SA Mechanical Engineer July 2018

S MECHANICAL A ENGINEER July 2018

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

The 2018 SAIT Annual Awards Dinner was held in the Gala Room at the Wanderers Club in Illovo, Johannesburg on Friday evening 18th May 2018

tackling industry 4.0

3D & Nimble garage-sized industries

THE SOUTH AFRICAN MECHANICAL ENGINEER

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July 2018

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AN ENGINEER’S VIEW

How does one build a decolonised bridge?

A/Prof Deborah Blaine

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I first heard this question as part of the somewhat facetious reaction that many engineers have to the call to decolonise science, knowledge, engineering. But let’s go back to one of the first communities of colonisers, the ancient Greeks, and reflect on Socrates’ statement, “The unexamined life is not worth living.” When thinking about what I could do to transform the engineering profession into one where we can build a decolonised bridge, I paused to reflect on my classroom.

hat made some students feel engaged, feel like they were firmly on their path to building their identity as a South African engineer?

Why do some students have no problem in feeling this way, while others feel alienated or disempowered? It is so easy to dismiss students as lazy, self-entitled millenials, but the truth is that a small percentage of matriculants gain entry into university, and engineering attracts top learners from this cohort. We have the privilege of having dedicated, determined and self-motivated young adults in our classrooms.

So why do we lose so many of them?

Educational research shows evidence, again and again, that feelings of engagement, belonging and identifying with the context and the community, are critical for successful learning.

How does this relate to decolonisation? If one believes that science was invented in Europe, by white men, and that a Western knowledgebase drives all technological development, it is easy to imagine that anyone whose identity lies outside of this construct would face a significant challenge in engaging with the disciplines supported by science and technology.

A myth

One of the first myths that I interrogated relates to the history and evolution of science. Let’s start with mathematics, as it is arguably the language of engineering. The most ancient mathematical texts date back to around 2000 BC, written in Mesopotamia (situated in the area currently known as the Middle East) and Egypt. As an example of the importance of history, one of the first mathematical theories that a student will learn (long before they enter the university halls) is the Pythagorean theorem.

Pythagoras (c. 570 – 495 BC) was a Greek philosopher who is probably most famously known for a theorem that he did not discover.

The Pythagorean triangle relationship was known to Babylonians and Indians centuries before Pythagoras was born! But Pythagoras was probably the first Greek to formally present the knowledge to the Greek communities, perhaps the first to formally set out the proof.

The revelation of “new to you” is something that anyone who has applied themselves to any study knows well.

So, one of the first lessons I learnt in my endeavour to unpack colonisation and decolonisation, is that a student’s perception of what is real or true may be very far from reality or the truth.

It is, however, their current reality and I need to be aware of it.

Perhaps the first step in decolonisation, is realising that much of what is assumed to be colonised knowledge is no such thing. Mathematics is not European, nor is science, nor is engineering. However, pretending that each student in my class is equal, that they enter our institutions with the same opportunities, privileges or challenges, is insanity. So how do I manage this environment of have and havenots, of blissful ignorance and painful realities?

Where is the space in the engineering curriculum to incorporate an ethic of care, of awareness and sensitivity?

Mathematics is not European, nor is science, nor is engineering Diversity of perspectives

Perhaps a decolonised bridge is designed by a local team of engineers who value and appreciate the diversity of perspectives that each team member brings. Perhaps one of the engineers is the daughter of one of the construction workers, the first person in her family to go to university.

Perhaps the bridge is reinforced with natural fibres, from crops grown in fields by local farmers who use sustainable agricultural practices.

Maybe it provides a means of connecting a rural community to an economic hub; maybe it carries power and clean water back to this community.

Engineers are expert problem-solvers. Colonisation was a reality in our society. The effects are still evident and continue to pose problems for our society. These are all concrete facts. Let’s use the tools and knowledge available to us, and find a way to build a decolonised bridge.

A/Prof Deborah Blaine SAIMechE council member and past-chair of Western Cape Branch

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S MECHANICAL A ENGINEER July 2018 VOLUME 68

On the Cover

Contents

Local Southern Africa Manufacturing Expo www.localmanufacturingexpo.co.za

Bearings & Lubrication

Engineering Feat

10 Long Life at Food Plants

31 First Complete Landing Gear Change

Steam Turbines & Boilers

Conference

13 Credibility and Confidence

32 Regional Connectivity

SA Institute of Tribology

Compressors

14 Annual Awards Dinner

34 First of its kind

Effective Process Plants

Report-back

20 Quick Density Data

36 Frigair hits the mark

Hydraulics & Pneumatics 25 Eastern Cape Hub

Regulars

Consulting Engineers SA 27 Surprisingly strong economic outlook

Deep Drilling 28 An African Record

3 7 39 46

An Engineer’s View Institution News Market Forum On the Move

Copyright

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

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

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June 2018

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SA INSTITUTION OF MECHANICAL ENGINEERING

Council 2016 - 2018 Office Bearers President............................................ Prof JL van Niekerk (Wikus) Vice President........................................................ A Roos (Andre) National Treasurer................................... G van den Berg (Gideon)

Branch Chairpersons Central ................................................................. C Kruger (Carel) Eastern Cape........................................... G van den Berg (Gideon) KwaZulu-Natal ........................................ Dr J Padayachee (Jared) Mpumalanga Highveld .....................................N Lecordier (Noel) Vaal.............................................................. N Swanepoel (Niekie) Western Cape ............................................... Dr M Venter (Martin)

Portfolios: Communications and Marketing..................G Bartholomew (Bart) Technology Programme..................................... SZ Hrabar (Steve) Engineering Education and Constitutional Matters.....Dr D Blaine (Debby) TBC......................................................H Makwarela (Hangwane)

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

Company Affiliates Amoricom

Mod-U-Flow CC

Autodesk as represented by Worldsview Technologies

Osborn Engineered Products SA (Pty) Ltd

Ainsworth Engineering (Pty) Ltd

PaCMan Projects & Maintenance

Alstom Power Service SA (Pty) Ltd

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

Babcock Ntuthuko Engineering Pty Ltd Bosch Projects Pty Ltd Esteq Group (Pty) Ltd Exxaro Resources (Pty) Ltd Festo (Pty) Ltd Fluor SA (Pty) Ltd Kelvion Systems (Pty) Ltd Green Plan Consultants (Pty) Ltd Hatch Africa (Pty) Ltd Howden Power (a div of Howden Africa) Howden Projects (a div of James Howden) MBE Minerals (SA) (Pty) Ltd Megchem

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PPS Insurance Co Limited Redheads Engineering Services (Pty Ltd) Rotek Engineering S.A.M.E Water (Pty) Ltd SA Power Services (Pty) Ltd Sasol Technology (Pty) Ltd Siemens Ltd Simera Technology (Pty) Ltd Spirax Sarco (Pty) Ltd Tenova Mining and Minerals SA Thyssenkrupp Engineering (Pty) Ltd Vital Engineering (Pty) Ltd Weir Minerals Africa

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SA INSTITUTION OF MECHANICAL ENGINEERING

System and Processes Symbiosis

It is sometimes difficult to understand the obvious,

by Jac Spies

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ystems consist of processes that enable people to find solutions for their functional needs.

For example, a typical functional need of many people is transportation, the ability to get from point A to point B in a large city. There are many systems that can provide this need, eg, using the City’s bussing system, or the public Rail System, hiring a Taxi etc.

A system is thus a combination of interdependent and interacting elements forming a unitary whole for a particular purpose. Systems must create value, because a system without any value will not be used, and eventually be trashed.

The interdependent and interacting elements of an effective and efficient system work in harmony. If some of the parts are not working correctly, the system will come to a standstill. These interacting elements or parts are called processes.

A process is a sequence of activities intended to produce a particular result. Processes can span organisational boundaries, linking together people, information, and other resources to create and deliver value to the system.

A system is the methodical way that provides specific goods or services to people. It is the “what,” as in, what value does it provide?

Processes are all the related activities inside a system that work together to make it function, eg, for a mass transit system, there’s a process for ticket sales, equipment maintenance processes, vehicle and track repair processes, safety processes, and so on.

Therefore processes are the “how.” As in, how do all the activities work together to provide that value?

Functional silos in organisations embracing “this is the way we do things around here” develop blind spots

for symbiotic relationships between the systems and processes that are essential for effective and efficient service delivery.

In fixing broken, ineffective, or inefficient systems and processes one must find a balance between process, systems, and systemic thinking.

• Process thinking considers the system as a collection of independent processes.

• System thinking considers the system as a collection of integrated processes.

• Systemic thinking considers the symbiotic relationships between different systems.

The two fundamental tools used to enable the diagnostics required to fix and improve ailing systems and processes are: ⇒⇒ Process Mapping to decompose and optimise each element of the process. ⇒⇒ Functional Analysis to decompose and optimise each element of the system.

Readers who require more detail on these two methodologies may contact Jac Spies at jac.spies@ gmail.com. Jac is the author of this article and the developer and facilitator of the one day workshop System Viability and Process Management. Alternatively, to receive the programme of this workshop and enquire about holding the workshop as an In-House event, please contact Linda Robinson of SAIMechE at linda@saimeche.org.za or Tel: (031) 764-7136.

Comment from a delegate at one of Jac’s SAIMechE training workshops: “Jac Spies is probably one of the foremost innovative thinkers in the country.”

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Centrifugal Pumps, Systems and Slurry Applications Seminar CPD accreditation number SAIMechE-1028-12/19 2 credits may be obtained under Category 1 expertise and venue kindly supplied by Weir Minerals Event Code : EPM18 - Event Date : 6-7 August 2018

-

Booking Closing Date : 27 July 2018

Venue : Weir Minerals, East Rand Standard Fee : R5 170.00 + VAT

Programme, registration form, and fee structure (including discounts) may be obtained from Carey Evans Tel: 031 764 7136 or carey@saimeche.org.za 2018 Forthcoming Training Workshops SAIMechE Training Events should be viewed by members and the industrial community as service benefits. Only events which have attracted sufficient delegates will take place. Events which do not have sufficient delegates by their bookings closure dates will be cancelled and all relevant parties will be notified accordingly. Therefore, if you book on an event, we recommend that you delay making your travel arrangements until you have been notified that the event will take place as planned.

Workshop programmes, 2018 Delegate registration forms, and Fees structure may be obtained from Carey Evans Tel: 031 764 7136 or email: carey@saimeche.org.za Event Code Event Title

Date Start

Date End

Region

Booking Closure Date

Developed and presented by: Dr. Herbert De Vries, B.Sc (Mech.Eng), Pr.Eng. G.C.C., MSAIMechE, MBL, DBL E3718

Pressure Vessel Design, Construction, Maintenance & Troubleshooting Workshop

15 August

15 August

East Rand

3 August

Developed and presented by: Mr. Dean Sawich, BSc, AAS A1218

The Psychrometrics Toolbox Its Principles, Uses and Applications Workshop

15 August

16 August

Durban

3 August

E1218

The Psychrometrics Toolbox Its Principles, Uses and Applications Workshop

19 September

20 September

East Rand

7 September

Developed and presented by: Dr. Anton Maneschijn, Ph.D. (Eng.), M.Sc. (Aero. Eng.), B.Sc. (Mech. Eng.), Pr. Eng. (Aero.), FRAeS E8918

Applying the Engineering Design Process in a Policy-Based Environment Workshop

22 August

22 August

East Rand

10 August

Developed and presented by: Mr. Malcolm Black, B.Sc.(Mech.Eng.), G.C.C., MSAIMechE, Th.B. E0618

The Engineer As Manager Workshop

5 September

6 September

East Rand

24 August

A0618

The Engineer As Manager Workshop

19 September

20 September

East Rand

7 September

Developed and presented by: Mr. Lionel Gordon, Pr.Eng., MSAIMechE, MICMEESA, MECSA E0918

The Management of Health and Safety at Work Workshop

12 September

13 September

East Rand

31 August

12 September

12 September

Cape Town

31 August

13 September

13 September

Cape Town

31 August

Developed and presented by: Mr. Petr Vavruch, Pr. Eng., Ing. (Prague) C2918

Practical Lubrication and Lubricants

Developed and presented by: Mr. Petr Vavruch, Pr. Eng., Ing. (Prague) C6918

Lubricants and Oil Monitoring

Special Offer on In-House Training Workshops • Save up to R2,735.00 per delegate by booking workshops totalling 6 days or more.

• Save paying delegate travel costs. We will travel to you!

• Work as a corporate team by sharing and solving common problems as you learn.

• Ask the developer to tailor the material or training methods to suite your corporate requirements.

To learn more about our 2018 special In-house training offer, please contact: Linda Robinson at Tel: 031 764 7136 or email: linda@saimeche.org.za.

The Local Manufacturing Expo Aims to:

21 – 23 MAY 2019

Promote local manufacturing

EXPO CENTRE, NASREC,

Demonstrate Southern Africa’s export potential

JOHANNESBURG, SOUTH AFRICA

Provide access to global markets

A Showcase of Southern Africa’s Manufacturing Capabilities Who Will Exhibit?

Networking opportunities Develop public / private partnerships Public / private sector collaborations Identify industry challenges and opportunities for growth

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BEARINGS & lUBRICATION

Long life at food plants In the food industry, comprehensive cleaning regimes are commonplace as companies look to meet stringent sector requirements on hygiene. However, such practices can prove detrimental to production line components, not least the bearings that provide motion in critical machinery, equipment and systems.

H

ere, spraying with hot steam, high-pressure water jets or very strong cleaning agents can cause two principal problems: foreign objects entering the bearings; and lubricant being washed out of the bearings. For these reasons, NSK offers a comprehensive range of Molded-Oil bearings that are purpose-designed to deliver extended operating life in harsh food industry environments.

these bearings as part of the original equipment.

However, they are also ideal for retrofit applications.

Food manufacturer

A case in point can be seen at a British food manufacturer, where the standard deep groove ball bearings in a seven-track conveyor system were only lasting for a period of four months. The reason was water penetration within the bearings during daily washouts, which resulted in costly mainteCannot nance work and damage to the conveyor belts. be washed

The lubricant within these bearings is durably incorporated inside a stable carrier medium, nameEach time there was a failure, away by steam or ly an oil-impregnated the company had to endure polyofin resin. This type liquids, and prevents downtime of 24 hours, of lubricant cannot be creating a considerable contamination from washed away by steam dip in productivity. After or liquids, and prevents entering the inspecting the bearings, NSK contamination from enterrecommended using stainless bearing ing the bearing. Moreover, steel bearings with Moldedas the carrier only releases Oil lubrication and DU seals on the lubricant slowly, sufficient both sides. Subsequently, bearing lubrication is maintained over a operating life increased three-fold, to 12 long operating period. months, while bearing-related maintenance A wide range of molded-oil bearings is available, including deep groove ball bearings, spherical roller bearings and tapered roller bearings, in several product series and in special forms such as housed bearing units. The range also includes molded-oil bearings made of stainless steel.

These advanced products are suited to a broad range of food industry applications, where many manufacturers of machines and systems install

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costs (including downtime) were reduced by more than â‚Ź52,000 annually.

Frozen pizzas

The story was similar at a manufacturer of frozen pizzas, where failures were being experienced every four weeks on the belt tensioner serving one of the company’s food conveyors. Regular cleaning of the production line with water had led to corrosion.

Moreover, the grease lubricant had been washed

July 2018

out of the bearings, and the seals were damaged.

NSK inspected the application and again recommended the use of molded-oil bearings made from stainless steel. This resulted in a significantly prolonged operating life, plus annual cost savings of approximately €15,700.

Cake-cutting

Elsewhere, the bearings of belt pulleys within the cake-cutting machines at a large bakery were failing on a constant basis. Each year, approximately 20 sets of bearings had to be replaced due to failures every 4 to 6 weeks. After analysis by NSK, it emerged that the primary cause was water and dust infiltrating the bearings.

NSK therefore recommended replacement with molded-oil bearings. A test was run and the operating life of the bearings increased to 26 weeks.

This significantly boosted the productivity of the manufacturing line, helping the user to save approximately €9,400 annually in maintenance and downtime costs.

Vegetable processing

In a final example, a vegetable processing company had installed a biogas plant in order to ferment organic waste from production and transform the resulting methane into electricity and heat for selfconsumption. However, problems had been found

with the rotary screen which filters-out coarse and non-fermenting material prior to the fermentation stage.

Failures were occurring repeatedly in the bearings of the rotary screen and disrupting the overall operation of the biogas plant. Every six weeks on average, the deep groove ball bearings with contact seals had to be replaced. Each rotor has two bearings and there are two rotors per rotary screen. Replacement time was one hour each. Experts found that the breakdowns were caused by contamination penetrating the bearing raceways.

The customer subsequently followed the recommendation to install molded-oil deep groove ball bearings made of stainless steel with DU seals on both sides, a move that has led to far fewer replacements. This yet again confirms one of NSK’s “rules of thumb”: in applications where the environment is contaminated by moisture and dust, the service life of molded-oil bearings in stainless steel is more than twice that of bearings with conventional grease lubrication.

NSK South Africa (Pty) Ltd. Geraldene Govender Tel: (011) 458-3600

Pompetravaini, a market leader in the manufacture of Liquid Ring Vacuum Pumps – A&VT are the Sole Agents for Southern Africa.

info@vactech.co.za

SALES, SPARES AND REPAIRS

0861 VACTEC (822 832) www.vactech.co.za THE SOUTH AFRICAN MECHANICAL ENGINEER

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StEAM TURBINES & bOILERS

Credibility and Confidence Southern Africa’s largest supplier of refurbished boilers is celebrating more than 65 years in business with renewed focus and energy. Record orders, expanded service and R&D teams, and new products for the gas market are three of EP Dryden Combustion’s recent successes.

Bradley Charles

Joachim Woolmer

S

A Mechanical Engineer’ visited their Alrode premises to see the steam and boiler specialists in action, and find out more about the company’s growth.

to add another two teams in the near future, all of whom are dedicated to delivering exceptional service in the fields of pipework, installations, statutory inspections and boiler repairs.”

Just over a year ago, Energy Partners, a member of the PSG Group, acquired 100% ownership of Dryden Combustion.

And growth is not limited to the service teams. System integration engineer Sean Melrose has recently joined the Monitoring and Control team headed by Jaco Liebenberg. The sole focus here is to produce the most efficient and reliable boiler controls using the latest technology and up-to-date systems.

Energy Partners is a leading supplier of steam energy. Dryden Combustion is the largest supplier of refurbished coal, oil and gas-fired packaged steam boilers in Southern Africa. Together, the two businesses provide the full spectrum of services and equipment required by industrial users of steam in Southern Africa and internationally.

We are proud of this achievement as it’s a very real demonstration of our capabilities “The two companies coming together gives us credibility and confidence,” Business Development Manager Bradley Charles, tells us. “The change has also introduced a more focused mindset to the business.”

Biggest order

EP Dryden received one of their biggest orders in the company’s history in the latter part of 2017. The order confirms the company is well on its way to being the preferred supplier for the region’s industrial steam users, and will see the supply, installation and commissioning of four new 10t/h coal-fired steam boilers, by EP Dryden on behalf of an engineering group for a client in the mining sector.

“We are proud of this achievement as it’s a very real demonstration of our capabilities,” Bradley adds.

Importantly, the company will also oversee the training of boiler operators for the project, illustrating their commitment to servicing their customers and ensuring they get the best out of their boilers.

Service teams

Service is a priority for the company and since the appointment of Joachim Woolmer as Customer Service Manager in March 2017, the number of site teams has grown significantly.

“Joachim has grown the department from one site team to five site teams,” Bradley tells us. “We expect

Again Bradley uses the word ‘proud’ when describing their Optiflame High Efficiency control panel which has been designed in-house to enable the user-friendly control of fans and stokers for optimised combustion efficiency.

“Better efficiency means lower operating costs, a further benefit for our customers.”

Reducing emissions

In addition, EP Dryden is on hand to assist customers adapt their coal-fired boilers to reduce emissions ahead of the expected implementation of emissions regulations in November 2018.

The latest emissions regulations require that particulate matter may not exceed 250mg/l. Higher specification grit collectors need to be installed to achieve this. EP Dryden is currently installing five grit collectors for customers who also have the option to use gas-fired boilers. The company has a range of oil and gas burners, and will be adding further gas options later this year.

“We’re very excited about this new addition to our portfolio which allows us to supply equipment at competitive prices, without compromising on quality and safety,” Bradley advises.

2018 has seen the company building on foundations laid by the new owners and management.

The Energy Partners business culture and style has been fully embraced, and the results speak for themselves. Customers now have access to total steam solutions through leading control technology, a range of boilers that can either be bought or rented, as well as steam outsourcing – all backed by multiple after sales service and repair teams and a warehouse fully stocked with spares.

Bradley Charles, www.drydencombustion.co.za

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South African Institute of Tribology Annual Awards Dinner, 2018

The 2018 SAIT Annual Awards Dinner was held in the Gala Room at the Wanderers Club in Illovo, Johannesburg on Friday evening 18th May 2018.

T

he large, airy room was set with tables elegantly draped in white damask cloths, gleaming silverware and sparkling glassware, with artfully displayed pink and blue hydrangeas as centrepieces. Following tradition, the menus were combined with the evening’s programme, held the SAIT Logo on their cover as a subtle reminder of the Institute’s standing in the field of Tribology.

The Awards Table was impressively decked with the Louw Alberts Award trophy, the Best Technical Presentation Award shield, Best Technical Achievement Award shield, and a couple of beribboned scrolls containing certificates.

To the left of the Awards Table was another table, bearing photograph albums filled with fascinating SAIT history.

As the room filled, members of the Outgoing 2017/18 Committee and the Incoming 2018/19 Committee mingled with SAIT Members, awardwinners, their colleagues, family and friends.

President of the SAIT, Dave Gamble, welcomed the guests, and the evening’s proceedings began.

Dave proposed a Toast to The SAIT, helping to lubricate the throats of those present with fine wine.

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The Louw Alberts Award of a floating trophy and a certificate was awarded, in absentia, to DR Herschell for his significant contribution to tribology and the SAIT over the years. This has been achieved through driving the fundamentals of tribology, and understanding the application, operating condition and the base fluid and chemistry required to solve issues.

The Award for Best Technical Presentation – a floating shield and certificate – was received by Noel J Pipkin for his talk on ”High Pressure Systems for Diamond Synthesis” given at the SAIT Technical Meeting, on 5 September 2017.

Dominic M Smit, studying at the University of the Witwatersrand under Associate Professor Natasha Sacks, received the Best Student Award for his project “The effect of polishing method on the surface finish of a turning insert’s coating under continuous cutting” Gill Fuller, SAIT Secretary since 1988, and recipient of the Louw Alberts Award in 2017, gave a humorous talk, illustrated with photographs, remembering some of the people who played a part in forming the South African Institute of Tribology.

The evening ended on a delicious note with desserts, coffee and good company.

July 2018

CONTRACT LOGISTICS SA INSTITUTE OF TRIBOLOGY

Dave Gamble presenting the SAIT Student Award to Dominic M Smit of the University of Witwaterrand

SAIT President, Dave Gamble, with SAIT Secretary, Gill Fuller, after her talk about the movers and shakers in the early days of the South African Institute of Tribology Dave Gamble presenting the Award for the Best Technical Presentation to Dr Noel J Pipkin

Prof Philip de Vaal of Pretoria University, and his wife, CornĂŠ

Carine Smit Dominic Smit

Karabo Ranthitong, Themba Khoza Gerard Perumal & Nathi Cele

SA INSTITUTE OF TRIBOLOGY Prof & Mrs Kucukkaragoz of the University of the Witwatersrand

Thomas Surmon and David Beard, both Past-Presidents of the SAIT Kathy and Thomas Surmon

Zandra & Hendrik Reinhardt, Jacobus Langehoven & Karabo Ranthitong

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Gertrude Fomo Tafenda Chingosho Brayner Nelwalani

Dr Noel J Pipkin, Leon Bradley Students from the University of the Witwatersrand

Alan Shemi, Anesu Magumise, Mulalo Nelwalani & Brayner Nelwalani Anesu Magumise, Alan Shemi & Thuli Mkhalipu

Dave Gamble Barbara Gamble

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EFFECTIVE PROCESS PLANTs

QUICK DENSITY DATA The RhoVol densimetric measurement system from De Beers Technologies SA (DebTech) gives process plants fast and accurate data on material density profiles. This vital information can inform timeous plant adjustments that make for better plant performance and higher recoveries.

Grant High, research and development manager at DebTech

T

he system allows plant operators to conduct density tests on-site and to generate the data they need within about an hour, rather than sending samples to third-party laboratories and waiting days or even weeks for the results.

Grant High, research and development manager at DebTech, says the usual delay in getting results presents a real lost opportunity for metallurgical plants. He points out that by the time the results of the sample tests are returned to the plant, it is often too late to adjust the set-up of a process with sufficient effect. Furthermore, the density profile of the material passing through the plant may have changed since the last sample was taken.

Mechanical engineers, electronic and software engineers, together with metallurgists and scientists, teamed up to produce a one-of-a-kind machine “The metallurgical industry has, for many years, been looking for the ability to measure the density of incoming material in real time, so that the plant’s settings can be optimised in time to make a difference,” says Grant.

Accuracy and speed

In the RhoVol, DebTech has combined its vision size frequency distribution (VSFD) technique, which is a camera-based system for measuring the size of particles, with a rapid weight measurement device.

This allows both the mass and the volume to be determined with great accuracy and speed, providing data from which the density of each particle can be calculated.

The system’s software creates a 3-D model of each particle, so that any physical dimensions or ratios can be derived; information about the shape of the particle such as elongation, flatness and compactness can be very valuable in understanding the particular behaviour of a metallurgical process.

“The simplicity of operation of the RhoVol means

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that a plant does not require any specialised laboratories on site, and a relatively unskilled operator can conduct the measurement,” he adds.

3D printing

Grant emphasises that plants can use the RhoVol to audit the density profile of the run-of-mine material entering the plant, as well as material on the output side, facilitating more effective monitoring of plant performance.

The machine, which comes in two sizes to accommodate two size fractions, has an optional sorting functionality, and can even raise the resolution of the 3D models by accommodating the multiple passes of material through the system. By ‘matching and merging’ images of the same particle, a very high fidelity 3-D model can be generated.

Grant concludes, “We took full advantage of 3D printing when developing this machine and on the cards for us in the future is adding coarse sorting ability and an ultra fines unit (-3mm +1mm).

Mechanical engineers, electronic and software engineers, together with metallurgists and scientists, teamed up to produce a one-of-a-kind machine

July 2018

Celebrating innovation

Sassda is proud to announce the official launch of its biennial stainless steel awards which this year centre around the theme, ‘Celebrating Innovation’ with the aim of rewarding world-class thinking and success at a local and international level.

RhoVol: Fact sheet

The RhoVol densimetric measurement system determines the density of an ore sample by measuring the mass and volume of individual particles. Key features of the machine include: • Accurate measurement of mass, volume, density and shape of particles • Applicable across a range of different commodities; any mineral or material can be measured for its volume and mass, as the density measurement range is not restricted and can be programmed to suit the product • Quick turnaround time for results allowing for real-time adjustment of plant processes • Data is displayed live as it is captured and made available in a standard spreadsheet format on a per particle basis • Process rate of 1 000 particles per hour • High levels of measurement repeatability • Two machine sizes: one for material sized 3-8 mm, and another larger machine for 8-24 mm material • Small footprint, so no complex laboratory facilities necessary • Simple operation: tests can be conducted by a semi-skilled operator • Small sample size • No consumables required in the testing process • No toxic liquids involved in the testing

De Beers Group Tel: (011) 374-7173 Email: Jackie.mapiloko@debeersgroup.com

The awards are open to individuals and companies (locally and abroad) that are involved in the design, production, conversion, distribution and use or specification of stainless steel and entrants do not need to be a member of Sassda.

Looking at the enhanced stature of the awards, Sassda Executive Director John Tarboton says, “We would like to encourage participation in what we believe is now the ‘Oscars’ of the stainless-steel industry and an initiative which has become synonymous with world-class products and skill.

“This year’s winners will also be the recipients of an ‘Award Winner’ logo that has been created, for them to use in their marketing campaigns, to ensure that the awards add value to their business on a day-to-day basis.”

The Awards draw winners from a broad spectrum of sectors to ensure they are fully representative of the depth and diversity of the industry thereby generating commercial awareness and a real return on investment. John adds, “At a practical level, they serve to strengthen the confidence and belief of industry players in both their sector and their own company culture, with employees becoming more cognisant of the pivotal role they play in underpinning the economy of a country.”

Top criteria

In 2016, the Sassda Columbus Stainless Awards recognised a record 39 world-class winners, up from the 12 awards presented in 2014 and saw an over-subscription of sponsors. The 2018 Awards promise to be as spectacular and will draw winners from an expanded number of categories as there are now 17 for entrants to choose from.

The full list is as follows: Student, Environmental, Services, Welding, Manufacturing Innovation, Art, Consumerware Catering and Hospitality, Agro-Processing, Food & Beverage, Architecture Building & Construction, Engineering, Duplex Stainless Steel, Ferritic Stainless Steel, Product Development, Most Transformed, Export Achievement, Business Excellence, Lifetime Achievement, as well as an Overall Winner. francis@sassda.co.za or call 011 883 0119. *The closing date for entries is 15 September 2018

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“THE LINK FOR AFRICAN TRADING”

TRANSNET FREIGHT RAIL

www.transnetfreightrail-tfr.net

HYDRAULICS AND PNEUMATICS

Eastern Cape Hub “Through the consolidation of our workshop facilities and field services into a centralised hub in the Eastern Cape, our dedicated Regional Service Centre (RSC) in Port Elizabeth is able to assist customers who are faced with a lack of engineering expertise, costly machinery repairs and unnecessary downtime periods,” explains David Dyce, business unit manager, Fluid Technology, BMG.

A

dvantages for customers include improved service, repair and delivery efficiencies, centralised technical support and easy accessibility to a comprehensive range of quality branded engineering components.

“An important focus of this service centre is on fluid technology services that integrate quality branded components, advanced hydraulic engineering and contamination control, as well as a test and repair facility, to ensure optimum performance and extended service life of every hydraulic system.

Most efficient solution

“We are able to assist with design, manufacture and assembly of all hydraulic and pneumatic systems, whether it is for a workshop improvement or a hydraulic system for an entire new plant. Our highly-experienced team works in consultation with customers to ensure the most efficient solution, for example, from small multi-purpose power packs to large power packs for mining and industrial applications,” says David.

BMG follows stringent ISO accredited procedures to ensure the integrity of every hydraulic system.

Each repaired component is assessed by the company’s testing facility and certificates are issued as assurance that equipment has passed the strictest performance standards. These products include variable and fixed displacement pumps, industrial and mobile valves, low and high speed motors, as well as cylinders and accumulators.

A critical element in any hydraulic system is con-

tamination control. BMG’s systemic approach to fluid analysis emphasises the benefits of a system that is maintained through the use of high quality filtration equipment, coupled with a regular sampling and testing programme. An efficient fluid analysis service ensures improved performance, extended life of components and reduced maintenance costs.

Systemic approach to fluid analysis emphasises the benefits of a system that is maintained through the use of high quality filtration equipment, coupled with a regular sampling and testing programme Mobile team

BMG’s mobile field service team conducts breakdown and routine maintenance on-plant and carries out trouble-shooting and advises on possible productivity improvements, for the highest level of plant output and reliability.

The company’s service to the hydraulics sector also includes a mobile workshop that is fitted with tools, equipment and quality branded spares, to be able to efficiently perform functions like troubleshooting, on-site repairs, installations, commissioning and system flushing. This service also incorporates on-site fluid analysis and hose and pipe assembly.

David Dyce, Business Unit Manager, Fluid Technology, BMG, Tel: (011) 620-1530 Email daviddy@bmgworld.net www.bmgworld.net

The South African Institute of Materials Handling

Sample

The South African Institute of Materials Handling (SAIMH) is a Non-Profit organisation set up with an objective to encourage the transfer of knowledge associated within the fields of Bulk Materials Handling (conveyors, stacker, reclaimers, tipplers, train loading systems, etc.) through a combination of seminars and networking sessions.

The SAIMH is made up of professional engineers, each practising their trade in a variety of organisations who volunteer their time to execute the SAIMH’s objective. The main aim is thus to promote the advancement of the art, science, theory and practice of the Bulk Materials Handling principles and techniques.

Company Affliates as at May 2017 Afripp Projects cc Brelko Conveyor Products (Pty) Ltd Bulkcon CPM Engineering CT Systems cc Conveyor Watch (Pty) Ltd David Brown Gear lndustries (Pty) Ltd ELB Engineering Services (Pty) Ltd Engicon Systems (Pty) Ltd Facet Engineering cc Flexco (SA) (Pty) Ltd

Hagglunds Drives SA (Pty) Ltd Hansen Transmissions SA (Pty) Ltd Hatch Goba (Pty) Ltd lllustech J & A Engineering Services Kimrae Engineering Prolects Loadtech Load Cells (Pty) Ltd MacsteelVRN Martin Engineering Melco Conveyor Equipment Morris Material Handling SA (Pty) Ltd

Osborn Engineered Products (Pty)Ltd PD Engineering Services cc PH Projects Holdings (Pty) Ltd Rio Carb (Pty) Ltd Sandvik Materials Handling Africa Screw Conveyors & Material Handling Senet SEW Eurodrive Spar Western Cape SSAB South Africa (Pty) Ltd Tenova Zest Electric Motors (Pty) Ltd

Tel: (011) 867-0902  Fax: (011) 867-0036  Email: saimh@global.co.za  www.saimh.co.za

consuLting engineers sa

Surprisingly strong economic outlook As one of the bodies which endorses “SA Mechanical Engineer”, the Consulting Engineers SA (CESA) invited us to their breakfast held recently in Midrand.

K

eith Katyora got things off to a lively start as head of the Young Professionals. They appear to be pretty active in industry even as some of the millennials are poached by the banking and insurance industries because of their discipline and their ability to think ‘big picture.‘ And with a comprehensive bursary system in place covering all the student’s expenses, many twentysomethings owe their graduate education directly to CESA. Lullu Krugel, Chief Economist at PwC SA next took delegates through the results of their global survey of CEO’s 2017/18 reflecting an immense amount of optimism among business leaders. A trend also being picked up by the World Bank and the IMF.

Chris Campbell, Chief Executive Officer of CESA

But the World Bank warns that we are sitting on the edge of a three-year window. They predict strong expansion followed by a subsequent cool down.

In Africa, Lullu talks about economies growing by 4 percent over the next three years. She singles out Ethiopia as being the fastest expanding economy over the last twenty years. She warns that in three decades, Ethiopia may well overtake South Africa as the biggest economy on the continent.

Rwanda has moved up 100 places in the Ease of Doing Business Index while in this time, South Africa has dropped quite a few places. PwC sees opportunities in Africa less on the smokestack front than in ICT, tourism, agro-processing and logistics.

New benchmarks

Chris Campbell, Chief Executive Officer of CESA, also had good news to share reporting that the number of previously disadvantaged members has risen to 27 percent of their 560 member companies. He does, however, sound a warning about the practice fee scales, now being deemed anti-competitive by

ECSA, as giving rise to the need for a new benchmarking standard for members.

He advises government to forgo ‘box-ticking’ which makes procurement costly, burdensome, ineffective and prone to fraud rather than concentrating on value for money. It needs to be less about procedural compliance and more about technically competent individuals at National Treasury making decisions based on the life of the project.

He says, “Clients need to adopt an eyes-on, hands-off policy especially now as discounts in the magnitude of 30 to 40 percent threaten quality.

Lowest cost is not valid when taking into account the whole lifecycle of the project especially as the consulting fee ultimately makes up a very small portion of the total cost.

But the World Bank warns that we are sitting on the edge of a three-year window. They predict strong expansion followed by a subsequent cool down “We must also point out the weakness in Section 32 of the supply chain management regulations regarding tendering which is often bypassed by municipal entities, sometimes wilfully, sometimes not.”

A specific course

And to support a great consulting engineering industry in South Africa, there is no substitute for education and upskilling, provided training money is spent wisely. Chris concludes, “We do not recommend a general MBA for our members which is far too generic. Rather we suggest they sign up for our Business Consulting Engineering (BCE) course which has seen many a member enjoy exponential career growth. And I have very little time for those who don’t train. They are worried about spending money on training only to have staff leave their employ. I ask: What if you don’t train them and they stay?”

CESA, Tel (011) 463-2022, www.cesa.co.za

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DEEP DRILLING

An African record Using diamond-impregnated bits and a standard rotary percussion rig, deep drilling experts Torque Africa Exploration (Pty) Ltd recently drilled their way into the record books with a hole drilled in the Springs area reaching 1 148m.

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his is an African record and one of the deepest rotary percussion holes drilled worldwide in mixed and largely unchartered geologies. And the contract calls for yet more and deeper holes in future. Nardus Bezuidenhout, Torque Africa director, explains that the company is part-way through its contract to bore several deep-level holes into disused mine stopes for the treatment of acid water mine drainage.

These range from a few hundred metres below the surface to over 1 200m for the deepest hole and require all the ingenuity of the company’s technical experts, as well as its owner, and renowned drilling expert, Nardus Bezuidenhout.

Challenge accepted

According to Nardus, Torque Africa took on the job despite other experts’ belief that the risk of failure

was too high. “We were never in doubt though and in conjunction with Pieter Coetzee and his team from Sandvik Mining and Rock Technology’s rock tools division, planned the technical details of the operation.”

Sandvik’s Product Manager – DTH Bits, Matthew Shoffner, also worked with the local team of experts to find the right technical solutions and it soon became apparent that the right tooling would be pivotal and that their bits and hammers were going to be key in getting the job done efficiently.

“Considering the unchartered nature of the geology of the area we chose to use standard bits and then switch to diamond impregnated bits as soon as formations became too hard or abrasive for them,” says Matthew.

“This is exactly what we encountered after the initial depth of about 300 metres of dolomite and shale and from there on it was mostly hard quartzite with some khaki shale, black slate shale, mixed dolomite and quartzite, diabase and more quartzite.

This made for some tough drilling, but was made considerably easier with the use of the diamond impregnated bits,” adds Nardus.

Fewer pullouts

He explains that considering the forces at these depths, only the highest quality bits could be used and even

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despite the higher cost of diamond impregnated bits, the durability was extended beyond 378m per bit. This far outweighed the standard bit alternative which would have been 70m and which would require constant pullouts.

Bit changes can be complicated and time-consuming as pull back of the rods would take up to 24 hours to retrieve the 6m lengths to replace the tooling. A shanked bit at these depths would be even more catastrophic and could require drilling of a new hole if the bit could not be retrieved.

ready to be used by our clients to receive pumped products that are a by-product of the treatment of millions of litres of acid-mine drainage.”

This made for some tough drilling, but was made considerably easier with the use of the diamond impregnated bits

“We had to deal with dolomite wetlands, dykes, voids and water ingress at all levels which made it tough. We were also required to drill the hole telescopically from its original diameter of 558.9mm at the top through various layers including a 310m deep grouted section, casing and eventual intersection of quartzite just beyond 300m at which point the drill diameter was down to a 172mm bit,” says Nardus.

Nardus concludes that in deep hole drilling operations, the use of good quality equipment means the difference between profit and loss. “There is limited room for error and drilling contractors can lose a lot of money if they wear out tooling too quickly or catastrophically break them deep underground. It is for precisely this reason that we settled on quality tooling from Sandvik.”

Early conclusion

Sandvik Mining Alice Ward Tel: (011) 929-5300 Email: alice.ward@sandvik.com www.rocketechnology.sandvik

“Thereafter we continued through various phases until prematurely intersecting the stope at 1 148m instead of the predicted depth of 1 200m. At this point the bit size was 124mm and the hole was

ENGINEERING FEAT

First complete landing gear change Emirates Engineering has successfully accomplished the first complete replacement of landing gear on A6-EDF, the first Emirates Airbus A380 aircraft to have its entire landing gear system replaced at one time.

Comprising five sets of landing gear: two under the wings, two under the body, and one nose landing gear, the work was planned and executed in-house, at the Emirates Engineering hangars in Dubai.

Every Airbus A380 aircraft has a landing gear system with a total of 22 landing wheels. In addition to the wheels, the landing gear mechanism of the aircraft includes the gear extension and retraction systems, braking and steering controls, and other monitoring systems.

The landing gear of the world’s largest commercial aircraft can support a weight of close to 570 tonnes on take-off and over 390 tonnes on landing.

The process of changing all the landing gears was completed in 14 days with the Emirates Engineering team clocking thousands of man hours during this period. For the duration of the work, the entire aircraft was lifted on jacks to support the body of the aircraft.

“The first complete replacement of landing gears on our Airbus A380 aircraft is an important milestone for us. This and other similar achievements our team reflects the degree of planning, preparation and expertise that goes behind the successful execution of complex projects such as this one,” says Mohammad Jaffar Nasser, Emirates Senior Vice President, Engineering Maintenance.

“By extending our services to third party airlines, we share our expertise and enhance engineering procedures globally,” he adds.

Two additional Airbus A380 aircraft from the fleet are scheduled

to undergo a complete change of landing gear systems in 2018.

In addition to investments in infrastructure and facilities including specialised tools, the team worked closely with Airbus, Field International, UTAS and Safran to plan and execute the landing gear replacement.

Emirates Engineering operates modern and extensive facilities in Dubai, including six heavy maintenance hangars capable of conducting C-Checks on the Airbus A 380 and the world’s largest dedicated aircraft painting facility, to maintain their fleet of over 260 Airbus A380 and Boeing 777 aircraft. The company also offers Maintenance, Repair and Overhaul (MRO) services to external parties. www.emiratesengineering.com

SKF Multilog On-line System IMx-8

More data capture opportunities.

Even in a limited space.

Configure your IMx-8 and monitor your data wirelessly from your iOS or Android device.

The IMx-8 can be fully configured via luetooth, and can use existing template configurations stored in the SKF Cloud. Machine data can then be viewed on your iOS or Android device.

And with direct access to world-class software, analytics and support through SKF @ptitude or SKF Enlight, it’s the cost-effective route to high performance.

SKF South Africa (Pty) Limited Tel: +27 11 821 3591, Fax: +27 86 677 7876 Email: sales.za@skf.com, Web: www.skf.co.za ® SKF is a registered trademark of the SKF Group. | © SKF Group 2018

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Regional Connectivity Conference “Making Inter-state Transport Work in Africa” Johannesburg, October 2018 “Supply Chain Today” together with Fesarta (Federation of Eastern and Southern African Road Transport Associations) and CVLC will be running a jam-packed and informative conference over 2 days in October 2018.

There will be a significant number of delegates from a wide range of African countries as well as a cross section of speakers representative of the continent.

WHO SHOULD ATTEND Regional Exporters and Importers

Freight Forwarders

Cross - border Transporters

Customs and Border Authorities

Transport Associations

Academics and researchers

Cargo owners

Logistics and Supply Chain Executives

PROVISIONAL CONFERENCE PROGRAMME

Setting the Scene - Overview of the Programme

Overview of Day One

Gerard de Villiers - ARUP

Gerard de Villiers - ARUP

SADC Perspective “Tripartite Transit and Trade Facilitation Programme (TTTFP)”

Maputo Corridor Logistics Initiative Perspective “Current Challanges and Possible Solutions for Regional Connectivity”

Lovemore Bingandadi - TTTFP - PMU

Barbara Mommen - MCLI

North-South Corridor Perspective “North-South Corridor Rail Pre-Feasibility Study”

Cross-Border Road Transport Agency Perspective “Streamlining Border Processes through System Improvements”

Gerard de Villiers - ARUP

Sipho Khumalo - C-BRTA

Security Perspective “Keeping Track of Your Goods”

Technology Perspective, Big Data in Regional Connectivity - “Need for and Use of Big Data in Regional Transport Movements”

Quinton de Villiers - CEO - Bridgewater Logistics

Dr Johann Andersen - Techso

Telematics Perspective “Tracking and Tracing Cargo from Origin to Destination through Connectivity”

Operator Perspective “Operator Challenges in Regional Transport”

Prof Alwyn Hoffman - NWU Potchefstroom Campus

Kamugelo Mmutlana - Barloworld Logistics

Customs Perspective of Cross-Border Operations Legal Perspective of Cross-Border Operations “Establishment of a Private Sector Grouping in “ Compliance Challenges” the ESA Region” Juanita Maree - South African Association of Andrew Pike - Bowmans Freight Forwarders (SAAFF) 03072018

ENQUIRIES

supplychain@promech.co.za, www.supplychaintoday.co.za Catherine Larkin, 083 300-0331

COSTS

R3 900 ex VAT - R3 200 for members

CONFERENCE REGISTRATION FEES The registration fee is PER PERSON and includes: attendance at the conference; morning and midmorning tea/coffee and snacks; light lunch

Registration for members

R 3200 - 00 (excluding VAT)

*Members of: • African Women in Supply Chain Association • the Chartered Institute of Logistics & Transport • Federation of Eastern and Southern African Road Transport Associations (FESARTA) • Kenya Transporters Association • Namibia Logistics Association • Responsible Packaging Management Association of Southern Africa • Road Freight Association (RFA) • South African Association of Freight Forwarders (SAAFF) • SA Express Parcel Association (SAEPA) • Tanzania Truck Owners Association • Transport Operators Association Zimbabwe

Registration for non-members

R 3900 - 00 (excluding VAT)

Terms & Conditions • FESARTA/The Event Organisers have the right to change the programme content, the speakers, the venue or the date. You will be notified in such an event • Once your registration form has been received, we will issue you with a Tax Invoice • The Registration Fee does not include travel, transport or accommodation • Cancellation Fees/Policy • All registrations are only confirmed on receipt of full payment • No registration or attendance will be confirmed without full pre-payment and no access to the conference will be allowed • Payment must be received in full 2 weeks before conference • Only cash payments or electronic transfers will be accepted • The individual registering for the conference is personally liable for the payment and undertakes to make payment for the event if his/her employer does not.

• Full amount of R3 900 excluding vat is payable before conference, upon verification of membership R700 will be refunded to members

SUPPLY

CHAIN

T O D A Y

COMPRESSORS

First of its kind In a first for South Africa’s compressor rental market, compressor and generator rental stalwart Rand-Air recently took delivery of an Atlas Copco DXT85VSD electrically-driven, oil-free air/nitrogen booster complete with high-pressure hoses.

C

oupled with their oil-free compressor and dryer, the company can now offer a total solution for 42 bar high-pressure, oil-free compressed air.

The 100kW DXT has a high outlet pressure range of 25 to 42 bars at volumes of 700 cubic feet a minute (cfm): which makes it eminently suitable for a range of specialised industrial applications, from food and beverage to packaging.

Despite our lengthy track record and market leadership position, we are however always ready to ‘positively disrupt’ the market with further innovations and developments

However, enquiries for high-pressure oil-free compressed air from the local soft drink manufacturing and bottling industry highlighted the suitability of

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“While in Europe the DXT is mainly used in steam production applications, we anticipate that in South Africa - as industry sees the potential of this compressor, there could be demand for more units of this type from a number of other industry sectors,” continues Craig.

For ease of handling and deployment, the DXT has the same dimensions and attaching points as a standard shipping container.

“Previously, we offered diesel-driven oil injected ‘boosters’ or compressors; which we provided to our customers in response to demand from the drilling and geological exploration market sector,” explains Rand-Air fleet manager, Craig Swart.

34

the Atlas Copco DXT compressor. Diesel-driven oil-injected boosters were not suitable for this application as there was a certain amount of oil residue in the compressed air they supplied. Also, diesel-driven oil-injected boosters are not designed to provide a 24/7 compressed air supply to manufacturing facilities.

“This unit is obviously more suited to long-term rental applications. Should we receive more enquiries for machines of this nature, we can speedily supply additional units from Europe,” adds Rand-Air marketing and communications manager, Byrone Thorne.

An expansion

“We are pleased to have added the DXT to our compressor fleet, as it is operationally an expansion of our high-pressure oil-free solution offering,” he comments.

July 2018

COMPRESSORS

“The safety, quality and reliability of all the equipment in our rental fleet is non-negotiable. As such, we have ensured that we have the appropriately qualified technical expertise to support all rental items including, of course, this new compressor,” says Byrone.

The new DXT compressor is a welcome addition to Rand-Air’s current fleet of some 400 rental compressors, which make up part of a total fleet of 1 100 compressors, generators and related equipment.

Craig comments that with units of this nature, on a long-term rental, customers have the advantage of knowing exactly what their future compressed air costs will be over the next five years, for example.

“This makes it much easier for our customers to project future input costs, total cost-of-ownership (TCO) and overall return-on-investment (ROI),” he points out.

Stringent standards

“We understand the pressures of working in industry today and, for that reason, we have developed an industrial rental model which enables our customers to focus on their core businesses, while we supply their portable air and power requirements. This has proven to impact positively on our customers’

productivity; while enhancing their operations and ultimately, their bottom line,” says Byrone.

“We have been in the equipment rental sector for the past 45 years, with consistent and stringent standards of safety, quality, reliability and availability. Despite our lengthy track record and market leadership position, we are however always ready to ‘positively disrupt’ the market with further innovations and developments, to our customers’ strategic advantage and benefit.

Customers have the advantage of knowing exactly what their future compressed air costs will be over the next five years, for example

“The introduction of the DXT compressor, the first of its kind in the local rental market, is a great example of our ethos of innovation and commitment to exceeding customers’ expectations,” he concludes. www.randair.co.za

much more than just a pump in a

BOX

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

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M La Grange of SAIRAC makes a point at one of the free seminars hosted by SAIRAC

Frigair hits the mark This year’s Frigair Expo saw over 4 000 high quality visitors over three days from 6 to 8 June checking out new developments in heating, energy, ventilation, air conditioning and refrigeration. “SA Mechanical Engineer” popped into most of the 140 local and international exhibitor stands.

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he event, organised in partnership with the South African Institute of Refrigeration and Air Conditioning (SAIRAC), only takes place once in every three years. This year it was held at Gallagher Estate in Midrand The largest show for this industry in Africa, the exhibition showcases the latest technology and innovations from the industry with thousands of products on display, offering HEVAC&R role-players the opportunity to experience the latest the market has to offer.

Frigair works for us because it brings together so many people under one roof, and then connects us with them Happiness all round

Exhibitors on average indicated they were very happy with the quantity and the quality of the visitors, who hailed from over 28 counties worldwide.

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In fact, one exhibitor who has taken a stand regularly over the last 15 years told us, ”This has been the busiest Frigair out of all the years I have been exhibiting. Our goal is to meet with contractors and consultants, as well as customers. A goal which came to fruition brilliantly this year.”

“The numbers were great,” agrees Themba Khambule, director of Rickard Air Diffusion. “Frigair works for us because it brings together so many people under one roof, and then connects us with them. It’s a good way to meet as many new people as possible and we also had the opportunity to showcase some of our new products to existing and prospective clients.”

Garid Glenn, application engineer for Baltimore Aircoil Company SA adds, “We invite our existing customers to take them through our new products and technologies. We also aim to reinforce the message that we are a professional firm through the quality of our stand which has borne fruit as we have quite a few leads to follow up.”

July 2018

Frigair was well attended. Exhibitors and visitors alike thought it was a very good show for the industry

Visitors were impressed too. Nicolaas Classen, NC Consult, Pro Med Tech says Frigair is great because all the stakeholders in the industry are under one roof. “It gives you the opportunity to meet people who you have emailed or spoken to on the phone but never met.�

Well-attended seminars and events

In addition to the exhibition, visitors could attend seminars hosted by SAIRAC for free. These were well attended, and again feedback from delegates on the speakers and the topics covered was good.

During the seminars, the seating area was full with additional delegates standing outside the low-walled seminar theatre area.

The courses presented included Designing and Operating High-Performing Healthcare HVAC Systems, Variable Refrigerant Flow (VRF) Systems: Design and Application, and Basics of High-Performance Building Design. Each short course of three hours earned its attendees CPD points. www.frigairexpo.co.za

It gives you the opportunity to meet people who you have emailed or spoken to on the phone but never met Space was sold out for the three American Society of Heating, Refrigerating, and AirConditioning Engineers (Ashrae) courses run at the show with three international Ashrae speakers specially flown in to present the material and to share their wealth of global knowledge.

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dŚĞ ƐƐŽĐŝĂƟŽŶ ŽĨ ^ŽƵƚŚ ĨƌŝĐĂŶ YƵĂŶƟƚLJ ^ƵƌǀĞLJŽƌƐ

QuanƟty Surveying… …at the heart of every successful construcƟon project

Find out more… info@asaqs.co.za

T 011 315 4140/1 F 011 315 3785

www.asaqs.co.za

P O Box 3527 Halfway House 1685 I Suite G6 Building 27 Thornhill Office Park Bekker Road Vorna Valley Midrand •

•

•

•

MARKET FORUM

Screens for food applications Known mainly for its large screens and feeders for mining, Kwatani has in recent years expanded substantially into various industrial and food sectors and is currently providing screening solutions for almost 50 different materials and products.

According to Warren Mann of Kwatani, the company is involved in screening a wide range of materials and foodstuffs from wax beads, carbon and bunker sand to tea, coffee, pet food and rice.

machine that will add optimal value to the customer’s operation.”

ate machine size and configuration as well as the optimum screen openings.

“Our strength is the ability to test the customer’s product or material in our own materials testing laboratory,” says Warren. “This is part of our solutionfocused approach to deliver a customised

These in-house facilities are vital in selecting the correct separator for each application. By analysing and testing under simulated production conditions, it is possible to determine the appropri-

Kwatani (Pty) Ltd Tel: (011) 923-9000 www.kwatani.co.za

The pristine finish of the round separator for the food and beverage sector

Digital Strategy In pride of place on the FLSmidth Electra Mining Africa exhibition stand this year will be a 1:20 scale model of its Reflux Classifier (RC) modular plant, representing the future of processing in the mining sector.

According to FLSmidth Commercial Manager Terence Osborn, the RC plant is a good example of an integrated solution designed to meet a customer’s tailings-related risks and requirements.

“The plant demonstrates how our insights and expertise make us more than an equipment supplier,” says Terence.

“Our focus is to bring the value of our

technical knowledge base – along with our range of advanced product offerings, directly to bear on improving customers’ sustainability and profitability.”

The RC plant embodies FLSmidth’s leading technologies as well as its innovative business approach. Equipped with advanced automation facilities, a full-size version of this plant is in operation for a mining customer on an outcomes-based toll treatment model.

It treats waste product, or tailings, and recovers valuable minerals as a saleable product for the customer, without adding extra workload or risk to their operation.

FLSmidth’s technical advancement in automation and digitalisation is vital in making these solutions more valuable; both the company and the customer can observe and assess the key operational parameters of the plant in real-time in their respective head offices anywhere in the world.

“Our appointment in May this year of a Chief Digital Officer at global group executive level reflects our focus on digital efforts to leverage solutions,” Terence concludes. www.flsmidth.com

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MARKET FORUM

SLIDING TRACK SOLUTION Apex General Purpose Strip Curtains have long been considered one of the most costeffective manners of cordoning off areas in a manufacturing or production area, and this solution was recently applied at Germiston-based CT Hydraulics’ facility.

In this particular application, the strip curtains were installed on a specially designed sliding track at the entrance into the spray booth area at this hydraulic manufacturing and refurbishment company.

Large hydraulic components are moved on trolleys into and out of the spray booth area, and while it was necessary to contain the spray and residue, it was also necessary to facilitate an opening big enough for the unimpaired movement of items.

Wim Dessing Jnr, sales director at Apex Strip Curtains & Doors, says that this was accomplished by using the sliding track which allows the strip curtains to be moved to the left and to the right, creating the desired opening.

“Had a fixed installation of strip curtains been used, it would have hampered the movement of the hydraulic components,

potentially affected the finished paintwork and over time the strip would have become damaged,” Wim concludes.

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

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THE SOUTH AFRICAN MECHANICAL ENGINEER

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A DIVERSE PORTFOLIO On display at Zest WEG Group’s large outdoor stand at Electra Mining Africa this year will be not only its growing range of products but its integrated approach that offers customers significant added value in the execution of large projects.

One of the new products being launched at the event is the WEG Motor Scan solution.

This innovative device facilitates the monitoring of electric motor performance from a mobile phone and will help mines to avoid unplanned downtime.

Says Alastair Gerrard of Zestt, “In today’s mining sector, it is no longer enough to come to the market with a good product. It is increasingly important to partner with customers in the design and delivery of integrated solutions that will enhance their bottom line and achieve lower cost of ownership.”

He emphasises the value of early engagement with customers which facilitates an in-depth understanding of the specific demands of projects. This enables Zest WEG Group to identify where it can contribute added-value offerings, drawing on its diverse product range that includes electric motors, vibrator motors, variable speed drives, switchgear, motor control centres, mini-substations, generator sets, transformers, containerised or mobile substations and E-houses.

Also of interest will be WEG’s recent acquisition of steam turbine manufacturing specialist TGM, which has a well-established reference base in the Brazilian market. Together with this, Zest WEG Group is growing its energy generation offering to include solutions in the renewable energy space.

Solar thermal plant Abengoa, an international company that applies innovative technology solutions for sustainability in the infrastructure, energy and water sectors, and its partners, the Industrial Development Corporation (IDC), the Public Investment Corporation (PIC) and the Community Trust, have officially inaugurated XiNa Solar One, the third solar thermal plant in South Africa developed by Abengoa. The plant, which has been operating for more than nine months at full load required an investment of R9.459-billion for its construction.

WEG Motor Scan is a performance monitoring solution for electric motor installations.

This innovative solution is designed to optimise access to information about the motor’s performance and allows data to be extracted and sent to the cloud. The access to real-time information allows preventive actions to be taken, avoiding unscheduled downtime.

Information is collected by the App using either a smart phone or tablet device, in either Android or iOS versions, and is sent to the cloud via Bluetooth or gateway. The stored data can be analysed on the device screen in a dynamic way or in greater depth on the WEG IoT Platform.

The software will allow the connection of all the sensors in the plant, enable naming and monitoring of as many electric motors as required, analyse data sent to the cloud and synchronise the data through the WEG IoT Platform. But, most importantly, this solution will allow end-users to find their motor from anywhere in the world.

Zest Weg Group Africa Tel: (011) 723-6000 Email : marketing@zestweg.com www.zestweg.com

According to Joaquín Fernández de Piérola, CEO of Abengoa, “We are very proud of Kaxu, Khi and XiNa Solar One, which contribute 250MW of renewable energy to the national grid. This is a huge milestone in relation to the country’s energy needs, using local clean resources, and we are excited at the prospect of participating in new projects.”

Speaking at the launch of the project, the IDC’s Divisional Executive for Agro-processing, Industrial Infrastructure and New Industries, Lizeka Matshekga, said the XiNa Solar One project primarily fulfills the corporation’s mandate of developing the rural economy XiNa Solar One is a 100 MW plant that uses by facilitating the creation of employment parabolic trough technology to generate re- opportunities in such remote areas. newable, sustainable and dispatchable power from the sun. Furthermore, this power plant “We expect small and medium size entities features a thermal energy storage system that spread across this area to benefit from siguses molten salts to store the necessary energy nificant supply chain opportunities created for a further 5½ hours supply, and thereby by this project,” she concludes. www.abengoa.com assists in meeting peak demand.

THE SOUTH AFRICAN MECHANICAL ENGINEER SAMechEng.indd 1

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12/12/2017 18:17:18

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PUMP RENTAL OPERATOR Integrated Pump Rental intends to reinforce its position as one of the leading pump rental operations in southern Africa with its participation at Electra Mining Africa.

The company will showcase a range of its pump rental solutions aimed at showing the diversity of product available, and its ability to service all pump rental needs within the mining sector.

Urban LED mobile tower lights have been added to the fleet

As the official representative of Sykes diesel driven self-priming pumps in the SADC region, Integrated Pump Rental offers a comprehensive range of these pumps for hire. Offering characteristics such as high head and high flow, these large pumps are trailer mounted for ease of use.

This range offers pumping capabilities up to 500 litres per second and a maximum head of up to

208 metres. Series and parallel configurations are available to facilitate higher heads and an increased flow.

Visitors to the stand can view a range of Grindex pumps. These robust units are easy to install, simple to operate and offer pumping efficiencies with low energy consumption. The Integrated Pump Rental fleet includes drainage, slurry and solid handling and sludge pumps as well as stainless steel pumps for use in highly corrosive or low PH applications.

The company’s hydro mining solutions have gained traction over the last few years, and both the SlurrySucker and the SlurryBlaster dredge unit will be on the stand.

Lee Vine, Integrated Pump Rental Tel: 072 627- 6350 Email: lee@pumprental.co.za www.pumprental.co.za

VSD to a Zambian copper mine

More fuel efficient Honda Aircraft Company has launched a new upgraded aircraft, the HondaJet Elite.

When a major copper mine in Zambia required a 110 kW Variable Speed Drive (VSD) urgently for a slurry application, it turned to SEW-Eurodrive South Africa.

As this was the first time that SEWEurodrive South Africa supplied this mine with a VSD, the company decided to go the extra mile by dispatching an electronics field service technician to site to assist with the commissioning and set-up.

“We also provided basic operator

training as part of our support service,” Export Sales Engineer Philip Steyn adds. “This project was a major achievement for us, not only due to the large size of the unit, which is one of the biggest VSDs we have ever supplied, but the fact that we have introduced this mining producer to our electronics line-up.”

A particular advantage of the VSD supplied is that the mine did not have to upgrade its control system in order to have it connected and up-and-running as soon as possible.

“Changing-out a VSD is not as simple a process as changing a motor, but the modularity and ease-of-use of our products makes this a quick and efficient procedure,” Philip concludes. www.sew-eurodrive.co.za

The jet Elite achieves an extended range of an additional 17% (+396km) and is equipped with a newly-developed noise attenuating inlet structure that lines each engine and greatly reduces high frequency noise to enhance cabin quietness. Additionally, the new aircraft’s advanced avionics system incorporates additional performance management functions for optimum flight planning and automatic stability and protection functions to enhance safety of flight.

The HondaJet Elite offers the best fuel efficiency in its class while also featuring best-in-class speed, altitude and range. The aircraft is type certified by the United States Federal Aviation Administration (FAA) and the European Aviation Safety Agency (EASA).

It is claimed that the HondaJet Elite is more fuel efficient than any other aircraft in its category and emits less greenhouse gases than similar sized business jets. www.hondajetelite.com

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“SUPPLY CHAIN TODAY” IS AN OFFICIAL MEDIA PARTNER FOR THE SAAFF CONGRESS 2018

MARKET FORUM

Impressive Growth to remember that it’s about so much more than only job creation at face value. Each breadwinner is supporting an average of five other people. If you look at it like that, then you begin to see how this kind of job creation is good for our entire country.”

Unseating his prime competitor to become South Africa’s number one LPG market leader makes Easigas-Reatile Gaz chairman Simphiwe Mehlomakulu extremely proud.

But arguably more proud are his partners at Engen, who Simphiwe credits with helping position his black-owned and managed company as a key player in southern Africa’s energy sector.

He started Reatile Gaz in 2006 with just three staff members, by 2010 there were 11, and by the time of the merger with Easigas the number stood at 90. In the past six years, Simphiwe has grown profitability 14 times, and boosted eightfold his sales volumes of Liquid Petroleum Gas.

Since the merger with Easigas, they have also built six depots around South Africa: two each in Cape Town and Gauteng, and one each in Port Elizabeth and Durban which currently employ 200 people.

Already Easigas-Reatile Gaz operates in four other southern African countries including Lesotho, Botswana, Swaziland and Zimbabwe, and Simphiwe has his sights set on further expansion to take in Mozambique, Zambia, Malawi and Tanzania.

Unathi Njokweni-Magida, Engen’s head of Transformation and Stakeholder Engagement says, “When Reatile Gaz creates so many new jobs, it’s also important

Engen Gavin.Smith@engenoil.com

Simphiwe Mehlomakulu

www.promech.co.za

Base stock supply chain commercial relationship will expand ExxonMobil’s global presence and provide local customers with additional access to base stocks capable of meeting a broad range of blending needs.

ExxonMobil has signed a new distributor agreement with Zestcor, a sales, procurement and supply chain management company in South Africa. The agreement is designed to support an efficient and reliable supply of high-quality base stocks in South Africa and the sub-Saharan region.

Zestcor has a distinct local business footprint in the South African petrochemicals industry as a BroadBased Black Economic Empowerment company. This

“We are committed to providing a reliable supply of high-quality products to our valued customers around the world,” says Julia Ruessmann, at ExxonMobil. “Zestcor not only complements our position in South Africa by providing local supply chain solutions, but supports our long-term commitment to meeting customer demands in country.”

Zestcor is uniquely equipped to receive bulk ExxonMobil shipments and handle both truck loading and delivery, as well as pipeline transfers, with their bulk onshore tank storage facilities at Bidvest Tank Terminals in Island View, Durban. www.exxonmobil.com/en/basestocks/products

Air & Vacuum Technologies are an authorised distributor for CompAir S.A. and thus can offer you the full range of Robuschi products. Roots blowers, Screw compressors and liquid ring vacuum pumps.

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MARKET FORUM

Blame the robot users in almost every industry, from chatbots which offer financial advice to helping doctors to diagnose cancer.

The technology is used to power driverless cars, better predict the weather, process financial transfers or to monitor and operate industrial machines. According to Accenture, AI could double the annual economic growth rate in 12 developed economies by 2035.

AI, also referred to as machine learning, is essentially software that is able to think and learn like a human.

Today, ‘weak’ or basic forms of AI are able to perform specific tasks, but future generations of so-called ‘strong’ AI applications will be capable of solving difficult problems and executing complex transactions. AI is beginning to find

But with these potential benefits come risks. Cyber risks, which are one of the biggest risks for businesses according to the Allianz Risk Barometer 2018, illustrate the two different faces of new technologies.

AI-powered software could help to reduce cyber risk for companies by better detecting attacks, but could also increase it if malicious hackers are able to take

On the Move

Neale Hill

Vinesh Surajlall

Ford Motor Company announces that Neale Hill will take on the role of Managing Director of South Africa and Sub Saharan Africa.

Vinesh Surajlall has been appointed sales and marketing director at Osborn Engineered Products.

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control of systems, machines or vehicles.

AI could enable more serious and more targeted cyber incidents to occur by lowering the cost of devising attacks. The same hacker attack could be replicated on numerous machines.

With regard to liability, AI agents may take over many decisions from humans in future, but they cannot legally be held liable for those decisions. In general, the manufacturer or software programmer of AI agents is liable for defects that cause damages to users. A solution to the lack of legal lability would be to establish expert agencies or authorities to develop a liability framework under which designers, manufacturers or sellers of AI products would be subject to limited tort liability.

Allianz Global Corporate & Specialty (AGCS), lesiba.sethoga@allianz.com

Please make sure to pop into “SA Mechanical Engineer’s” stand at Electra Mining Louise Cresswell: Tel: (011) 781 1401

SALES, SPARES AND REPAIRS

0861 VACTEC (822 832) www.vactech.co.za

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 68

July 2018

DEMAG V-GIRDER CRANES – NOW AVAILABLE UP TO 50 TON LIFTING CAPACITY.

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