S MECHANICAL A ENGINEER March 2016
Publication of the SA Institution of Mechanical Engineering, incorporating News of Associate Organisations
SA Institute of Tribology
Leaders in Technology and Training TWO NEW ENDORSEMENTS FOR “SA MECHANICAL ENGINEER”: VAMCOSA AND SAPPMA THE SOUTH AFRICAN MECHANICAL ENGINEER
VOL 66 March 2016
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SEW-EURODRIVE–Driving the world
1THREAD_3190_SAM
We drive the mining industry
SEW-EURODRIVE offers a new solution for the mining industry - a completely new type of planetary geared motor which offers impressive product advantages. The compact gear units are designed so that the gearmotor is mounted directly in front of the planetary gear unit. Couplings, intermediate flanges and adapter flanges that take up space and increase the price are a thing of the past. The P-Series has been successfully used in bucket wheel, apron feeder and milling applications. The SEW-EURODRIVE modular concept results in a cost-effective performance relationship with shorter delivery times. SEW-EURODRIVE - Driving the world.
Tel: +27 11 248-7000 Web: www.sew.co.za
AN ENGINEER’S VIEW
Will Gold Shine Again? Studying the current state of the world economy following, among other effects, the end of the commodity cycle, there is a growing concern that the worlds’ currencies, which have since 1913 been effectively fiat based (ie, no value backing such as gold), will eventually collapse. Historically currencies do this.
Chris Reay
T
he US Dollar as the world’s reserve currency might remain the strongest of the lot until there is the impact of deflation and hyper-inflation resulting from the quantitative easing with fiat currency. Ultimately, it is all a result of the deb- based currency systems which have been manipulated to create the biggest debt bubble in the history of money and currencies. Anyone interested in the impact this is having on world trade should look up the Baltic Dry Index records. It is a very interesting metric that measures the shipping movements between continents. It is at the lowest index level in its history. Out of most misfortune, one hopes for the glimmer of positivity. In the current economic saga is the possibility that there will be a replacement world reserve currency that would be based on a value backing, and the most obvious is gold. Silver may have its role as well.
Where to now?
Chairman of the Working Committee: Communications (SA Institution of Mechanical Engineering)
For one hundred years, we have effectively grown our economy based on mining and commodities. Investment into this area has almost ceased. Have we learnt anything from history that should have prepared us for the end of the boom, and undertaken development of other industries?
The NDP has proven to be stillborn and the excitement created in 2012 on the need to train up skilled resources to enable us to build the SIPs has waned into a dilemma whereby we now have surplus skills and no projects. It appears we have no funding for them now.
Some protagonists of this are predicting a massive hike in the gold price
Observable action?
Some protagonists of this are predicting a massive hike in the gold price. Two interesting issues are evident. China is buying large quantities of gold, and the USA banking system and Fed are doing their best to suppress the price. Gold is no longer following the commodities index and going its own way. South Africa does not have any perceptible agenda on the table, let alone observable action, to get economic growth going to uplift the rate of wealth generation and make an impact on the rating agencies. Would such a rise in the gold price provide acceptable margins above the cost of recovery in a stable manner and be an option to get our gold mines going as before?
Did anyone have any confidence in the budget speech and its rhetoric? I did not. If I had not known we have a serious economic recessionary environment on our hands, I could have believed it was a business-as-usual budget. Do you really believe that government will cut back on the blue label and the top of the range Mercs? Please, where is the real strategy to create growth?
It is of concern that we are losing, and have lost, a significant number of our experienced resources including Mining Engineers who have in the past managed our gold mining industry. We see them leaving the industry: retiring, leaving the country or moving onto other careers. From our historic role as number one, we are way down now, not sure where?
THE SOUTH AFRICAN MECHANICAL ENGINEER
VOL 66 March 2016
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S MECHANICAL A ENGINEER On the Cover SAIT
March 2016 VOLUME 66 NUMBER 3
www.sait.org.za
Contents Cover Story 8
New Engineering Qualification Replacing the B Tech Degree
Company Profile
11 Protecting Our Resources
Power Transmission
12 Making Sensible Choices 14 Small But Brainy 16 Unbelievable Value Proposition
POWER GENERATION TODAY
17 21
Industrial CO2 Footprint Reduction by Utilisation in AMD Treatment and Gypsum Processes Power Generation News
Manufacturing
27 Integrating Processes and Data
African Expansion
28 Robust ERP Platforms
Hydraulics and Pneumatics 30 Heading North
Wastewater Treatment 33 Desalination Test Rig
Regulars
3 An Engineer’s View 6 Institution News 34 Market Forum
Oils and Lubrication
25 A First for Africa: Turbine Oil Coalescer
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. Produced by: PROMECH PUBLISHING, P O Box 373, Pinegowrie, Official Publication of THE SA INSTITUTION OF MECHANICAL ENGINEERING 2123, Republic of South Africa and endorsed by: Tel: (011) 781-1401, Fax: (011) 781-1403 Email: samecheng@promech.co.za, www.promech.co.za Managing Editor Susan Custers Editorial Contributors Liesl Venter/Patricia Holburn Advertising Sales: Louise Cresswell Cell: 071 886 1263 DTP Lindy Fobian/Anne Rotteglia Circulation Catherine Macdiva
Subscriptions Please email us at accounts@promech.co.za if you wish to subscribe to “SA Mechanical Engineer” at R550,00 (excl postage and VAT) per year; R1 380,00 per year for Africa/Overseas. Disclaimer
PROMECH Publishing and The South African Institution of Mechanical Engineering as well as any other body do not take responsibility for the opinions expressed by individuals.
Printed by: Typo Colour Printing, Tel: (011) 402-3468/9 FSC (Forestry Stewardship Accreditation)
CONSULTING ENGINEERS OF SA CORROSION INSTITUTE OF SA INSTITUTE FOR CERTIFICATED MECHANICAL AND ELECTRICAL ENGINEERS NATIONAL SOCIETY OF BLACK ENGINEERS NUCLEAR INSTITUTE SA ASSOCIATION FOR ENERGY EFFICIENCY SA CAPITAL EQUIPMENT EXPORT COUNCIL SA INSTITUTE FOR NON-DESTRUCTIVE TESTING SA INSTITUTE OF TRIBOLOGY SA PLASTIC PIPE MANUFACTURERS ASSOCIATION SA PUMP MANUFACTURERS ASSOCIATION SA PUMP SYSTEMS DEVELOPMENT ASSOCIATION SA VALVE AND ACTUATORS MANUFACTURERS ASSOCIATION VALUE & ACTUATORS MANUFACTURERS CLUSTER OF SA
THE SOUTH AFRICAN MECHANICAL ENGINEER
VOL 66 March 2016
5
SA INSTITUTION OF MECHANICAL ENGINEERING
Council 2014 - 2016
Company Affiliates Autodesk as represented by Worldsview Technologies
Office Bearers President................................... KK Nyangoni (Kudzai) Vice President................................... E Zawilska (Ewa)
Ainsworth Engineering (Pty) Ltd
National Treasurer............................... A Roos (Andre)
Branch Chairpersons
Alstom Power Service SA (Pty) Ltd
Central .............................................. C Kruger (Carel) Eastern Cape......................... G van den Berg (Gideon)
Babcock Ntuthuko Engineering (Pty) Ltd
KwaZulu Natal .............................R Walker (Raymond) Mpumalanga Highveld .......... PJ Jansen van Rensburg
Bateman Projects (Pty) Ltd
(Jansen) Vaal........................................ Prof LM Masu (Leonard)
Bosch Projects (Pty) Ltd
Western Cape .............................. S Pietrangeli (Sven)
DCD Rolling Stock A division of DCD Group (Pty) Ltd
Portfolios: Communications/ Strategic Planning/ Specialist Groups . . .................................. CD Reay (Chris) Company Affiliates. . .....................................R Mills (Bob)
ELCIME Engineering (Pty) Limited
To be confirmed.................... Prof JL van Niekerk (Wikus)
Festo (Pty) Ltd
Professional Development
Hatch Goba (Pty) Ltd
Chief Executive Officer: Vaughan Rimbault National Office Manager: Anisa Nanabhay
Howden Power
PO Box 511, Bruma, 2026
Howden Projects
Tel: (011) 615-5660 Fax: (011) 388-5356
Industrial Water Cooling (Pty) Ltd
Email: info@saimeche.org.za Website: www.saimeche.org.za
Kelvion Thermal Solutions (Pty) Ltd
Membership Email: membership@saimeche.org.za
Mod-U-Flow CC Osborn Engineered Products SA (Pty) Ltd PaCMan Projects & Maintenance PPS Insurance Co Limited Rotek Engineering S.A.M.E Water (Pty) Ltd SA Power Services (Pty) Ltd Sasol Technology (Pty) Ltd SEW Eurodrive
Spirax Sarco (Pty) Ltd
Hansen Transmissions SA
Technology Programme.. ...................... SZ Hrabar (Steve)
Megchem
Siemens Ltd
Fluor SA (Pty) Ltd
Programme........................................ M Black (Malcolm)
MBE Minerals (SA) (Pty) Ltd
Tenova Takraf Africa – a division of Tenova Mining Thyssenkrupp Engineering (Pty) Ltd Ultra-Flow Engineering Services CC Vital Engineering (Pty) Ltd Weir Minerals Africa Winder Controls (Pty) Ltd
SAIMechE Forthcoming Training Events Fees, Booking Forms & Terms and Conditions Carey Evans, Tel: 031 764 7136 & Email: carey@saimeche.org.za Pressure Vessel Design, Construction, Maintenance and Troubleshooting CPD Validation Number: SAIMechE-0930-12/18
Developer/Presentor: Dr. Herbert de Vries
Code E3716 C3716 A3716
Days 1 1 1
Start Date 5 Apr 2016 5 May 2016 9 Jun 2016
End Date 5 Apr 2016 5 May 2016 9 Jun 2016
The workshop will explain: • The applicable design codes of pressure vessels • How to specify pressure vessels. • How to design and manufacture a pressure vessel. • Selection of materials for pressure vessel manufacture. • The systems related to the operations of pressure vessels • How to safely operate pressure vessels
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THE SOUTH AFRICAN MECHANICAL ENGINEER
To • • • • • • • • •
VOL 66
Region Gauteng Cape Town Durban
Bookings Closure Date 21 Mar 2016 21 Apr 2016 26 May 2016
do this it will cover: Pressure Vessel Design Codes Vessel Geometry & Construction Strength of Materials Vessel Specifications Materials of Construction Pressure Vessel Design Rules Fabrication, Inspection and Testing Maintenance planning and control Safety aspects considered for pressure vessels March 2016
SA INSTITUTION OF MECHANICAL ENGINEERING Inspection and Non-Destructive Testing (NDT)
Total Productive Maintenance
CPD Validation Number: SAIMechE- 0943-12/18
CPD Validation Number: SAIMechE-0942-12/18
Developer/Presenter: Shamsheer Singh
Code
Days Start Date
C1616
1
E1616
1
A1616
1
12 Apr 2016 19 Apr 2016 26 Apr 2016
End Date 12 Apr 2016 19 Apr 2016 26 Apr 2016
Region
Booking Closure Date Cape Town 29 Mar 2016 East Rand 5 Apr 2016 Durban
12 Apr 2016
The Inspection & NDT workshop provides a general appreciation of Inspection & NDT. It covers the regulatory authorities, new fabrication and in-service plant and equipment. It embraces the involvement of various departments within an organisation, such as design, engineering, fabrication, construction, process, operations and maintenance. This workshop explores the conventional and advanced methodologies utilised in NDT – its advantages, disadvantages and limitations. It shall create an awareness in the selection of appropriate methods and techniques to enhance the detection/evaluation of corrosion0 and degradation mechanisms. As an effective Asset Integrity Management tool, the implementation of Inspection & NDT programs contributes significantly to safety, efficiency, reliability, availability and capital stewardship.
Managing a Coal Fired Firetube Boiler CPD Validation Number: SAIMechE-0817-12/17
Developer/Presenter: Mr. Malcolm Black, Council Member of SAIMechE Code
Days Start Date End Date
A1416
1
C1416
1
E1416
1
13 Apr 2016 20 Apr 2016 28 Apr 2106
13 Apr 2016 20 Apr 2016 28 Apr 2016
Region Durban Cape Town East Rand
Booking Closure Date 30 Mar 2016 6 Apr 2016 13 Apr 2016
The workshop will explore the important aspects of managing a coal-fired firetube boiler. Given that South Africa still enjoys a relatively cheap supply of coal, this type of boiler is still very common in industry, typically delivering saturated steam at pressures below 1000 kPa for general heating and drying applications.
Introduction to Adhesives Science
CPD Validation Number: SAIMechE-0911-12/16 1 credit, in Category 1, may be claimed for this event. Standard Fee: R2 216.00 + VAT Expertise provided by Pratley (Pty) Limited Code
Days
KAD16
1
AAD16
1
Start Date 14 Apr 2016 29 Apr 2016
End Date 14 Apr 2016 29 Apr 2016
Region
Booking Closure Date Krugersdorp 31 Mar 2016 Durban
15 Apr 2016
● Why Use Adhesives? ● Adhesive Principles ● Structure and Composition of Adhesives ● Selecting an Adhesive ● D.I.Y. Adhesives vs. Industrial Adhesives ● Examples of Adhesives
Fees, Booking Forms & Terms and Conditions Carey Evans, Tel: 031 764 7136 Email: carey@saimeche.org.za
Developer/Presentor: Dr. Herbert de Vries
Code
Days Start Date
E5716
1
C5716
1
A5716
1
26 Apr 2016 4 May 2016 8 Jun 2016
End Date
Region
26 Apr 2016 4 May 2016 8 Jun 2016
East Rand Cape Town Durban
Booking Closure Date 12 Apr 2016 20 Apr 2016 25 May 2016
Total productive maintenance covers a maintenance program which embraces all the disciplines of reactive, predictive and preventive maintenance, however, including all the employees of the organisation to participate in the process. The 6 major losses are clearly articulated in this presentation. The workshop explores the philosophy of Total Productive Maintenance (TPM), which is describes as a plant improvement methodology which enables continuous and rapid improvement of the manufacturing process through use of employee involvement, employee empowerment, and closed-loop measurement of results.
Heat Exchangers
CPD Validation Number: SAIMechE- 0915-12/16 1 credit, in Category 1, may be claimed for this event. Standard Fee: R2 216.00 + VAT Expertise provided by Steinmüller Africa (Pty) Ltd and Front End Technology (Pty) Ltd. Code Days Start End Region Booking Date Date Closure Date CHE16 1 6 Apr 6 Apr Cape 22 Mar 2016 2016 2016 Town EHE16 1 22 Jun 22 Jun Gauteng 7 Jun 2016 2016 2016
● Basic Heat Transfer ● Types of Heat Exchangers ● Mechanical Design of Pressure Vessels ● Economics of Heat Transfer Technology ● Troubleshooting and Maintenance of Heat Exchangers.
Unpacking the Pressure Equipment Regulations CPD Validation Number: SAIMechE-0935-12/18
Developer/Presenter: Mr. Mark Sloan
Code Days Start Date E0716
1
C0716
1
A0716
1
4 May 2016 1 Jun 2016 14 Jun 2016
End Date
Region
4 May 2016 1 Jun 2016 14 Jun 2016
East Rand Cape Town Durban
Booking Closure Date 20 Apr 2016 18 May 2016 31 May 2016
Understanding and appreciating of the Pressure Equipment Regulations (PER) and the correct application of the legislated requirements found within the South African pressure equipment environment. ● Definitions (Including the role of the Guidance Notes within the PER) ● Scope of application ● General requirements and introduction to SANS 347 ● The role of SANS 347 and brief overview ● Duties of manufacturers ● Duties of importers and suppliers ● Duties of users ● Approval and duties of approved inspection authority ● Registration of a steam generator ● Pressure equipment marking ● Pressure and safety accessories ● Inspection and test ● Risk-based inspection ● Repairs and modifications ● Records ● Access and door interlocks ● Gas reticulation equipment and systems ● Transportable gas containers ● Fire extinguishers ● Offences and penalties, Repeal of regulations and annexures & Short title.
THE SOUTH AFRICAN MECHANICAL ENGINEER
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COVER STORY
A New Engineering Qualification Replacing the B Tech Degree The Higher Education Qualifications Framework was first published for comment in July 2004 in accordance with the Higher Education Bill of 1997. This new framework was designed to be the roadmap of qualifications for the future. It contains post Grade 12 qualifications at all levels from a one-year Higher Certificate right through to a PhD.
T
echnology qualifications in South Africa have a history of changing every ten to fifteen years, and this instance is no different. The B Tech as we know it, with the diploma as basis containing an industry component, topped up with an extra academic year to grant the degree, was afforded no place in the Framework, and will therefore be terminated. At the time of publication of the Framework for comment, a number of professions and industries, like the tourism industry, health, financial and engineering professions, all petitioned the Minister, but the B Tech was to be discontinued. The National Diploma, however, was allowed to stay, but some changes were introduced there as well.
A great numbers of diploma students were not able to find sponsors for their industry year and hence could not receive their diploma Debating the Change
There was great debate at the universities of technology about the accommodation of the present qualifications in the new Framework. If a diploma and advanced diploma were decided on, candidates would end up without a degree which would not be acceptable, and the universities did not have the
Comparison of Engineering Qualifications Minimum ECSA required credits in knowledge areas Diploma
BET
BSc Eng
Mathematical Sciences
35
42
56
Natural Sciences
28
28
56
Engineering Sciences
126
140
180
Computing and IT
21
21
-
Complementary Studies
14
28
56
Work Integrated learning
30
-
-
Sub Total
282
308
420
Re-allocation of the above areas
78
112
140
Total Credits
360
420
560
Table 1. Comparison of Engineering Qualifications
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THE SOUTH AFRICAN MECHANICAL ENGINEER
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resources to offer both a diploma and a degree. The industry had become used to a technology degree, and the universities as well as their students and parents insisted on a degree. When the idea of a three-year degree was mooted to the Department, they adamantly insisted that it had to be a totally academic degree with no “practical” or “industry” component. The engineering industry favoured a practical component, but this was refused. A delegation went all the way to the Minister, where they were afforded a very friendly reception but nevertheless received a negative answer. The reason for this was that a great numbers of diploma students were not able to find sponsors for their industry year and hence could not receive their diploma despite having completed all their academic subjects. Therefore, if an industry component was required in a new qualification, it would have to be added after attainment of the qualification.
Introducing the new three-year degree
The only logical way to introduce a new qualification was to glean from the four-year degree model that proved successful at the traditional universities, and introduce a three year academic degree, with no industry component. This new qualification, which is being introduced from 2017 onwards, will be called the Bachelor of Engineering Technology (BET) degree. Many people in industry maintain that the practical or industry component is absolutely essential for technology qualifications, that it is the hallmark of technology qualifications, and that graduates would not be able to function in industry without it. This hails from the time that the technology qualifications were introduced in the late fifties and early sixties as the “sandwich courses,” with the student doing alternate academic and practical semesters in class and in industry. When I took over a Civil Engineering Technology Department in 2007, the rule still was that the student had to do his industry year before being allowed to do his final academic semester. This model worked well for the construction industry, but it was found that the consulting engineers preferred students who had completed all their academic subjects. We had to conform with most other people in academia who allowed the industry
March 2016
COVER STORY
year either during or after the academic semesters. This situation proved that students who gained industry experience after their academic semesters were not inferior to those who gained industry experience during their academic tour. The argument that the industry experience was an essential component of technology qualifications therefore does not hold water, and technology graduates are well able to hold their own having gained their industry experience after completion of their academic subjects.
The New Bachelor of Engineering Technology (BET) Degree
The question arose as to how to design the new Bachelor of Engineering Technology degree? Was it to be a four-year BSc Eng “light� or a National Diploma on steroids? This would be an easy trap to fall into. However, much thought was given to the development of a unique qualification, catering for both the requirements for accreditation of the qualification as set up by the statutory Engineering Council of South Africa (ECSA) for registration of Engineering Technologists, and the needs of industry. To achieve this ECSA requirement, the minimum guidelines as set out in Table 1 had to be satisfied. The nature of the work done in practice by the
engineer, technologist and technician also had to be taken into account. This can best be illustrated by Figure 1 describing the construction-productprocess-system life cycle profile on the conceivedesign-implement-operate continuum.
It was found that the consulting engineers preferred students who had completed all their academic subjects The new Bachelor of Engineering Technology degree was therefore designed with more pure mathematics and science than the old qualifications, with an emphasis on broadly defined problem-solving and design, and a fine balance of theoretical and applied knowledge. It teaches the technologist to go beyond established standards and codes in a disciplined and informed manner, and provides a theoretically-based but hands-on and practical focus beyond that of the engineer, and with less front loading of mathematics and science. It is therefore a functionally focused qualification with direct industry application and relevance. It aims to produce the educational base for a well-rounded professional engineering technologist. SAIT (SA Institute of Tribology), J. J. de Koker Pr Tech Eng, Committee Member www.sait.org.za
Conceive 40%
Design 30%
Implement 20%
Operate 10%
Conceive 10%
Design 20%
Implement 30%
Operate 40%
Conceive 20%
Design 40%
Implement 25%
Operate 15%
Figure 1: Construction-product-process-and-system lifecycle profile on the conceive-design-implement-and-operate continuum.
THE SOUTH AFRICAN MECHANICAL ENGINEER
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2012: Cindy Ross, attorney at law, is fed up with the crime, alcoholism and abuse of women and children in the Diepsloot community. Her smart solution is to create The Diepsloot Mountain Bike Academy. Cindy gathers a support group of other concerned professionals and together they provide disadvantaged and disillusioned youth with a positive outlet of expression, through cycling, life skills programmes and enterprise development. The young cyclists in the programme are turning the wheels of opportunity for themselves, achieving both locally and internationally. The spin-off? A community with reduced levels of crime and abuse. Cindy is another PPS member who uses her professional acumen as a transformational tool. Her story proves to us once again that professional thinkers are a unique breed with the power to change the world. That’s why at PPS we pride ourselves on our 75-year track record, understanding the world, needs and wants of graduate professionals like Cindy Ross, so that we can tailor solutions that match their needs.
For more inspirational stories like this, visit pps.co.za
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Investments
Financial Planning
Short-Term Insurance
Medical Aid
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COMPANY PROFILE
Protecting our Resources In this new column, we feature one of SAIMechE’s company affiliates (list on page 6). This month, we get the low-down on S.A.M.E Water.
S
ome might say that S.A.M.E. Water is a bit obsessed about water. They are probably right. But water is not simply our business, it is everybody’s business.
As a country which has scarce fresh water resources, every South African should be concerned with harnessing and protecting this scarce commodity.
“No other humanitarian intervention produces a more dramatic effect on life than access to clean water and sanitation.” – World Vision
industrial and commercial treatment plants, as well as supply, installation and commission of Frank Schulz
At municipal level, government is responsible for effective water resource planning, infrastructure development and effective service delivery. At an industrial level, business ought to be proactive in mitigating its impact on the environment, particularly with respect to waste management and pollution. At S.A.M.E. Water, our business is focused on harnessing the collective skills, expertise and experience of our team to create water and waste management systems and services that lend themselves towards sustainable communities.
Services
With offices in Johannesburg and Cape Town, S.A.M.E. Water trains and retains the best in the industry who are able to harness both their skills and passion for water in the services we deliver. Our team includes mechanical, process and environmental engineers, project engineers and a superior design team who are meticulous in their approach to every project we commit to. Backed by nearly fifty years of experience in the water industry, S.A.M.E. Water is able to assist with: 6 6 Tender preparation 6 6 Project planning 6 6 Mechanical Plant design 6 6 Commission and successful handover of water and waste water treatment plants. 6 6 After sales equipment repair and maintenance. Simply put, we offer turnkey solutions for municipal,
one or all of the individual mechanical items from inlet to outlet.
Projects (from 2014 to December 2015)
6 6 Acid Mine Project - Central Basin TCTA 08-041, 72 ML/day (New Plant) (Jan 2013 - April 2014) Mixing Equipment, Aeration, Pump Stations, Lime Dosing, Poly Dosing, Thickeners, Overhead Cranes (2014) 6 6 Driefontein WWTW Mechanical Upgrade JW9018, 50 ML/Day Upgrade (Apr 2013 - Aug 2014) Mechanical equipment for the HOW, PST, SST, Fermenters and Thickening Equipment (2014) 6 6 Bushkoppies WWTW - Belt Presses Mechanical/ Electrical Upgrade - JW 9048, 200ML/Day Plant Capacity (June 2010 - July 2012) Upgrade of the Sludge Dewatering Facility consisting of Mechanical Belt Presses, Electrical Control and Instrumentation (2014) 6 6 Makhado WWTW - VDM/TECH/27/01/2012/01, 5ML/Day Upgrade (June 2012 - Dec 2015) Mechanical & Electrical Upgrade of complete plant (2015)
S.A.M.E Water, Tel: (011) 902-4900 (HO Gauteng) Email: sales@same.co.za, www.samewater.co.za
find out if you qualify to #joinourtable at pps.co.za PPS is an authorized Financial Services Provider.
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POWER TRANSMISSION
Making Sensible Choices Maintenance is now a big word in industry. Repair rather than replace is fast becoming the norm. “SA Mechanical Engineer” speaks to Paul Barkway, field service manager for Voith, South Africa.
D
owntime associated with equipment failure, which can be prevented by timely maintenance, costs far more than replacing machinery. Productivity and sustainability have become closely linked with a clear understanding of the role maintenance plays in this regard.
By using OEM’s, there is a certain confidence instilled that the products will stand the test of time and perform according to requirements. With each sector under extreme pressure, cost-effectiveness is key. “Business has had to rethink operations to ensure utmost efficiency,’ says Paul. “In the past, where machines would be replaced, now the first
port of call is to repair with replacement only being considered when there is no other option. And this trend holds true even among some of the biggest players in industry. “We are also seeing a definite preference to use Original Equipment Manufacturers (OEM) rather than any other supplier. This is not only due to the warranties that are in place but also the quality of workmanship that is guaranteed.” By using OEM’s, there is a certain confidence instilled that the products will stand the test of time and perform according to requirements.
Preference for OEM’s
Paul adds, “Several factors play a role. Is the manufacturer using the right tooling, is the manpower properly trained and is manufacture being undertaken under the correct conditions to the original standards?” While OEM parts and repairs might initially be more expensive, the long-term cost saving are real. No
Paul Barkway, field service manager for Voith, South Africa.
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POWER TRANSMISSION
modifications are required on parts and quality can be relied upon first time round.” There is no denying the long-term cost benefits being realised through proper and correct repair works as well as predictive or planned maintenance programmes. “The trend of running equipment to failure is now commonly accepted as being counterproductive. Maintenance has become nonnegotiable and good maintenance at that.”
Training and skills
Given the focus on repairs, Paul says it’s essential that companies have the necessary expertise on hand yet the skills shortage remains one of the biggest challenges in the local market and there is just not enough training happening to address the problem. “We are increasingly being asked for training on our equipment as people don’t necessarily always understand how fluid couplings work. We welcome opportunities to train because that’s precisely how you prevent breakdowns. Too often equipment fails because of a lack of know-how.” In an effort to address ongoing skills shortages in the industry, Voith has become actively involved with several technical colleges. “It had come to our attention that fluid couplings formed a very small part of the curriculum being presented at schools and so when we were approached to present a training course on this very subject, we jumped at it,” says Paul. In fact this exercise was so successful, that the company is targeting several schools to offer their training services.
Noticeable improvement
“Because of increased training and skills development, along with the OEM approach, we are starting to notice a drop in re-occurring breakdowns.” He cites the example of two problematic drive packs that were being serviced by other service providers who were unable to rectify the persistent premature failures occurring in the drive line. “The plant engineer was considering replacing the Voith couplings with variable frequency drives due to the reliability issues,” he explains.
Our service technicians quickly realized that the premature failures were occurring due to serious misalignment as a result of distortion in the bell housings. “Fortunately the engineer first afforded us the opportunity to address the issue. Our service technicians quickly realised that the premature failures were occurring due to serious misalignment as a result of distortion in the bell housings. This was proven to be the case through further investigation and dimensional checks executed in our works.” With the drive packs restored and working optimally, instead of replacing the couplings, the company in question awarded Voith a contract to refurbish the drive packs along with a complete rebuild of the gearboxes and motors. Voith, Paul Barkway, Tel: (011) 418-4000 Email: Info.VTZA@Voith.com, www.voith.com
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POWER TRANSMISSION
Small But Brainy Power has a crucial role to play in water management as an efficient system can make a significant contribution to keeping costs down. “SA Mechanical Engineer” speaks to Regal Beloit’s sales and marketing director, Hilton Fortmann about their competencies and capabilities to provide efficient and intelligent water supply and management systems.
G
overnment has called on municipalities to set aside 8% of their operational budgets to maintain water infrastructure. “Municipalities have to review new technologies and how they apply themselves to electricity and power savings. Our initiative regarding electrical motors, specifically designed for use in water projects, should go some way towards achieving this goal,” notes Hilton. Apart from a scarce resource and supply challenges, the country also faces an aging water supply infrastructure. In some cases, pipelines and systems are more than 30-40 years old and will require massive maintenance initiatives. In addition, numerous infrastructure projects with more focus on water and water purification, which will require water sourced and fed from other areas, will present many business opportunities.
Water desalination
As one of the world’s largest motor manufacturing company, Regal Beloit believes that one method that could go some way to alleviating water supply in a water-poor country like South Africa, is water desalination. South Africa’s more than 2 500kms of coastline provides easy access to sea water and Hilton envisages desalination as one of the country’s fastest growing industries over the next few years.
“VSDs simply make such good sense and I am encouraged by the fact that we are seeing increasing interest in these drive solution packages and receiving more queries on what they can do.” Coastal development of more desalination plants will require massive investments. Extracting salt from water is a very costly process and in order to keep costs down, efficient across-the-board approaches will be imperative to ensure that it remains a viable industry. Most of South Africa’s existing desalination plants are sourced from overseas but costs can be reduced drastically by using local solutions where possible. “Our highly efficient electric motors are specially designed and engineered for desalination plants,” Hilton points out.
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Hilton Fortmann
Managing variable demand
When demand for a resource is variable it makes sense to match supply accordingly. Water demands fluctuate according to time and season. “By using variable speed drives, municipalities will be able to supply according to current demand, and not waste electricity by always supplying to maximum demand when demand is minimal.” Hilton explains that there are three important concepts to understand when it comes to starting methods of electric motors: Direct online, Soft Starters and variable speed drive (VSD). “Controlling the current demands of your electric motor is directly proportional to controlling the running costs of your system”. Direct on-line provides immediate access to the respective resource – light, electricity, water – at the push of a button. Because everything has to work at full tilt immediately, starting up this system draws a lot more current, using approximately eight times the current required to run on start-up. Soft starters, with their more gradual approach on start-up, use only 3 ½ times the current and present a more cost-effective alternative depending on the application. VSDs (Variable Speed Drives) meet fluctuating demands and allow full variable control of the systems frequency, current and output power on start–up and during the duration of the running cycle of the system. For example, if a system is made up of four pumps required to supply maximum demand, using all four pumps when demand is at a minimum wastes both current and power when starting up the system together and while the system is running. A VSD (Pump Software Program) will individually alternate the pumps on start-up (reducing maintenance) by monitoring the demand March 2016
POWER TRANSMISSION
and acting accordingly using all four pumps when demand is at a peak. “VSDs simply make such good sense and I am encouraged by the fact that we are seeing increasing interest in these drive solution packages and receiving more queries on what they can do.” Just varying the speed is the tip of VSD technology iceberg, however. “A VSD acts like a small brain that calculates requirements; for example, in a cooling tower system, the VSD can be interfaced with temperature thermistors (PT100’s) calculation variances to estimate demand and adjust supply, according to the seasonal temperature conditions offering great savings and retrun on investment,” shares Hilton. Proactive maintenance is also now a reality with VSD technology. An alarm could trigger that a system is in trouble; high temperatures or low water levels for example, can be communicated via the cloud to the right person so that proactive maintenance can be performed to prevent a serious problem from occurring. While top of the range drives will cost a little more, they render significant savings and end-users will realise rapid returns on investment.
Condition monitoring
Another value add from Regal is condition monitoring, where problems can be detected and dealt with before a breakdown occurs reducing the risk of costly equipment failure, unexpected stoppages and downtime. The company takes the price of the unit and the savings into account when calculating the total cost of ownership and the payback period for each customer and system.
While top of the range drives will cost a little more, they render significant savings and end-users will realise rapid returns on investment As South Africa’s coal resources dwindle and infrastructure and supply management remains problematic, electricity, which has always been relatively cheap, is becoming increasingly expensive. Companies have to save on costs to remain profitable. Instead of staff reductions, which will add to our unemployment statistics, there are other much better ways to realise substantial savings. “Instead of reducing the overhead in people, rather do it in electrical equipment which we’ve shown is entirely possible.”
Healthy competition
The country has a wealth of local and global engineering talent, in Hilton’s view. Technology has raised the bar of what’s available and what will be available in the years ahead, and has made for a highly competitive and dynamic industry with many lucrative opportunities. “Competition brings out the best in everybody,” he concludes. Regal Beloit, Hilton Fortmann Tel: (011) 453-1930
Endorsements
T wo New
Susan Custers with office security, Cilla and Clarence
“SA Mechanical Engineer” has been honoured with the endorsement of two further bodies in the mechanical engineering and related fields, viz: u VAMCOSA (Valve & Actuators Manufacturers Cluster of SA) u SAPPMA (SA Plastic Pipe Manufacturers Association of SA). These prestigious bodies join the current long-standing endorsers of the publication: SAVAMA (SA Valve And Actuators Manufacturers Association) SAPMA (SA Pump Manufacturers Association) SAPSDA (SA Pump Systems Development Association) CESA (Consulting Engineers of SA) SAEE (SA Association For Energy Efficiency) SAIT (SA Institute Of Tribology) NSBE (National Society Of Black Engineers)
SACEEC (SA Capital Equipment Export Council) - see page 10 for info on the brand-new and South African-first “Engineering World” publication Promech Publishing is putting together in co-operation with SACEEC.
Look out for the next issue where we kick off with highly relevant and targeted information on our two new endorsers to the benefit of all readers of “SA Mechanical Engineer”. Best Regards Susan Custers Managing Editor Promech Publishing
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Unbelievable Value Proposition While many engineering companies bemoan the state of the economy, Zest WEG Group Africa has staked a big claim in local manufacture, backed by its global parent company, WEG Brazil. Beginning in 2010 with the acquisition of Hawker Siddeley, the group went on to acquire TSS Transformers in 2015 to strengthen its maintenance and repair offering.
A
t a total investment of R250 million, the company has literally performed a radical refurbishment of its premises including the installation of all new cranes, a move from core stacking to the far less labour-intensive system of stacking tables and rods, and an ethos of natural lighting in the interests of worker productivity and energy efficiency. Also impressive is the reversal of the 60% standard efficiency/40% high efficiency motors offering in 2015 to a 40% standard efficiency/60% high efficiency split in 2016. It is quite significant that Zest WEG Group Africa was the first equipment supplier to move from IE2 motors to IEC3 compliant motors, and a key aspect was that this change was introduced at no
While the extended guarantee will cover customers for unexpected electrical and/or mechanical failures giving them absolute peace of mind, it’s not going to cost them more
Louis Meiring, group CEO of Zest
additional cost to its customers, thereby reducing the total cost of ownership.
Extended guarantees
Such is the confidence and level of commitment of Zest WEG Group Africa to its customer base that Louis Meiring, group CEO, at a launch attended by “SA Mechanical Engineer” announced guarantees have been extended across all WEG products. “This is another very important first for us,” says Louis. “While the extended guarantee will cover customers for unexpected electrical and/or mechanical failures giving them absolute peace of mind, it’s not going to cost them more.” Louis adds that this was a prime consideration for Zest WEG Group Africa as the organisation is well aware of the additional financial pressures that many of its customers are operating under in the current financial climate. “By extending our product guarantees we are increasing the peace of mind that customers have with WEG products and opening the door for potential customers to examine what we know is an unbelievable value proposition.”
With ease
Extended guarantees will vary from product to product: W22 low voltage motors guarantee extended to five years; Variable Speed Drives and Softstarters to two years; where WEG motor and drive combinations are used, the WEG drives guarantee is extended to three years; switchgear guarantee extended to three years; transformers to three years and; if WEG transformers are acquired with a WEG Service Plan, the guarantee is extended to five years. “We have reviewed the performance of all WEG products over an extended period and are confident that all will meet the guarantee with ease,” Louis concludes. Zest Weg Group Africa, Kirsten Larkan, www.zest.co.za Tel: (011) 723-6000, Email : kirstenl@zestweg.com
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SAEEC
POWER
T O D A Y
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 Contributors: Liesl Venter and Patricia Holburn Advertising: Louise Cresswell 071 886 1263 Circulation: Catherine Macdiva DTP: Lindy Fobian 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.
Industrial CO2 Footprint Reduction by Utilisation in AMD Treatment and Gypsum Processes This article explores the opportunity to reduce the industrial carbon footprint of industry, by utilising the produced CO 2 in Acid Mine water treatment plants and Gypsum processing. The production of carbon is inevitable in industrial manufacture, which may be captured and utilised during treatment of sulphate wastes. The CSIR’s ABC- and the Gypsum processes are consumers of CO 2, where the required CO 2 is currently produced from coal. The economic gain, from the combination of industrial waste CO2 and the consumption of part thereof in these water treatment processes, extends both ways, ie, CO2 producing industries can reduce their carbon footprint and, where used, the CO2 production for the ABC and Gypsum can be reduced.
Dr D Johnson, Royal HaskoningDHV, South Africa
CO 2 producing industries
In South Africa, the largest single source of CO2 is from the generation of electricity emitted by coal-fired power stations. The second and third largest CO2 sources are Sasol (coal- and gas to liquids) and ArcelorMittal (steel manufacturing plants). Eskom’s coal-fired power plants are mainly situated in Mpumalanga, in proximity to the coal fields, from where the electricity is distributed throughout Southern Africa. Coal is combusted in boilers, producing steam, which is used to generate electricity for the national electric grid. Sasol has plants based at Secunda and Sasolburg and produces about 30% of South Africa’s liquid fuels and synthetics from coal and gas. Secunda has two coal-to-liquid plants (CTL), supplied by adjacent mined coal, while Sasolburg is a gas-to-liquid (GTL) plant, supplied from a Mozambican gas pipeline. The process involves the production of syngas, consisting of Carbon Monoxide (CO) and Hydrogen (H2), which is converted to synthetic fuel and other products. The efficiency of well to wheel for CTL is about 50%
Prof. J Maree, Environmental, Water and Earth Science Department, Tshwane University of Technology
Figure 1: South Africa’s 2013 Industrial CO 2 Emissions
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Despite the high CO2 footprint of the coal- and gas-to-liquid processes, it is anticipated that future production is to increase, in order to mitigate the effects of peak oil, as is evident in GTL projects in the USA, Uzbekistan, Nigeria and a feasibility study for a new plant in Mozambique. ArcelorMittal owns and operates South Africa’s largest steel manufacturing plants and has about 60% market share. The steel manufacturing industry produces large quantities of CO2, as the steel production process uses carbon as reducing agent. This is supplied in the form of coke, which is produced by thermally driving the volatiles off coking coal. ArcelorMittal has plants at VanderbijlPark, Vereeniging, Newcastle, Pretoria and Saldanha. In 2013, Arcelormittal produced approximately 2.26kg CO2, directly related to the process, per kg of steel. Their total CO2 footprint is about 15 million tons per year, of which 11.3m tons is directly related to the process. As shown in Table 1 and Fig. 1, the remaining South African CO2 producing industries are dwarfed by the first three. Company
CO 2 [Mt/yr] (Scope 1)
Eskom
227 900 000
Sasol
59 880 000
ArcelorMittal
11 318 077
PPC Ltd
4 437 330
BHP Billiton
2 947 000
Sappi
2 620 570
Anglo American
1 954 091
Gold Fields Ltd
792 618
Mondi Plc.
733 832
Anglo American Platinum
524 028
AngloGold Ashanti
96 000
Table 1: SA 2013 CO2 Emissions Industry (direct emissions)
Limestone neutralisation process
Lime (Ca(OH)2) is normally used for neutralisation of acid mine water. The limestone neutralisation process has been developed and implemented on full-scale, at several places in South Africa, Botswana and Australia with considerable cost savings. The use of limestone for neutralisation of acid mine water offers the benefit that only 50% the amount of CO2 is produced when acid water is neutralised with CaCO3 (Reaction 1) compared with when neutralised with lime (Reactions 2 and 3). Lime is produced by heating limestone (CaCO3) to 800°C to produce CaO and CO2. Coal is burnt to raise the temperature. The mass of coal needed amounts to 12% of the mass of CaCO3. Since the
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mole mass ratio of C : CaCO3 = 12 : 100, the mole ratio of coal/CaCO3 is 1. Thus, an equal amount of CO2 is produced when limestone is heated by burning coal, than the amount of CO2 released from CaCO3. Another benefit of limestone neutralisation is a 50% saving in alkali. This is due to the fact that limestone, the cheapest alkali, can be used for removal of iron(II), the main component in acid mine water. It also results in partial sulphate removal through gypsum crystallisation (Reaction 4). CO2 that is generated is utilised for partial calcium removal in the last stage to produce water that is under-saturated with respect to calcium carbonate. The volume of mine water in Gauteng and Mpumalanga that can be treated with limestone amounts to 200 mega litres per day. If the average acidity is 1 500 mg/l (as CaCO3), 132 t/d CO2 will be produced compared with 164 t/d CO2 if lime is used. CaCO3 + 2H+
CO2 + Ca2+ + H2O (1)
CaCO3
CaO + CO2
(2)
C + O2
CO2
(3)
Ca2+ + SO42- + 2H2O CaSO4.2H2O
(4)
Desalination of neutralised water
Using the barium processes, offers the benefit that saleable products such as sulphur and calcium carbonate can be produced. Western Utility Corporation has contracted the CSIR, among other technology suppliers, to demonstrate the CSIR ABC (Alkali-Barium-Calcium) desalination process on pilot scale. The CSIR ABC desalination process was designed to achieve neutralisation, as well as metal and sulphate removal, by using the cheapest chemicals in the most efficient way. Precipitated CaCO3, a by-product from the paper industry, was used for neutralisation of free acid. BaS or BaCO3 can be used for sulphate removal. BaCO3 was selected because it does not require H2S stripping from the main water stream, only from a small stream in the sludge processing stage. This novel process consists of the following stages: • Pre-treatment using CaCO3, for neutralisation of the free acid and precipitation of iron (III) and aluminium (III), • Lime treatment for magnesium removal and partial sulphate removal through gypsum crystallisation pH adjustment, • Removal of sulphate as BaSO4/CaCO3, • Processing of the BaSO4/CaCO3 sludge to recover BaS and CaO (dewatering and thermal processes), and finally • Processing of BaS to produce BaCO3. CO2 that is produced in the kiln is utilised here to produce BaCO3. The amount of CO2 that would be needed for CaCO3 production from BaS, the intermediate product, is calculated to be 237.6 tons per day. March 2016
SAEEC
Gypsum processing
A process has been developed for the processing of gypsum to valuable sulphur and calcium carbonate. In this process, gypsum powder is thermally reduced in a kiln, using coal as reducing agent, to produce calcium sulphide (CaS) as starting material for the production of calcium carbonate and sulphur. South Africa imports 600 000 tons per year of sulphur, the raw material for sulphuric acid production. The gypsum process allows recovery of sulphur, calcium carbonate and rare earth metals using coal as reducing agent and energy source. At an average cost of R2 000/t, sulphur importation amounts to R1.2-billion per year. Rare earth metals that will be produced have a significant higher value than that of sulphur. The amount of CO2 that would be needed for CaCO3 production, when 600 000 tons per annum of sulphur is recovered from waste gypsum, will amount to 2 750 tons per day.
Environmental impact
The mentioned technologies will have a major impact on environmental remediation. Water contaminated CaCO 3
Ca(HS) 2
by sulphate, metals and radioactivity will be treated to produce drinking water and saleable products. Coal ash will be the only solid waste product and CO2, the only waste gas. Coal ash can be utilised in brick-making and in the cement industry while CO2 can be processed via a proposed algal growth project to produce biomass, from which methane gas and hence electrical power can be produced, or to produce CaCO3, as quantified above. By implementation of cost-effective treatment technologies, water of good quality will be discharged into water-courses, while valuable by-products, eg, high quality calcium carbonate, used as filler material in the paper and pharmaceutical industries, sulphur and carbon dioxide can be recovered. The pollution of the environment will be drastically curtailed as all sludge produced will be processed into reusable or saleable products.
Carbon mitigation potential
For the ABC and Gypsum processes to have mitigation potential, the CO2 has to be captured and Ca(OH)2
CO 2
H 2O
AMD
H2
Coal
CaSO 4 Mg(OH) 2
MS
BaSO 4 CaCO 3
BaCO 3
Sludge processing stage
CaCO 3
Ca(HS) 2
Ca(OH) 2
CO 2
Figure 2: Process flow diagram for the CSIR ABC Desalination process.
Gypsum
Hydrogen sulphide
Coal
Carbon dioxide
Rotary kiln
Reactor 1
Pump 1
Filter
Reactor 2
Pump 2
Cyclone
Calcium carbonate
Figure 3: Process flow diagram for the Gypsum to sulphur process.
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Absorption
Methane injection
H 2S enrichment
GTL industry, is too costly for CO2 separation at power plants and the steel industry.
Regeneration H 2S fraction
Here, processes such as the hot potash process, with relatively low investment, may be more appropriate. The total CO2 utilisation potential for desalination and Gypsum processing is estimated at 1.1 million tons of CO2 per year.
C.W. Refr.
Feed gas
Stm.
Conclusion
Industry produces large amounts of CO2, continually being discharged into the atmosphere. While being a pollutant and important GHG, it is simultaneously a reagent in the Gypsum and CSIR ABC processes.
Tail gas CO 2 Syngas
The cost of supply of CO2 from Sasol is expected to be free of charge and will consist of compressing and bulk transport to site.
Methanol water mixture
Stripping N2
Figure 4: Linde Rectisol Process (Picture: Linde Engineering)
transported to the treatment plants. To be economically viable, these costs have to be lower than that of coal. The main CO2 separation processes are: absorption, adsorption, membrane separation, biological transformation or combinations of these. The CO2 from power plants and the steel industry are released in a mixed gas flue from the combustion process, and consist of a range of gases. The cost of carbon capture in power plants decreases the plant efficiency by 20- to 28%. In the Sasol process, however, acid gas (CO2 and H2S) is separated with the Rectisol process (Figure 4), by dissolving in cold Methanol, and separated into almost pure H2S and CO2 streams. The H2S is processed into elementary sulphur and the remaining CO2, which is almost pure, discharged to atmosphere. The Secunda plants are adjacent to their own coal mine, and can be delivered to site via a short pipeline. The Linde Rectisol process is an expensive CO2 separation process and, while necessary for the
By combining these processes, with the capture of CO2 from industry, a net mitigation can be achieved. The process will be especially valuable for a company such as Sasol, where high purity CO2 is produced, which can be partially consumed in acid mine water treatment. Furthermore, large quantities of CO2 can be consumed in the Gypsum process. Comparatively, the net mitigation potential of these two processes alone, is only a fraction of the total CO2 production, but is a step in the right direction. Similarly, CO2 producing industries may find more potential CO2 consumers to offset part of their carbon emissions. Presented at the Southern African Energy Efficiency Convention (SAEEC) 2014, www.saee.org.za, Tel: (018) 293-1499 Presented by: Dr D Johnson, Royal HaskoningDHV, South Africa, Email: David.Johnson@rhdhv.com Prof. J Maree, Environmental, Water and Earth Science Department, Tshwane University of Technology, Email: mareej@tut.ac.za
find out if you qualify to #joinourtable at pps.co.za PPS is an authorized Financial Services Provider.
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POWER GENERATION NEWS
Refuse Derived Fuel Plant
World-class Surface Coating The wide range of surface coating and Plasma Transferred Arc (PTA) cladding process solutions, from Thermaspray, are ideally suited to a host of demanding applications in the power generation industry. In the steam cycle, equipment and components that handle steam and water (including steam generators, pumps and turbines) operate in very harsh environments. “These components require a variety of control, safety and shut off systems and this is where a lot of wear occurs,” says Thermaspray’s metallurgical engineer, Shaik Hoosain. He explains, “High pressure steam, high temperatures and metal-to-metal wear at seating areas are the main contributors of wear in steam and water valves. In addition, valve seats and spindles need to inhibit oxidation on the surface, which can lead to adhesion damage at high temperatures. “Our thermal spray and PTA capabilities enable us to refurbish and repair a wide range of components used by local power stations. These include fan blade and steam side spindles, servo motor and rack spindles, stator pump bearing and accumulator housings, fan blade shafts and liners, pump impellers, nose tip liners, deflector rings, control casings, sleeve and rotation plates, sleeves and bushes as well as a range of valves.” Thermal spraying provides increased resistance to high temperatures and oxidation, traction, cavitation, chemicals and corrosion as well as wear resistance (resulting from erosion, abrasion and sliding). “The result is an extension of component service life and the subsequent increased uptime and improved production translate to significant cost savings for the end-user,” concludes Shaik. Thermaspray, Tel: (011) 316 6520 www.thermaspray.co.za
Interwaste has announced the launch of South Africa’s very first Refuse Derived Fuel (RDF) plant. The plant aims at reducing waste to landfill and pioneering general, industrial and municipal waste to alternative fuels, ensuring less reliance on South Africa’s vital resources and resources that are carbon intensive. The current plant, which is the first of four lines, is expected to see a minimum of 12 000 tonnes of waste converted to alternative fuel, annually, for use in the South African manufacturing sector. The plant, which was imported in 2015, is located in a facility built by Interwaste at the company’s Germiston depot. It is currently producing a solid recovered fuel to European specified standards, which is equivalent to A Grade coal. “Through the commissioning of such solutions, companies are able to lessen their reliance on fossil fuels, which have a high environmental impact including acid mine drainage and reject coal, businesses are able to drastically improve their emissions profile and pay back their investment within a mere five years because the fuel is substantially more economical,” says Allan Willcocks, CEO at Interwaste.
The company has also pioneered the process in alternative fuels within the hazardous waste environment, ensuring that hazardous waste can be diverted from landfill, which is not only expensive, but toxic to the environment if not managed correctly. Interwaste, Tel: (011) 323 7300 www.interwaste.co.za
Toughness and Portability Chicago Pneumatic has introduced a host of new optional features to its CPDG mobile diesel-powered generator range, including higher capacity fuel tanks, road trailer options and a galvanised skid, to provide contractors with enhanced portability, toughness and extended run-times.
Available with a variety of tow bar and coupling combinations to fulfill the needs of different customers. The new road trailer options mean the generators can be easily transported between sites, without the need for major adaptations. An optional galvanised skid has been introduced to add extra robustness to the base-frame of the generators. It is specifically designed for applications where the unit will reside on uneven surfaces, or moved across the ground over short distances. To provide operators with the option of extended run times, CPDG generators can now be equipped with higher capacity fuel tanks, with 48 hour or 1 000 litre variants available depending on the power mode.
The company has also added a new single phase version of the CPDG generator to the range, which provides the same reliability and performance as previous models, but specifically for single phase load applications. The rugged and easy-to-move CPDG range provides dependable and consistent power to any construction site, with five models available in 9, 14, 20, 30 and 40 kVA ratings. Chicago Pneumatic, Tel: (011) 821 9000 www.cp.com
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POWER GENERATION NEWS
Rooftop Solar Power Plant
feeds into two 100KW inverters in parallel, tied to the grid. The pay-back period is estimated at five to six years. The total voltage is 750v DC which is converted into 3-phase AC. Passat Energy has partnered with 3M for advice on attaching the solar installation to existing roof structures, minimising roof penetrations. “3M has assisted with the installation of the solar panels by providing a unique solution for attaching the solar panels to the roof of the factory,” says Pierre Lombard, a director of Passat Energy. The solution provided by 3M consists of a VHB (Very High Bonding) double-sided, adhesive-rolled acrylic tape, initially used for high-speed trains in Japan.
Passat Energy has commissioned a 220kWp rooftop solar power plant of 880 solar panels of 250W each at TW Profile Services in Boksburg and anticipates a significant reduction in electricity consumption.
bending. “Due to our high electrical consumption, we needed to look at possible solutions and selected PV as the most viable. We anticipate about a 25% saving in our monthly electricity bill,” says Joost Smuts, MD of TW Profile Services.
“The adhesive is stronger than a mechanical fastener, will last longer - up to 15 years, and bonds immediately,” says Pierre, “The adhesive is also visco elastic, meaning it has no thermal expansion caused by changes in temperature and therefore creates zero fatigue on the roof or panel.”
TW Profile Services specialises in plasma cutting, guillotine cutting, rolling and
The panels are installed in four arrays giving an output of 55KW each. This
Passat Energy, Tel: (011) 894 4283 www.passatenergy.co.za
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POWER GENERATION NEWS
Reducing Energy Costs The installation of Sew-Eurodrive frequency inverters has resulted in the Volkswagen Autoeuropa vehicle manufacturing plant in Portugal achieving a 28 percent reduction in energy consumed by large fans that dry car paint on the production line. This has resulted in annual cost savings of +- R450 000, and a reduction of 250 tonnes in CO2 emissions.
Sew-Eurodrive prepared two energy audits, one before and one after the new frequency inverters were installed, and presented the report and the predicted
energy savings to VW and the Portuguese government, which subsidised the new installation. Sew-Eurodrive, www.sew.co.za
The operational speed of the fans was the main focal point. “We first had to establish how far the speed could be reduced without having a negative impact on the drying process,” says Reis Neves, Sew-Eurodrive Portugal technical manager. The first step was to install new air filters. Reis explains that this enabled the speed to be reduced further, without negatively affecting the fans’ thermal capacity. A total of 17 Movitrac LTP-B frequency inverters were installed in the fans.
V14841
The planning and installation process barely affected day-to-day operations and the co-operation with VW went smoothly.
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Tel: +27 11 418 4000 info.vtza@voith.com www.voith.com
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► EIA Process
► Environmental Risk Assessments
► Geographical Information Systems
► Agricultural Assessment and Advise
► Project Managment
► Wetland and Riparian Services
► Natural Resource Services
► Visual Impact Assessments
► Ecological/Biodiversity Services
► Public Participation Process
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► Developement Research, Monitoring and Evaluation
N2 Mnini ECO Duties
Plant rescue
Durban Coal Terminal Site Inspection
Ohlanga Pump station ECO Duties
Freightpak Warehouse Site Audit
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Ballito Interchange Botanical survey
Site assessment Sundumbili pipeline
l Tel: (031) 303-2835 l Fax: 086 692 2547 l l Email: info@afzelia.co.za l www.afzelia.co.za l
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March 2016 Skills on Site
Septmeber 2012
1
OILS & LUBRICATION
A First for Africa: Turbine Oil Coalescer “Centrifuge removes only free water, while vacuum dehydration removes free and dissolved water, although it does generally take a lot more time. This prompted us to find the most effective and fastest free water removal machine, which led us to the Pall HCP200 Turbine Oil Coalescer,” says Steven Whitcher, general manager of Filtration Management Solutions.
D
eveloped by Pall Corporation, the coalescer is used in the filtration and water removal of turbine oil, incorporating the functions of absolute fine filtration with the latest high performance Pall Coralon efficiency free water removal of the oil. Notes Steven, “It effectively removes solid particles, emulsion and free water from the oil, and is able to achieve an ISO 4406 cleanliness code of up to 12/09/07. Furthermore, the content of free water may be lower than 100 ppm (parts per million).”
A unique patented ‘helical wrap’ pleat support system, as well as composite element structure for unsurpassed strength, optimum performance and service life Particle filtration
The HCP200 comes with a host of functionalities and benefits. It can be used independently as a solid particle filtration unit, which means that it can bypass the coalescer function if water removal
is not required. The unit uses high performance Pall Coralon filters, which incorporate state-of-the-art design technology, including a unique patented ‘helical wrap’ pleat support system, as well as composite element structure for unsurpassed strength, optimum performance and service life. “This makes the Pall HCP200 a cost-effective solution that is clearly superior to traditional filter designs,” remarks Steven.
Water removal
The HCP200 can also be used to remove both particle contamination and free water in turbine oils. When oil enters the coalescer unit, after particle filter, its point of contact is the coalescer elements. Free and emulsified water become larger droplets of water after passing through the filter elements due to the peculiar polarity molecules in the coalescer element materials. “Before the oil enters the separator element, gravity causes the relatively large water drops in the oil to fall into the water bag below. However, as a result of inertia, some water droplets go up to the separator element along with the oil. The separator element is made up of special hydrophobic materials, so that when the oil passes it, water droplets are kept outside,” explains Steven. “The oil then enters the separator element and discharges from the machine outlet. Water droplets gather and become larger and at last, they fall into the water bag. Once the water bag reaches a level of 221mm, it discharges the free water through its own outlet pipe.”
Real-time
After debugging, the unit can run smoothly during normal operating conditions and requires no manual operation. It is equipped with an emergency alarm, which will automatically sound when abnormal conditions occur or when maintenance is due. In case of an emergency, the automatic emergency stop will shut down the system. The computer interface is able to display current and previous operating data and the status display offers realtime and current operating conditions of the system.
To the test
The HCP200 is dedicated for particle filtration and water removal of turbine oil
Two typical field results from Pall Scientific Laboratory Services on two of the HCP200’s precursors, the HCP150 and HCP100, showed highly favourable results on the water removal efficacy of the units.
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OILS & LUBRICATION
content of 6 950ppm after 32 hours. Initial ISO 4406 results of 21/19/16 reduced to 17/15/12 after 32 hours of operation. A second field test, also on a 10 000 litre tank, used the HCP100, with water removal capacity of 100 litres per minute or 6 000 litres per hour. The results showed the initial water content of 587ppm reduced to 163ppm after 31 hours of operation. “In recent months, FMS offered the HCP200 to a selection of its clients on a trial basis for the purpose of compiling data for a case study. Trials were run on two turbine oil tanks and proved highly successful.”
The team from left to right: Molefi Kamba - sales engineer; Mika Jama technical engineer; and Steven Whitcher - general manager
A field test on a 10 000 litre tank using the HCP150, with a water removal capacity of 150 litres per minute or 9 000 litres per hour, showed a water content reduction to 157ppm from an initial water
The results showed the initial water content of 587 ppm reduced to 163 ppm after 31 hours of operation
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All FMS rental machines are serviced and repaired by Pall South Africa using OEM’s parts, come with a Certificate of Conformity and are in accordance with ISO9001:2008 standards. “This launch represents not only a first for South Africa, but for Africa at large – and a great step forward in oil filtration and separation technology on the continent,” Steven concludes. Steven Whitcher, FMS, Tel: (011) 996-4060 Email: steven@fmsafrica.co.za, www.fmsafrica.co.za
March 2016
MANUFACTURING
Integrating Processes and Data The best way to achieve agile, synergistic and efficient supply chains is to integrate processes and data across all elements of the supply chain including ERP, WMS, PLM, legacy systems, thirdparty services, and more. If an integration solution is tightly coupled with point-to-point coding, it can be just as inflexible and limiting as the original information silos.
"
In our experience, enabling the free flow of information through the supply chain requires long-range thinking and a flexible integration solution that can adapt easily to new technologies, best-of-breed systems, and a rapidly changing business environment. A right-sized integration solution also makes it easy for companies to mobilise their business processes, scale up, and integrate with CRM and other systems," says Lindsay Britz, marketing manager of Magic Software SA. "We cite three local success stories of manufacturers who streamlined their supply chains using our integration platform to automate and accelerate the flow of information between multiple systems providing customers with the flexibility to adjust to future technological and market changes.”
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A steel product manufacturer wanted to improve visibility and optimise their entire product life cycle, from production to inventory levels. In order to accomplish this, they used our integration platform to connect their legacy production and planning systems with their SAP BusinessOne ERP system. By automating and optimising their supply chain processes across systems, they were able to shorten lead times and lower inventory costs. By maintaining optimal stock levels, they also eliminated unnecessary handling and storage expenses.
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A local branch of a medical supply manufacturer wanted to synchronize their cloud-based warehouse management system with their ERP system to meet governance and compliance requirements. They used the integration platform to synchronize master data across systems, including batch numbers, customer orders, inventory,
Lindsay Britz, marketing manager of Magic Software SA
and shipments. This not only streamlined administrative processes and eliminated duplicate data entry for improved data accuracy and productivity, they also gained greater visibility which improved customer service.
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One South African food manufacturer implemented an innovative cloud-based warehouse management system enabling real-time inventory management from anywhere in the warehouse through the use of cutting-edge hand-held scanners. However, the lack of synchronization with their financial systems reduced its potential positive impact. Magic’s application integration platform was introduced to improve efficiency by enabling each inventory transaction, including dispatches, bin and warehouse transfers and job and purchase receipts, to be automatically updated in their Syspro ERP, keeping inventory master data up-to-date at all times and eliminating time-consuming and error-prone data entry. Companies need to integrate information from a variety of sources to improve efficiency. Every transaction typically touches several systems, including an organisation’s CRM, ERP, manufacturing resource planning systems and financial systems. In many cases, information also needs to be shared with parallel systems owned by customers, partners and suppliers. Point-to-point integrations are inflexible and difficult to maintain as systems and processes change, making it difficult for companies to maintain a best-of-breed software strategy. A robust and friendly integration platform, such as successfully implemented by these three South African manufacturers, provides the agility, speed and performance needed for South African businesses to succeed in today’s highly competitive market.
Magic Software SA, Tel: (011) 258-4442, www.magicsoftware.com
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AFRICAN EXPANSION
Robust ERP Platforms Expansion into Africa brings with it a range of challenges in terms of managing the laws, financial reporting requirements, and tax regulations of multiple countries
S
ays Keith Fenner, Chief Sales Officer, Sage X3 AAMEA, Executive Director and Head of Sage, “In addition, companies suddenly find themselves needing to manage multiple currencies and languages in their businesses. With French, English, Portuguese and other languages used for official business, companies need a multilingual platform. They also need one that can support the dozens of currencies used across Africa.
The trouble is that Africa, especially its smaller countries, isn’t a major focus for all of the world’s large software companies. The result is that support can be patchy and changes to cater for new laws and regulations are often made slowly “Many companies in Africa are still running their businesses on home-grown legacy systems or even using manual processes,” he adds. “In many cases, they don’t have the appetite for the time, risk, and cost attached to rolling out a complex, high-end platform. For that reason, we’re seeing a lot of demand in the market for systems that can be rapidly deployed to address the growing pains of a company on a global expansion drive.” He adds that enterprises should be looking for alternatives to the monolithic ERP packages of the past, since the global environment demands that
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they evolve quickly in response to changing laws, regulations, and business conditions. “Today’s enterprise applications must be flexible and modular to cater for the complexities of a global business.” As stated in Gartner, “The automatic quest for on-premises, single instance, single mega-vendor ERP capabilities (ie, monolithic ERP) is dead.”
Managing different tax regimes
Each country’s tax authority and treasury has different requirements in terms of financial reporting, return submissions, calculations, invoice formatting and data retention. A company’s financial system thus needs to be flexible enough to support each country’s needs, while also making it simple to consolidate figures for the expenses and revenues across the global business. The payroll poses further challenges for businesses, Keith explains. “For many of our clients, complying with payroll rules in different African countries has been a complex and timeconsuming exercise. Really large companies can outsource management of the payroll to one of the large outsourcing firms that specialise in processing for multinational companies, but it’s not an affordable option for mid-sized companies.” Alternatively, some have tried to make do with an ERP system from one of the traditional vendors. The trouble is that Africa, especially its smaller countries, isn’t a major focus for all of the world’s large software companies. The result is that support can be patchy and changes to cater for new laws and regulations are often made slowly.
Point pain
Another option is to use a point solution, be it a custom-developed tool or a locally supported package. But integration of this system with the global ERP platform can be complicated and expensive. “Our Sage HR Management software is fully localised for the needs of most major African markets and complies with all tax regulations and labour laws. The package streamlines compliance and helps organisations to stay on top of a dynamic and changing HR landscape. “It is completely attuned to the nuances of different African countries, catering (for example) for the different demands of Nigeria’s federal and state tax authorities. We’ve made it a point of staying at the forefront of HR and payroll legislative changes in Africa, and update our solutions in a timely manner for the latest laws and regulations in conjunction with government and local authorities.”
A fluid environment
Keith notes that Africa’s regulatory and legal environment is in constant flux, with financial reporting
Keith Fenner
standards, tax regulations, and industry legislation (for example, mining royalties or Mozambique’s New Petroleum Regime) constantly changing. That means companies need flexible solutions that are kept up to date with the latest changes. He recommends that organisations look for ERP platforms that allow for a choice of cloud and onpremises deployments so that the company can choose the solution that makes sense for each region or country. Modern cloud-based systems make it relatively quick to get a new country upand-running with a business system ready for local market conditions, yet able to provide consolidated reporting information for head-office.
Modern cloud-based systems make it relatively quick to get a new country up-and-running with a business system ready for local market conditions, yet able to provide consolidated reporting information for head-office “Such solutions are a credible alternative to the rigid ERP architectures of the past. They improve agility and simplify software management, free up IT resources and reduce costs, accelerate implementation and benefit from a faster delivery of new features and functions. “Globalisation is forcing African enterprises to keep costs under control and increase efficiency, while boosting productivity. The right business solution gives them instant, real time access to business critical data, providing them with maximum control over their operations,” Keith concludes. Sage ERP Africa, www.sage.com
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HYDRAULICS & PNEUMATICS
Heading North Expanding into Africa is top of the agenda for Hi-Force South Africa. “SA Mechanical Engineer” speaks to general manager, Sean Sandham.
A
ccording to the United Nations Trade Agency (Unctad) the continent offers the highest return on direct foreign investment in the world and is of increasing strategic interest to the global economy. It, therefore, makes sense that more and more local companies are extending their reach into Africa.
We have high quality products and are committed to taking our approach of a global brand, local service approach into Africa Since his appointment as general manager of HiForce South Africa several months ago, Sean has made Africa his major emphasis. “Historically, Hi-Force SA has not done much cross border business development to date. However, we now have ambitious plans in place to expand into the region. Already we are spending two weeks of a month developing business partners in several countries.” With the local market having been under pressure it makes sense to look at opportunities elsewhere in Africa. Sales, says Sean, have been low due to low commodity prices especially in the iron ore industry.
ment and have even closed down certain operations such as at the Kumba-Thabazimbi Mine,” he says. “At the same time, power generation is under pressure and the parastatals are spending a lot less than previously. But we remain positive as we expect growth to come from the cross border operations we’re developing.”
“Mines are just not spending money on new equip-
Hi-force anticipates growth in exports to copper-
The new TPA and TPE range
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Sean Sandham, general manager of Hi-Force.
THE SOUTH AFRICAN MECHANICAL ENGINEER
Hydraulic torque wrench pumps from Hi-Force.
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HYDRAULICS & PNEUMATICS
producing countries like Zambia and the DRC. Mozambique and Angola’s markets will also start coming on line with the development of the offshore gas/oil fields.
Moving forward
The company’s focus is on Sub-Saharan Africa which is still largely undeveloped, and offers real opportunities. “We have high quality products and are committed to taking our approach of a global brand/local service approach into Africa.” Sean adds that developing a presence across several countries is on the cards. “Our aim is not only to offer our products but also training so that we ultimately add value to customers’ business. This could be in the form of calibration services, rentals, rent to buy programmes and such. “There has been an increase in the importation of low cost products from China and, while this has not had a major or significant impact on our established markets due to our quality and service levels, we do believe that businesses in Africa should concentrate less on low cost and more on quality.”
a case in point. “The TPA and TPE range offers a 3-stage design, providing a faster flow at mid-range pressure thus enabling projects with demanding time constraints to be completed as safely and efficiently as possible.” There are several challenges facing South African companies locally, Sean points out.
With the world’s eye firmly on our continent’s developing countries, there is no denying the importance of a strong footprint in this market “At the same time, China’s growth is slowing down and South Africa is not doing enough to attract international investors into the mining/petrochemical/ industrial sectors. “Hence our focus on Africa. With the world’s eye firmly on our continent’s developing countries, there is no denying the importance of a strong footprint in this market. “And we are working hard to do just that,” he concludes.
Not without challenges
Hi-Force aims to retain a high degree of flexibility while establishing itself as a force to be reckoned with across Sub-Saharan Africa. The company’s recent launch of the TPA and TPE range of air and electric driven hydraulic torque wrench pump, is
Hi-Force SA Sean Sandham Tel: 011 314 0555 sean.sandham@hi-force.com www.hi-force.com
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An accessible and clear guide on how to grow your business through export
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ngineers receive a broad education in the nuts and bolts of machinery, equipment and systems but not much attention is paid to the commercial aspects of running an engineering concern.
“Engineering World”, a new annual publication being produced by Promech Publishing, in co-operation with the SACEEC (SA Capital Equipment Export Council), will serve to make financial and commercial decisions easier for engineers to make. The publication will focus on the export market but also on local content as a reliable tier of suppliers and supplier industries is vital to local manufacture. SACEEC will share its experience and expertise on a variety of elements that must be taken into account to become a successful exporter, such as:
Freight forwarding Tax matters Forward cover Deciding on what to sell to whom The culture and customs of the export destination country Building a robust supply chain The financial implications of exporting Marketing internationally Building a presence in the destination country Getting the correct legal advice. The SACEEC has assisted many companies in navigating the pitfalls of going over our borders. They remain committed to growing South African exports and have generously agreed to share their knowledge with the readers, in the interests of the country and our economy.
Eric Bruggeman, MD of SACEEC: “What you didn’t think to
ask? We trust that this first-of-its-kind publication will prompt capital equipment companies, who are contemplating the export route, to ask the right questions before setting off on what can only be described as an exciting and potentially lucrative journey.”
Contact the SACEEC on admin@saceec.com For advertising, contact Louise Cresswell on Tel (011) 781-1401 or 071 886 1263 For editorial: contact Patricia Holburn (B Comm BA Eng.Comm) on pathl@mweb.co.za
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WASTEWATER TREATMENT
Thomas Holtz, Multotec CEO
Rikus Immink, MD of Multotec Processing Equipment
Desalination Test Rig “SA Mechanical Engineer” recently spent an enjoyable and instructive morning with the team at the Multotec Group of Companies in February to gain an overview of their services and expertise. Having over 40 years under their belt in the mineral processing arena, the company has recently expanded into the process water industry.
Faan Bornman, Technical Manager of Multotec Process Equipment
T
he CIF test rig forms part of the testing facilities at Multotec’s Technology Division. The test rig consists of a dual stage CIF system, called DeSAlx. The desalination process uses two stages of CIF to desalinate brackish water to produce water with low dissolved solids content and a neutral pH. A cationic resin is used in the first stage to remove cations (such as calcium and magnesium) from the water, and an anionic resin is used in the second stage to remove anions (such as sulphates and nitrates) from the water. The technology reduces the comparative size of the ion exchange plant, giving much higher extraction of target species and reducing reagent consumption. The test rig has the capacity to treat water at a flow rate of 1 m3/h, yielding water recoveries of 90% and higher (depending on the feed water quality). The rig is fully automated and has the ability to log the pH and conductivities of both the feed and product water for the duration of the test.
Giving much higher extraction of target species and reducing reagent consumption Fully mobile
It is fully mobile and can typically be relocated to customer sites for pilot work. Steady state is reached after 16 hours of operation. The rig requires around 16 000 litres of throughput before steady state is reached and thus the need for a constant feed and relocation to customer sites for test work purposes. In addition to the test rig, Multotec has invested in a dedicated water treatment laboratory. The laboratory is equipped to do the upfront test work required to proceed to pilot scale test work. These include ion exchange isotherms and column loading and elution tests. Multotec also has a lab-scale DeSAlx unit which accurately simulates the continuous and counter current movement of resin that is the trademark of the efficient CIF technology. The labscale unit requires around 200 to 300 litres of solution to complete a test. Multotec Process Equipment, Faan Bornman Tel: (011) 923-6013, Email: faanb@multotec.com www.multotec.com
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MARKET FORUM in just over three months. It involved a complete rewind of the rotor, which has a cruciform-type winding configuration.
Quick Turnaround
“It was complicated by the fact that we found it necessary to redesign the winding and insulation,” Craig Megannon, general manager at Marthinusen & Coutts, explains. “The original coil had developed a fault due to the fact that it had been vacuum pressure impregnated, which by forming it into a solid block caused differential expansion between the copper windings and the steel of the rotor body. We solved this problem by introducing thicker insulation and thinner copper windings, which were neither VPI’d nor glued to the pole body. From left: Rudi Els, coil shop manager; William Martin, specialist winder and Craig Megannon, GM during the rewind of the Xinavane mill’s alternator rotor at the company’s Cleveland facility
Marthinusen & Coutts recently performed a rush job for sugar producers, Tongaat Hulett, in repairing the rotor of the 20 MW salient pole synchronous alterna-
tor at its Xinavane mill near Maputo, Mozambique. The division carried out the complex task at its Cleveland, Johannesburg, facility
“This achieved the desired result, as proven by the tests we carried out on the rotor windings on completion of the job,” Craig concludes. Marthinusen & Coutts, Richard Botton, Tel: (011) 607 1700, Email: richardb@mandc.co.za, www.mandc.co.za
Cut Price and Costs Easy to use and set up, and low running costs are the hallmarks of Afrox’s extensive range of automated plasma cutting equipment. “We strive to implement turnkey profiling solutions that match the longer-term cutting needs of fabricators,” says Afrox Applications Development Manager, Heating & Cutting, Hennie Van Rhyn. “Specifically for cutting stainless steels and aluminium, we offer customers a range of packaged plasma solutions built around combining cutting tables from leading European manufacturer Pierce with Thermal Dynamics’ plasma cutting technology. “We couple Pierce’s flexible range of precision CNC profile cutting tables with Thermal Dynamics’ water mist plasma technology, which offers an excellent combination of features for metallic materials such as stainless steel,
aluminium, copper and titanium,” says Hennie. The Thermal Dynamics automated plasma cutting range includes the Standard Cutmaster A series, a light duty cycle, entry-level air plasma system that provides an economical and flexible solution. With benefits that include easy setup and use, as well as superior cut quality up to 120 Amps, the Cutmaster A series offers solutions for light, medium and heavy applications. “By combining the Ultra-Cut XT series with Pierce CNC cutting tables, and customisable widths and lengths, we can offer fabricators HD plasma cutting
The Benefits of ISO Certification It has become hugely important for suppliers to the mining industry to comply with the International Organisation for Standardisation (ISO). Not only do international standards have economic, societal and technological benefits but they also balance technical specifications of products and services, making the industry more efficient by
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breaking down barriers to international trade. Rand-Air highlights that an ISO certification is especially significant in providing customers with assurance of quality management. Rand-Air has been servicing the mining industry for the past 40 years and believes that an ISO accreditation is critical in this highly competitive and
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solutions at a fraction of the price of competing technologies. And by adopting water mist technology, ongoing production costs can be slashed, too,” Hennie concludes. Afrox, Hennie Van Rhyn, Email: Hennie.vanrhyn@afrox.linde.com
demanding sector. “Customers need to be met with the highest possible standards in terms of reliability and performance, this in turn increases customer satisfaction as well as improves the standard of health and safety. ISO is intended to assist organisations to meet the needs of customers and other stakeholders while meeting statutory and regulatory requirements,” explains Bongani Thobela, SHEQ Manager for Rand-Air.
MARKET FORUM
Customised Facility In Growthpoint’s largest manufacturing sector transaction, both by deal value and square metres, CSI now occupies its new Isando facility on a ten-year triple-net lease basis. The premises will be used for manufacturing, storing and distributing its range of aluminium, stainless steel and roofing products. It spans a whopping 48 000sqm, made up of a 44 500sqm factory and warehouse space and 3 500sqm of offices. CSI, a subsidiary of Tiso Blackstar, has recently merged its two principal operating divisions, Global Roofing Solutions and Stalcor.
Growthpoint’s refurbishment of the property was extensive. The upgrade involved the casting of a 10 000m² concrete floor in the factory area, constructing a new 2 500m² office block and a complete upgrade to all the existing offices with new carpets, ceilings and energy-efficient lighting and air conditioning. Growthpoint Properties, Engelbert Binedell, Tel: (011) 944-6128, www.growthpoint.co.za
Level 4 BEE Certification
Engelbert Binedell, Growthpoint Industrial Division Director, says, “This is a significant transaction for Growthpoint
and it has proven to be unique and multifaceted. We’ve worked closely with CSI to optimise this property to meet its business needs, invested considerable capital of R40 million in refurbishing the facility to client specifications and acquired two new properties as part of the transaction.”
Apprentice at the Secunda workshops
Sister companies Aesseal and Aespump are to expand their apprenticeship programmes to ensure retention of Level Four BEE certification, recently re-assessed upwards from Level Five. The two companies, which together employ a staff of some 110, have seven active apprentices undergoing alternate terms of theoretical training at Dinyane Education in Secunda, while on-the-job mentorship at the company’s Secunda workshops ensures a steady stream of
“A major benefit for organisations that are ISO certified, is that it increases credibility with current and prospective clients. This advantage reveals itself not only in the increase of customer retention, but also in heightened ability to enter new markets and the rise in customer acquisition. It is a strategic vision that serves to improve image and brand equity by ensuring that organisations are better equipped to win new opportunities
qualified fitters and turners after completion of their two-year course. An annual intake of between three and five apprentices each year, ensures programme continuity, and AES group management believes that the programme is already delivering a return on investment. Commenting on the progress of this programme, AES general manager and company secretary Craig Murray says that he believes the training of apprentices
in a progressively competitive global marketplace. International Standards also help to optimise operations which improves the bottom line and in turn is cost saving,” he adds. “International Standards are tactical guidelines and tools which help companies to tackle the demanding challenges of modern business. Essentially, they ensure that business operations are ef-
Engelbert Binedell, Growthpoint Industrial Division Director
and their integration into the group workforce will prove to be the ultimate manner in which to grow South Africa’s skills base. At the same time, it helps companies to meet the government’s recently-revised black economic empowerment targets in the medium term. “Our highly rated apprenticeship programme has been at the heart of our recent upgrade to Level Four accreditation,” explains Craig, “but we want to expand it further because we believe that this emphasis on skills development will over time lead to a self-correction of the key pillar of black ownership.” Aesseal (Pty) Ltd, Rob Waites, Tel: (011) 466-6500, Email: rwaites@aesseal.co.za
ficient, which increases productivity and positions companies to access new markets. Our ethos for exceeding customer satisfaction is echoed through our ISO certifications. We can see the benefit from taking part in the standard development process,” concludes Bongani. Rand-Air Tel: (011) 345-0700 www.rand-air.co.za
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MARKET FORUM
Making Welding a Breeze
tion, they make it easy to weld out of position, including vertical up, vertical down, overhead and horizontally. Gasless wires are also easy to use on both thin and thick gauge material, and fill gaps effectively, without burning through your plate or tubing,” says Johan Bester, welding sales manager at Renttech South Africa.
Effects of wind, or even just a breeze, during the welding process can be a serious problem. Put simply, valuable shielding gas can all too easily get blown away, resulting in porosity, excessive spatter and inferior weld quality. A simple solution is gasless flux cored welding using a Lincoln Innershield wire, a process that was originally designed to replace stick or ‘arc’ welding. As the name suggests, Innershield wires produce their own shielding gas to protect the weld from the atmosphere. This process is perfectly suited for outdoor use, particularly in extreme operating conditions in industries such as agriculture, construction, shipbuilding, mining, and wherever maintenance is required.
“Gasless wires eliminate the inconvenience and expense of shielding gases being blown away, as is often the case with traditional MIG welding. In addi-
Cutting-off Wheels
Renttech SA, Tel: (011) 824 0410, www.renttechsa.co.za
This new range is available in two sizes, 115 mm diameter x 1,0 mm width x 22, 23 mm bore and 125 mm diameter x 1,0 mm width x 22, 23 mm bore, at a maximum operating speed of 80 m/s.
Magnet’s range of Klingspor abrasive products, designed for finishing surfaces and cutting off materials, now encompasses newly-launched Kronenflex A960 TZ Special cutting-off wheels.
Magnet provides a technical and advisory support service to ensure the selection of the correct product for each specific application. The company also offers the services of an abrasive specialist to go on-site, to trial these abrasives and offer solutions for improved production efficiency, optimum safety and extended service life of every component.
These high speed cutting-off wheels ensure optimum cutting performance in specific tasks in diverse applications, including maintenance and repairs, metal working and plant and steel construction. “Kronenflex A960 TZ Special cuttingoff wheels, with an optimised binding system, offer short cuttings times and extended service life,” says Shaun Bradbury, Magnet’s Klingspor product specialist. These wheels, which are free
“In the case of gasless flux cored welding, the filler metal for the weld is basically an arc-welding electrode turned inside out,” Johan explains. “This mild steel tube or sheath becomes the main filler metal to the arc and the flux inside becomes a light slag deposited on top of the weld.” He adds that the flux shapes the weld, while protecting it against the atmosphere throughout the solidification period. It also aids in removing impurities in the base material.
of iron, sulphur and chlorine, have a low thermal load and low burr formation.
Magnet, Shaun Bradbury, Email: shaunb@magnetgroup.co.za, www.magnetgroup.co.za
Ultrasonic Gas Flow Meters The Fluxus G series of ultrasonic gas flow meters sets a new industry benchmark for non-intrusive clamp-on flow metering of gaseous media. The series is available from Peter Jones Electronic Equipment, which falls under the Actum Industrial division of the Actum Group. Robert Howes, technical sales manager at Peter Jones, explains that the Fluxus G series of gas flow meters is available as either portable or permanent versions. Applications are wide-ranging, from gas exploration to transportation and storage, as well as industrial processing. “The critical criteria of any gas flow meter are accuracy and reliability,” says
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Robert. Flexim’s ultrasonic transducers are specifically matched and paired, and therefore guarantee a high zero stability, as well as high precision at low-flow velocities. With more than 1 000 measurement cycles a second and superior measurement algorithms embedded in the flow computer, together with the fact that the transducers are calibrated in-house or directly at the measurement point, Flexim’s clamp-on systems are no less accurate than inline gas flowmeters, but much more reliable, as they do not suffer from wear and tear inside the pipe,” explains Robert. By integrating additional process param-
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eters such as pressure and temperature as well as the individual gas coefficients, the gas flow meters can measure the mass flow rate as well as operational and standard volume flows, all with the highest precision. The gas flow meter can be applied at inner pipe diameters ranging from 10mm up to 1 100mm, with no limitations on pipe wall thickness or material, and pipe wall temperatures from –40 °C up to 100 °C. Moreover, the measurement system is independent of the pressure inside the pipe. Actum Group, Kevin Klaff, Tel: (011) 608 3001, Email: kevin@actum.co.za
MARKET FORUM ers, drills and impact wrenches. The professional hand tool range consists of bit sets, combination wrenches, standard and impact sockets, hex key sets, heavy-duty screwdrivers, various types of pliers and toolbox sets.
Largest Tool Range The largest tool range under one brand in South Africa is currently available from Jonnesway, distributed by Bearings International (BI), part of the Hudaco Group. This extensive range caters for the aviation, industrial, automotive and refinishing industries. It comprises a complete automotive, pneumatic and hand tool range. Specialised tools from Jonnesway include automotive kits, body tools, bearing-related products, brake and suspension undercar tools, electronic tools, files, garage and workshop tools,
Advantages of the Jonnesway range is that it is manufactured to meet and exceed DIN and ANSI standards, and caters for both metric and imperial sizes. It is also very competitively priced in the professional tool market, with a lifetime warranty on hand tools. as well as hydraulic gear/bearing pullers. Pneumatic power tools include air grinders, air ratchets, air saws, knives and hammers, air control units, air screwdriv-
Bearings International, Gugulethu Nkutha, Tel: (011) 899 0000, Email: gugulethu@bearings.co.za, www.bearings.co.za
Still Growing Strong During these tough economic times, people tend to cut back and downsize. This is not the case for AZ-Armaturen South Africa. The company has been growing and investing continuously during the last few years and has increased its market share in the stagnating valve market. AZ South Africa has invested further and introduced a new CNC (Computerised Numerical Control) machine into the production. The new CNC lathe with live tooling (multiple
axes for milling) allows the company to increase productivity, flexibility and improve quality with their plug valves. This has also furthered AZ staff’s education on world class technology. AZ-Armaturen, Tel: (011) 397-3665, www.az-armaturen.co.za
Proud programmer and operator of the new CNC machine
Extending Machine Life
The growing cost of maintenance, especially given the current exchange rate, has spurred the growth of low cost, low quality spurious replacement parts. Andrew Yorke, director at Metric
Automotive Engineering, says that this is especially true in sectors such as earthmoving and mining equipment, where maintenance costs dominate the lifetime of equipment.
“While many service providers stake their hard-earned reputations on extending the life of a machine, there are those who are less ethical and see an opportunity to make a larger profit. Add to this scenario that some buyers within the larger organisations may not actually understand the long term ramification of using sub-standard replacement parts,” says Andrew. Metric Automotive Engineering can refurbish large diesel engine components and offers services such as cylinder head remanufacture, cylinder block line boring, milling, honing and boring, camshaft grinding, crankshaft grinding, engine assembly and dynamometer testing. Subsidiary Reef Fuel Injection Services offers Bosch, Delphi and Denso approved fuel injection services and is acknowledged as the specialist in CAT fuel systems. Metric Automotive Engineering, Andrew Yorke, Tel: (011) 873-2350, Email: andrew@metricauto.co.za, www.metricauto.co.za
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VOL 66 March 2016
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MARKET FORUM The HY-PRO diesel coalescing filter unit
Super Dealer
Hytec Fluid Technology (HFT) has been appointed ‘Super Dealer’ for Cummins Filtration’s range of Fleetguard engine protection products for southern Africa, as part of a recent distribution agreement. HFT now offers complete engine protection in addition to its total hydraulic fluid management offering across the sub-continent.
Acid Technology (OAT) engine coolant. HFT will market and distribute the entire Fleetguard range, including NanoNet. “NanoNet fuel filtration extends the life of an engine and the service intervals, without increasing the breakdown risks. A typical mining vehicle has fuel and oil filters changed every 250 hours, with the air filter changed every 500 hours. Fleetguard filters are now designed to be changed every 1 000 hours, resulting in less vehicle maintenance downtime, improving productivity,” HFT general manager, Sandor Bottyan concludes.
Coinciding with this collaboration was the recent opening of Cummins Filtration’s new filtration and coolant manufacturing plant at its new regional distribution centre for Southern Africa in Woodmead, Johannesburg. The premises incorporates Cummins Filtration’s component warehousing and local manufacturing facility, which produces Fleetguard fuel and air filters, and the modern Fleetguard Organic
Hytec Fluid Technology, Sandor Bottyan, Tel: (011) 976 7300, Email: sandor.bottyan@hft.co.za, www.hytecgroup.co.za
Water Vapour Removal
In order to increase protection of expensive automation equipment, factory compressed air must remove as much water vapour as possible to avoid any condensation further downstream. This is done by lowering its dew point.
Failure to remove water vapour from factory air can quickly become a costly maintenance headache.
Brian explains, “Drying compressed air at the highest pressure consistent with the facility’s demands will result in the most economical dryer operation. For most industrial applications, the rule is to first set the pressure dew point to meet general requirements, then adjust it between -6°C to -10°C lower than the facility’s lowest ambient temperature. Hence, factory air dryness or dew point is relative to the application’s specific requirements.”
According to Brian Abbott, product manager at SMC Pneumatics SA, water vapour and the resulting water condensate are the foremost causes of costly downtime and increased maintenance. “The blame is often laid on the more visible culprit, oil or contaminants, both of which are easily removed with proper filtration. “Moisture in facility airlines can cause corrosion and rust which can break loose to the air passageways causing blockages in narrow restrictions and filter elements. This can lead to increased pressure drops and loss in machine performance, not to mention energy loss and costs of the compressed air” adds Brian. Aftercoolers, drip legs and water separators are used to remove water condensate from factory compressed air. However, this air is still at 100% relative humidity
The costs of energy, downtime, replacing production components, end product defects or even loss of brand value are just a few factors to consider when determining an appropriate dew point.
IDH Thermo Dryer
and is still at risk of condensing into water should the surrounding temperatures drop to its dew point.
SMC Pneumatics, Brian Abbott, Email: sales@smcpneumatics.co.za www.smcpneumatics.co.za
Index to Advertisers Afzelia 24
PPS
BMG 22
RFA Convention
Outside Back Cover
Engen 26
SAIT
Outside Front Cover
Engineering World
23
10, 11, 20
SEW Eurodrive
Inside Front Cover
GEA 31
The Peartree
Inside Back Cover
ILS 4
Voith 23
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THE SOUTH AFRICAN MECHANICAL ENGINEER
VOL 66
March 2016
Your boutique business destination Surrounded by lush gardens in the hub of Johannesburg’s northern suburbs, The Peartree in Craighall Park caters for groups of two through to 100 guests in nine well-appointed and equipped business suites. Breakfast meetings, working lunches, indoor or outdoor dining, half-day and full-day packages including all welcome refreshments, teas and lunches are offered in Standard, Gold and Platinum packages. Secure parking, business centre, fibre optic broadband AV, lockable space, and an onsite Hair & Beauty Boutique, all underpinned by highly qualified and helpful staff dedicated to ensuring your event is a success, make The Peartree a destination of choice.
www.thepeartree.co.za e-mail: info@thepeartree.co.za Tel: 011 781 0682 41 St. Albans Ave, Craighall Park
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THE SOUTH AFRICAN MECHANICAL ENGINEER
VOL 66
March 2016