THE SOUTH AFRICAN MECHANICAL ENGINEER
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THE SOUTH AFRICAN MECHANICAL ENGINEER
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AN ENGINEER’S VIEW
A Giant Scheme? Chris Reay Chairman of the Working Committee: Communications (SA Institution of Mechanical Engineering)
Is the Modern Economy a Giant Pyramid Scheme? Think about it. As a taxpayer and voter, you are promised by politicians that if you vote for them they will provide you with all sorts of benefits in exchange for your vote. You earn money in your job and pay tax to the government so that it has funds to provide you with the promised benefits: education for your children, health services, and infrastructure in the form of roads, municipal services, police services, judiciary, economic and fiscal responsibility to name some of them. The mix depends on the policies of each government. In South Africa you may only get the party’s tee shirt.
L
et’s take a look at our situation. We have what the population has been assured is the best constitution money can buy. If you look carefully you realise that, in fact, you cannot be assured that the person you vote for will represent you because the political party will decide who to appoint to that role. But let’s not get into politics; we have enough hot air on that topic to cause climate change. What we do witness is that the persons appointed to government at the top are very well paid and appear to earn a lot more than the delivery for which they are responsible. The rules set up by the government whether by statute or by practice enable this to happen. They could be said to be taking money from the down-line without providing the appropriate product in return. How does this differ from the structures of a pyramid scheme? There is no observable exchange of value.
Many irate investors (read taxpayers and consumers) get active to ban the scheme Obscene amounts of money
Let’s rather look at what happens to a lot of the money that feeds upwards to the top both via taxes as well as the flow of money to the providers of many near monopolistic trade structures. It seems fairly welldocumented globally that the rich are getting richer while the poor are getting poorer. This is happening whether one is in a typically western capitalistic economy or a socialist economy as we can observe in both the USA and Europe. Think of the outcome of the credit crisis: many top bankers and investors made huge and obscene amounts of money via a system they developed to get the money out of the general population.
all will benefit from the process. Does the tendency for economies to exhibit this shifting of the wealth upwards then correlate to the emergence of large monopolistic businesses and over-indulgent government, and to the impact of the lack of bank credit to the small business and individual who were, and are, so affected by the credit crisis? It is otherwise commonly called greed. It is interesting to note that in Australia, most of the millionaires are from the small, entrepreneurial business sector and that the impact of the credit crisis was minimal on that country. The chances of the big banks, financial institutions and businesses taking risks with others’ money was clearly lower. Is this a lesson to South Africa and the world at large to enable small business to thrive? If the poor continue to get poorer then there must at some stage be a situation where the inevitable happens: the pyramid scheme collapses, and many irate investors (read taxpayers and consumers) get active to ban the scheme.
Accountants before engineers
Where would engineering as a role fit into this? I do believe that in any engineering transaction which has an objective to create the built environment, the exchange of money for product is probably pretty reasonable. The product is evident, well defined, built to proven specifications by persons who are qualified and usually sufficiently experienced to do it right. When, however, I see evidence that the lawyers are likely to make more out of the renewable energy contracts than many of the Engineers involved, I wonder if that is contributing to the award of wealth without commensurate productivity. No names are mentioned in order to protect the guilty.
The overwhelming common factor behind all these processes is that money is flowing up to the top without the commensurate product or service flowing back down accompanied by broken assurances that THE SOUTH AFRICAN MECHANICAL ENGINEER
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SAMHYDRAULIK, which is one of the leaders in the field of hydraulic transmission, has been operating for over 25 years in the international market, offering a complete range of orbital hydraulic motors and power steering units, axial pumps and motors for medium and high pressure ranges, all characterised by excellent performances. SAMHYDRAULIK employs 120 people who operate inside a very modern and efficient plant that spans over 6 000 square metres to assure a high standard and flexible production capacity. The latest computer technology is used for both design and production, combined with strict quality control procedures during all production phases, which translates into innovative, reliable and functional products that meet the various needs of the market. Its ISO 9001 certification, held since 1994, is the result of a qualityorientated philosophy on which SAMHYDRAULIK has always based its operation.
AXIOM
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THE SOUTH AFRICAN MECHANICAL ENGINEER
17 Heidelberg Road, Village Main, Johannesburg, 2000 P O Box 260248, Excom, South Africa, 2023
VOL 62
July 2012
July 2012
Cover Story
Exhibitions
8
31 Electra Mining Africa
Clean Air for Top Performance
CESA
Hydraulics & Pneumatics
10 Lack of Skills
32 Spill-free Connectors 35 Bionic Learning Network
Monthly Column 11
Prominent Professionals
Opinion 12 Soapbox
Copyright 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.
NUMBER 7
Contents
On the cover: Munters Tel: (011) 997-2000 www.munters.co.za
VOLUME 62
HVAC - Heating, Ventilation & Cooling 13 Quality at Low Prices? 15 Chilled Water Project
Regulars 3 6 30 37 39
An Engineer’s View Institution News SAINT SAIT Market Forum
Com mp presso ssors, ss s Air ir Motors & Vacuum Pump ps s 17 Explosive Dust 19 Joining Forces for Better Service
SAEE 22 National Energy Barometer Survey
POWER GENERATION TODAY 23 PV Power for South Africa 26 Power Generation News The monthly circulation is 4 242
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THE SOUTH AFRICAN MECHANICAL ENGINEER
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THE SA INSTITUTION OF MECHANICAL ENGINEERING
Soap Box Opportunity for Exhibitors at Electra Mining 2012
Council 2011/2012 Office Bearers
President .................................................. G Barbic (George) Vice President .............................................. D Findeis (Dirk) National Treasurer ............................... KK Nyangoni (Kudzai)
Branch Chairpersons
second largest mining show in the world Expo Centre, Cnr. Rand Show and Nasrec Roads, Nasrec, Johannesburg 10 – 14 September 2012
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)
Be sure to visit Electra Mining, the world’s second largest mining exhibition, and gain free attendance to the Exhibitors Soapbox sessions organised by SAIMechE in the MAN Building, Expo Conference Centre, Nasrec. 30 minute corporate presentations on products, services, technologies and trends will be given throughout each day of the exhibition.
Chief Executive Officer: Vaughan Rimbault National Office Manager: Anisa Nanabhay
This first time ever Electra Mining Exhibition feature is designed to give the discerning user/purchaser the opportunity to make informed decisions. A programme of the sessions will be published in due course.
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
Rotek Engineering
Babcock Africa Limited
RSD a division of DCD-Dorbyl
Bateman Engineered Technologies
S.A.M.E Water
Bosch Projects
Sasol Technologies
Fluor SA
SEW Eurodrive
GEA Air-cooled Systems
Siemens
Hansen Transmissions SA
SNC-Lavalin SA
Hatch Africa
Spicer Axle SA
Howden Power
Spirax Sarco SA
Howden Projects
Technical Systems
Industrial Water Cooling
Thyssenkrupp Engineering
MBE Minerals (SA) (Pty) Ltd (previously KHD Humboldt Wedag SA)
Transvaal Pressed Nuts & Bolts
Megchem Eng & Drafting Services Mod-U-Flow Osborn Engineered Products SA
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Ultra-Flow Engineering Services Vital Engineering Weir Minerals Africa Winder Controls
THE SOUTH AFRICAN MECHANICAL ENGINEER
VOL 62
Obtain a Soap Box application form from: Carey Evans - carey@saimeche.org.za Tel. (031) 764-7136, www.saimeche.org.za
Western Cape PostGraduate Students Showcase their Research at Local Conference Over 20 & 21 June, around 100 post-graduate engineering students from Western Cape higher education institutions Cape Peninsula University of Technology, University of Cape Town and Stellenbosch University gathered at CPUT’s Bellville Campus to share their research in the fields of materials, manufacturing and mechanical engineering. The two-day conference, funded by a donation from the Cape Initiative in Materials and Manufacturing (CIMM), was endorsed by SAIMechE WC and drew a strong July 2012
THE SA INSTITUTION OF MECHANICAL ENGINEERING
National Welding and Fabrication Multi-Speaker Seminar East Rand 22 August 2012 Contributing expertise from: Air Liquide Afrox Genrec Engineering NDE Stainless Steel
Workshops
Steinmuller
Code
Abbreviated Title
Date – Start
Date – End Region
Featuring
A2712
25 Jul 12
26 Jul 12
Durban
Effects of various components of shielding gases during mig-mag welding of ferrous & nonferrous materials
Refrigeration Explained – Advanced
E0112
Introduction to Steam; Steam Principles
1 Aug 12
3 Aug 12
East Rand
National standards on gas equipment & safety
B2512
Effective Management Roles
1 Aug 12
1 Aug 12
Port Elizabeth
Duplex & super duplex materials
C4412
Pump Technology – 1
7 Aug 12
7 Aug 12
Cape Town
C4512
Pump Technology – 2
8 Aug 12
9 Aug 12
Cape Town
E4412
Pump Technology – 1
14 Aug 12
14 Aug 12
East Rand
E4512
Pump Technology – 2
15 Aug 12
16 Aug 12
East Rand
Welding gases Welding 3CR12 (chrome steels) Controversy of low cost fabricated steel vs. reduced mass
F2512
Effective Management Roles
15 Aug 12
15 Aug 12
Secunda
A0112
Introduction to Steam; Steam Principles
29 Aug 12
31 Aug 12
Durban
C2512
Effective Management Roles
26 Sep 12
26 Sep 12
Cape Town
E2912
Lubrication & Lubricants
17 Oct 12
17 Oct 12
East Rand
C0212
Boiler House; Safety Valves 5 Sep 12
7 Sep 12
Cape Town
E0212
Boiler House; Safety Valves 3 Oct 12
5 Oct 12
East Rand
A0212
Boiler House; Safety Valves 10 Oct 12
12 Oct 12
Durban
Preferred welding processes
crowd of vibrant engineering students engaged in their masters and doctoral studies. Presentations from the students were of an excellent caliber, and it was a proud couple of days for academic supervisors and the organisers to witness the professionalism and engineering expertise of participants. In an environment in South Africa where education quality is critical and in which pressure on graduate engineering students is high, it was very encouraging to see how well our postgraduate students faired. The participants were a shining example of the future for collaboration between research groups, exchanging constructive and thoughtful ideas on each other’s work, moving towards a multi-disciplinary, inter-institutional, interactive space where the goal is the pursuit of knowledge and advancement of science. The topics presented covered a wide range of fields, from research into explosive blasting, internal combustion engines and new types of fuel, novel materials and metal alloys, compressor design, to
Carey Evans - carey@saimeche.org.za, Tel. 031 764 7136 or via SAIMechE’s Website www.saimeche.org.za
reconfigurable manufacturing systems. The skills and capabilities of the various research units and departments at the institutions were well-represented. This conference was run as a pilot project with the vision of scaling it up to run regionally throughout South Africa, and ultimately culminating in a national conference for post-graduate research in mechanical engineering and related fields. If the success of this first run is anything to go by, South Africa should look forward to exciting forums for sharing of ideas and networking opportunities for our post-graduate students. Dr Deborah Blaine, Senior Lecturer, Mechanical and Mechatronics Engineering, Stellenbosch University, WC SAIMechE chair
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COVER STORY
Clean Air for Top Performance In a similar way that harmful particles are removed from the air streams of process gas, or that chemical particles are taken out of chemical processes, so can unwanted particles be removed from air intake systems to eliminate damage to equipment down the line utilising the air.
S
alty air filled with corrosive particles is, for example, the last thing you want to go into an internal combustion engine driving a generator or pump on the coast, not only in terms of internal damage to the engine, but also to prevent external damage to electronics and other components around the engine. A company which specialises in mist elimination and air scrubbing from either an intake or an air outlet perspective is Munters, based in Edenvale near Johannesburg. “SA Mechanical Engineer” speaks to managing director, John Andersen, about a particular challenge they faced recently with the air intakes of a power generator installation on the tropical coast of Madagascar.
The equipment we designed as a solution not only protects the equipment from water ingress in heavy rain, but it also scrubs the sea mist entering the generator units to eliminate corrosion
John Andersen, managing director of Munters
Removing salt
“Cummins Diesel South Africa approached us for an air cleaning solution for the diesel generators sets they installed at a power generation plant for a new cobalt and nickel processing plant right on the coast,” he explains. “Apart from sea-spray air being taken directly into the engines of the plant, the area is plagued by cyclones which create even more moist air, hampering the performance of the large diesel engines driving the generators. Being a critical component in the aluminium-making process, the client cannot afford for this genset to fail unexpectedly through environment-based corrosion. “The equipment we designed as a solution not only
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Phillip Dickinson, sales manager at Munters
COVER STORY
protects the equipment from water ingress in heavy rain, but it also scrubs the sea mist entering the generator units to eliminate corrosion,” says John. “With our mist eliminators being effective right down to 10 micron and sea mist salt crystals being 13 micron, it’s the ideal system to prevent these harmful particles from getting into the containers housing the generators and ancillary equipment.”
Based on experience
The effective design of this system is based on a similar problem Munters faced a while back on a large compressor plant on the West Coast near Saldanha. “Moisture from the sea mist was settling on the elements of the air filters, wetting the filters and thereby blocking them to create a pressure differential which ended up tripping the compressor system,” explains John. “The technology we used to solve this problem, combined with our experience with air cleaning technology in mine shaft ventilation and cooling, meant we could design a specific solution for Madagascar which is second to none,” says Phillip Dickinson, Munters’ sales manager heading the team working on the Madagascar project.
produced during wood pulping, contains a high concentration of chemicals and solid wood fibres. Multi-stage evaporation, followed by efficient mist elimination capable of handling high velocities, can yield up to 70% dry material together with the recovery of process chemicals.”
Flue gas
Munters also has a long list of clients in the process gas industry. “We’ve been awarded Flue Gas Desulphurisation (FGD) elimination systems for one of the new Eskom power stations currently being built,” says John. “The growing efficiency of wet gas scrubbers in removing contaminants from industrial process gas streams requires highly efficient mist eliminators to remove entrained scrubber reagents or contaminants. By preventing the carry-over of liquid by efficient elimination, the downstream components are protected from damage. An added bonus is an energy efficient and safe process.
Multi-stage evaporation, followed by efficient mist elimination capable of handling high velocities, can yield up to 70% dry material together
“The three generator sets are housed in special twelve-metre by three-metre squared containers, purpose built for this project, but initially they only had weather louvres fitted for the air intakes at each end of the container. This may be aesthetically pleasing but it does not stop any salt ingress, especially down to the 10 micron size.
“Stack rain is one consequence of the most visible industrial process, occurring when saturated and warm exhaust gas is released into a colder atmosphere. Our solution to this problem is spin vane technology which can also be used very effectively to avoid product loss inside a process.”
It’s all in the profiles
HVAC
But eliminating particles from air intakes is not all mist eliminators are good for. “We’re very actively involved in the pulp & paper industry for which we have a whole list of application-orientated solutions,” says John. “Black liquor, for example,
Phillip Dickinson, Munters, Tel: (011) 997-2000, Email: phillip.dickinson@munters.co.za
“The generator solution utilises a vertical mist eliminator for horizontal air flow,” adds Phillip. “It’s just one of the various technology combinations we can use to solve specific problems in different applications. The choice varies from an array of blades with different profiles depending on the pressure drop, in flow rate in the system and the micron size of the particles you want to eliminate from the air flow.”
Yet another discipline where Munters’ mist elimination technology is widely used is air intakes for HVAC systems. “Specific profiles and combinations of mist elimination technology are used to remove moisture and droplets from air before it enters HVAC systems to prevent filters from getting wet and restricting the flow and directly impacting on the efficiency of air cooling system,” John says in conclusion. “Regardless of the application, when it comes to clean dry air, we have a mist elimination solution for each and every challenge that may crop up.”
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CONSULTING ENGINEERS SOUTH AFRICA
Lack of Skills
co-locating in hall 9
Tr a n s p o r t f o r t h e M i n i n g I n d u s t r y
Consulting Engineers South Africa (CESA) has reiterated the need for Government to get its house in order. The lack of infrastructure development due to projects not being undertaken as well as tender processes taking up to three years to materialise is in large part, due to the lack of leadership within the government organisations.
SKETCH 4490/12
VISIT
G IN DE A IN R A R IC M T L T AF ES IC A R N 2 G E R G 01 BI ECT UTH 2 E L r f ric a T H D E SO e A N b I h AN W ut m o O e S SH pt ec,
Se, Nasr 4 re - 1 ent
C 10Expo
PRE-REGISTER AND BE PART OF THE IN-CROWD
Graham Pirie
S
INTERNATIONAL MINING, INDUSTRIAL, CONSTRUCTION AND POWER GENERATION EXHIBITION SHOWCASES NEW INNOVATIONS, PRODUCTS, SERVICES AND TECHNOLOGIES
ays Graham Pirie, CEO of CESA, “At provincial and municipal level, there is a grave lack of general engineering skill. The internal staff are not equipped to produce clear Terms of References (TORs) or even assess the final tenders due to lack of experience. This causes backlogs in the project process and spills over to the overall monitoring of deliverables.”
Pre-registration is now open for Electra Mining Africa, the ultimate market place for all stakeholders involved in the mining, construction, industrial and power generation industries. Visitors can expect to see leading local and international industry players in the packed halls and outside precincts. It’s the ideal place to view the latest in technology and equipment, innovative products and new supplies and services.
But experience is not the only problem, the lack of infrastructure projects being undertaken is also the result of the inconsistency in management and top leadership. Currently a significant number of CEOs, Director-Generals and top management are under suspension due to alleged corruption.
Experts will be on hand to give advice, live demonstrations will be happening daily and co-located conferences and workshops will add even greater value. Electra Mining Africa is recognized as the second largest mining show in the world and the biggest trade exhibition in southern Africa with global recognition for its broad reach across mining, construction, industrial and power generation industries.
The internal staff are not equipped to assess the final tenders due to lack of experience
Electra Mining Africa and co-located Elenex Africa, Machine Tools Africa and Transport Expo runs from 10-14 September 2012 at the Expo Centre, Nasrec, Johannesburg, South Africa.
No decision-making
This leads to top posts being under custodianship and the substitute person simply ‘gatekeeps’ the position with absolutely no decision-making undertaken during that time. Says Graham, “It is time to sort out the corruption and improve the process of procurement in the built environment. The private sector has a great deal of skill and experience and should be encouraged to assist government.” CESA is also concerned about the resignations of CEO’s and senior staff from various parastatal’s and government departments coupled with no clear succession plan or announcement of incumbents.
PRE-REGISTER FOR FREE ENTRY It’s simple – just complete the registration form at www.electramining.co.za R15 per vehicle, per day for secure parking
Contact the Marketing Director at Specialised Exhibitions Leatitia van Straten leatitiavs@specialised.com +27 (0) 11 835 1565 www.electramining.co.za
Graham Pirie, CESA, Tel: (011) 463-2022, Email: gspirie@cesa.co.za
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THE SOUTH AFRICAN MECHANICAL ENGINEER
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MONTHLY COLUMN
Prominent Professionals Mlamuli Martin Buthelezi:
Transnet Freight Rail Chief Operating Officer.
Academic School:
Matriculated from Vukuzakhe High School, 1982, Post Matric: Hilton College.
Graduate studies:
National Diploma: Mechanical Engineering, Mangosuthu University of Technology; Higher National Diploma: Mechanical Engineering, Durban University of Technology, 1987; Bachelor of Science: Mechanical Engineering, Tulane University, New Orleans, USA, 1993.
Post-graduate:
MBL, University of South Africa, 2003.
Mlamuli Martin Buthelezi
Professional Bodies
SAIMechE, NSBE (National Society of Black Engineers).
Most challenging
Career Path
Construction of the Port of Ngqura.
First employer
Most rewarding
Sapref, Assistant Engineer in 1987.
Growth path
Refinery Engineer, Engen, 1993; Packaging Engineer, South African Breweries (SAB) Prospecton, 1997; Engineering Manager, SAB Prospecton, 1998; GM: Marine and Engineering, Transnet National Ports Authority(TNPA), 2000; GM: Landlord Services, TNPA, 2001; GM Rosslyn Brewery and Polokwane Brewery, SAB(2004); Entrepreneur in the energy sector, 2008; Chairperson of Ithala Bank, 2010.
Present employer and position
Chief Operating Officer (COO), Transnet Freight Rail.
Achievements A design
Millenium Tower – Port of Durban.
Future – a concept, a dream or a wish
An integrated logistics network across Africa.
Projects
Port of Ngqura – completion of first phase and subsequent flooding of the port.
Commentary Are there shortcomings in the Mechanical Engineering Industry in South Africa?
Yes. Not enough pipeline to meet the needs of the economy and the continent. Skills plight has also left us with a gap that needs urgent attention.
How would you mend this?
We need incentives for industries to train engineers and technicians again. This must be coupled with a deliberate effort to mentor and remunerate our up-and-coming technocrats.
Message to young engineers
This is a very exciting period to have an engineering qualification in Africa. Be part of the generation that led the reconstruction of our continent.
THE SOUTH AFRICAN MECHANICAL ENGINEER
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OPINION
Soapbox On his rounds, Kowie Hamman, our Editor, is conducting an informal survey on the lighter side of engineering. We follow up from last month with two pertinent questions.
If you weren’t a mechanical engineer, what would you be?
Tom Esterhuizen of Tom Esterhuizen & Associates
An Architect or Civil Engineer
Phildy Schlotz of DRA Be a dentist – because you’re your own boss and can work anywhere you like… as opposed to engineering where you usually have to work in groups and be based in a main centre like Johannesburg where the work is.
In general, electrical engineers are much more detail driven than mechanical engineers. This is probably something we can learn from them, pay more attention to the finer details…
Thalefang Mtombeni of Schaeffler We’re better than them, of course…
Izak van Niekerk of Bell Equipment
Thalefang Mtombeni of Schaeffler I’d be a dancer – that’s what I do part time now anyway. I do ballroom, Latin, contemporary…
They are extremely clever!
Izak van Niekerk of Bell Equipment
In your book, what is the most pivotal invention ever?
A doctor…
Konnie de Boom of Megchem As an alternative I would have preferred a professional route such as a veterinary surgeon or possibly a dentist (specializing). But I must say that being a mechanical engineer is fabulous! Having been involved for almost 40 years at a petrochemical plant in Mpumalanga, the plant has gone through various stages such as grass roots, commissioning, process modifications, upgrading etc. Challenges such as erosion, corrosion, fatigue, maintainability and safety are now becoming major concerns, which is a Mecca for mechanical engineering, especially for young engineers.
Probably fire or the wheel because without them we would not have been able to make any of the later inventions
Phildy Schlotz of DRA Ummm, the wheel…
Tom Esterhuizen of Tom Esterhuizen & Associates
Thalefang Mtombeni of Schaeffler
Brian Volk of PHC Projects I know many good Electrical Engineers who are good people as well, so I respect their knowledge and ability.
Phildy Schlotz of DRA They are absolutely necessary. At DRA we’re VOL 62
Brian Volk of PHC Projects
Haven’t thought about this at all, but I’d imagine the personal computer has made huge changes in all our lives and has made engineering much easier…
What do you think of Electrical Engineers?
THE SOUTH AFRICAN MECHANICAL ENGINEER
X
a multi-disciplinary company and we all work together to deliver a product, we just can’t do it without each other…
Brian Volk of PHC Projects
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SO
BO AP
A bearing… Yes, definitely a bearing. If you look at the evolution of a bearing since 1883, it’s just amazing how much technology actually goes into making a good bearing today. You can’t move anything without a bearing.
Izak van Niekerk of Bell Equipment Mobile phones!
July 2012
HVAC - HEATING, VENTILATION & COOLING
Quality at Low Prices?
R22 gas imported to South Africa
Very often, low prices are an indication of fake or inferior products, or it could simply mean that the supplier is prepared to take a lower mark-up than others. Some buyers look askance at Fazal Patel of Refrimate, for example, who believes he is to a certain extent the victim of this disbelief in terms of the refrigeration equipment, components and parts which he imports. This, despite that fact that the company is an agent for wellknown international brands in cooling and refrigeration systems.
“W
Fazal Patel of Refrimate
e are appointed as one of only three agents in South Africa for Bock compressors from Germany and also deal extensively in Danfoss refrigeration equipment, yet some competitors are now saying our products are fake just because our prices are low,” he tells “SA Mechanical Engineer” during an interview at the company’s warehouse in Randfontein. “As a fairly new player in this market, we’ve adopted a business strategy of low margins so that we can get into the market, but there’s been some resistance from some of the long-standing players.”
Shown one thing during your visit to China, and then getting something completely different Fazal came from India to settle in South Africa over 20 years ago to work in the oil and gas industry as an IT systems engineer for many years before getting involved in the refrigeration industry. Today he owns the Coldpoint brand of coolers and industrial fridges manufactured in Swaziland and recently opened up
Refrimate to design and supply industrial cooling systems into the local market.
Middle market
“We cover the middle market in industrial and commercial cooling, mainly supplying spare parts to contractors who do the repair work to existing installations,” he says. “In terms of new installations, we have the experience to design complete chilling, cooling and freezing systems for which we supply all the components needed by the installation contractor. We also have extensive experience in developing control programming for the systems we design. “With Bock being the premium brand in cooling system compressors, we obviously always recommend the brand, but it’s up to the client to decide and therefore we do deal in other brands as well,” Fazal says. “Some of our product is imported from China but this is strictly from manufacturers who we’ve dealt with before and whose products we’ve tried and tested for quality and reliability.
Direct business
“One of the other reasons we’re able to offer good quality products at lower prices is because we don’t
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The same applies to refrigerant gases, which varies in price dramatically from one supplier to the next. “The R22 gas is still the most general refrigerant gas used locally and is totally imported,” Fazal says. “Our gas is competitively priced because we import large batches at a time, but here again, you have to be careful who you buy from as there are many backstreet gas suppliers in some countries who fill cylinders in their backyard to sell on very cheaply. In this regard we have learnt to only buy from big suppliers who have been in the business for a long time.”
Components
An area of specialisation for Refrimate is in controller and sensor PLC units, components which the company has manufactured for them under their brand name. This is an area where people are often taken for a ride,” says Fazal as he takes one of the units from a display cabinet to show us. “It took a while to find a reliable supplier who can make the sort of good quality product we’re prepared to put our name to, but we’ve pinned one down now and the product has been doing very well locally.”
Well-known brands in stock on the shelves
He continues, “Just as an example, we sell these units at a third of the going rate for similar components in the market. The same applies to a sensoring unit which we sell at 35% of the price of what some suppliers charge. These are highly sensitive parts of the cooling system and an area where you simply can’t get away with using an inferior product, you’d just be throwing away the good name you’re trying to build in the market.”
Time will tell Refrimate designs complete chilling, cooling and freezing systems for which they supply all the components
The sort of good quality product we’re prepared to put our name to buy through an agent like most importers do,” adds Fazal. “We only purchase product from factories I have personally visited. We then deal with them directly. Dealing direct ensures you’re not being shown one thing during your visit to China, paying an agent in between and then getting something completely different very likely made in a different factory altogether.”
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According to Fazal he’s spearheading a pioneering breakthrough in the refrigeration market with his sourcing and pricing approach but he is confident he’s on the right path. “It’s been a steep learning curve and challenging in terms of resistance in the market, but it’s just a matter of time before the industry realises that we’re in this for the long haul,” he remarks in conclusion. “Already we’ve had so many instances where customers recognise the advice and recommendations we give as professional assessments based on a thorough understanding of the systems and the products we supply.” Fazal Patel, Refrimate, Tel: (011) 692-2782, Email: fsoil@yebo.co.za
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Chilled Water Project The detailed process, mechanical, piping and civil design of a new underground refrigeration system, comprising refrigeration machines, condenser spray chambers and closed circuit cooling coils for Hecla’s Lucky Friday silver, lead and zinc mine in northern Idaho, USA, has been completed. This fast-track project was conducted as a sub-contract awarded by Cementation USA, the main contractor for the construction phase on the mine’s No 4 Shaft Project.
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he contract was the fastest project that BBE Consulting has undertaken to date, requiring 4 000 design man-hours over a period of four months. The design was required to complement existing equipment, while remaining flexible for future expansion. Raymond Funnell, lead engineer at BBE Consulting, says, owing to the complexity of the piping, the entire design was carried out using a 3D model. The mine’s shallower reserves have been accessed from the existing Silver Shaft, but new, deeper reserves will be accessed from the new 1 100m deep No 4 sub-shaft.
Provision has been made in the design to upgrade the chiller plant Considerable depth
“The new reserves will be mined at considerable depth, requiring the intake air from the Silver Shaft to be cooled on 5900 Level, which is 1 800m below surface,” says Raymond. “This is achieved by installing a bank of high-pressure cooling coils. The new chiller plant will be located on 4900 Level
and about 500m from the No 4 Shaft. “The plant initially comprises three R134a dual screw-compressor machines, providing a total cooling capacity of 3.4 MWR. These machines are relatively compact, which suits the underground layout in terms of installation and future maintenance work. For example, these machines don’t require an overhead crane gantry, as the semi-hermetic compressors weigh less than a ton. The machines produce chilled water at about 5ºC, which is distributed to the 5900 Level bulk air cooler via high pressure pipes in No 4 Shaft. “
Longer term
Raymond says provision has been made in the design to upgrade the chiller plant in the longer term to a maximum of six machines, with a total cooling capacity of 6.8 MWR. The smaller module size is important to provide some redundancy during shut-down for routine maintenance. The additional chilled water will be used for secondary cooling nearer the workings. A high-efficiency condenser spray chamber has been constructed near the upcast shaft — No 2
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Shaft — to allow the full heat from the six machines to be rejected to the return air. This spray chamber cools the hot return water from the machines to about 37ºC, before being pumped back to the machines via an 1 100 m long HDPE pipeline. HDPE was selected for its lower cost, rapid installation, lower friction and non-corrosive characteristics. “One of the innovative features of the system design is that up to 75% of the chiller plant heat can be rejected directly to cooling water which is piped from a nearby mountain stream,” says Raymond. “This feature is useful for short periods of operation, when it is necessary to shut down the heat rejection spray chamber to conduct maintenance work in the upcast shaft.
75% of the chiller plant heat can be rejected directly to cooling water “However, this mode of operation is quite energy-intensive, since the cooling water must be pumped out of the mine using high-pressure pumps. Therefore the preferred normal mode of operation will be heat rejection to the return air.” BBE provides EPCM or full turnkey service depending on specific customer requirements. Expertise covers a wide range of mining methods in various ore bodies in countries such as South Africa, Australia, Botswana, Brazil, Canada, Ghana, Lesotho, Namibia, Peru, Portugal, Tanzania, USA and Zambia. BBE Consulting, Raymond Funnell, Tel: (011) 706-9800 Email: rfunnell@bbe.co.za
The art of drilling
Atlas Copco understands the importance of reliable, high-pressure compressors that are cost effective and easy to maintain. Our DrillAir™ compressors deliver high capacity and high pressure, effectively allowing you to drill deeper and larger holes at fast penetration rates, with higher productivity. Atlas Copco Construction Technique P O Box 14110, Witfield 1467 Tel: (011) 821 9000, Fax: (011) 821 9106/7 www.atlascopco.co.za
Visit us at
Stand G21 Hall 6
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Explosive Dust The worst mining accidents in history have been caused by coal dust explosions principally because this dust suspended in air is highly combustible. Coal dust has far more surface area per unit weight than lumps of coal and is more susceptible to spontaneous combustion. This means that a nearly empty coal store is at far greater risk than a full one.
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hus, coal dust collected in bag filters poses a higher danger than the actual pollution risk of coal dust being released into the atmosphere. “A bag filter filled with coal dust is a potential bomb ready to explode from just one small spark,” Waldo van der Merwe, business unit manager of Engart and Safanco at Howden Fan Equipment, tells “SA Mechanical Engineer.”
Removing 97 to 99 % of total dust and 92 to 95 % of respirable dust. The extractor consists of three main components; the fan, a dust box and a sump A fan solution
“We’ve developed a very simple fan-driven solution w which has been proven iin over 300 installations iin the USA to remove ccoal dust effectively,” W Waldo adds. “It is called tthe Howden Engart Dust E Extractor which has a gguaranteed efficiency of removing 97 to 99 % of total dust and 92 to 9 95 % of respirable dust. T The extractor consists of th three main components, th the fan, a dust box and a sump. This unit takes th the contaminated air th through just three stages to remove the dust from the air and deliver dry dust dust-free air at the other end of the unit.”
The spray bank is in continual operation whereas a second bank of sprayers is used for flushing the coagulating medium
Initially the extractor was developed to fit onto continuous mining machines to extract dust in the immediate working environment, but it has subsequently been applied successfully in all dusty mining situations underground as well as on the surface such as transfer points and rail car tippers where volumes of dust fluctuate.
Cost effective
“The system is not well-known locally as yet, but since we now have a proven track record of a costeffective solution to remove coal dust efficiently, we’ll be promoting the product much more actively in the coming months,” says Waldo. “Apart from costing a fraction of bag filtration systems, the extractor is very flexible in its application as it can be placed just about anywhere out of the way to process air before pumping it back into the working environment. For higher volumes, for example, you simply add more units.” Axial fans are designed specifically to accommodate large volumes. The Engart units, however, can also handle an extremely aggressive environment. Waldo explains, “Spray nozzles inject water onto a high speed impellor which forces the dust to mix with this water. This dirty wet air then passes through channels around the motor, leaving the motor to operate in a clean safe environment.” No return air is allowed to either flow or leak over the unit’s motor and, as an added protection, the impellor track is lined with either fibre glass or marine brass. The dust extractor is, therefore, one of the safest dust extraction systems for coal dust available in the world.
Dust box
Next in line is the dust box consisting of a spray chamber, a demisting section and the flow diverter. “The operational spray system directs water against the airflow to cause the dust and air to mix thoroughly before it reaches the coagulating medium,” says Waldo. “This spray bank
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is in continual operation whereas a second bank of sprayers is used for flushing the coagulating medium, also refered to as a filter meduim. These sprays are activated at pre-determined intervals every half an hour or 15 minutes or any other predetermined interval.”
a bank of demisting vanes captures the dust laden water. The mesh contains 15 layers of two sizes of knit mesh where the dust particles are separated from the airstreams within the panel which is continually washed by the action of a multi-nozzle spray bank.
The flow then goes into the demisting section where
The ‘catchment’ vanes are placed in such a way so as to gather and remove all the water which is then dropped into a sump allowing only the dry, clean air to pass through and exit at the rear of the scrubber. Finally a flow diverter simply diverts the system’s exhaust air in the desired direction.
The dust extractor is, therefore, one of the safest dust extraction systems for coal dust available in the world The sump
The sump is a compartment built into the bottom of the dust box and is designed in such a way so as to receive the water slurry from the knit mesh and demisting panels. “It is designed to allow the slurry to flow out as soon as possible,” explains Waldo. “The sump is as important as any part of the dust extractor, so it is important to ensure free flow into and out of the sump at all times.” Maintenance on this system is minimal compared with other dust extraction systems. Being essentially self-cleaning, the efficiency of the extractor remains consistent over time even though the volumes of air through the system may fluctuate between high and low extremes. Waldo remarks in conclusion, “The system, designed and built locally entirely, has thoroughly proven itself in coal dust removal under various different conditions, but in future we may very well look at other applications as well.” Waldo van der Merwe, Howden Fan Equipment, Tel: (011) 240-4000, Email: waldo.vandermerwe@howden.co.za
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Joining Forces for Better Service It’s not everyday that you come across a product which, even at a premium, has so many advantages in its favour, not only technically, but also in terms of service and support. This is the positive impression “SA Mechanical Engineer” walks away with after chatting to Jayson le Roux, the managing director of Goscor KLG, distributors of Sullair compressors in South Africa. compressors, and the vacuum pumps from Sullair, more reliable than any other air products on the market,” says Jayson. “The cherry on top is we now have the backing of experienced technical teams to service, repair and maintain the products we’ve installed throughout Southern Africa.”
Jayson le Roux, managing director of Goscor KLG
I
n short, this product has a ten year warranty, something unheard of in terms of compressors. “We have mechanical energy-saving features, bio-degradable compressor oil which lasts a lifetime and above all, particularly robust machine construction which simply makes these
Th h e ch er ry r y on to to p is is w e no n o w ha h avvee t h hee b a acc kin ng of exx p er i ence d te chnical te t e am am s tto o ser vice , r e p aiirr a nd ma in n t a in t h e p ro d u cts ct s we ct we ’vv e in inst s t a l le d th hroughout So o u t h er n A ffrriicca
This ‘new’ player in the compressor market came about when Imperial-owned Goscor, the agents for Sullair in the USA, bought out KLG, a compressor service company in Alrode who’d been around for thirty years. “It was a case of Goscor farming out all their service work to contractors and KLG not having a specific brand to sell. Therefore, both were losing a large slice of the cake,” Jayson says. “The marriage of the two companies has turned out to be a perfect match between a premium compressor product and a service company with many years’ experience in support and service of all makes of compressors.”
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has long gone where you just sell a product and walk away,” says Jason in terms of his business approach. “Today the differentiator in this highly competitive market is to be able to provide solutions to customers’ air requirements and doing so cost effectively in terms of life cycle costs.” “Take our warranty, for example, normally you’d get a guarantee of not more than five years, but then it’s provided the user takes out a maintenance contract with the supplier,” elaborates Jayson. “Ours is a warranty for ten years with the only provision that the client only use genuine Sullair spare parts and lubricants in that time. What’s more, the lubricant is a superior grade oil which does not to be changed at all during the ten year guarantee period.”
Energy
Apart from variable speed control systems contributing to energy consumption on compressors, the Sullair range also has a mechanical system which controls the capacity in the compressor continuously. “An outstanding feature of VCC (Variable Capacity Control) compressors is its perfected capacity control system, which consists of a spiral valve and an inlet butterfly valve,” explains Jayson. “This system delivers greatly improved part-load performance, especially when compared with compressors having suction throttling or no load controls. The compressed air volume is varied by rotating a spiral valve, which opens and closes through by-pass ports in the stator, and returns air to suction rather than compressing it. By matching compressor displacement with output need, this energy-saving system uses up to 17% less power.”
A refurbishment ready for delivery
The entire range of compressors has undergone some redesign resulting in energy-efficient machines overall. Jayson adds, “Our products have two modes of operation where you can either run them under constant pressure, or you can have them load and unload which is where the energy savings come in.
Speed control
The life cycle costs on rebuilds are a quarter that of other makes of compressors
Ou u rss is a wa rr antyy for o r t en en yea ears r s wit rs it h tth h e o n llyy p r o vi s io n th h a t t h e c liien t o n ly u s e gen u in ne S ulla a ir sp a ree p ar t s a n d lu ub riica n t s in t h at t iim me Guarantees
Jayson is a young MD, telling us how he started at KLG from the age of 13 when he worked during school holidays for pocket money. He’s been with the company ever since, becoming MD when the two companies joined forces recently. “The time
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“However, where required we can also fit variable speed control systems to our range of compressors,” Jayson adds. “Using variable speed drives, coupled with Sullair’s Smart Technology system, compressors can run more efficiently in environments where demand may vary from season-to-season or from shift-to-shift. In periods of low demand, the control system reduces the compressed air output by reducing the drive speed. This reduction in drive speed saves power and trims operating costs, improving the bottom line.” In general the Sullair compressor is known as a robust product. “Just take the air ends as an example,” says Jayson. “On a daily basis we hear of air ends that crash at anything between 20 to 25 000 hours. On our smaller units we comfortably achieve 45 000 hours while the bigger units do 80 000 hours. Other OEM’s specify bearing changes at 20 000 – 24 000 hours while Sullair’s recom-
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Stripped for repairs
says iin conclusion. l i “ If th the ttechnicians h are not busy with installations or servicing customers, they’re in the workshop where we undertake rebuilds and repairs to all makes of compressors. As much as we believe in building long-term relationships with our clients, so we believe in proper training. To this end our technicians are constantly kept up to date with the latest technology.” Jayson le Roux, Goscor KLG, tel: (011) 908-2394, Email: jleroux@goscor.co.za
The Sullair mobile compressor power by Caterpillar
mended bearing replacement is only at 10 0000 hrs. This means that the life cycle costs on rebuilds are one quarter that of other makes of compressors.
Vacuum specialists
A market, where Goscor is at the forefront of technology, is the medical field where vacuum pumps and compressors are critical equipment in hospitals and clinics. “We have a large installed base of vacuum pumps and compressors at hospitals across the country. In fact, we’re currently busy with a series of upgrades at some of these hospitals,” says Jayson. “As this equipment is critical equipment and cannot be switched off, a special method of installation means we often don’t have to switch the vacuum off at all to do the upgrade which takes less than an hour. We literally set up a complete temporary plant which is up and running before any work is carried out on the old one.” Goscor KLG has eight service and maintenance teams on the road constantly. “We’ll appoint at least another two technicians this year in a drive to increase our technical strength even more,” Jayson THE SOUTH AFRICAN MECHANICAL ENGINEER
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SAEE
National Energy Barometer Survey Local as well as international studies have shown energy savings of 20% to be an achievable target in the commercial building sector. In some buildings, the expected energy savings could be much higher, but in others, it could be lower. The challenge is to start looking at the buildings with the biggest potential for energy savings.
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he National Energy Barometer Survey was developed to enable users to quickly access the potential for energy savings in a building.
The National Energy Barometer Survey invites participation in the 2011 survey by registering before 25 July 2012. Categories available for assessment are hotels, shopping centres, hospitals, bank branches, corporate head offices and general office buildings. The top three in each category is announced annually, past winners include Exxaro, Oriental Plaza, CEF House, Imperial Hotel and N1 City Mall.
How will you benefit from the survey?
Find out if your building’s consumption is below or above your industry average. Get a practical starting point for your energy efficiency strategies and planning (great for facility managers with a large portfolio). Get an idea of the energy savings potential to get your building to the industry average. Annual participation will track improvements and progress. To complete the survey, before 25th July 2012: 1. Register online for participation 2. We will send you an invoice for R 1750 (excl VAT) per annual entry and a link to complete your survey. 3. Discounted packages are offered for multiple entries. Thieda Ferreira, Tel: (041) 367-1041, Email: thieda@energycybernetics.com
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POWER GENERATION
PV Power for South Africa
(011) 781-1401 (011) 781-1403 samecheng@promech.co.za W
s
www.promech.co.za
or
Kowie Hamman
or Susan Custers r s r
Mark Bennett o
Catherine Macdiva
While the rest of the world is already generating around 67 000 MW of power utilising photovoltaic technology, South Africa is taking its first baby-steps in harnessing an abundance of sufficient sunlight energy as a renewable energy source for the generation of electricity.
Zinobia Docrat/ Donovan Vadivalu s r PROMECH Publishing does not take responsibility for the opinions expressed by individuals.
Copyright
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.
A typical PV solar farm as will arise on the South African landscape soon
O
ne of the companies involved in two of 18 chosen solar projects is Tenesol in Cape Town who’ll be building the two PV (photovoltaic) solar farms near Douglas in the Northern Cape province. “SA Mechanical Engineer” visits the company’s factory in Epping to talk to Fabien Gouzil, director and general manager of Tenesol South Africa to find out more about this French company.
Locally made panels
Fabian explains, “Although our core function is that of an equipment manufacturer, we also devise, design, manufacture, install, operate and perform maintenance operations by creating efficient, turnkey PV installations, both on-grid and off-grid. “We operate globally with installations
R28bn power projects chosen in the second bidding window (IPP) announced by the Department of Energy sends a clear message that the vision of a South Africa powered to a larger extent by renewable energy is destined to become a reality. These projects have potential to produce 1 044 megawatts (MW) of power. A total of 7 059 jobs during construction and 328 jobs during operations would be created by the projects.
ranging from large solar farms to smaller rooftop units making a total installed base of just over 14 000 solar generator installations around the world.” Fabien adds, “This market is supplied from our two PV module manufacturing facilities, one in Toulouse in France and one in Cape Town, both with the same capacity. Due to growing demand, our production capacity at each facility peaked at 170 megawatt-peak (MWp) during 2010, the equivalent of 800 000 photovoltaic modules a year.”
Projects
Although Cape Town has been producing for the international market until now, this is bound to change with the number of PV solar farm projects getting underway in South Africa. “For both the projects at
Eskom is keen to understand undersea operations to harness electricity out of the sea, with the R155 million Oceanus power-generating unit, which is a prototype system to harness the power of ocean currents. Eskom effected a saving of 250 gigawatt-hours of electricity a year with the installation of more than 262 000 solar water heaters across the country. It aims to have a million of these heaters installed by 2014. Eskom said the minister of finance had allocated R4.7 billion for the programme over the next three years, ending in March 2015.
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POWER GENERATION
We can meet that need with solar energy solutions comprising the usual array of PV modules, junction boxes, storage batteries and a controller
Douglas we’ll be providing turnkey solutions, not only by supplying all the PV modules, inverters, structures and control equipment, but installation of the systems as well,” says Fabien. “We have also been appointed as the operator of these facilities which will have a combined capacity of 33 MW to make it one of the bigger solar farm projects now underway in South Africa.” Tenesol is also well-positioned to open new, largely untapped markets for solar, especially in Africa where a strong presence has already been established with many off-grid systems.
When line workers break for tea, for example, everyone stops right where they are. Work only starts once everyone on the line is in position again On-grid systems
On-grid PV systems, like the projects now rolling out in South Africa are large power-generating systems in the form of banks of PV modules mounted on rooftops, warehouses, public buildings or open ground in the form of solar farms. The PV solar panels supply direct current which is converted into alternating current by an inverter and then injected directly into the grid.
Off-grid
TICKER TAPE
Originally, photovoltaic solar power took its first steps in out-of-the-way places with no connection to the public electrical grid. These days, it has become
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Still under construction, a rare earths and thorium mine, near Vredendal in the Western Cape, is scheduled to start production in the first half of 2013. Rare earths are used in the production of X-ray machines and some medical devices. The mine contains an approximate 4 000 tons of thorium. The mine will create 150 jobs and a further 150 jobs by the three beneficiation factories in the Western Cape, South Africa.
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an attractive option for owners of private homes, commercial buildings and industrial or agricultural facilities. “This is usually called an off-grid, or onsite system,” explains Fabien, “of which there are many installed by us all over South Africa in various applications ranging from water pumping to oil and gas pump stations, remote telecoms relay stations, rural electrification schemes and even small-scale game farm power needs.” Remote locations and the oil and gas industry go hand-in-hand. Pipelines carry these diminishing resources across some of the most isolated environments on the globe. “In the past, power was supplied to these locations using diesel generators,” explains Fabien. “But for over 25 years, Tenesol has supplied customised turnkey solar solutions to the oil and gas industry at remote on- and off-shore locations. Such installations are designed to suit specific project needs and can cater for any situation regardless of location, power requirement or activity. Systems typically provide power for exploration, tracking, boring, transporting, cathodic protection, lighting, security and emergency shut-down equipment.”
Applications
In the world of telecoms, equipment does not require vast amounts of power so the system does not need to be very large. A solar system can be easily installed without much preparation to surrounding land and it begins generating power immediately. “There is a growing need for telecommunication
SAEE (Southern African Association for Energy Efficiency) invites nominations for the SAEE Energy Awards 2012. Nominations close 30 September 2012. Nominations open to members only. Categories: company, project, newcomer, patron, excellence award. Email: info@saee.org.za
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POWER GENERATION
infrastructure in both remote off-grid locations and in urban areas which has raised the need for suitable on-site power sources,” says Fabien. “We can meet that need with solar energy solutions comprising the usual array of PV modules, junction boxes, storage batteries and a controller. We’ve supplied such installations for multiple telecommunication applications including fixed, mobile and radio operated networks.
Light and water
Apart from its industrial uses, solar power is ideally suited to humanitarian applications, the most common being rural electrification to bring power to remote off-grid areas. Fabien elborates, “These solar systems are installed on rooftops or small structures and linked to people’s homes. They are provided either on a turnkey basis or as selfcontained PV kits, which provide all the necessary components to create a small solar installation without external support.”
Many solar power companies do not manufacture their PV modules themselves, but Tenesol decided to incorporate this factor in 1999 in order to have full control over the photovoltaic chain. Fabien says in conclusion, “This key step means we can attain superior reliability and efficiency in your systems. Not only are our modules guaranteed for ten years, but we also guarantee the production of our photovoltaic panels to 80% of the power over 25 years and 90% of the power over ten years.” Fabien Gouzil, Tenesol South Africa, Tel: (021) 797-7377 Email: f.gouzil@tenesol.co.za
In addition to rural electrification, solar water pumping is another on-site humanitarian application. “Tenesol began to explore the use of solar energy for water pumping in West Africa during the 1980s,” says Fabien. “Since then, the company has installed more than 4 000 solar water pumping systems pumping around 80 000 cubic metres of water a day. We have worked with many different organisations and charities to bring fresh, safe drinking water to rural locations and isolated communities in Africa.”
The factory
Walking through the factory where PV panels in various stages of completion are progressing down a production line, Fabien explains that they have adopted a production line principle similar to the automotive industry. “Not only do we work on a Just in Time (JIT) principle like they do, but the whole operation is run to minimise any chances of faults slipping in because people take breaks during manufacture. When line workers break for tea, for example, everyone stops right where they are. Work only starts once everyone on the line is in position again. This has dramatically reduced faulty units which then have to be rebuilt after the final test.”
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POWER GENERATION NEWS
Motor lifetime
Optimistic According to estimates, the BRICs countries alone account for more than 50% of total infrastructure investments in the world. At present, 15% of the total global gas turbine market revenue comes from the BRICs nations. The BRIC gas turbine market is expected to experience a considerable growth from $1,432 million in 2005 to $2,623 million in 2015. The major contributing factor for the growth will be growing environmental concerns. At present, BRIC nations are heavily
er en e v . ati tor ov mo n 2 in 's W2 EG ient W ic e ff
WEG’s innovative three phase W22 motor, available locally from Zest WEG Group, provides an energy efficient solution for reducing industrial energy consumption. By cutting down on wastage in specific industrial and mining applications, these electric motors not only reduce costs and improve profitability, but also make an important environmental contribution by decreasing the national energy consumption of electric motors. The potential energy saving when using a WEG W22 motor is assumed to be around 30 to 60%. High efficiency and low cost of ownership throughout the entire motor lifetime have guided the WEG W22’s development. Innovative improvements, supported by patent and registered design applications, deliver lower noise and vibration, even
gy The fea WEG tu W term r e s a n 2 2 m o and i n a l b o o v e r s t o r iz x s mai afer co for ea e d ns a s nd a nnectio ier cce n sso of ries .
The terminal box mounting on the WEG W22 motor allows optimum flexibility enabling reduced inventory and quicker modification.
better reliability with a longer working life, easier maintenance and lower cost of ownership. Maximum heat dissipation is achieved through the WEG W22 motor’s extended
Largest single rooftop PV array in Africa Vodacom has announced that it is fitting its Century City in Cape Town office with the largest array of solar panels on a single building in Africa and that it has appointed In-Toto Solutions (Pty) Ltd as the EPC contractor for the project. Nearly 2000 mono crystalline solar panels will cover the 3 600m² roof of the building. The solar array will be completed by August 2012 and is expected to provide up to 75% of all power required by the
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frame area. Heat dissipation is boosted by the quantity and distribution of the fins, as well as the quantity of air delivered due to the innovative cooling system developed using the latest design techniques.
building during peak production. The power produced will feed into the two main distribution boards. A display panel installed in the reception area of the building will display instantaneous power yield, energy yield and carbon emission savings. The photovoltaic array will supply 500 kilo-watt peak (kWp) at peak production to the building and the total annual energy savings is expected to be around 830.1MWh
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Zest Electric Motors Jamie Wilson, Tel : (011) 7236000 Web: www.zest.co.za
"The position of the Century City rooftop is perfect for generating a high yield of solar power throughout the year," says Suraya Hamdulay, executive head of corporate citizenship at Vodacom. This project is a part of Vodacom's ongoing drive to reduce the amount of energy it consumes. To date Vodacom has reduced the energy inputs by 12% per base station across the Vodacom Group. In-Toto, Darryn Brackenridge, Tel: (011) 493-0344, Email: brackenridge@in-toto.co.za Web: www.in-totosolutions.co.za
POWER GENERATION NEWS
Trends dependent on coal for fulfilling their power needs but gradually BRICs focus is shifting towards gas-based power generation due to its clean nature. The major part of gas turbine revenue comes from China and Russia so any fluctuation in these markets directly affects the entire BRICs scenario. The future looks promising, however, with many gas-fired projects scheduled to go live in the next few years. GlobalData, Laura Ward, Email: LWard@globaldata.com
Power Market in Africa 2020 Africa has huge untapped reserves of fossil and hydro resources that can be used for generating electricity. However, electrification and consumption levels are low, particularly in the rural areas as the continent is unable to utilise its reserves due to drought, high oil prices, conflicts and lack of funds. Often the existing transmission and distribution networks are incapable of supporting the entire power supply to an entire nation and there is an urgent need to overhaul entire systems.
To improve the power scenario, countries have introduced reforms such as the restructuring of power utilities, privatising the vertically integrated monopolies, legalising the entry of foreign players and Foreign Direct Investments (FDI) in the power sector and allowing Independent Power Producers (IPPs) into the respective countries. The Private Public Partnership (PPP) in Africa is expected to increase going forward as private players gradually show interest in the continent. The UKbased utility company IPSA's combined heat and Power (CHP) plant in Newcastle is South Africa's first privately-financed independent power plant, which is also South Africa's first independent gasfired power station. Artumas Group, a Canadian based company is setting up a 300 MW gas plant in Tanzania which is expected to come online in two years. aes-sonel is setting up a 250 MW plant in Cameroon. GBI Research, Jonathan Cain, Email: jcain@gbiresearch.com
Significant reduction in emissions Voith SteamTrac, a compact, modern waste heat recovery system for combustion engines used in marine applications as well as for rail-, road- and industry applications, achieves a significant reduction of fuel consumption and emissions of toxic and hazardous gases. Apart from its ecological advantages and lower fuel consumption the SteamTrac system also enhances the economy of shipâ&#x20AC;&#x2122;s drivelines. The operating principle of our system can be resumed as follows: the heat from the exhaust system is used to warm up the operating medium in the evaporator to superheated steam. The steam is expanded into the expander and generating mechanical energy which can be fed back into the combustion engineâ&#x20AC;&#x2122;s crankshaft or to a gearbox power take in (PTI). The operating medium is liquefied downstream from the piston expander in a condenser followed by storage into an operating medium tank. The entire process is controlled and monitored by a control module. The new technology is suitable for both new marine developments and retrofits and in principle, SteamTracs can be installed to all combustion engines such as inland waterway vessels, short sea ships, fishing boats and ferries. Voith Turbo, Graham Russell, Tel: (011) 418-4000, Fax: (011) 418-4080 Email: graham.russell@voith.com, Web: www.rsa.voithturbo.com
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POWER GENERATION NEWS
54 Locomotives delivered to date GE Transportation a subsidiary of GE (NYSE) and one of the world’s leading suppliers to the railroad, transit, and mining industries, providing freight and passenger locomotives, has announced that the most recent locomotive was delivered with local content that exceeds the commitment from GE’s initial Transnet order of 100 locomotives. The locomotive is the most advanced diesel electric locomotive ever built in South Africa. Lorenzo Simonelli the global President & CEO, GE Transportation says, “We are celebrating the first South African product delivered by our joint venture company GE South Africa Technologies. These locomotives represent great opportunities for Transnet and South Africa as well as GE. Transnet will be able to significantly improve hauling capability while reducing fuel consumption and greenhouse gas emissions.”
With this order, GE overshot its self-imposed target of 30% local content. The locomotives assembled in South Africa have 37% local content. The partnership has also produced a significant investment in job development, economic advancement and infrastructure growth for all parties. GE's C30ACi is the first locomotive in the South African region to meet stringent UIC2 emissions standards. The addition of these new locomotives, which will be used to haul freight and coal, will decrease life-cycle costs,
Pictured above: Chief Executive of Transnet Rail Engineering Richard Vallihu and Global President & CEO of GE Transportation Lorenzo Simonelli all smiles after unveiling of Loco 42. The locomotive is the 42nd locomotive and is the most advanced diesel electric locomotive ever built in South Africa. The official unveiling of the locomotive took place at an event held at Transnet Rail Engineering’s facilities in Koedoespoort, Pretoria
improve fuel efficiency and reduce emissions. Two GE locomotives do the work of three older locomotives, saving 600,000 litres of fuel a year and lowering emissions. It can reduce emissions by 1 500 metric tons of CO2 annually, equivalent to eliminating the emissions from 310 cars on South African roads. GE’s Model C30ACi is first AC diesel-electric locomotive to be introduced to sub-Saharan Africa. Its engine delivers 3,300 Gross Horse Power (GHP) using an electronic fuel injection system that automatically supplies the exact amount of fuel needed for optimal engine efficiency. These locomotives also feature GE’s unique AC propulsion technology and dynamic braking. GE Corporate Africa, Thulisile "Thuli" Phiri Tel: (011) 237-0001, Email: thulisile.phiri@ge.com Web: www.ge.com/za
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POWER GENERATION NEWS
Wind turbine bearings SKF has introduced an extended range of SKF Nautilus bearing solutions that offer advanced, versatile and integrated features to meet the demands of wind industry. The Nautilus bearing solutions provide designers with the freedom to develop a wide variety of turbines including direct drive; turbines equipped with a gearbox; with outer or inner ring rotation; and mounted on shafts or directly bolted onto the surrounding structure. The industry trend toward increased turbine size, remote locations and harsh environments calls for technology advances - more compact and lighter nacelles, and components with built-in reliability and serviceability. The new features of SKF Nautilus include the option to incorporate a bolted inner ring, eliminating the influences of fits and tolerances of the structure surrounding the bearing, reducing pre-load variation and resulting in higher operational reliability and safety. Another feature is the integrated seal and pre-greasing to provide optimised lubrication while reducing the risk of contamination and leakage. SKF South Africa, Samantha Joubert Tel: (011) 821-3500, Fax: (011) 821-3501, Email: samantha.joubert@skf.com, Web: www.skf.co.za
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SAINT
Education is Key SAINT introduced the NDT education village idea at the recent highlysuccessfull international conference in April in Durban. Not only has this concept been picked up by all other NDT societies worldwide but SAINT is also spreading its net by getting more closely involved with allied training facilities in South Africa.
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Dr Mike Farley, (centre) Chairman of the International Committee for NDT, pictured with children who were delighted to be exposed to the NDT inter-active exhibits
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EXHIBITIONS
Electra Mining Africa The South African mining industry is the mainstay of South Africa’s R3-trillion-a-year economy. Mining revenue in 2010 was R420-billion and expenditure R440-billion, with R225-billion of the R440-billion expenditure spent on locally-procured goods and services, including steel, cement, electricity and rail transport. Given that 40% of the world’s natural resources reside in Africa, where spectacular population growth is projected, South Africa is in a strong position to sell its services and products.
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nternational mining, industrial, construction and power generation show, Electra Mining Africa, taking place in September, will help to support and facilitate growth in the South African and African mining sector. Electra Mining Africa is the second largest mining show in the world and the biggest trade exhibition in Southern Africa.
Second largest mining show in the world Gary Corin, Managing Director of show organisers Specialised Exhibitions, says: “Electra Mining Africa is an exciting show that attracts a high-level of local and international interest and produces offthe-floor sales, valuable sales leads and excellent
business connections for its exhibitors.” Together with co-located shows Machine Tools Africa, Elenex Africa and Transport Expo, Electra Mining Africa will provide visitors with the “ultimate platform to view a vast array of new innovations, products, services, technologies, trends and industry developments in the mining, industrial, construction and power generation industries.”
Captive audience
This year’s show will include an Exhibitor Soapbox hosted by the South African Institution of Mechanical Engineering. The Exhibitor Soapbox will give exhibitors a 30 minute opportunity to present their products and services to a captive audience in a separate presentation room, with no restriction on either the format or the content of the presentation. Attendance at the Exhibitor Soapbox will be free to all Electra Mining Africa visitors. Electra Mining Africa, Expo Centre, Nasrec, Johannesburg, from 10-14 September. Visitor pre-registration is open at www.electramining.co.za
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HYDRAULICS & PNEUMATICS
Connectors Mobile hydraulic equipment is common in the agricultural, construction, logging, and mining machinery markets. Mobile hydraulic equipment usually requires quick and easy coupling and decoupling to the system on a regular basis. This is commonly achieved with a special quick-release coupling system.
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lthough this makes the change-over of equipment a simple plug-in and plugout operation, the first couplings on the market did have drawbacks in that they increased the chances of fluid spillage, polluting the environment. Apart from the extra costs incurred to clean up polluted areas, the open end of these connectors made the hydraulic system more susceptible to dirt, causing costly damage and reducing the performance of equipment.
Th h e co a l m inin ng in n d u sttryy latt cheed on n to o thee a dvv an n ta ages off th h iss co u p leer ver y q u icck lyy i n s p itt e o f it co o sttin n g a bitt m o ree th h a n an o r din na r y q u icck-rr elea as e coup p lingg
The flat-face
Today this is almost a thing of the past because of a new design, Albert Epprecht of Alba Hydraulics the flat-face hydraulic connector, which specifically addresses the problems of connector spillage and fluid contamination. “SA Mechanical Engineer” visits hydraulic equipment supplier, Alba Hydraulics in Edenvale to speak to owner Albert Epprecht. “We were the first supplier to bring the flat-face coupling design into South Africa some years back,” he says. “The coal mining industry latched onto the advantages of this coupler very quickly in spite of it costing a bit more than an ordinary quick-release coupling. “In the beginning everyone said they were too expensive, but gradually, as people realised how easy and quick it makes the change-over of equipment, they started switching over,” Albert adds. “Despite the flat-face couplings costing more than double, they last much longer than the ordinary pin-and-ball type coupling. Today we literally supply hundreds of flat-face couplings to all industries, especially where they have problems with dust and dirt or where there is the slightest chance of spillage polluting the environment.”
The flat-face couplings on the left with the old type on the right
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Advantages
The flat-face coupling’s obvious advantage is not only that there is no open hole where dirt can settle when the coupling is disconnected, but the flat surface is easily wiped clean if any dirt does happen to stick to it. It takes just a gentle push against the flat surface to pop the valve away and allow the nipple of the connector to lock into place firmly without a drop of fluid being spilled. This can even be done with only one hand, making connection and disconnection fast and easy. During connection, the coupling and nipple automatically lock into place. Some makes of this type of coupling even have a locking ring for extra protection against involuntary disconnection. The coupling design includes a manual security-locking feature which is engaged by manually turning the locking sleeve after the connection is made. The lock is released by returning the sleeve to its original position during disconnection.
A variety of hydrualic pipe mountings
Th e co u p liing d esiggn in ncllu dess a m an u al seecuritt y -lo o c k in g f eatt u re w h icch is en ngag e d b y m a n u a llyy turn n ingg th h e l occkingg sleee ve af t er t h e c o n necc tio o n is m ad e Majority retained
Albert has been in the hydraulic market for over twenty years, importing top quality brands mainly from Germany, Switzerland and Italy. “As each of these manufacturers has expanded their product range, so we’ve followed them, constantly bringing the latest technology to South Africa,” says Albert. “We’ve hired more staff over the years to enable us to service our ever-increasing customer base. For the past 21 years we’ve been able to retain a majority of our staff, which has allowed us to the competence of our staff in order to develop unique relationships with each customer. Today we have more than 16 distinctive product lines, from 13 manufacturers.”
Special equipment for bending hydraulic pipes
Stock holdings
The company’s primary focus is on hydraulic steel tube fittings, hydraulic line tubing and pipe clamps. “Normally bookkeepers complain when you hold too much stock, but we’ve learnt that having enough stock available at all times has been a major differentiator for us in the local market,” says Albert. “Apart from always having stock, especially the parts our regular customers use frequently, we believe in keeping customers informed about technology and changes in product requirements elsewhere in the world. “For example, in Europe the yellow chromate plating which has been used for ages to protect steel components is today strongly discouraged and in some cases even discontinued by most OEMs because of its toxicity,” says Albert. “Many people don’t know this and when we present them with
A special machine for crimping hydrualic fittings
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plating is actually a poisonous process which causes severe damage to the environment, they’re fully on board. After all, it’s still the same part from the same manufacturer.”
N orm m allyy b o o kkee p er s co o m pla ain n when n yo o u h o ld d to o o m uch st occk Clean fluid
A wide variety of pipe for hydraulic application is stocked
parts which are now a matt silver colour they insist it’s wrong because they’ve always used the yellow ones. Once we explain that the yellow chromate
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In hydraulics the cleanliness of the fluid is a critical factor for long machinery life, but still an aspect many people grossly neglect. “In our effort to educate people involved in the hydraulics industry we make a point of advocating the importance of clean filters and proper filtration systems,” Albert says in conclusion. “Most of our bigger clients are listening and have programmes in place to ensure regular maintenance on filtration. But there are still many who don’t consider the consequences of unexpected breakdowns, or premature wear because of dirt in their fluids. As a member of the Fluid Power Institute it’s our duty to follow the organisation’s lead in educating users on the importance of proper filtration.” Albert Epprecht, Alba Hydraulics, Tel: (011) 458-1200, Email: albert@alba.co.za
July 2012
HYDRAULICS & PNEUMATICS
Bionic Learning Network The Bionic Learning Network, is an alliance of educational establishments and specialist companies tasked with exploring bionic solutions for evolutionary automation applications.
Elephant trunk: Drawing inspiration from nature, Festo mimicked the flexibility and versatility of the elephant trunk for its latest design
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rawing inspiration from nature’s ability to achieve maximum performance with minimal energy consumption, the Bionic Learning Network develops decentralised, self-controlling and self-organising systems. The network’s main focus is on utilising bionics in the formulation of new principles of operation for the delivery of energy efficient, mechanical engineering innovations.
Open up a host of new application areas that involve direct, non-hazardous contact between humans and robots Mass-payload ratio
The Bionic Handling Assistant is the network’s newest offering, providing a completely flexible and safe means of moving objects from one position to
another. Inspired by an elephant’s trunk, the assistant employs innovative biomechatronics technology and introduces a new concept, whereby direct contact between machines and their human operators is no longer hazardous. In the event of contact between the Bionic Handling Assistant and a human, the assistant will yield immediately without modifying its desired overall dynamic behaviour, and will resume its operation once the threat has been averted. Unlike other heavy industrial robots, this assistant is characterised by an excellent mass-payload ratio. In addition, it provides smooth operating motion with more degrees of freedom and makes efficient use of its resources in production and operation.
Extra degrees of freedom
Another pioneering handling solution from Festo, the BionicTripod 2.0 is derived from the tail fin of
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The Bionic Handling Assistant offers complete flexibility and the ability to safely move objects from one position to another
a fish and can be described as a horizontally-arranged tripod that is rotated at 90° from the conventional tripod configuration. It consists of a drive unit, a tripod structure free to move in all spatial directions, a flexible hand axis and an adaptive FinGripper soft handling unit. The hand axis is structured similar to that of the Bionic Handling Assistant, with the added advantage of three extra degrees of freedom and a 30° range of deflection. The highly versatile FinGripper constitutes the interface between the object and the actuators and consists of a pneumatic actuator in the form of a bellow and three gripping fingers.
Forms energy efficiency may take in the future of automation technology Pliable and flexible
A particular advantage of the BionicTripod 2.0’s horizontal configuration is that objects can be picked up from the working surface and deposited to the side at a different level, a beneficial feature for versatile agricultural applications and for the sorting of materials for recycling. Since the structure is pliable and flexible, it is ideal for tasks in humanmachine interaction and can be used in sorting applications or as a “third” hand. Joanne Dexter, Festo Tel: (011) 971-5560 Fax: (011) 974-4203 marketing.za@za.festo.com
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SAIT
Unintended Consequence “It seems that no residential University of Technology is planning to provide for technician education” was an opinion expressed at a recent meeting of the Technology Programme Accreditation Committee at the Engineering Council of South Africa (ECSA). This seems to be the prevalent thinking in the Universities of Technology (UoTs), or former Technikons. They seem to be planning to provide only the new three-year Bachelor of Engineering Technology (BET) degree, which will be the new benchmark qualification for professional engineering technologists.
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ow did we arrive at this juncture? Technology engineering qualifications, contrary to the traditional four-year engineering degrees, have suffered major overhauls every ten to fifteen years since the late fifties/early sixties when the T4 Diploma was established to replace the ATC II. This culminated in the present National Diploma and the BTech degree. The fact that, for the first time, technology professionals had a degree as benchmark qualification was a huge success, as well as a thorn in the flesh of many.
Additional laboratory space, lecture halls and lecturing staff would be required to provide two parallel qualifications Not to be revived
Johan de Koker
In 2007 the Department of Education announced their vision for future tertiary qualifications in the Higher Education Qualification Framework (HEQF). This framework laid down principles and guidelines wherein all tertiary institutions would develop their qualifications. It did not allow for a BTech degree at all, and, if a UoT wanted to offer a diploma for engineering technicians, that university would have to guarantee the student a placement for his or her year of work-integrated learning. ECSA (for the engineering profession) and many other stakeholders offered comment and sent delegations to the Department of Higher Education, but the BTech degree was not to be revived. Meanwhile ECSA’s Engineering Standards Generating Body (ESGB) was hard at work generating suitable benchmark qualifications for engineering technology professionals, which would be in alignment with the HEQF vision. Since no UoT could guarantee work-integrated learning placements for students, due to the cyclical nature of the South African economy, the only workable qualifications provided for by the HEQF for technicians would have been the consecutive Higher and Advanced
Certificates, each a one-year 120-credit qualification, with industry making its own provision for introducing the students into the work environment.
Three to four years
For engineering technologists, the most suitable qualification would be a three-year Bachelor’s degree in Engineering Technology (BET). At a meeting with officials from the Department of Higher Education and Training (DoHET), it was clear that this proposal was not well received, until we explained that we did not foresee any work-integrated learning component in this qualification. It would be a purely academic three-year degree. The HEQF therefore placed the UoTs into a position where no work-integrated learning would be provided for as an integrated part of the technology qualifications. ECSA seems to consider increasing the minimum three-year candidate phase for technicians and technologists to four years to compensate for this loss.
Top-up
The DoHET revised the HEQF last year, and the latest guidelines provide for a two-year 240-credit Diploma, suitable for the education of engineering technicians, and a three-year 360-credit BET for engineering technologists. The present consecutive model with the BTech degree as a top-up of the Diploma is, however, not acceptable to the DoHET. The Engineering Faculty of the Tshwane University of Technology did a controlled study, approaching the engineering industry represented through its various Advisory Committees, to determine what qualification industry favoured, and the overwhelming response was for the three-year BET. It remains to be seen what the final decision of the other UoTs will be, but none of these institution has the capacity to provide two parallel qualifications for technicians and technologists. Additional laboratory space, lecture halls and lecturing staff would be required to provide two parallel qualifications. It seems therefore that the unintended consequence of the demise of the BTech degree will be a crisis for the education of engineering technicians. This begs the question as to how our future engineering technicians will be educated. Will this be left to the FET colleges? Engineering technology education is indeed at a crossroads again. Quo Vadis? This ‘opinion’ was first published in the March 2012 edition of “Civil Engineering”, the magazine of the South African Institution of Civil Engineering”. Johan de Koker, SAIT Committee Member SAIT, Gill Fuller, Tel: (011) 802-5145/6, Email: secretary@sait.org.za, www.sait.org.za
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Significant Advantages
The dry milling of ore in Loesche vertical roller mills has shown significant process advantages, as well as economic and ecological benefits. To demonstrate these, a mobile ore-grinding plant, the OGPmobile, has been developed. This allows the customer to test the effectiveness of Loesche’s grinding technology and its influence on the total material flow of the existing processing plant. The degree of mineral liberation, particle size distribution,
energy consumption and throughput can be optimised individually for each deposit and each treatment process, depending on the ore characteristics. Past experience shows that considerable benefits are achievable on various ore types with differing characteristics, such as lead/zinc and nickel. The OGPmobile is a fully functional grinding plant, which is comparable with the test circuits in the Loesche Test Centre in Neuss Germany. The flexible circuit allows operation in
an airflow as well as in overflow mode without gas sweeping. Large samples of milled material – 200300 tons for further direct processing in subsequent process steps – can be produced. The quality of the milled products is checked by analysis in the integrated laboratory. Loesche South Africa, Alana Ridley, Tel: (011) 482-2933, Fax: (011) 482-2940 Email: aridley@loeschesa.co.za, Web: www.loesche.com
Local Water Intake Projects A continuous rise in the demand for scarce water resources is resulting in an increased need to develop more water intake systems in South Africa, and new process equipment company Ludowici Meshcape stocks a comprehensive range of environmentallyfriendly wedge wire screens that
perfectly complement these systems. Ludowici Meshcape technical consultant David Owen points out that water intake systems are designed for use in seawater and freshwater applications, specifically to remove any debris and particles from the water, before it is transported for its final use. “A water intake system is a pump that draws in water at low velocity, while solids such as marine life, sand and seaweed are prevented from entering the intake system by the Ludowici Meshcape wedge wire screen, which consists of two wedge-shaped woven wires, spirally
wound to create s m a l l apertures that typically allow for fine separation of between 300 microns (μ) to 1 mm,” he explains. Ludowici Meshcape manufactures wedge wire to ISO 9001-2008 standards, thanks to the company’s R15-million Euroslot manufacturing machine, imported from France in 2009, which ensures that the quality of the aperture finish is world class. Ludowici Meshcape, David Sibley, Tel: (011) 609-1120, Fax: (011) 452-2545 Email:d.owen@ludowicimeshcape.co.za, Web: www.ludowicimeshcape.co.za
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Industrial Recycling Recycling Scrap metal merchant and recycling specialist Envirocycle has become recognised as an nationwide-leader in the disposal of ferrous metal, non-ferrous metal and industrial waste, by making use of a range of specially-modified Hyundai excavators supplied by HPE Africa – the sole distributor of Hyundai earthmoving equipment in Southern Africa. Envirocycle executive director Stefan Pretorius stresses that recycling is a critical and essential part of modern life in South Africa and worldwide. Envirocycle’s fleet of 40 heavy-duty transport vehicles currently consists of one Hyundai R360LC-7 tracked excavator, a Hyundai R220LC-9 excavator and two Hyundai R210LC-7 tracked excavators. The machines, the company also placed an order for an additional two R220LC-9 excavators and a second-hand HL740-7 wheel loader, which were delivered in March 2012. All Hyundai excavators can very easily be fitted with auxiliary piping, which
ensures that Envirocycle is able to easily fit the claws for picking up scrap. “Thanks to the option of auxiliary piping on the entire Hyundai range, the user simply has to change the attachment, fit the piping, and finally set the pressure of the pipe for the claw. An HPE Africa technical team can complete this simple
process in a short period of time,” says HPE Africa national service manager Hein Stander. HPE Africa, Kirsty Denholm Tel: (011) 397-4670, Email: kirsty@hpeafrica.co.za Web: www.hpeafrica.co.za
Major Order in Record Time KEW Foundries has just completed a multi-million rand order for Gunric Valves, to cast seven valve body and disc sets for use by a large water utility.
KEW Foundries sup supplied p plied d Gunric Gu Valves with seven DN DN250 0 0 valve v DN2500 weighing bodies and discs, wei eigh h ing five tonnes and six and a half ha a l f tonnes ton used on each respectively, to be us isolation duty
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The biggest butterfly valves that this manufacturer of high quality valves has supplied to the local market to date comprised DN2500 valve bodies and discs, weighing five tonnes and six and a half tonnes each respectively, to be used on isolation duty. KEW Foundries, John Bryson, Tel: (053) 841-0474, Fax: (053) 841-0473 E-mail: john@kewfoundries.co.za, Web: www.kewfoundries.co.za
MARKET FORUM
Alien Systems & Technologies (Pty) Ltd (AST Africa) is proud to announce the launch of the Astex range of vehicle fire suppression systems. The company offers an array of suppression and protection products including the award winning Pyroshield total flooding system. Managing director Paul Wright says, "There is very little AST Africa cannot protect, from gas fire extinguishing systems, enhanced detection to conventional fire protection. Our highly experienced and industry respected engineers are able to tailor make the best possible
solution for business operating in almost any industry." Pyroshield currently protects the buildings and server rooms of some of South Africa's biggest industry players while the Pyrogen in-cabinet fire extinguishing system features in substations in mines all over the African continent. Paul says vehicle systems were simply the next step. The protection offered by the Astex systems encompasses everything from small vehicles to large non-road equipment. The likes of excavators, drag
lines, dozers, graders, underground mining equipment, buses, forklifts, medium-sized commercial vehicles and four-wheel drive vehicles for mine sites are all afforded the option to utilise the Astex system for maximum fire suppression and protection. Three systems are now available to the African market and specifically designed to cope with the extremes of the African mining industry. Alien Systems & Technologies, Sam Wright, Tel: (011) 949-1157, Web: www.astafrica.com Email: sam@astafrica.com
More Powerful Solutions
Largest Centrifugal Fan Seen here close to completion in ACTOM Mechanical Equipment’s Germiston plant is the 4 m diameter centrifugal mine vent fan for Palabora Mining Company’s expansion project.
Actom Mechanical Equipment has produced its largest-ever centrifugal fan to date for a mine vent system to serve the expansion of local copper producer Palabora Mining Company’s underground mining operations at Phalaborwa, Limpopo Province. At 4 m diameter the new fan is substantially larger than the largest the company has previously produced, which had a diameter of 3,4 m. The new mining operations will be at a depth of 1600 m below surface, 400 m deeper than the present workings. “Production is due to start in 2016 and will be increased over the subsequent three years as production in the existing mine tapers off,” explaines Gavin Meredith, Palabora Mining Company’s
Senior Advisor Engineering. The new fan has been installed near the existing main vent fans halfway down the old open pit at a depth of about 300 m below surface. “The two existing 1,25 MW ventilation fans running in parallel have a combined output capacity of 600 m3/sec at 2000 Pa pressure. The new 3 MW power fan will have an initial output of 500 m3/ sec at 2700 Pa pressure, ramping up to 400 m3/sec at 5500 Pa pressure as the mine develops,” explaines Mike van Oerle, Actom’s Product Manager, Mining Fans. Actom Mechanical Equipment, Craig Johnston, Tel (011) 871-6789, E-mail craig.johnston@actom.co.za, Web: www.actom.co.za
HP has launched new, more powerful cloud-based solutions, allowing architecture, engineering and construction (AEC) professionals to print where the job takes them. Users are connected to HP’s web-connected, large-format Designjet ePrinters and eMFPs for printing on the go, whether at a partner’s office, in a taxi or at the construction site. An expansion of HP’s partnership with Autodesk enables remote printing from the highly popular AutoCAD WS. By registering for HP ePrint & Share, AutoCAD WS users can use the new Plot to Print function to print their designs and automatically archive a copy on any web-connected HP Designjet or HP ePrinter. This new feature provides full control over plot styles, paper sizes, layouts and more. Additional capabilities for the HP ePrint & Share mobile application, HP’s free, cloud-based printing and sharing tool for Designjet users, include full functionality for the iPad and the ability to send PDF e-mail attachments to print. Previously, all documents printed from the mobile app were selected from the user’s HP ePrint & Share library. Now, users can print PDFs received via e-mail as well, providing access to more documents when and where they need them. HP, Hedy Gorton, Tel: 086 000 1030, Email: hedy.gorton@hp.com
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Very LARGE order Pit Viper 351 blasthole drilling rigs
Atlas Copco has received one of its largest orders ever in South Africa, to deliver Pit Viper 351 blasthole drilling rigs for around R 290 million to Kumba Iron Ore, a unit of Anglo American, one of the worldâ&#x20AC;&#x2122;s largest mining companies. The equipment will be supplied to the Sishen Mine in Kathu, northwest South Africa. The units are scheduled to be delivered from July 2012, and the last unit should be introduced into productivity in March 2013. The order was received during the first quarter.
Consistancy is Vital Almost all refrigeration air dryers only show the actual physical gas or compressed air temperature within the dryer itself. The temperature shown on the dryerâ&#x20AC;&#x2122;s fascia panel is not a dew point, itâ&#x20AC;&#x2122;s merely a temperature indicator. When, or if a drain valve fails, the condensing of water vapor to a liquid contamination still continues, thereby flooding the airline with liquid water. In similar vein, if the refrigeration Freon compressor trips on internal thermal overload the majority of air dryers will not display this fault on the fascia panel, so again the air line is flooded with water contamination. Many engineering staff do not realise that that when a dryer fails or an automatic drain malfunctions, that the water injected into the ring main will take anything up to 30 days to be re-adsorbed by dry air for a (rectified or repaired) air dryer. To prevent these occurrences regular maintenance of dryers should be undertaken by trained staff familiar with a dryerâ&#x20AC;&#x2122;s operating systems. Routine planned service maintenance should be undertaken by trained outsource engineers to check gas loads, switching hysteresis and hot gas valve set-ups etc.
The innovative SlurryRat floating dredge system is ideal for the removal of slurry from process water and according to local distributor, Xylem, is set to change the way companies approach the removal of sediments from process water
An innovative new floating dredge system for the removal of slurry from process water is poised to forever change the way local companies approach the removal of mineral sediments from process ponds, dams and storage tanks. Incorporating Flygt slurry pumps, the SlurryRat, developed by UAT in Australia and distributed throughout sub-Saharan Africa exclusively by Xylem (formerly known as ITT Water & Wastewater South Africa), is an industrial strength pond cleaner, providing a robust and efficient means of dealing with slimes and slurries produced from a range of mining industries. Without requiring cutter heads, the electrically powered and remotely controlled SlurryRat operates via a unique combination of suction and
$UWLF 'ULHUV ,QW $OOHQ &RFNÂżHOG Tel: (011) 425-3484, www.articdriers.co.za Two pass direct expansion dryer, Artic Driers style
Atlas Copco was recently identified by Anglo American as one of two preferred suppliers of surface drills with a drill diameter bigger than 165 mm. Sishen, one of the seven largest open-pit mines in the world, already has an existing fleet of ten Pit Viper 351s. â&#x20AC;&#x153;We are proud to have been chosen as a strategic long-term partner to Anglo American and we look forward to building the relationship further in the future,â&#x20AC;? says Bob Fassl, business area president, Atlas Copco Mining and Rock Excavation Technique. â&#x20AC;&#x153;The Pit Viper 351 has a good reputation among our customers and we see great interest in this product from mining companies around the world.â&#x20AC;? Atlas Copco, Bob Fassl, Tel: (011) 821-9000, Web: www.atlascopco.com
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Removing Min
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Security of Supply
agitation that protects valuable plastic liners, while extracting most high density sediments for re-processing. “No downtime is necessary while the slurry is being removed, because the SlurryRat is able to operate while the pond remains online,” Xylem SA’s application engineer: mining and minerals, Lee Vine, says. “Companies who have already made use of this technology have been impressed by its efficiency and cost effectiveness, as well as the fact that the system can be customised to suit the specific conditions at each site. Xylem, Lee Vine, Tel : (011) 966-9300, Fax: (0 11) 552-87421, Web: www.xylemwatersolutions.com/za
Book now for 2012 September
Oils and lubrication Compressors, air motors and vacuum pumps Mills Power Generation - wind
October
Power transmission Computers in engineering Pipes, pumps and valves Power Generation Materials and Machine Tools Contact Mark Bennett on Tel: (011) 781-1401 Fax: (011) 781-1403 or E-mail: samecheng@promech.co.za for further details
Afrox’s Project Execution and the Ecovar team has successfully relocated a fullyfledged hydrogen plant from an existing site in Atlantis in the Western Cape, to a customer site 130 km from central Cape Town. Ecovar stands for ECOnomical and VARiable and is a concept developed by Afrox’s parent company, The Linde Group, for supplying standardised oxygen, nitrogen and hydrogen via on-site production plants dedicated to supplying a single customer. Due to the site security, risks, and equipment pilferage, a decision was taken to dismantle and relocate this plant onto the Afrox site at Duferco Steel Processing, a longstanding customer located 5 km away from the Port of Saldanha. Duferco, also a major Afrox LPG customer, produces in excess of 600 000 tons per annum
of steel products, including hot rolled pickled and oiled, galvanised and cold rolled products, using state-of-the-art technology. The plant was dismantled at Atlantis, containerised and transported to Saldanha on a flatbed truck. All pipework was re-used and replicated Says Ecovar manager, Busty du Preez, “Apart from ensuring Durferco had an uninterrupted supply of hydrogen during the relocation, another of our Western Cape clients, a leading manufacturer and exporter of metal powder precision components, was reliant on us in this period to provide sufficient hydrogen to fulfil a large contract for the European motor industry.” Afrox, Busty du Preez, Tel: (011) 490-0400 Email: casper.dupreez@afrox.linde.com Web: www.afrox.co.za
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BMG Fasteners has recently opened a new concept store in New Germany, Durban.This specialist fasteners store stocks a wide range of fasteners, tooling and abrasive products for all industrial requirements, as well as to satisfy demand from the DIY enthusiast
Concept Store BMG Fasteners has recently opened a new concept store in New Germany, Durban. This specialist fasteners store stocks a wide range of fasteners, tooling and abrasive products for all industrial requirements. “What’s unique about this specialist store is we offer our customers a unique self-service, ‘touch and feel’ shopping experience, whether they need a single fastener or have bulk requirements,” says Darryl Campbell, general manager, BMG Fasteners. “We have had very positive feedback from our customers who appreciate their one-stop shopping experience for the exact product they require. “A full technical advisory and support service at the store ensures the correct product is selected for each specific application.” Included in the range available from the concept store are hand,
air and power tools, abrasives, tapes, silicones, as well as welding and safety wear. Premium fastener brands include Huck fasteners and Nord-Lock bolt securing products, washers and truck wheel nuts. Other well-known brands are Gedore, Somta, Klingspor, Pferd, Matabo, Bosch, Black & Decker and Gearwrench. BMG Fasteners plans to open more concept stores in other key regions. BMG Fasteners, which boasts the largest stockholding in the Southern hemisphere, supplies diverse industries with a comprehensive range of quality branded of fasteners, bolts, nuts and related products. BMG Fasteners, Darryl Campbell, Tel: (031) 576-6200, Email: darrylc@bmgworld.net Web: www.bmgworld.net
Engineer Placements www.engineerplacements.com
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First-of-its-kind Laser The Institute for Advanced Tooling (IAT) at Stellenbosch University (SU), has commissioned a M2 laser cusing machine The highly advanced laser can build any 3D object by simultaneously fusing and micro-welding fine metal powder. Therefore, there is huge opportunity for design freedom and production of components without the use of any tools, stimulating innovation and leading to product development time reduction, productivity improvement and mass customisation
This high-tech system is the only one of its kind in South Africa and is a result of intensive research and development work conducted by the IAT engineers
in collaboration with postgraduate students at SU. Stellenbosch University, Tel: (021) 808-9184, E-mail: essie@sun.ac.za
A further major advantage is the large variety of processed materials it can handle such as aluminium, stainless steel, various hot-work steels, titanium, cobalt-chrome, nickel-based alloys and other. This allows a large utilisation of the equipment in demanding applications from the aerospace (critical hollow parts made out of titanium), automotive, medical and dental industries (various implants), beyond its primary use for production tooling.
Shortened delivery periods Pan Mixers South Africa (PMSA) has improved control over the supply chain of its critical steel parts, after entering into a service agreement with newlyestablished steel merchant, TWR Steel Service Centre. TWR Steel is based in Graniet Street in Jet Park, Boksburg, and consists of a 2 800 m2 manufacturing facility. It is a wholly-independent company that serves as a preferential supplier of steel products to PMSA.
outside companies,” he explains. “Due to long lead times; however, we were often forced to wait for several weeks before receiving certain materials, and resorted to overstocking of certain items to reduce the impact of delays for customers.”
Walter adds that the establishment of TWR Steel now ensures that PMSA has full control of all of the components of its manufactured machinery. PMSA, Quintin Booysen, Tel: 086 100 7672, Email: quintin@panmixers.co.za , Web: www. pmsa.com
TWR Steel, which officially began production in March 2012 after being established in late 2011, sets itself apart from the competition due to the fact that it specifically-focuses on improving the predominantly prolonged and delayed service delivery periods that currently dominate the local steel market. PMSA director Walter Ebeling notes that since its inception, TWR Steel has already made a measurable improvement to their turnaround times. “PMSA manufactures between 60 to 70 percent of the components for its machinery in-house. In the past, we would outsource the profiling, bending, laser cutting and rolling functions to
Oxy-fuel cutting
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Local repair centre Servo motor
SEW Eurodrive has announced the launch of a repair service for servo motors at their Cape Town branch in Montague Gardens. “The maintenance requirements of SEW servo motors are generally relatively low. However, breakdowns can happen to any product, and when it does happen, the motor needs to be re-paired as fast as possible to ensure minimum loss in productivity and maximum factory availabil-ity” comments Paul Strzalkowski, Electronics product manager. In the past these units were sent to the headquarters in Germany for repairs and most often cus-tomers would replace the unit to minimise their downtime. Since the launch of the new service, customers now have the option of sending their motors to the servo specialists at the
Cape Town branch of SEW Eurodrive, for a rapid repair. “Not only does this new initiative save the customer time, it also saves money. Servo drives are relatively expensive as a result of the high quality permanent magnets which are used in their construction. It is quite a complex product to work on as it requires specialised tooling and dedi-cated software, to align the motor feedback components. The Cape Town branch is now fully equipped to handle all of these repairs in house” adds Paul. The current turnaround time is ap-proximately 1 to 2 working days subject to spares availability.
Chris Spencer
Sew-Eurodrive, René Rose, Tel: (011) 248 7000, Email: rrose@sew.co.za, Web: www.sew.co.za
Herbert Msagala
Floris Pretorius
Transnet National Ports Authority has annouced the appointment of Herbert Msagala as General Manager: Port Operations effective June 2012.
Linda Brown
The OMSA Group has appoined Linda Brown as their new Engineering Manager and Chris Spencer to the newly-created position of Thermoplastic Valve Specialist.
Hugo Pretorius
Richard Rudling
Richard Rudling has been appointed general manager at Ecochem Pumps, while Floris Pretorius has been appointed sales representative, Vaal Triangle, and Hugo Pretorius is sales representative, Secunda’
Index to Advertisers Artic Driers Atlas Copco
18 16, Outside Back Cover
Axiom Hydraulics
4
Engineer Placements Europair
44 Inside Back Cover
KDP Services Munters
Festo
14
Nkosi’s Haven
21 Outside Front Cover Inside Front Cover
Chem Systems
16
Garnet Cross
44
PPS
11
Compressed-Air
27
Horne SA
25
Rodecon
28
Electra Mining Africa
10
Hytec
36
SAEEC
22
Engen
34
Interbuild Africa
29
SAID
30
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Together making the difference
Clean, energy efficient air for every industry - and our planet Atlas Copco is a leading manufacturer of fully comprehensive, technologically advanced compressors; as well as a range of fully compatible filters and dryers. We offer a solution for almost all applications, and are dedicated to excellent customer care and after sales service. • Compressors (oil-free & oil-injected) • Automatic Drains • Water Separators • After Coolers • Rotary Screw • Centrifugal • Dryers • Filters • Scroll • Tooth Atlas Copco Compressor Technique P O Box 14110, Witfield 1467 Tel: (011) 821 9000, Fax: (011) 821 9106/7 www.atlascopco.com / www.atlascopco.co.za
Visit us at
Stand G21 Hall 6
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