferâ&#x20AC;&#x2122;s decision to retire.

Humulani Marketing (Pty) Ltd, trading as CSE Equipment, part of the Capital Equipment Group (CEG) of Invicta Holdings Limited, has made the following appointment announcements: Graham Forte is Divisional Managing Director, and Andrew Lotter is Kwazulu-Natal Branch Manager for CSE Equipment.

Andrew Lotter

Derek Halstead-Cleak Derek Halstead-Cleak has been appointed Chief Executive Officer of Kwikspace.

Statutory inspection of gas-storage tank In a first for rope-access specialist Skyriders, ultra highpressure blasting was used to systematically remove a layer of cementitious fireproofing and insulating material from a 19-m-diameter, 22-m-high spherical gas storage tank at a major petrochemical producer in Mpumalanga. The complete scope of work for Skyriders was, firstly, to remove the deluge fire sprinkler and piping system before the cementitious fireproofing insulation material could be accessed from the top of the structure downwards, Marketing Manager Mike Zinn explains. The pressurised gas storage tank requires statutory inspection and testing every couple of years, in addition to replacing the fireproofing and insulating material to ensure the ongoing integrity of the structure. Skyriders was tasked with devising a safe and efficient means of achieving this, in order to allow for third-party contractors to carry out their own scope of work.

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An eight-person team from Skyriders took 18 days to complete the project, at the end of which the deluge fire sprinkler and piping system had to be put back in place. The major challenge was carrying out high-pressure blasting at height. Hence this process was monitored closely by the client and its safety team. Major industrial customers such as petchem and chemical plants and refineries, among others, often have separate budgets for both maintenance and access. The key differentiator for Skyriders here is that it can offer a per-square-metre rate that represents a 20% to 35% budget saving, in addition to benefits such as enhanced health and safety and guaranteed quality of any work undertaken. Skyriders, Mike Zinn Tel: (011) 312 1418 Email: mike@ropeaccess.co.za, www.ropeaccess.co.za

VOL 70 Jan/Feb 2020

High security welded mesh

Pallisade

Gates

Gate Automation

Razor wire and more ....

What is High Security Weld Mesh HIGH Security Weld Mesh is wire fused and welded at a Horizontal distance of 76.2mm and a vertical distance of 12.7mm also known as 35B/3510 where 3 denotes 3”(distance between vertical wires), 5 denotes 0.5” (distance between horizontal wires), and B or 10 denotes gauge of wire

Salient Features • Difficult to Climb: The spaces between the Horizontal wires are too narrow for fingers to have grip • Impregnable: Extremely difficult to cut with a hand cutter as the beak of a wire cutter will not be able to penetrate the horizontal wires • Excellent Replacement option to Solid Wall as: 1. More economical than a solid wall 2. Faster to install than a solid wall 3. CCTV Camera has a clear view • Further upgrade possible with electric security system • Anti-corrosive & low maintenance

Standards

• Manufactured according to BS EN 10016-2 • Wire Sizes in accordance with BS EN 10218-2 • Tolerance on Mesh Size in accordance wiht EN 10223-7 • Tolerance on Panel Size in accordance with EN 10223-4 • Welding Strength in accordance with BS EN 1461 • Zinc Coating in accordance with EN 10245-1 • Anti Corrosion in accordance with BS En 3900 E4/F4

Tensile Strength • Wire has a tensile strenght of min 550 MPA

MARK: 083 454 6488

Email: mark@palifence.co.za

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VOL 70 Jan/Feb 2020