SA Mechanical Engineer March 2013

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 63

March 2013

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LEADERS IN CLOSING THE SKILLS GAP Scarce skills in the engineering and manufacturing sectors in South Africa The merSETA’s major focus in respect of new skills development and the alleviation of skills shortages is the development of artisan skills. To this end, the merSETA has a wide spectrum of registered learnerships and apprenticeships in place. ,n the ¿nancial \ear, the merSETA registered apprenticeship contracts, learnership agreements and skills programme learners. ,n the same period, learners oEtained full Tuali¿cations and skills programme learners oEtained statements of results towards various levels on the 1ational 4uali¿cations )ramework 14) . &hallenges within the puElic Easic education and )ET s\stems have impacted the availaEilit\ of engineering skills, directl\ through their impact on the generic skills levels within the workforce and through the generation of Tualit\ artisans, as well as indirectl\ through the negative effect on the Tualit\ of higher education Tuali¿cations. /ow levels of laEour productivit\ not onl\ drive capital intensive growth within the sector, Eut are also considered one of the major factors undermining South Africa’s aEilit\ to emErace new technolog\ and innovation and thus compete internationall\. The perceived economic growth, massive infrastructural development, government policies and gloEal advances in manufacturing technolog\ have also increased skills demand. Engineering Tuali¿cations now generall\ eTuip graduates with skills in new technolog\. +owever, for the e[isting workforce, skills gaps in these areas must Ee ¿lled with additional training. )or more information visit www.merseta.org.]a

HEAD OFFICE merSETA House, 95 7th Avenue, Cnr Rustenburg Road Melville Johannesburg Tel: 010 219 3000 Fax: 086 673 0017 Call Center: 086 163 7738

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3rd Floor, Fassifern Old Mutual Building, 35 Ridge Road, Berea

Tel: 0861 637 733 Fax: 051 447 8873

Tel: 0861 637 736 Fax: 031 201 8732

THE SOUTH AFRICAN MECHANICAL ENGINEER

GAUTENG NORTH & NORTH WEST Automotive Supplier Park 30 Helium Road Rosslyn Ext. 2 Tel: 0861 637 731 Fax: 0866 700299

Tel: 010 219 3000 Fax: 086 673 0017

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5th floor, Catnia Building Bella Rosa Office Development Bella Rosa Road, Tygervalley

Tel: 0861 637 735 Fax: 013 656 4629

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VOL 63

March 2013

AN ENGINEER’S VIEW

Absolute Power Disrupts Absolutely The Editor mentioned to me the other day that she should issue a health warning with some of my leader articles because they often create an acute case of depression. This will in future be issued with the articles as it becoming increasingly difficult to construct positive and encouraging articles about the state of the nation and the environment in which engineering has to play its role.

L

ast month we took a look at the status of the mining industry and it’s pretty difficult not to be negative about the trend it has taken over recent years. From being top spot so to speak for decades, we have slumped to a Chris Reay mediocre level that replicates a number Chairman of the Working Committee: Communications of other circumstances in our country.

(SA Institution of Mechanical And the bell tolled loud and clear this Engineering) week when four major employers in the EPCM industry advised that they were about to institute section 189 retrenchment programmes. They inevitably become the victims of the lack of new mining spend because investors have made it clear that other countries are able to offer a less risky investment climate. Most of the analyst commentary on the issue has confirmed this view.

Costs escalated and are exhibited in the horrific escalation on the price of Medupi for example Appalling and unreasonable

It is just appalling and almost treasonable that those in government allowed the talk about nationalization to go so far without taking a firm hand, ably assisted by incoherent mining policy. It only goes to show that in matters of global economics and investor confidence, they do not know. And worse is that they do not know that they do not know.

It had little to do with the Euro crisis which gets blamed for everything including lack of local service delivery. Don’t mention the State of the Nation address because I will then need the advice of the intended health warning.

On the matter of power, we note with some relief that NERSA saw fit to refute giving Eskom the 16% escalation over the next five years, which on top of the increases over the last three would have been catastrophic for industry, business and the average citizen. Even the 8% is severe enough which means a doubling of the price of electricity in less than 9

years, and it does not include the mark-up that most municipalities will add on before charging the consumer.

It causes one to reflect on what has happened to Eskom, and while the parastatal gets the blame for such drastic price increases, it is really government policy that caused the whole crisis. To have left the power capitalisation industry to virtually collapse from 1994 to 2007 was the collective decision of policy makers who again demonstrated that they did not know that they did not know.

In that period Eskom became a cash-cow for government. It also became a showpiece of transformation where most of the established intellectual capital and memory was methodically removed to satisfy a political whim. It became evident that political identity was more important than experienced engineering and project management skills that had been built up over decades of designing and building the best six pack stations in the world.

Political whim

The effective owner’s team had been removed and replaced with the outsourcing to foreign based project houses. Costs escalated and are exhibited in the horrific escalation on the price of Medupi for example. Where was the sinking fund to finance the new station build? It became necessary to charge the current consumers to fund the capital expansion. Therein lies your 16% requirement.

Whatever Eskom may say to the contrary, it is borne out by the current irreversible nightmare that personifies our electrical energy generation and distribution structures. Absolute power has certainly disrupted the economy and will do so for the foreseeable future.

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THE SOUTH AFRICAN MECHANICAL ENGINEER

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March 2013

On the Cover

March 2013

Tel: (011) 061-5000 www.mieo.org.za

VOLUME 63

NUMBER 3

Contents Cover Story 8

Mining and Industry Energy Optimisation (MIEO)

Monthly Column 11

Prominent Professionals

Power Transmission 13 Italian Gearboxes Now in SA 15 Save on Maintenance Promech Publishing is proud to announce that an the SA Capital th Equipment Export CounEx x cil has h endorsed “SA Mechanical Engineer”.

We welcome the SACEEC on board and look forward to working together.

CESA

More news next month!

Opinion

Susan Custers, Managing Editor

29 Soapbox

18 Empowering Municipal Engineers

Hydrau ulics s & Pneumatiics 19 New Life for Old Machines 21 Compressed Air at Work

POWER GENERATION TODAY 23 Harnessing the Powers of the Ocean 27 Power Generation News

Material Selection 30 Managing Tooling

Surface Finishing 33 Starting from Scratch

IT Trends 36 Mobile Computing

Electric Drive 37 The World’s Most Powerful Powerboat

Environment 38 Water Disclosure Reporting

Exhibition 39 Boosting the Manufacturing Sector

Regulars 3 An Engineer’s View 7 Institution News 40 Market Forum

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.

The monthly circulation is 4 326 Produced by: PROMECH PUBLISHING, P O Box 373, Pinegowrie, 2123, Republic of South Africa Tel: (011) 781-1401, Fax: (011) 781-1403 Managing Editor Susan Custers Editor Kowie Hamman Circulation Catherine Macdiva Advertising Mark Bennett DTP Zinobia Docrat / Donovan Vadivalu Subscriptions Please email us at accounts@promech.co.za if you wish to subscribe to “SA Mechanical Engineer” at R440,00 (excl postage and VAT) per year; R1 100,00 per year for Africa/Overseas.

Disclaimer PROMECH Publishing and The South African Institution of Mechanical Engineering as well as any other body do not take responsibility for the opinions expressed by individuals.

Printed by: Typo Colour Printing, Tel: (011) 402-3468/9 FSC (Forestry Stewardship Accreditation)

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THE SOUTH AFRICAN MECHANICAL ENGINEER

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March 2013

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THE SA INSTITUTION OF MECHANICAL ENGINEERING

Invest in in-house workshops convened by SAIMechE

Council 2012 - 2014 Office Bearers

President ............................................. KK Nyangoni (Kudzai) Vice President .............................................. D Findeis (Dirk) National Treasurer ........................,................. A Roos (Andre) Immediate Past President............................ G Barbic (George )

Branch Chairpersons

Central ................................................. S Murefu (Stephen) 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..................................G Bartholomew (Bart)

Chief Executive Officer: Vaughan Rimbault National Office Manager: Anisa Nanabhay PO Box 511, Bruma, 2026 Tel: (011) 615-5660, Fax: (011) 388-5356 Email: info@saimeche.org.za

When it comes to correct practices and effective productivity, is there anything to rival teamwork and group training? The benefits of ensuring that all relevant personnel are well informed on common topics are obvious. For instance, group learning fosters team spirit and co-operation between personnel who may not be interacting successfully in their workplace. SAIMechE recommends that instead of incurring travel costs to send staff on engineering related courses, corporations should book In-House workshops with SAIMechE. To obtain a comprehensive list of workshops (also available on website www.saimeche.org.za), or to discuss your corporate short course training needs, kindly contact National Events Manager Linda Robinson on Tel: 031 764 7136 or E-mail: linda@saimeche.org.za Scheduled Forthcoming Training Events â&#x20AC;&#x201C; Open to All Code

Abbreviated Title

Date Start

Date End

Region

C0913

Refrigeration Explained

19Mar13

19Mar13

Cape Town

C6613

Effective Negotiation Methodologies for Engineers in Practice

20Mar13

20Mar13

Cape Town

F6213

Technical Communications and Report Writing

20Mar13

20Mar13

Secunda

F5713

Total Productive Maintenance

26Mar13

26Mar13

Secunda

C2513

Materials Section: Processes, Parameters & Performances

27Mar13

27Mar13

Cape Town

F5813

Continuous Flow Processes: A Methodology for Engineers in Practice

27Mar13

27Mar13

Secunda

A3613

Project Management: A Review of Essentials

3-Apr13

3-Apr13

Durban

F2913

Practical Lubrication and Lubricants

3-Apr13

3-Apr13

Secunda

A4713

Capital Budgeting for Projects

4-Apr13

4-Apr13

Durban

F6913

Lubricants and Oil Monitoring

4-Apr13

4-Apr13

Secunda

Website: www.saimeche.org.za Membership: Central, Eastern Cape, Mpumalanga, Highveld & KZN: membership@saimeche.org.za Membership: Western Cape: saimeche.wc@vodamail.co.za

Company Affiliates Alstom Power Service SA Babcock Africa Limited Bateman Engineered Technologies Bosch Projects DCD Rolling Stock A division of DCD Festo (Pty) Ltd Group (Pty) Ltd Fluor SA (Pty) Ltd GEA Air-cooled Systems Hansen Transmissions SA Hatch Africa Howden Power Howden Projects Industrial Water Cooling

Inenzo Water (Pty) Ltd MBE Minerals (SA) (Pty) Ltd (previously KHD Humboldt Wedag SA) Megchem Eng & Drafting Services Mod-U-Flow

6

Osborn Engineered Products SA Rotek Engineering S.A.M.E Water Sasol Technologies SEW Eurodrive Siemens SNC-Lavalin SA Spicer Axle SA Spirax Sarco SA Technical Systems Thyssenkrupp Engineering Transvaal Pressed Nuts & Bolts Ultra-Flow Engineering Services Vital Engineering Weir Minerals Africa Winder Controls

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 63

6SHFLÂżF HYHQW SURJUDPPHV DQG D GHOHJDWH UHJLVWUDWLRQ form may be obtained from Carey Evans on Tel: 031 764 7136 or Email : carey@saimeche.org.za. All event programmes are posted on website www.saimeche.org.za

March 2013

THE SA INSTITUTION OF MECHANICAL ENGINEERING

SAIMechE Student Road Shows - Western Cape Vaughan Rimbault (SAIMechE CEO) and Anisa Nanabhay (National Office Manager) recently conducted student road shows at Stellenbosch University, Cape Pensinsula University of Technology and University of Cape Town. Students were addressed on matters

that directly concern and effect them, as well as benefits of SAIMechE membership, which is free for students. The presentations were well received and there was a lot of interest in what SAIMechE offers to students.

SAIMechE Student Awards – Stellenbosch University The award winners for the 2012 SAIMechE Student awards from Stellenbosch University Mechanical and Mechatronic Engineering were: 1. Best Final Year project Mechanical (Trophy, medal, prize money & certificate) – Elizna Miles 87% 2. Best Final Year Project Mechatronics (Trophy,

medal, prize money & certificate) – Willem Pienaar 87% 3. Best Mechanical Presentation (medal & certificate) – Elizna Miles 90% 4. Best Mechatronic Presentation (medal & certificate) – Henri van Eetveldt 82%

All the 2012 departmental award winners, including the SAIMechE award winners.

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COVER STORY

Mining and Industry Energy Optimisation (MIEO) Charles Ntsele, Grinding Manager at Metso Southern Africa, has been elected to Chair the MIEO for the next two years.

T

he MIEO is a not for profit independent association that serves the mining and industry sectors of the southern African economy by promoting awareness, informing and educating within the realm of energy efficiency and saving.

Charles Ntsele

Comparatively speaking, the industrial and mining sector combined,

Serves the mining and industry sectors of the southern African economy by promoting awareness, informing and educating within the realm of energy efficiency and saving

Industrial

Patterns of usage quite different between mining and industry

Mining

8

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March 2013

COVER STORY

Electricity Consumption by Sector

use 67% of Eskomâ&#x20AC;&#x2122;s grid capacity, classifying this sector as intensive energy users. However, it is also the sector that contributes to the majority of the countryâ&#x20AC;&#x2122;s economy. Hence the focus for a sustainable and secure energy supply in South Africa, logically, lies with optimising the energy use within this sector.

The MIEO constitutes a membership base that not only supply products and services to the mining and industrial sector, but has collaborated in assisting energy intensive users to employ a systematic, or holistic approach to energy management challenge in their organisations, so that energy saving can be optimised.

Systematic approach

The collaboration involves a series of seminars, presented by the MIEO, across the country. In this way, information on energy optimisation opportunities is taken to the end user.

The MIEO initiative brings together leading manufacturers and suppliers of service and technologies for improvement of energy efficiency in all major energy-consuming plant items. Through seminars the MIEO aims to achieve the following objectives: 1. To promote awareness of the benefits available to industry and mining in the products and services for energy efficiency from members of the association.

2. To support Eskom and the Department of Energy of the Republic of South Africa in their common objective of increasing energy efficiency in the industrial and mining sectors of the economy.

3. To promote opportunities for the dissemination and sharing of information about products, services, technologies, programmes, approaches, strategies, best practice, and operational experiences in the field of industrial and mining energy efficiency.

4. To promote the adoption of energy efficiency products and services available from members of the association.

5. To promote opportunities for training in the methodology and technology for sustained achievement of energy and cost saving when utilising energy efficiency products and services available from members of the association.

Credentials

Charles Ntsele, currently Grinding Manager at Metso Southern Africa, obtained his NHD Extraction Metallurgy from the University of Johannesburg in 1994 and has fulfilled various roles such as research metallurgist, applications engineer, process engineer and product manager. He is an associate member of the Southern African Institute of Mining & Metallurgy Tel: (011) 061-5000, Fax: 086 688 7005 Email: mieo@vdw.co.za, www.mieo.org.za

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THE SOUTH AFRICAN MECHANICAL ENGINEER

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MONTHLY COLUMN

Prominent Professionals Carel Kruger, Engineering Manager

the project engineer who worked on this project.

Future â&#x20AC;&#x201C; a concept, a dream or a wish

Academic

Using the technology and engineering knowledge available to make South Africa more sustainable.

If we could use this know-how to overcome the challenges that the country faces, it would be a major breakthrough for the nation.

School/ Graduate studies:

Rob Ferreira High School, Whiteriver, B Eng at University of Pretoria.

Post-graduate

B Tech degree in Pulp & Paper. Management Development Programme through Unisa. Government certificate of competence.

Professional bodies

Registered with Ecsa as Pr Eng and Pr Certificated Engineer.

Career Path

Most Challenging Project

First employer

Started with Sappi at the Enstra Mill as an engineering trainee after doing national service in the army.

Growth path

After a few years at Sappi I left to work for a small engineering company for five years. I went back to Sappi as a project engineer. I was then promoted to a number of positions at Enstra Mill, these included maintenance engineer, project manager, services manager and maintenance manager before I took up my current position.

Present employer & position

Sappi Enstra Mill as an engineering manager

Achievements

A few years back we did a recovery optimisation project to improve the recovery of by-products from the pulping process. The main product is caustic soda used in the cooking process. We installed a new causticizing plant, pulp screening plant, scrubber and refurbished the fluidised bed reactor.

The challenge was combining the new plant installation with the refurbishment work, all in an existing plant within a very limited time span.

Most Rewarding Project It was the installation of an A-4 sheeting and packaging line.

We bought a second-hand machine in Germany and just to get the machine up and running was a challenge in itself.

Commentary

A project Most of our work in the maintenance environment involves minimising breakdowns, optimising the performance of the equipment and working on continuous improvements to either overcome business challenges or increase the success rate of our production plant. One of our teamâ&#x20AC;&#x2122;s notable project was to de-bottleneck the bleach plant. The project involved stabilising the pulp consistency control in a refurbished high density chest system. At the same time we installed a new feed system into the oxygen reactor.

This was a major breakthrough in terms of availability of equipment and the throughput of the plant because of reduced breakdowns and blockages. It was a case of applying new technology in a very old plant, challenging our engineering skills to the maximum.

Any awards

Iâ&#x20AC;&#x2122;d also like to see more being done in terms of renewable energy. We are, for example, closely studying further possibilities to use biomass as a fuel to generate steam and electricity in our processes. Weâ&#x20AC;&#x2122;re also looking at fluidised bed boiler technology so that we can use the abundance of low-grade coal in the country.

A Sappi internal silver engineering award was given to me and

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

Yes, we have a shortage of maintenance professionals. When I was at university we were not trained in maintenance at all. Mechanical engineering has a major role to play in this field where the scope for improvement in todayâ&#x20AC;&#x2122;s industry is enormous. We need to start training in maintenance at an academic level, much like some of the universities have now started doing. However, mentorship and in-house training has a very important role to play as well.

Message to young engineers

Young engineers have to take ownership of their own development and not expect somebody else to do it for them. Many young engineers feel the employer owes them something.

They must get involved at all levels and work their way up so that when theyâ&#x20AC;&#x2122;re the seniors they know what goes on at the lower levels. Remember, youâ&#x20AC;&#x2122;re never too clever to learn.

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SAMHYDRAULIK, which is one of the leaders in the field of hydraulic transmission, has been operating for over 25 years in the international market, offering a complete range of orbital hydraulic motors and power steering units, axial pumps and motors for medium and high pressure ranges, all characterised by excellent performances.

SAMHYDRAULIK employs 120 people who operate inside a very modern and efficient plant that spans over 6 000 square metres to assure a high standard and flexible production capacity.

The latest computer technology is used for both design and production, combined with strict quality control procedures during all production phases, which translates into innovative, reliable and functional products that meet the various needs of the market.

Its ISO 9001 certification, held since 1994, is the result of a qualityorientated philosophy on which SAMHYDRAULIK has always based its operation.

A H 1214

AXIOM HYDRAULICS (PTY) LTD Tel: (011) 334-3068 / 334-3086 Fax: (011) 334-4543 E-mail: axiomjhb@mweb.co.za

THESOUTH SOUTHAFRICAN AFRICANMECHANICAL MECHANICALENGINEER ENGINEER THE

17 Heidelberg Road, Village Main, Johannesburg, 2000 P O Box 260248, Excom, South Africa, 2023

VOL6362 March May 2012 VOL 2013

POWER TRANSMISSION

Italian Gearboxes Now in SA With South African industry, particularly mining, being very similar to that of Australia, some international companies build up a strong footprint in Australia and then use this experience to bring their expertise to the South African mining industry as well.

R

ossi, a power transmission equipment manufacturer from Modena in Italy, did this by establishing the company’s first permanent subsidiary in South Africa. “SA Mechanical Engineer” speaks with the deputy general manager of Rossi South Africa, Kyle Dick, about the range of new products they’re now offering locally.

The product range as such is thus not new to the South African market, but we’re now offering a much wider range incorporating the latest in drive train technology for a wide variety of applications “Initially Rossi was represented in South Africa through my company, DDI Transmissions in Springs, as an agent for their comprehensive range of gearboxes, but now operates as a subsidiary for Rossi SPA to service the whole of sub-Saharan Africa,” roduct he explains. “The product range as such is thuss not can new to the South African market, but we’re ofer fering a much wider range incorporatingg n the latest in drive train technology for a widee variety of applica-tions.”

The Rossi range of products has done extremely well in Australia, leading to the establishment of a main subsidiary there and three regional offices,” says Marcello Cassanelli, the other deputy general manager from Italy who is helping Kyle in the coming years to get the business going at Tongaat

Kyle Dick (left) and Marcello Cassanelli of Rossi South Africa

in KwaZulu Natal, “Not only is the market in South Africa very si similar to the mining industry there, but many of the mining companies and major project houses op operate in both countries. This made us realise tthat the South African market could certai certainly be expanded from the footprint whic which Kyle has already established here.”

New ranges Ne

The Rossi Group is one of Europe’s largest industrial groups for the production and sale of gear reducers, gear motors, electric standard and brake motors. Kyle elec comments, “They constantly undertake comm extensive research into new drive soluexte tions.

A typical example is the EP range ti of planetary units and the H-series of new helical and bevel-helical gear units specifically developed for heavy industry applications.”

Manufacturers of bulk handling equipment Ma like conveyor systems, ship loaders, stacker reclaimers and mine processing machinery are all familiar with Rossi drives and have been direct clients of the company for many years. The gear reducers and gear motors include planetary, worm, coaxial, right angle, parallel shaft gear reducers and

THE SOUTH AFRICAN MECHANICAL ENGINEER T

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POWER TRANSMISSION

speed reducers specifically bring flexibility to the market. The system is completely modular allowing each solution to be tailor-made to a specific application, yet it’s still cost effective as all products emanate from a standard production unit. The new H series covers 82,5 kNm through to 1700 kNm while the EP series can cover up to 3000 kNm. “Complementary and ancillary equipment such as cooling fans, coils or independent cooling units, oil heaters and labyrinth seals are of an equal quality and toughness as our rugged gear units which are built and customised for the most challenging conditions or environments any industry can possibly present,” Marcello adds. The company is so confident in the quality and reliability of their product range that they’re offering a worldwide warranty on all their geared products.

I prefer to go on site and help out with tricky problems, but I also have good experience in gearbox selection, a critical factor in today’s market gear motors while other standard products are large size parallel and right angle shaft gear reducers and gear motors for heavy duty applications.

Extras

Marcello adds, “The new EP and the H range of

Central base

“We based the new South African headquarters in Tongaat because it puts us close to a port for bringing in components so we can assemble geared units more cost-effectively,” says Kyle. “We’re in the heart of the sugar industry, yet right next to an international airport so that we’re in reach of anywhere in Africa within a couple of hours. In addition, we’ve established a sales office in Johannesburg.

“The fact that Marcello brings to the table his international experience to complement my knowledge of local conditions and requirements, gives me the confidence that we’ll be able to provide the local market with services and products both the endusers and competitors will regard with respect,” adds Kyle. “To top this off, we have direct support from highly-experienced engineers in Italy.”

Selection

Kyle is a hands-on man who has worked his way up in the company through the ranks, in the workshop, on site and in the office. “I prefer to go on site and help out with tricky problems, but I also have good experience in gearbox selection, a critical factor in today’s market,” he says in conclusion.

“Although most project houses do the selection, we’re always prepared to share our experience with others in order to make the right selection right from the start. I am confident that we now have the right product, the right facilities in terms of support and the experience to serve the local market with competitive pricing.”

Kyle Dick, Rossi South Africa, Tel: (032) 944-3505, Email: kyle@ddirossi.co.za

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POWER TRANSMISSION

Save on Maintenance Condition monitoring is an integral part of asset management, ultimately impacting directly on a company’s bottom line, not only in terms of reducing the risk of unexpected breakdowns, but also affecting machinery life. Deciding on what to monitor and how, is a scientific task which should be undertaken by specialists. “SA Mechanical Engineer” speaks to Kobus van der Westhuizen, director of Ideas Solutions, a South African company specialising in engineering analysis solutions, with offices in Cape Town and Pietermaritzburg.

H

e kicks off by telling us, “If you’re not saving money in the end, condition monitoring serves no effective purpose. Also, if you can Kobus van der Westhuizen, director of Ideas Solutions afford the consequence of a failure, then you don’t need to do condition monitoring.

A good example is found in the food processing maintenance strategy, a process called the RCM industry where they use hundreds of small pumps (reliability centred maintenance) plan,” explains throughout a plant. Instead of having to monitor all Kobus. “First off a hardware breakdown structure these pumps, they now use low-cost plastic pumps of the whole plant is drawn up, and a Failure Mode which can be replaced quickly without holding up and Effects’ Criticality Analysis (FMECA) performed, so that you can decide which of the machines are the production process.” critical to the operation of your plant, the ones We can predict how close that bearing is to failure which will bring the whole lot to a halt if they fail.

Part of asset management

“Typically, you start the development of the condition monitoring process by determining the company’s

Kobus continues, “Through this process, the company can also determine what spares to carry as well as the level and types of skills which will be needed to maintain the critical machines in the plant.”

Methods

Ideas Solutions not only assists companies to undertake this initial criticality audit, but will also advise which one of the four main condition monitoring technologies is most appropriate for each specific application, fit it and analyse the data as part of a maintenance contract.

“The solution could take the form of vibration monitoring, alignment monitoring, any one of a number of methods of temperature measurements, or oil analysis,” clarifies Kobus. “In the case of a gearbox, for instance, we carry out an oil analysis to check whether there are any particles of the same material as the bearings, or the gear teeth, and so on.

Vibration

The “Operational Deflection Shape”

“In our experience, ninety percent of the machines with high maintenance costs are the ones where vibration is the highest,” adds Kobus. “Being a destructive phenomenon, the extent of vibration indicates whether the machine is balanced, running in alignment and gives insight into the condition of the bearings, regardless of the type of bearing.

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less costly exercise than an unexpected failure,” Kobus says. “You can then order a replacement bearing in good time and make sure you have the right skills on hand to do the replacement.”

What to fit

Being such a clear indicator of a number of problems in machinery, vibration monitoring equipment can be fitted in a variety of ways.

If it’s a critical machine, permanent vibration protection instrumentation is typically fitted on the machine.

Such a system monitors the machine in real time while constantly evaluating vibration in terms of bearings, alignment or imbalance in the machinery.

Simultaneously measuring all the channels of vibration in real time “If, for example, we find that the load on the bearing remains constant, we can predict how close that bearing is to failure and plan when the machine can be shut down for a bearing replacement, a much

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“Our systems are so refined today that you can not only pinpoint which bearing is showing faults, but we can even see which part of that bearing is showing strain and why,” Kobus adds.

“We can also programme the system against certain parameters so that it trips the machine when certain levels of vibration are exceeded. This is the highest level of protection we can provide.”

An interesting development in the deployment of an online monitoring system is the technique called “Operational Deflection Shape” (ODS) analysis. This is possible when an online system has the capability of simultaneously measuring all the channels

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POWER TRANSMISSION

of vibration in real time. This preserves the phase relationship between channels, resulting in a visual representation of the machine vibration. It makes it easier to observe, analyse, and document noise and vibration problems in machinery and structures.

ODS analysis is used to display and analyse experimental multi-channel time or frequency domain data, acquired during the operation of a machine, or forced vibration of a structure.

This provides an interactive animated display with which users can observe spatially defined data such as operating deflection shapes (ODS's), mode shapes, acoustic sound and intensity fields, or other engineering data such at temperatures or pressures. By animating the spatial response of a structure in slow motion, users can view a structure’s overall motion, and the motion of one part relative to another. Locations of excessive vibration or high levels of noise are easily identified.

The fact that condition monitoring saves companies money has been proved over and over again if it’s done right Next level

The next level down is a surveillance system, often used in conjunction with a protection system. “In contrast to a protection system, the surveillance system provides answers as to why things did go wrong,” explains Kobus. “In a fan application, for example, the system will tell you that vibration has increased, yet the signature reading from the machine has remained constant. This can be as a result of dust build up on the blades, or a blade has broken off, causing an imbalance which prompts the protection system to stop the machine. The system will even tell you which blade has been affected by the fault.”

extent to which it is integrated on a plant, should be part of every company’s maintenance strategy.”

Kobus van der Westhuizen, Ideas Solutions, Tel: 082 552-4790, Email: kobus@ideas-online.co.za www.ideas-online.co.za

The surveillance system can also be used on its own but still in an online mode. “This feature is used to trend parameters, leaving the decision to stop a machine at the discretion of the maintenance engineer,” explains Kobus. “These online solutions can either be wired or wireless, transmitting data from each sensor to the receivers on the system.

The data is then channelled to whomever needs it in his or her format of choice.”

Options for all

On smaller plants that cannot afford an online system, less critical machinery data from machinery is collected by hand and transferred to a computer for analysis, either by the maintenance engineer or, under a maintenance contract, to an engineer at Ideas Solutions.

“It’s no longer in question, the fact that condition monitoring saves companies money has been proved over and over again if it’s done right,” Kobus says in conclusion. “Condition monitoring, regardless of the THE SOUTH AFRICAN MECHANICAL ENGINEER

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CESA

Empowering Municipal Engineers

Corruption and tenderpreneurship, fraud, financial mismanagement, lack of understanding of technical issues/ priorities, difficulties with job creation and skills shortages are just some of the challenges that face municipal engineers in South Africa.

C

onsulting Engineers South Africa (CESA) President, Naren Bhojaram believes that if South Africa is serious about the empowerment of properly-qualified municipal engineers, it should invest in various interventions such as training, development and capacitating of young engineers for employment by the local authorities and make the municipal engineering profession attractive.

Currently municipal planning is done rather superficially and only a real municipal engineer and a competent team of visionary planners can sort that out.

CESA President, Naren Bhojaram

CESA calls for the embracing of the municipal engineer as a trusted advisor as well as creating a working environment to attract and retain municipal engineers. The municipal engineers must be incentivised (long term employment, purpose in life, emoluments, respect and freedom) and unqualified people should be discouraged from trying to do the job of the municipal engineer.

Unqualified people should be discouraged from trying to do the job of the municipal engineer Stumbling Block

Infrastructure delivery’s biggest stumbling block is the lack of business integrity which involves among other things; socialising with clients, conflict of interest, use of agents and partners, collusion and bribery and the disregard of procurement regulations.

CESA strongly urges structural changes to the way in which municipal engineers operate including the abandonment of long-term employment contracts for key technical and managerial staff. Tender and

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bid evaluation committees must include technical, legal and financial executives in joint sittings and professional teams must be allowed to compile reports in an independent manner on tenders for the bid evaluation committees.

Name and shame

CESA unreservedly supports the call for the banning of public servants from doing business with the state including deals/tenders with another department or municipality.

“What is at stake is not the rights of state employees to do business, but rather the integrity of the state procurement system.

The current public procurement environment in the construction sector is highly complex and conducive to corruption and manipulation,” warns CESA President Naren Bhojaram.

The problem is further compounded by the lack of accountability and punishment for procurement irregularities and wasteful expenditure.“The country has good rules but no-one is playing by them” he adds.

CESA believes that it is irresponsible and foolhardy to place employees in positions where they can (or are tempted to) manipulate procurement and other procedures to unfairly benefit themselves at the expense of the state/taxpayer.

The South African procurement legislation should include a Bribery and Corruption Act such as the UK Bribery Act of 2010, enabling the Courts to prosecute corruption and related issues more effectively as well as the naming and shaming of firms contravening the requirements of the Act. Consulting Engineers South Africa (CESA), Graham Pirie, Tel: (011) 463-2022 Email: gspirie@cesa.co.za, www.cesa.co.za

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HYDRAULICS & PNEUMATICS

New Life for Old Machines Very often the spare parts for old machinery, imported and installed twenty or more years ago, is hard to come by and if it is available, it costs an arm and a leg to import. If the problem happens to be hydraulic, there is a local hydraulics company that specialises in updating systems so that local, easilyavailable spares can be used to keep the machine going for many years to come.

CNC machining

Overhauled cylinders ready for delivery

Large cylinder

Willie Muller, general manager at KDP Services

“

SA Mechanical Engineer” speaks to Willie Muller, general manager at KDP Services, about the modernisation of old hydraulic machinery. “In terms of upgrading we’ve just done extensive work at a steel mill to re-design

Analyse the operation and specifically the machine’s function in situ before returning to the drawing board to redesign the hydraulic system for better functionality and implement new technology on a large 1 200 tonne cutting press and a shredding machine,” he explains. “Both the machines were imported from Germany originally, but have lately started picking up problems, seriously hampering production flow.

Hydraulic motor of all makes and sizes are serviced

“After consulting with the supplier’s engineers, the problems persisted and the client then called us in to investigate,” Willie says. “We found that the hydraulics on both these old machines were outdated, but could be updated with new technology rather than replacing the old pumps and valves with costly new imported OEM components.

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New technology

As the designer in the company, Willie goes out to analyse the operation and specifically the machine’s function in situ before returning to the drawing board to redesign the hydraulic system for better functionality. This provides the opportunity not only to introduce the latest technology into the upgrade, but also to ensure that easily available local components are used. He adds, “Since our upgrade, the shear which can cut through a 150 by 300mm block of steel in one cut, has been running smoothly with none of the previous problems cropping up again.”

Similarly, the shredding machine, where a whole vehicle is fed in one end and comes out in pieces of scrap metal the other end, has also been upgraded to run consistently ever since. Willie adds, “Through this success we’ve now not only landed the maintenance and service contracts for this mill, but they’ve asked us to audit the entire plant to investigate other hydraulic systems which can be improved. We’ve already re-designed one of the production lines to introduce an integrated, fully automated operation.”

That people think they can treat the hydraulic components roughly just because they are big and rugged The full Monty

Hydraulic system design, from the circuit to pumps, motors and all the necessary connecting piping are designed in-house at the 22-year old company. “We design the complete circuit, specifying all the components necessary to achieve certain functions,” explains Willie. “Similarly, all engineering is undertaken in-house except the honing and chroming of shafts when we overhaul cylinder sets.

New cylinders are manufactured from tubing and shafts which have already been prepared.

“In terms of piping we’ve built up a good name in many industries, both in new installations, during maintenance shutdowns or when a fixed installation needs to be moved,” he adds. “Not only do we design the layout, but we physically carry out the installation work ourselves, especially when it is a stainless steel pipe installation that requires argon welding to fit the fittings.”

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First project

Willie might be young, but he has worked with KDP since his student days, gaining invaluable hands-on experience in all aspects of hydraulic work from the owner of the company, Karel Podges. “One of my first projects as a student was designing the hydraulic system for a container lifting and tilting machine used in steel mills to collect and handle scrap metal,” he recalls as we come across the remnants of the prototype when we walk in the yard behind the workshop. “This is probably what got me hooked on hydraulics because nothing of the sort existed and I had to design it from scratch around a structure someone else had built.”

Inside the workshop we find engineering equipment ranging from lathes to modern CNC machines all humming away as hydraulic components are turned out of a variety of metals. At the hose crimping machine, Willie points out the neat final product for a custom-made installation they’re doing. One of KDP’s specialities is hydraulic motor overhauling which is evident when we see several large Hagglunds drives in various stages of repair in the drive section of the workshop.

Testing

Finally we get to the test-bench area where a large cylinder is under test for leaks before being taken apart for a complete overhaul. “One of the biggest mistakes generally made when it comes to hydraulic equipment is that people think they can treat the hydraulic components roughly just because they are big and rugged,” Willie remarks. “They lose sight of the fact that dirt is the biggest enemy and they don’t take the necessary care to keep the oil or equipment clean, causing irreparable damage to seals and delicate surface areas in a system.”

One of the main advantages of KDP is that they are not officially tied up with a specific brand of hydraulic equipment, allowing them to work on and supply any make on the market. Willie concludes, “In addition, we’re a small company where you learn and get the opportunity to work on all types of applications. So each and every problem, big or small, is tackled with great personal attention to detail.”

Willie Muller, KDP Services, Tel: (011) 392-5750, Email: willie@kdp-services.co.za

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HYDRAULICS & PNEUMATICS

Compressed Air at Work Pneumatic systems are extensively used in industry, where factories are commonly plumbed with compressed air or compressed inert gases. This is because a centrally-located and electrically-powered compressor which powers cylinders and other pneumatic devices through solenoid valves is often able to provide motive power in a cheaper, safer, more flexible, and more reliable manner than electric motors and actuators.

S

A Mechanical Engineer” visits a company in Randburg, aptly named Applied Pneumatics, to speak to managing director Dave McNair. “In a pneumatics application we supply everything beyond the compressor. This includes everything down the line, the filtration system, water traps, regulators and then the lubrication system before you get to the actual application which could be a cylinder, control valves, actuators or even solenoid valves for the control of liquid flows in a process. We also do vacuum applications where suction cups pick objects up to move them about.”

Range includes pneumatic cylinders and actuators, valves and logic processing, air preparation equipment as well as a whole host of other pneumatic components and accessories

The Parker range of pneumatic equipment includes actuator and motors

Premium brand

Applied Pneumatics, established 22 years ago, is a South African distributor of Parker Hannifin products.

“At a time when everyone is increasingly becoming aware of the benefits of buying premium products which last longer and have proven to be value for money, Parker has come up with new innovations which extend this value even further,” says Dave.

“Take valves, for example. Most low-cost valves are throw-away items which are discarded completely if something goes wrong. Our premium valves, which cost a bit more initially, are serviceable. This means we can repair and service them at a fraction of the cost of even a cheap complete unit.

From left: Andrew Livesey, applications engineer at Applied Pneumatics, Teven McNair, sales and Dave McNair, managing director

“If the premium repairable valve breaks, for instance, it’s quick and easy to strip it right there and then, fit new parts and have it up and running in no time as opposed to having to order and wait for a complete replacement unit,” adds Dave. “All you need to have in stock are a couple of O-rings for the different valves in a system.”

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element and clip it together again within a minute.

New concept

Similarly the air preparation systems from Parker are of a modular design and fully repairable so that just worn or damaged components can be replaced.

“They have now taken this even further,” says Dave. “A new concept in regulators, the Moduflex clip technology system, has just been released. No special tools, in fact, no spanners at all are needed

“On a forklift, for example, the glass bowl of the air preparation unit is often damaged when the forklifts bump into something,” elaborates Dave. “On a lowcost throw-away unit, you’d have to carry a spare unit to replace the whole unit. With the new technology, however, you simply clip off the damaged part to zap a new one into place. In terms of cylinders and actuators, the latest development is self-lubricating seals which require no additional lubrication whatsoever.”

No special tools, in fact, no spanners at all are needed to take the unit apart to replace a filter element, for instance to take the unit apart to replace a filter element, for instance. You simply clip the unit apart by hand, replace the

One of the main drawbacks of pneumatics over hydraulics is that a pneumatic cylinder has to be much larger than a hydraulic cylinder in order to deliver the same power. However, this does not rule out using pneumatics in heavier applications, especially underground where the use of air is generally safer and cleaner than hydraulic oils in the first place.

Underground

“A while back we were approached by a platinum mine to design a pneumatic system to open and close underground tips,” Andrew explains. “To prevent people from falling into the ore tip, it had to be closed with a heavy steel lid between offloading operations. We not only designed a suitable pneumatic system, but also took part in the installation on various levels all the way down to three kilometres underground.”

Like many other products, there are cheap and nasty pneumatic products on the market and cost is not always an indication of inferiority. “The safe route is to always buy from reputable companies who have been around for a long time and who trade in well-known brands,” Dave says in conclusion.

“Serious consideration should also be given to the repairability of the equipment. It’s no use installing a low cost system which has to be replaced regularly while another could last a lifetime if properly looked after.”

Dave Mc Nair, Applied pneumatics, Tel: (011) 792-3381, Email: daven@appliedpneumatics.co.za

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

Copyright 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.

T O D A Y

Harnessing the Powers of the Ocean Tidal power has long been utilised as an energy resource, used early on in tidal mills to grind grain throughout the Middle Ages. More recently, it has also been used to generate electricity, for instance, in the 240 MW tidal barrages at La Rance, France. Tidal currents, however, are still largely an untapped energy source. While several marine current turbine prototypes have been tested in the last few years, there are only a few of these prototypes deployed to generate electrical power to smaller communities, mainly to demonstrate the viability of the technology.

T

here is currently a renewed interest in using the ocean to generate electricity, using both traditional hydropower technologies and new hydrokinetic technologies. This interest is being spurred on by official and private initiatives to promote the development of cleaner energy sources and diversification of energy supplies through use of alternative and renewable sources.

Tidal energy

Luciano Garcia-Baylleres, COO at HAE

TICKER TAPE

POWER GENERATION

The International Finance Corporation (IFC), the World Bank’s private-sector lending arm, is partnering with Sasfin Bank to develop a portfolio of energy efficiency and renewable-energy financial products for small, medium-sized and microenterprises (SMMEs) in South Africa.

Alstom South Africa and the South African Nuclear Energy Corporation (Necsa) have signed an agreement under which the local branch of the French power generation, power transmission and rail infrastructure

Tidal energy projects hold the promise of producing indigenous, renewable, predictable electricity without greenhouse gas emissions and with higher power densities in terms of power output per unit area, than either solar photovoltaic or wind projects.

group will invest R8-million in buying equipment for the new coded welding centre being established at Necsa’s Nuclear Skills Development (NSD).

The operation and maintenance (O&M) costs of wind farms in South Africa were expected to be in the mid-range of the international market, Mott MacDonald consultant Matthias Vinard has reported, adding that O&M costs ranged from €28/kW a year to €68/kW a year in international markets.

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ocean currents driven, for instance, by thermal gradients or differences in salinity. Along the South African east coast, the Agulhas Current is one of the most consistent sea currents in the world and this area has now been identified as the ideal spot to test technology developed by an American company, Hydro Alternative Energy (HAE) from Florida, USA.

Flow anlysis carried out for current simulations

Tidal energy projects may also be useful in ‘filling in the gaps’ in generating power from other intermittent energy sources, such as wind farms.

Marine current energy conversion concerns the potential generation of electricity from kinetic energy of freely-flowing water. This contrasts with traditional hydro power, like a dam, where the amount of energy extracted from a river is dependent on the head between the reservoir and the water level below the dam.

Another way to generate electricity from water would be to convert the kinetic energy of flowing water similar to the way a wind turbine extracts energy from the wind A similar hydro power approach can in fact be used for tidal power in areas with high tides. In this case, a barrage can be constructed in a narrow bay or estuary to utilise the head between low and high water.

Consistent current

Another way to generate electricity from water would be to convert the kinetic energy of flowing water similar to the way a wind turbine extracts energy from the wind. In such a case, a dam or reservoir is not necessary, but rather sites are chosen where the currents are strong, such as a narrow sound, straight, estuary, around a headland or in a river.

TICKER TAPE

The term ‘marine current’ constitutes any kind of water current, be it tidal, unregulated rivers or other

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Zimbabwe Power Company (ZPC) MD Noah Gwariro says the state-owned company needs at least $300-million to refurbish thermal power stations in Bulawayo, Harare and Munyati and to increase their generation capacities.

The planned Karuma hydropower project will have capacity to generate 700MW

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Current plans, with the local government of eThekwini Municipality in Durban supporting the concept of a hydrokinetic energy project off the city’s coast, calls for HAE to initially develop a $20 million, 1MW demonstration unit, utilising the company’s Oceanus technology to generate electric power from the Agulhas current flowing past the city. Additional units, each with an anticipated electric power generation capacity of 8 megawatts, may then be built and likewise be submerged approximately 30 metres below sea level, to prevent interference with shipping traffic.

“SA Mechanical Engineer” has a Q&A session with Luciano Garcia-Baylleres, the Chief Operation Officer (COO) of HAE, about the project;

Q: Some background on HAE?

A: HAE, founded in March 2009, is an emerging independent power provider (“IPP”) focused on utilising hydrokinetic and other power development sources to generate electric power worldwide, safely, cost-effectively, reliably and profitably, with minimal or no ecological impact.

Our business model provides for utilising certain of our own proprietary technology, identifying and locating existing and new technologies, and, when appropriate, partnering with others, for our power development and generation needs.

Q: The South Africa connection with the company?

A: Research by our technical department, identified several places throughout the world as optimal for the initial deployment and commercialisation of our technology. After extensive research of each location and is one of the high-priority projects in Uganda’s National Development Plan.

The State-owned Ethiopian Electric Power Corporation (EEPCo) has signed a $120-million contract with UK-based company Canbridge Industries for the construction of a 50 MW waste-to-energy power plant.

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POWER GENERATION

and all the surrounding benefits, apart from the presence of good quality currents, such as political stability, port infrastructure and focus on green projects, we determined that South Africa with its infrastructure, qualified human resource and an approach to facilitating large scale green projects, was the appropriate site for our first endeavour.

Q: Background on what the project is all about?

A: OceanusTM, our first power generation system which we are currently developing, and which utilises much of our own proprietary technology, is planned to harness the kinetic energy of the ocean to produce safe, clean, reliable, cost-effective, electric power.

Oceanus will consist of two primary modules, the amplification module (the shroud) and the engine module. The shroud is a housing that will multiply the normal incoming water flow to a faster velocity as it passes through the engine module, generating more kinetic energy. This will, in turn, result in potentially greater electrical power generation capability as well as potentially increased usable offshore locations worldwide.

Velocity is the major factor which dictates the hydrokinetic energy that can be extracted from water. Within the hydrokinetic energy sector of the renewable and/or clean energy industry, we have seen that research and development has generally focused on developing energy generation technologies for environments that can only work in very high water velocity environments, such as 3, 4, 5 metres per second. While these areas of extreme water velocity are very high in hydrokinetic energy, they only exist in a very small percentage of the world’s waters.

Our goal is to provide electric power to locations

How the energy is harnessed

The Aghullas current and eThekwini Municipality with their infrastructure, qualified human resource and an approach to facilitating large scale green projects, was the appropriate site for this first endeavour worldwide utilising the kinetic energy in ‘typical’ water conditions. Our current design specifications have a base need of 1 metre per second of water

Engine module

Shroud

Combine modular design

The components of a sea current power gererating system

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flow which, by amplifying the velocity, is planned to produce 1MW of power. This design specification, once successfully tested, may then be adapted into higher velocity waters. As most locations in the world have lower velocity waters, a turbine designed to work in 3, 4, or 5 metres per second water flows will not work in waters that have velocities of 1-2 metres per second.

Q: How does it work?

A: The theory behind the development of the system is quite basic, having been previously used in other energy production systems such as wind and tidal energy generation. Basically the engine is composed of an energy extraction system such as, but not limited to, our perpendicular access turbine, a gorlov turbine, a darrieus turbine and an Axial turbine.

We will focus on potentially building / assembling the units in Durban, thus taking advantage of the excellent and qualified infrastructure it has The other module is the shroud which handles two functions, serving as an accelerator of the water velocity, thus increasing the amount of kinetic energy that can be extracted. Secondly, it houses the engine, protecting marine life from direct contact with the tip of the blades. Also, Oceanus is designed to be positively buoyant and either secured to the ocean floor or to float at a certain predetermined depth while moored to the ocean floor, utilising the same techniques that are currently used in mooring floating oil rigs, buoys or floating windmill systems.

Q: How will it work in KZN?

A: There will be a demonstration unit initially and then we will start the commercial phase by entering into the normal contracts and procedures for energy generation in the country. This entails a very large investment from our company, where we will focus on potentially building/assembling the units in Durban, thus taking advantage of the excellent and qualified infrastructure it has.

Q: Who is involved locally?

A: We have no partners as far as investors or concerns as yet on the South African project but we are not against this possibility in the future. From the facilitation point of view, we have received a lot of support from Derek Morgan at the eThekwini Energy Office, and Russell Curtis at DIPA each with their respective teams, and other government offices that have been very forthcoming with information and support.

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Q: What equipment does it use â&#x20AC;&#x201C; where will this be made?

A: We have already scouted several facilities in Durbanâ&#x20AC;&#x2122;s ship building industry, as well as other possible suppliers ranging from the maritime industry, financial sector, to legal consultants in order to make sure that we are in compliance with all regulations and that our perception of excellence from the South African maritime industry is, in fact, there.

Q: At what stage is the project now?

A: The project is currently at an initial logistics stage, where we are looking at a more site specific design for the demonstration unit. At the same time we are gathering all the information with our lawyers and possible suppliers for the norms, procedures, permits and licences necessary to comply with local and national regulations.

Q: Where will power go to?

A: From our initial discussions with the regulatory bodies, this energy can be locally distributed and then taken up by the grid as needed. This will depend on the results of the demonstration unit and the first commercial unit operation, which we are confident will exceed expectations.

Q: Are there sceptics, critics?

A: As discussed before, the basic technology has been used in other sectors of the energy generation industry; what is being developed by us is the efficient shroud and the maintenance systems, which include buoyancy controls and depth determination in order to locate the most efficient current.

Q: Are there any future plans from your company for South Africa in particular?

A: We believe that we have a good relationship with eThekwini municipality and once we fulfil our project with KZN, we would then consider further expansion throughout South Africa.

Q: What about the other parts of Africa?

A: Eastern Africa in general presents very good conditions for our technology, but for now we are going to concentrate our efforts on deploying this endeavour in South Africa before entertaining new opportunities.

Luciano Garcia-Baylleres, COO at HAE, Tel: 561-900-7200, Email:Lgarcia@HAE-USA.com, www.HAE-USA.com

March 2013

POWER GENERATION NEWS

E m e r g i n g Po w e r M a r ke t s Countries across South East Asia, Africa and the Middle East have been amending their regulatory frameworks and embarking on privatisation, as many of them are in serious need of external funding to ensure that their respective electricity industries are capable of dealing with the inevitable surge in demand. The cumulative installed power capacity for these regions, according to 2012 estimates, will be 212 Gigawatts (GW). However, this figure is expected to shoot up to 349 GW by 2020, climbing at a Compound Annual Growth Rate (CAGR) of 6.4%.

Carbon Credits MTN has announced that it has entered into a commercial arrangement to sell its carbon credits to EDF Trading in an industry first. The credits will be produced by MTN’s tri-generation plant at 14th Avenue Office Park in Fairland, Johannesburg.

EDF Trading is a wholly-owned subsidiary of Electricité de France SA, one of the largest compliance buyers covered by the European Union Emissions Trading Scheme (EU ETS).

The carbon credit project utilises a Clean Development Mechanism (CDM) methodology developed by MTN, approved by the United Nations Framework Convention on Climate Change (UNFCCC).

It is currently in the process of being registered with the UNFCCC. Once registered, MTN will sell the carbon credits from the project to EDF Trading.

The project will make use of the MTN energy-efficient 2MW tri-generation plant at its Fairland office park. Tri-generation is the concurrent production of electricity, heating and cooling which provides

Rising industrialisation, ever-increasing population figures and growing economies all point to an electrical future that most infrastructure systems are currently incapable of handling. Therefore, to achieve greater industry efficiency and encourage competition, governments across this region are opening up their electricity markets and increasing private sector participation.

The region will have to invest heavily in order to increase its installed capacity and improve its existing infrastructure.

power, hot water, space heating and cooling for air conditioning from a single source.

Egoli gas is used for the operation, sourced from the Sasol pipeline in Mozambique.

The plant displaces grid electricity from Eskom, reducing greenhouse gas emissions and providing up to 85% efficiency on fuel. The excess heat, at some 400°C, is captured and used to supply heating and to operate an absorption chiller, which, creates cool water that is used to power an extensive air-conditioning system.

Natural gas is clean burning and offers a consistent supply, but simply using this to generate electricity would have been too expensive. The saving achieved by capturing the waste heat, combined with the additional revenue from the sale of the carbon credits, however, makes the project economically viable.”

Promethuim, Robbie Louw, Tel: (011) 706-8185, Email: Robbie@promethium.co.za www.promethuim.co.za

Transmission networks in many of these countries are already under tremendous pressure to supply power without interruption, and many new transmission projects are already underway or in the pipeline. Therefore, energy policy reforms are set to open the doors and create positive opportunities for growth in in the near future, this according to Jonathan Cain of GBI Research GBI Research, Jonathan Cain, Tel: +44 1204 543 533, Email:jcain@gbiresearch.com, www.gbiresearch.com

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POWER GENERATION NEWS

Bioclimatic building Greywater recycling systems located at basement and at mid-level have been installed to collect greywater generated from lavatory or bathtub for reuse; reducing potable water demand for the office tower by about 40%.

The ice storage system shifts part of the peak electricity demand of the chillers into the night mode/off peak operation. Storage capacity is 26 400 Refrigerant Ton (RT) which reduces about 30% of the summit demand by about 3% through this ice cooling storage system and save up to the yearly energy cost for the user.

With Gensler Architects, Aurecon has completed the design on the façade of what will be Chinaâ&#x20AC;&#x2122;s tallest building. At 632m, the Shanghai Centre is more than 100m taller than the recently-completed Shanghai Financial Centre and is designed as a sustainable eco-tower that sets a new benchmark not only for the region but also the world.

Sustainable green features include tri-

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generation plant consisting of two sets of 1.1MW natural gas turbine generating electricity, chilled water, hot water and heating water. Simultaneous heat recovery of the hot flue gas produced from the turbines reduces carbon dioxide by 49% compared with the regular electrical cooling system.

15 nos. of 3kW vertical axis wind turbines (VAWTs) on the roof provide 157 500 kWh of clean and renewable electricity annually.

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A large volume water deluge system with rotational nozzles installed at mid-level of the atria delivers a large volume and accurate water spray onto fire with the assistance of Infra-red detection to lock the exact location and very early warning smoke detection apparatus system.

A double curtain wall design provides better control on solar energy entering the tower building resulting in energy saving.

Aerecon Group, Jody Boshoff, Tel: (012) 427-2066, Email: Jody.Boshoff@aurecongroup.com www.aurecongroup.com

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 three pertinent questions.

What do you think of computers and the digital world?

Elbie Cornelius of National Oilwell Varco Awesome; changing our world.

Chris Coetzee of Resonant Solutions

Ninety percent of all engineering is done using computers, but if you rely solely on them, you’ve missed the plot because you always have to verify results by going back into the field to test what you’ve done on the computer.

Rudolph Beer of Martin Engineering

Willem Sullivan of Hansen

A better artificial heart for people who are not eligible for natural heart transplants.

Jean Schoeman of National Oilwell Varco My own jet aeroplane.

Chris Coetzee of Resonant Solutions

The problem in industry is practical engineering experience. Young engineers don’t get the opportunity to learn the practical stuff. I’d start an academy which teaches the practical side where you can learn from your mistakes. Unfortunately mistakes cost money, but if you have all the money in the world, they can afford to learn from mistakes.

You can’t do without them.

Willem Sullivan of Hansen

It is where I do all my design work. So if it was not for computers, we would be decades behind in terms of what we can do. I absolutely love it.

Greg Perry of SEW

They have definitely made things faster but the engineer still needs to understand the theory and pay attention to the detail, or you make mistakes faster.

Jean Schoeman of National Oilwell Varco

Very useful, until they give problems. Then you just want to hit them with a hammer. But the digital world has managed to speed up the communication of information.

If you had all the money in the world, what would you design?

Elbie Cornelius of National Oilwell Varco

A solar and wind power station to supply the whole continent with electricity.

In your book, what is the most pivotal invention ever?

Elbie Cornelius of National Oilwell Varco The computer

Chris Coetzee of Resonant Solutions

I can’t see how you can run a business without cellphones.

Rudolph Beer of Martin Engineering The wheel.

Willem Sullivan of Hansen

For me personally: Excel. Without it my world will be dull and lifeless. For the world at large: Electricity, because without it Excel will not be possible.

Jean Schoeman of National Oilwell Varco The personal computer.

Rudolph Beer of Martin Engineering

Develop the safe harvesting of atomic energy.

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MATERIAL SELECTION

Managing Tooling In most machine shops the tooling is usually under lock and key, to limit access to high-value tool inserts such as endmills, drills, reamers and burrs. Even so, many companies suffer considerable losses as these costly tools get lost, are pilfered or are misused because there isn’t a proper management system in place, over and above lock and key, to control who takes what from the store.

Managing machine tools saves money

Dave Goodman, managing director of Spectra Carbide Tooling Technology

“

SA Mechanical Engineer” speaks to Dave Goodman, managing director of Spectra Carbide Tooling Technology in Cape Town, about the various management models they have developed specifically to control tooling. “Our tool management systems were developed through our involvement with some of the major automotive OEMs in South Africa,” he says. “The management system, where we take over full control of the tooling facility on the premises, has been running for twelve years now at some of these plants.

To meet different requirements we now have four levels of management on offer, each requiring a different level of active involvement from our side Systems for all

“But, these systems are not only for OEMs and

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large operations,” Dave remarks. “To meet different requirements we now have four levels of management systems on offer, each requiring a different level of active involvement from our side.

This varies from purely holding stock to supply for a customer’s specific needs, right through to taking over full control of tooling by having a permanent on-site office manned by fulltime Spectra staff.”

A typical level 4 operation with a Spectra team permanently stationed on the customer’s premises will be equipped with a fully-computerised store inventory system to control the purchasing of all tooling, from spindle to point. “The team will control all the new stock and used tools by negotiating and dealing with tier two suppliers as well,” explains sales manager, Wayne Williams. “They are also responsible for presetting tools ready for production as well as collecting and delivering tools to and from the machines, in addition to providing technical support 7 days a week 24 hours a day.

Benefits

One of the cost saving benefits for the customer is less administration because the Spectra team consolidates all invoices so the customer receives March 2013

MATERIAL SELECTION

Special carbide drills, reamers, end mills and special inserts are manufactured in South Africa

one invoice per month. In addition, the customer has a highly skilled specialist in-house on tap to provide technical assistance for all tooling drilling, tapping, milling, boring, gundrilling, honing and line boring on CNC and conventional machines. “From the management system we can draw extensive reporting for the customer regarding the costs per unit manufactured. We produce monthly graphs for trending as well as daily incident reports on tool breakages, weekly costs on scrapped tools and we also work out action plans to reduce scrap and improve up-time of the machines,” Wayne adds.

In essence this value-add for the customer allows preventative action which ultimately saves the customer money. Dave explains, “Given the skills shortage out there, no company can afford the personnel purely to manage the machine shop in so much detail. With this system we not only fill the skills-gap by integrating with the company, but we add value to the company so that they can focus on what they manufacture.”

New product development

Integration into the customers’ operation has proved particularly beneficial when it comes to new product developments. Wayne elaborates, “We’re always up to date with the latest technology in tooling and know what can be done in the best possible way. Usually it will take a machine shop a while to select the right tooling and method to produce

a new part, but with our experts right there on site they can be assured of finding the most suitable solution using the right tooling from the start.”

Vending system

On a lower level of tool management where the operation does not justify a permanent Spectra team on site, the company has a tooling vending machine solution. “All the tooling is stored in a vending machine and access to draw the tools out of the machine is controlled by a card or fingerprint reader,” explains Dave. “Such a system does however, have a reporting function which allows the customer to draw the machining cost against each specific job.

From the management system we can draw extensive reporting for the customer regarding the costs per unit manufactured “This system has proved popular in South Africa because it can be customised to control the specific functions relevant to each customer,” adds David.

“Part and parcel of this cost-saving solution is training the customer on how best to utilise the system for his needs, be it purely controlling the use of tooling or integrating reporting and costing into the business system of the company.”

Wayne Williams, Spectra, Tel: (011) 827-8957, Email: waynew@spectra-sa.co.za

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SURFACE FINISHING

Starting from Scratch

“To scratch the surface, as the saying goes, of most modern materials and coatings is not as easy as it used to be. That’s why we developed Cubitron Abrasive Grain”, says Kelly Hunt, sales and marketing manager of 3M. Cubitron can be used to finish, profile and or polish materials with high tensile strengths and is particularly useful to extend the lifetime of belts and discs in industrial environments where hard materials are the order of the day.”

Consistent cut

Finishes are little changed through the entire duration of a Cubitron belt from new to completely worn out. The secret, is that the cutting edges wear in a controlled manner. This means that the tiny individual scratches are the same when the belt is first

put on until it is worn and ready for replacement.

“There are a multitude of cutting edges on each individual grain of the extremely hard ceramic based grain. As the grain wears, new cutting edges are exposed in a predictable and measured manner to ensure that a consistent action is applied to the surface,” she adds.

Using the same ceramic platform 3M developed Cubitron II, providing even better results than its predecessor. 3M engineers were able to electrostatically orient triangular, precision shaped ceramic grain, acting like a cutting tool. This means that the grain slices through metal, as opposed to grinding, and continuously self-sharpens as points break off.

This results in discs and belts running cooler and longer. The Cubitron II technology is applied in

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SURFACE FINISHING

belt, fibre disc, and Roloc form, offering a unique solution for wide range of grinding needs.

Scratching the surface

Kelly is an abrasives fanatic. She says scratching the surface of abrasives technology is to open a complex science. Analysis of different materials and techniques of cutting or finishing has in recent years become a necessity as materials develop and advance. Bonding of abrasive onto materials for discs and belts is also more complex than before as manufacturing becomes automated and the tolerance for down-time reduces.

Scratcc hingg th h e surff ace of n ologg y is to o o pen abrasivv es tecc hn p lex sccience a comp But, for the average operator, technician or engineer it is not so much a matter of what goes into the development of a product, but rather finding the solution that suits the intended process. The minimum requirement is for a product to perform reliably over an extended period of time and to produce the right finish.

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SURFACE FINISHING

“Using the abrasives to determine a finish can be as simple or as complicated as the producer of finished goods chooses to make it. With so many choices available in the market, we recommend that industrial users identify the requirements of the abrasive and then speak to trained service technicians from suppliers such as 3M.

Sometim m ess a less u t mo ree expeensii ve, bu suita ablee ab b rass ivee can give bett terr ree sultt s Not about price

“Price is not always the determining factor. Sometimes a less expensive, but more suitable abrasive can give better results and, in other instances, the use of cheaper materials in the wrong application may be costly as materials will need to be replaced more often.”

Kelly recommends that users of industrial abrasives take the time to research new products and assess their suitability for their processes. “You’ll be surprised that some of the new abrasives can do the job better and in half the time than older technology abrasives can,” she concludes.

3M, Dylan Ian Hunter, Tel: (011) 806-2186, Email: dhunter@mmm.com, www.3M.com

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IT TRENDS

Mobile Computing Mobile computing is growing momentously and is set to account for as much as 57% of worldwide T market growth in 2013, says Derick Roberts, CEO of TruTeq Devices, a Pretoria-based company focusing on wireless connectivity solutions. “it is going to account for the lion’s share of growth – even more than the cloud computing.”

“Mobile computing continues to grow and, alongside other IT trends such as cloud computing, social technologies and the era of big data. It is going to play a pivotal role in the IT industry this year. In fact,” Derick adds,

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The IDC predicts that worldwide IT spending will exceed $2.1 trillion, up 5.7% from 2012. The research company also states that mobility will be the biggest driver. Sales of smart mobile devices, including smart phones and tablets, is expected to grow by 20% and will contribute a significant 57% of all IT growth. Excluding smart mobile devices, IT industry growth will clock in at only 2.9%.

Truteq Devices, Derick Roberts, Tel: (012) 667-1530, www.truteqdevices.com

March 2013

ELECTRIC DRIVE

The World's Most Powerful Powerboat

Mercedes-AMG and Cigarette Racing launched the latest development of their cooperation at the Miami International Boat Show in February. Numerous components from the SLS AMG Coupé Electric Drive have been integrated in the design of the "Cigarette AMG Electric Drive Concept" engineering design. The high performance drive fitted in the electric super sports car makes the off shore powerboat the world's most powerful and fastest electrically-driven motor boat. With an output of 1 656 Kilowatts and a maximum torque of 3 000 Newton metres, the "Cigarette AMG Electric Drive Concept" is a fascinating new development.

T

he technology, performance and design of the Cigarette powerboat is closely based on the electric super sports vehicle made in Affalterbach, Germany.

The 11.6 metre long "Cigarette AMG Electric Drive Concept" powerboat uses two drive units, each featuring six independent electric motors. At the rear of the boat, each drive unit has its own transmission, one on the left and one on the right. The boat is fitted with the twelve compact, liquid-cooled permanent-magnet synchronous electric motors which are the signature piece of the SLS AMG Coupé Electric Drive: each electric motor delivers 138 kW and 250 Newton metres.

Combine to reach a staggering top speed of over 160 km/h The maximum output of 1 656 Kilowatts and maximum torque of 3 000 Newton metres combine to reach a staggering top speed of over 160 km/h making this locally emission-free "Cigarette AMG Electric Drive Concept" the world's fastest electrically driven powerboat. The low centre of gravity and optimum weight distribution ensure sublime

handling characteristics during more dynamic changes of direction.

The high-voltage battery boasts an energy content of 60 Kilowatt hours, an electric load potential of 600 Kilowatts and a weight of 548 kg – all of which are absolute best values in the automotive sector. The liquid-cooled lithium-ion high-voltage battery features a modular design with a maximum voltage of 400 V. It consists of 12 modules each comprising 72 lithium-ion cells. “Cigarette” integrates four high-tech batteries with a total of 48 modules and 3 456 cells which generate a total capacity of 240 Kilowatt hours and an electric output of 2 400 Kilowatts respect even in the boat building industry.

The "Cigarette" on-board chargers as standard.

Adapted to fit the infrastructure standard of many American marinas, the boat has a charging capacity of 44 Kilowatts. The battery is fully charged in approximately seven hours. To reduce the charging time to less than three hours, the powerboat can be fitted with four on-board chargers as an option.

Mercedes-Benz, Shirle Greig, Tel: (012) 677-1904, Email: shirle.greig@daimler.com, www.mercedes-benzsa.co.za

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ENVIRONMENT

Water Disclosure Reporting Just as companies are addressing their carbon emissions and provide carbon reporting to the Carbon Disclosure Project (CDP), water is becoming a growing priority.

Reporting on it is becoming another critical sustainability issue.

ing countries. In meeting this crisis, South Africa will have to resolve tough trade-offs in water use between agriculture, key industrial activities such as mining and power generation, and the supply to rapidly growing urban centres.

Evidence is clear

2

011 saw a marked increase in the number of the world’s largest companies reporting on their water usage, on the risks that water presents and on their responses to that risk. Responses from these companies indicate that water is impacting global business now, and yet water is not nearly as high on the corporate agenda as climate change.

In 2011, the response rate to the CDP Water Disclosure amongst South African companies was 46% (26 out of 56 companies). Many of South Africa’s most significant corporate water users are therefore not yet able to, or are not yet ready to, report on their water-related risks.

Promethuim, Robbie Louw, Tel: (011) 706-8185, Email: Robbie@promethium.co.za, www.promethuim.co.za

ai_ait_44.0_en aik

Evidence is mounting that South Africa is facing a water crisis of substantial proportions. This crisis encompasses all aspects of water management on both the demand and supply side. The mounting impacts of acid mine drainage and declining water quality add to the crisis. South Africa’s water security is likely to be further complicated by an increasingly uneven and unpredictable supply of rainfall as a result of climate change and by a reliance on significant water transfers from neighbour-

JSE 100 companies will need to show leadership in sustainably managing the water resources on which they rely for their day-to-day business operations.

The available evidence is clear. It is not sustainable to continue exploiting water resources by following a ‘business as usual’ approach. If this is the case, South Africa’s freshwater resources will be depleted and unable to meet the needs of people and industry in the next 20 years, if not before.

Protect Your Belt Conveyors with Voith Fluid Couplings They have been in service for decades under the toughest conditions – and have proven themselves worldwide.

Voith fluid couplings protect belt conveyors and drive components by providing smooth acceleration and torque control allowing for frequent loaded starts with the least amount of stress on the drive and belt.

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In multi-motor drives they ensure precise load distribution. Result: fewer downtimes – and the service life of the belt and the drive components is increased. The latest product innovation is the Voith TurboBelt 780 TPXL. info.vtza@voith.com www.rsa.voithturbo.com

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EXHIBITION

Boosting the Manufacturing Sector 32 of South Africa’s leading industrial and engineering professional and employer associations, Chambers and Councils have collectively endorsed Indutec, the recently launched South African Industry and Technology Fair 2013.

T

he Steel and Engineering Industries Federation (SEIFSA), the Lifting Equipment Engineering Association of SA (LEEASA) the Engineering Council of South Africa (ECSA) and the SA Institute of Welding (SAIW) have thrown their weight behind the biggest industrial and engineering trade show in Africa.

Edgar Sabela - ECSA’s Strategic Services Executive

The three-day, 10-shows-inone event takes place from 14 to 16 May 2013 at Gallagher Convention Centre in Midrand, Johannesburg.

SEIFSA Conference at Indutec

The Steel and Engineering Industries Federation of South Africa (SEIFSA) will hold its annual conference at Indutec, celebrating 70 years of active support for its members, industry and business in Africa. The federation has over 2 220 member companies which employ more than 224 000 people, comprising 53% of the industry’s workforce.

SAIW Adelia Pimentel - Marketing and Communications Manager: SEIFSA

“We take our affiliations with leading industry players very seriously, including our endorsement of Indutec,” says Jim Guild, chief executive officer of the SA Institute of Welding. “These industry ties form part of our strategy to create strong relationships which support our objective, and Government’s mandate, to enhance the manufacturing sector in South Africa.”

LEEASA

Jim Guild, CEO of the SA Institute of Welding

The Lifting Equipment Engineering Association of South Africa (LEEASA), which is a division of the Chamber of Engineering Tech-

nology (COET), will also be using its endorsement of Indutec to promote its activities in the engineering and technology sectors in general. Chamber spokesperson Viv Nel says its exposure at the fair will create more awareness of the Chamber’s role in all engineering and technology-driven industries.

ECSA

Industry regulator, the Engineering Council of South Africa, shares these aims. “As a custodian of engineering intellectual capital in South Africa, our endorsement of Indutec provides us with a platform to publicise our role in the engineering sector and government infrastructure initiatives,” says Edgar Sabela, ECSA’s Strategic Services Executive.

“We need to produce 10 times more engineers to compete with developed economies. Involvement with the Indutec show will allow us to promote engineering as a career through our Engenius Programme, and showcase our existing engineering excellence. Most importantly, it enables us to network with all key players in the field and even conclude some business.”

Tenfold Benefits to Exhibitors

John Thomson, managing director of Exhibition Management Services, organisers of the 10-in-one Fair, says the unqualified support from leading industry bodies indicates the show’s tenfold value to the engineering, industrial and technology sectors.

“This undoubtedly translates into multiple benefits for the show’s exhibitors and ultimately to show visitors,” he concludes.

Indutec, Serean Thomson, Tel: (011) 783 7250, Email: marketing@exhibitionsafrica.com, www.exhibitionsafrica.com

Promech Publishing, through "SA Mechanical Engineer" and "Bulk Handling Today" will produce and publish the Official Catalogue for this prestigious show.

Make sure your presence is felt before, during and after the show, by advertising in this oneof-a-kind reference publication.

Contact: Mark Bennett, Tel: (011) 781-1401, Email: samecheng@promech.co.za

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MARKET FORUM

Total Solution

2400 Robots ABB started with a bang following the order of 2 400 robots by BMW Group. Over the next three years, the robots will be installed at factories in Regensburg and Leipzig, Germany, as well as in Tiexi, China. The ABB robots will mainly be used for material handling tasks, as well as gluing and spot welding processes.

“BMG, has identified a need in diverse sectors for on-site maintenance services to overcome production challenges,” says Dave Russell, technical director, BMG. “Recognising the extreme constraints of high energy prices, low productivity, the critical skills shortage and a highly competitive economic environment, BMG brings a total solutions service to the fore.

“Industry can now access all critical production efficient products and services from one supplier. What this means is lower production costs and higher production efficiency, giving South African industry a distinct competitive advantage.

“BMG’s on-site services include applica-

tion design, evaluation and optimisation, as well as installation, trouble-shooting and service exchange contracts. The company also offers predictive, planned and breakdown maintenance and energy and reliability studies.”

The company also offers extensive training, which covers electrical, mechanical, hydraulic, pneumatic, electronic and materials handling disciplines, as well as predictive maintenance and component failure analysis.

BMG – Bearing Man Group, Veronique van Niekerk, Tel: (031) 576-6221 Email: veroniquev@bmgworld.net, www.bmgworld.net

ABB robots enable customers to implement efficient manufacturing systems that sustainably produce high-quality products. The company’s range of products and solutions for lean manufacturing cover the range from body-in-white to the final assembly of complete car bodies.

They improve competitiveness and at the same time, optimally comply with customer specifications. ABB has installed more than 200 000 robots worldwide.

ABB Robotics, Natasha Mathebula, Tel: (010) 202-6156, Email: natasha.mathebula@za.abb.com, www.abb.com

Unique SAG Mill in Canada Tenova Takraf Africa (formerly Bateman Engineered Technologies) is putting the final pieces together in completing an order for the supply of a 5.5m x 2.75m, hydraulically-driven SAG mill to Ontario Graphite, operators of the Kearney Mine located in Kearney, Ontario, Canada.

“Tenova’s scope

of work includes the engineering, manufacturing, shipping and technical assistance during erection of the SAG mill’s feed end, shell, discharge end, drive and main bearings, as well as all supporting equipment (lubrication and jacking systems),” says Tenova Takraf, engineer Pieter van der Walt. “The main hydraulic motor and rubber shell liners were outside our commercial scope of supply, but inside our technical scope of supply,” he adds.

The mill is a conventional SAG (semi-autogenous grinding) mill in all ways apart from its drive assembly and, it is centre-driven

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at the discharge end using a Hagglünds hydraulic motor and powerpack. “To date, this is the largest hydraulic motor installed on a SAG mill, with 950kW of power, torque of 1 200 kN.m (start-up) and 650 kN.m (operational), and speed of 13.86 rpm,” adds Pieter.

Since the mill had to be retrofitted to an existing foundation, a number of adaptations were required to maintain the mill centreline, as well as feed-end and discharge-end positions. Certain additions were required to anchor the main motor torque arm.

Tenova Takraf, Pieter van der Walt, Tel: (011) 899-2372, Email: pieter.vanderwalt@bateman.com, www.tenovagroup.com

MARKET FORUM

World Record FLSmidth designs and manufactures indirect heated carbon regeneration kilns and calciners from half a ton per day and larger. These kilns and calciners can be fuel gas, oil, or electric, and are skid mounted, pre-wired and pre-piped.

The company’s patented bellows kiln seal has proved effective in eliminating air ingress and process gas egress and can be retrofitted to kilns from other manufacturers. FLSmidth holds the world record for the lowest emissions on a carbon plant.

And at the company’s Merrill Crowe plant capacities range from skid mounted 3.4 cubic metres per hour modular plants to full size 2 100 cubic metres per hour.

The range of supply for plants includes clarification filters, de-aeration towers, vacuum pumps, zinc dust feeders, lead nitrate feeders and zinc cones, precipitate filter feed pumps, filter pre-coat and body feed systems, as well as precipitate filters used by refinery and smelting facilities to produce gold bullion.

These plants incorporate proprietary zinc dust/lead nitrate feeder and mixing cone system. The company offers individual plant components and partial or complete plant equipment packages, together with total plant design.

FLSmidth, Terence Osborn, Tel: (010) 210-4820, (PDLO PDULQGD NHUU#ÀVPLGWK FRP ZZZ ÀVPLGWK FRP

The ADR plant at Kisladag Mine

4 x Longer Magnet has extended its range of abrasive products to include 3M’s new Cubitron II abrasive belts, with enhanced grinding performance, improved productivity and extended service life.

“3M’s new technology has resulted in increased speed, improved consistency and extended belt life,” says Brian Howarth, MD Magnet. “These new abrasive belts ensure up to 30% faster cutting on hard to grind metals, like stainless steel, nickel alloy and cobalt chrome.

They also divert heat from the workpiece and belt to the swarf, which means cooler cutting. This helps eliminate burnishing and minimises heat stress.

Cubitron II abrasive belts last up to four times longer than conventional ceramic aluminium oxide belts.”

3M Abrasives, Bradley Reddy, Tel: (031) 274 1050, Email: bradleyr@magnetgroup.co.za www.magnetgroup.co.za

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MARKET FORUM

Say No to Corrosion X-Calibur is one of the latest product offerings from TAL and was specified to protect the concrete structure of the world’s second longest cable-stayed bridge against corrosion throughout its design life.

Stonecutters Bridge is a high level cablestayed bridge which spans the Rambler Channel in Hong Kong, connecting Nam Wam Kok, Tsing Yi Island and Stonecutters Island. Hong Kong is well known for its hot summer weather, which is also humid and unstable. Temperatures

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usually exceed 30oC during the day, which coupled with high humidity, can result in an extreme heat index.

“Hot and humid environments have a great effect on the durability of concrete.

As a rule of thumb we say for every 10oC increase in temperature the possibility of corrosion induced damage to concrete is doubled. Add humidity in a marine environment then protection of the structure is of paramount importance,” says Brian Davies, CEO X-Calibur International.

In order to guard the bridge from corro-

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sion, X-Shield EpoxySeal CR was supplied to shield the prestressed concrete cable anchorages from the effects of the environment. In addition, X-Shield FlexCoat was used in various areas of the structure. This provides corrosion protection to reinforced concrete from chloride and carbon dioxide.

“The main challenge was compliance with the strict project specifications as the engineer wanted to ensure that protection would be provided throughout the design life of the structure. X-Calibur

MARKET FORUM

Large Water Supply Project Fluid conveyance and pumping solutions expert Incledon has supplied a large water supply line project in the Free State with a total of 4 km of Ultraflo pipes manufactured in-house by DPI Plastics - a leading manufacturer of water reticulation, drainage and pipefitting systems in South Africa.

had the products independently tested to prove compliance to all aspects of the specification,” John adds.

The materials were applied by specialist painters who had been trained

by X-Calibur. “Materials were mixed and applied strictly in accordance with method statements supplied by X-Calibur to ensure working time and recoat windows were not exceeded,” concludes John.

TAL, Andrew Dekker, Tel: (031) 579-2263, www.tal.co.za

DPI Plastics technical and product manager, Renier Snyman points out that the company’s range of Ultraflo pipes are manufactured from modified polyvinyl chloride (mPVC), which is specifically designed to provide similar tensile strength and greater resilience than standard PVC piping products. “The Ultraflo range of pressure piping systems are ideally suited to bulk water supply projects, due to the fact that mPVC is considerably more ductile than industry standard unplasticised polyvinyl chloride (uPVC),” he explains.

Renier notes that the ductility of the Ultraflo uPVC piping system ensures that

the pipes have exceptional resistance to crack propagation under pressure. “The product being supplied to the water supply line project is the 500 mm Ultraflo system, which is the largest in the DPI Plastics range. It boasts a pressure rating of 12 bar, with a design stress of up to 18MPa, making it ideally suited as a large underground piping system.”

According to Renier, Ultraflo pipes offer environmental advantages too. “Due to its superior toughness, the wall thickness of mPVC is less than that of uPVC. This ensures that less materials are used during the manufacturing process, which ultimately results in a lighter product that is easier to transport and install, thereby minimising the carbon footprint of the pipe.”

DPI Plastics, Martine Goodchild, Tel: (021) 957 5600, Email: mgoodchild@dpiplastics.co.za www.dpiplastics.co.za

Don’t Miss Out! Promech Publishing is putting the Visitors’ Catalogue together for this Show.

Contact Mark Bennett on Tel: (011) 781-1401 or Email: samecheng@promech.co.za to book your space.

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MARKET FORUM

Strategic Alliance The Bearings division of Actom group company Wilec has formed a strategic alliance for the supply of Dodge housed bearings into southern Africa. The partnership agreement with Johannesburg-based Specialised Bearings & Transmission, the local distributor for Dodge, extends Wilec’s ability to satisfy the requirements of industry and mining in a diverse range of bearings applications.

“The most exciting thing about our tie-up with Dodge is that housed bearings, while already widely accepted in the US and other leading industrialised countries, is a relatively new concept locally, but one which offers advanced features to users compared with conventional plummer block arrangements,” said Frans Odendaal, Wilec’s Technical Specialist, Bearings.

“Dodge housed bearings are supplied pre-assembled and sealed, so eliminating all risk of contamination during fitment.

The advanced sealing arrangement and unique adapter system guarantees longer

Displaying and discussing some of the Dodge housed bearings on offer to local industry and mining are (from left): Tony Patten of Specialised Bearings & Transmission, Peter Small-Shaw, Wilec’s Product Manager, Bearings, and Frans Odendaal, Wilec’s Technical Specialist, Bearings

life – up to six times that of a conventional plummer block. Other cost-saving advantages are that they can be installed by a semi-skilled technician very quickly, normally in less than 15 minutes, and the need to measure pre- and post-reduction clearance is eliminated.”

and offers benefits that are of real value to customers. A particularly important aspect to bear in mind is that the total cost of ownership of a Dodge bearing is significantly lower than that of the conventional product, due to its greater reliability and durability.”

“It is a differentiated product and with it we are able to provide a bearing that is especially well suited to local conditions

Wilec, Frans Odendaal, Tel: (011) 629-9300, Email: franso@wilec.co.za

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MARKET FORUM

Proloc protection and control relays

Optimum Protection Emis Sales 2002, part of Becker Mining South Africa, supplies a wide range of electrical equipment, up to 1 100 V, for use in hazardous and non-hazardous areas in the mining, petrochemical and surface industry sectors.

New to the Emis range are Proloc protection and control relays which are suitable for thermal overload protection of conveyors, compressors, crushers, fan and pump motors, as well as shuttle cars and flitting panels.

“The stand-alone Emis ProLoc electronic protection and control relay system, which has been designed for the optimum protection of motor and feeder circuits connected to outlet sockets, has a wide choice of six user-selectable protection features to meet exact requirements,” says Frikkie Quirk, managing director, Emis Sales 2002. “An important advantage of this system is a door mounted infra-red link that enables a laptop, with Proloc software, to manage all settings

Superheated Vacuum Steam

and downloads, without having to open the panel door and expose personnel to dangerous live equipment. This is a critical requirement in the OHSA act.”

This system is easy to set up via the Proloc MMI 420 display man-to-machine interface, or via a laptop with Proloc software.

Emis Sales 2002, Tel: (016) 341-6134, Email: info@za.becker-mining.com, www.za.becker-mining.com

a maximum middle temperature when applying direct drying to heat sensitive materials, and even more important to avoid the excessive local and boundary temperatures that frequently damage the drying product. Both heat and material transport need to be considered, and while convective drying processes such as spray drying largely avoid these problems, they are only effective if a surface is available for the hot gas flow.

Adjustable for both direct and convective drying and processing, Evactherm driers overcome these obstacles while providing a number of further benefits.

The Evactherm drier

Birkenmayer, a material processing systems supplier in South Africa and local supplier of German-engineered Eirich material processing technology, recently released the Evactherm drier, a new product that marries the advantages

of mechanical and thermo dynamical processes to provide cost-effective and highly efficient drying and processing of filter cake and sludge’s using superheated vacuum steam.

Until now, it has been important to observe

Super-heated vacuum steam performs drying and granulation, while the combination of mechanical and thermo dynamical processes allows for low drying temperatures and gentle processing of temperature sensitive materials. It also enables continuous drying for long periods of time, as fresh material may be continuously added into the fluidized bed, replacing material that has already been vaporised.

H Birkenmayer, Louis Eksteen, Tel: (011) 970 3880-8, Email: louis@birkenmayer.co.za www.birkenmayer.co.za

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MARKET FORUM Left to right: Chris Mashigo, Executive Manager - Business Development Coega Development Corporation, Themba Khoza, Executive Manager – Operations Coega Development Corporation, Seelan Gounden, GM - Supply Chain, Air Products, Pierre Fourie, Area Sales Manager – Eastern Cape, Air Products, signed the lease agreement between the CDC and Air Products South Africa

delivery to our existing customers who have to depend on product being trucked over vast distances. Thus, we identified the Eastern Cape as a key priority investment destination, with a clear need for a new air separation facility dedicated to servicing the region. We chose the Coega IDZ after careful market analysis.

We are pleased to be able to be a part of the growth and development of the region, through providing a long-needed security of supply and value-added service.”

A Long-term View The Eastern Cape’s Coega Industrial Development Zone (IDZ) is one of a number of industrial regions in South Africa to benefit from Air Products South Africa’s strategy of long-term capital investment.

A region which has long been underserved when it comes to reliable gas supply, the Eastern Cape will soon have

its own air separation unit (ASU) – the first of its kind in the province. Seelan Gounden, GM, supply chain at AirProducts, explains the reasons behind the company’s latest investment.

“Currently there is no local industrial gas supply in this area, and cryogenic gases have to be procured elsewhere.

This situation compromises the service

Ayanda Vilakazi, head of Marketing and Communications at the Coega IDZ adds, “The viability of the new ASU is indisputable. It will mean not only security of gas supply to the region, benefiting the many industries here, but it also means job security for other investors, jobs along the value chain and scope for training and human resource development, as well as enhanced Corporate Social Investment initiatives.”

Seelan Gounden, AirProducts, www.airproductssouthafrica.co.za

Index to Advertisers Axiom SKF South Africa recently appointed Anton Theunissen as Distributor Develpoment Manager for South Africa and neighbouring countries

Jeanne Els has been appointed as Hatch’s Managing Director of Operations

Jeanne Els

Anton Theunissen

12

Bearings International

36

Bibby Turboflex

28

Bonfiglioli

10

Engen

34

Festo

35

Hansen

44

Horne SA

29

IDC

Inside Back Cover

ILS

32

KDP Services

22

Loesche

31

Polysius

4

PPS

Mark Walsh

Ronald Lange

Robert Ramshaw

Gavin Rosslee

ART Solar, specialists in the manufacture of solar photovoltaic (PV) modules, for the sustainable generation of electrical power, has made the following appointment announcements: Mark Walsh as managing director, Dr. Ronald F.M. Lange as chief operating officer, Robert Ramshaw as financial manager and Gavin Rosslee as production manager.

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11, 29

Mercedes

Outside Back Cover

Merseta

Inside Front Cover

MIEO

Outside Front Cover

Transmission Components

14

Voith

38

Yellotec

16, 17

Driving new market innovations The IDC supports high-impact job creation projects, acting as a catalyst to lead new sector development, and support existing industry and sector growth in alignment with governmentâ&#x20AC;&#x2122;s New Growth Path (NGP), National Development Plan (NDP) and Industrial Policy Action Plan (IPAP).

The IDC Strategic High Impact Projects (SHIP) Strategic Business Unit, in partnership with the IDC Innovation Department, has launched an Open Innovation Challenge to encourage the development and implementation of sustainable high-impact industrial initiatives and projects.

The IDC calls upon individuals, engineering communities, corporates, project sponsors and other related entities to enter into a partnership to develop qualifying projects that result in sustainable and profitable industries; exploit the value-adding opportunities of existing and new value chains; and enable the development of innovative local economies.

SHIP wishes to ensure that the projects undertaken play a major role in industrial development and employment creation within the South African and SADC regions.

Interested applicants are invited to submit their project proposals online at: http://openinnovation.idc.co.za/idc-ship-challenge between 'FCSVBSZ BOE "QSJM "QQMJDBOUT GPS TVDDFTTGVM project proposals will be informed in May regarding SHIP wishing to partner with them in the development of the proposed project.

Please contact Bertie Strydom BertieS@idc.co.za and 3FUJFG #SVXFS RetiefB@idc.co.za for more information.

Chillibush9119IDC

What/who qualifies? t 1SPKFDU JOWFTUNFOU WBMVF PG OP MFTT UIBO 3 NJMMJPO t 5IF QSJNBSZ GPDVT JT PO OFX BOE JOOPWBUJWF ANFHB JOEVTUSJBM projects, which enable the development of new industries across multiple IDC focus sectors

t )JHI JNQBDU QSPKFDUT XJUIJO UIF 4PVUI "GSJDBO DPOUFYU UIBU introduce new markets and value chains, or revolutionise existing ones, through the use of disruptive technologies or new approaches t &DPOPNJDBMMZ TVTUBJOBCMF OFX QSPKFDUT UIBU IBWF B NBKPS development impact and employment creation t 1SPKFDUT UIBU FOIBODF FYJTUJOH MPDBM JOEVTUSZ DBQBDJUZ across mandated IDC industrial sectors

Telephone: 086 069 3888 Email: callcentre@idc.co.za To apply online for funding of R1 million or more go to www.idc.co.za

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You built the bridges, the roads and the tunnels. We built the car.

As a member of the Engineering Council of South Africa, you could qualify for exclusive offers,* a guaranteed 3-day service booking as well as PremiumDrive, our 6 year/100 000km maintenance plan. To take advantage of this outstanding opportunity, inform your nearest dealer of your ECSA status.

A Daimler Brand

*Not in conjunction with other Mercedes-Benz Fleet Programmes/Offers. Excludes AMG and Limited Edition models.

Vehicle specifications may vary for the South African market.

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